Solid catalyst component for olefin polymerization, catalyst, and propylene block copolymer

Abstract

A propylene block copolymer with a high proportion of ethylene-propylene copolymer particles (rubber component) well dispersed in a propylene polymer exhibiting well-balanced rigidity and impact resistance can be obtained by using a solid catalyst for polymerization of olefins comprising (a) a solid catalyst component with controlled morphology, comprising magnesium, titanium, and a halogen atom, having an average particle diameter, specific surface area, and pore volume in a specific range, and having a pore size distribution in which an cumulative pore volume with a pore size of 100 Å or less is more than 50%, (b) an organoaluminum compound, and (c) an organosilicon compound. The block copolymer is very useful particularly for the application of vehicle parts such as a bumper and parts for household electric appliances.

1 - 6 . (Canceled)  
     
     
         7 . A propylene block copolymer comprising 20 to 80 wt % of a propylene polymer and 20 to 80 wt % of an ethylene-propylene copolymer, with the ethylene-propylene copolymer being dispersed in the propylene polymer as amorphous sections, wherein when the amorphous ethylene-propylene copolymer sections are converted into a circle with the same area, the circle has an average diameter (Dr) satisfying the following formula (2),  
           Dr (μm)≦0.005 ×A    (2)  
       wherein A indicates the amount (wt %) of the ethylene-propylene copolymer in the propylene block copolymer, satisfying the formula 20≦A(wt %)≦80.  
     
     
         8 . A propylene block copolymer comprising 20 to 80 wt % of a propylene polymer and 20 to 80 wt % of an ethylene-propylene copolymer, wherein the propylene polymer and ethylene-propylene copolymer are entangled with each other, forming amorphous propylene polymer sections and amorphous ethylene-propylene copolymer sections, wherein when the amorphous ethylene-propylene copolymer sections are converted into a circle with the same area, the circle has an average diameter (Dr) satisfying the following formula (2),  
           Dr (μm)≦0.005 ×A    (2)  
       wherein A indicates the amount (wt %) of the ethylene-propylene copolymer in the propylene block copolymer, satisfying the formula 20≦A(wt %)≦80.  
     
     
         9 . The propylene block copolymer according to  claim 8 , wherein when the propylene polymer sections is converted into a circle having the same area, the circle has an average diameter (Dpp) satisfying the following formula (3),  
         5.0 ≧Dpp (μm)≧ e   −0.002×A    (3)  
       wherein A is the same as defined above.  
     
     
         10 . The propylene block copolymer according to  claim 7 , comprising 30 to 70 wt % of propylene polymer and 30 to 70 wt % of ethylene-propylene copolymer.  
     
     
         11 . The propylene block copolymer according to  claim 7 , wherein the diameter of particles at 90% of the accumulative particle diameter distribution of the ethylene-propylene copolymer sections (Dr90) satisfy the following formula (4),  
           Dr 90(μm)≦0.01 ×A    (4)  
       wherein A is the same as defined above.  
     
     
         12 . A propylene block copolymer comprising 20 to 80 wt % of a propylene polymer and 20 to 80 wt % of an ethylene-propylene copolymer, wherein the propylene block copolymer is in the form of particles with an average particle diameter of 100 to 5,000 μm and the proportion of the ethylene-propylene copolymer on the surface of the particles is 0.3 vol % or less of the total amount of the ethylene-propylene copolymer particles.  
     
     
         13 . The propylene block copolymer according to  claim 7 , produced by the polymerization of propylene, followed by the copolymerization of ethylene and propylene.  
     
     
         14 . The propylene block copolymer according to  claim 7 , produced by first polymerizing propylene and then copolymerizing ethylene and propylene using a catalyst containing a solid catalyst component comprising magnesium, titanium, and a halogen atom, having an average particle diameter of 1 to 100 μm, a specific surface area of 100 to 500 m 2 /g, a pore volume of less than 0.2 ml/g, and a pore size distribution in which an cumulative pore volume with a pore diameter of 100 Å or less is more than 50%.  
     
     
         15 . The propylene block copolymer according to  claim 8 , wherein the diameter of particles at 90% of the accumulative particle diameter distribution of the ethylene-propylene copolymer sections (Dr90) satisfy the following formula (4),  
           Dr 90(μm)≦0.01 ×A    (4)  
       wherein A is the same as defined above.  
     
     
         16 . The propylene block copolymer according to  claim 8 , produced by the polymerization of propylene, followed by the copolymerization of ethylene and propylene.  
     
     
         17 . The propylene block copolymer according to  claim 13 , produced by the polymerization of propylene, followed by the copolymerization of ethylene and propylene.  
     
     
         18 . The propylene block copolymer according to  claim 8 , produced by first polymerizing propylene and then copolymerizing ethylene and propylene using a catalyst containing a solid catalyst component comprising magnesium, titanium, and a halogen atom, having an average particle diameter of 1 to 100 μm, a specific surface area of 100 to 500 m 2 /g, a pore volume of less than 0.2 ml/g, and a pore size distribution in which an cumulative pore volume with a pore diameter of 100 Å or less is more than 50%.  
     
     
         19 . The propylene block copolymer according to  claim 13 , produced by first polymerizing propylene and then copolymerizing ethylene and propylene using a catalyst containing a solid catalyst component comprising magnesium, titanium, and a halogen atom, having an average particle diameter of 1 to 100 μm, a specific surface area of 100 to 500 m 2 /g, a pore volume of less than 0.2 ml/g, and a pore size distribution in which an cumulative pore volume with a pore diameter of 100 Å or less is more than 50%.