Morphology controlled olefin polymerization process

Abstract

A catalyst composition, method of formation and process of use in the polymerization of olefin monomers, said composition comprising a catalyst compound, an activator capable of converting said catalyst compound into an active catalyst for addition polymerization, optionally a carrier, further optionally a liquid diluent, and a hydroxycarboxylate metal salt additive.

1 . A catalyst composition comprising;
 a catalyst compound selected from the group consisting of Group 4 metal complexes containing one or more ligands that are π-bonded to the transition metal, and metal complexes of the formula   
       
         
           
           
               
               
           
         
         wherein 
         R 1  is selected from alkyl, cycloalkyl, heteroalkyl, cycloheteroalkyl, aryl, and inertly substituted derivatives thereof containing from 1 to 30 atoms not counting hydrogen, 
         T is a divalent bridging group of from 1 to 20 atoms not counting hydrogen, 
         R 2  is a C 6-20  heteroaryl group containing Lewis base functionality, 
         M is the Group 4 metal, 
         X e  is an anionic, neutral or dianionic ligand group, 
         x is a number from 0 to 5 indicating the number of such X e  groups, and 
         bonds, optional bonds and electron donative interactions are represented by lines, dotted lines and arrows respectively; and 
         an activator capable of converting said catalyst compound into an active catalyst for addition polymerization; 
         optionally a carrier; 
         optionally a liquid diluent, and 
         a hydroxycarboxylate metal salt additive corresponding to the formula: 
       
       
         
           
           
               
               
           
         
         wherein R e  and R f  independently each occurrence are hydrogen, halogen, or C 1-6  alkyl. 
       
     
     
         2 . A catalyst composition according to  claim 1  wherein the catalyst compound is a π-bonded Group 4 metallocene. 
     
     
         3 . An olefin polymerization process wherein one or more olefin monomers are polymerized in the presence of a catalyst composition characterized in that the catalyst composition corresponds to any one of  claims 1  or  2 . 
     
     
         4 . A polymeric composition comprising the polymerization reaction product of:
 one or more olefin monomers in the presence of a catalyst composition comprising;   a catalyst compound selected from the group consisting of Group 4 metal complexes containing one or more ligands that are π-bonded to the transition metal, and metal complexes of the formula,   
       
         
           
           
               
               
           
         
         wherein 
         R 1  is selected from alkyl, cycloalkyl, heteroalkyl, cycloheteroalkyl, aryl, and inertly substituted derivatives thereof containing from 1 to 30 atoms not counting hydrogen, 
         T is a divalent bridging group of from 1 to 20 atoms not counting hydrogen, 
         R 2  is a C 6-20  heteroaryl group containing Lewis base functionality, 
         M is the Group 4 metal, 
         X e  is an anionic, neutral or dianionic ligand group, 
         x is a number from 0 to 5 indicating the number of such X e  groups, and 
         bonds, optional bonds and electron donative interactions are represented by lines, dotted lines and arrows respectively; and 
         an activator capable of converting said catalyst compound into an active catalyst for addition polymerization, 
         optionally a carrier; 
         optionally a liquid diluent, and 
         a hydroxycarboxylate metal salt additive corresponding to the formula: 
       
       
         
           
           
               
               
           
         
         wherein R e  and R f  independently each occurrence are hydrogen, halogen, or C 1-6  alkyl. 
       
     
     
         5 . The polymeric composition according to  claim 4 , wherein the catalyst compound is a π-bonded Group 4 metallocene. 
     
     
         6 . A polymeric composition comprising the polymerization reaction product of:
 one or more olefin monomers in the presence of a catalyst composition comprising;   a catalyst compound selected from the group consisting of Group 4 metal complexes containing one or more ligands that are π-bonded to the transition metal, and metal complexes of the formula,   
       
         
           
           
               
               
           
         
         wherein 
         R 1  is selected from alkyl, cycloalkyl, heteroalkyl, cycloheteroalkyl, aryl, and inertly substituted derivatives thereof containing from 1 to 30 atoms not counting hydrogen, 
         T is a divalent bridging group of from 1 to 20 atoms not counting hydrogen, 
         R 2  is a C 6-20  heteroaryl group containing Lewis base functionality, 
         M is the Group 4 metal, 
         X e  is an anionic, neutral or dianionic ligand group, 
         x is a number from 0 to 5 indicating the number of such X e  groups, and 
         bonds, optional bonds and electron donative interactions are represented by lines, dotted lines and arrows respectively; and 
         an activator capable of converting said catalyst compound into an active catalyst for addition polymerization; 
         optionally a carrier; 
         optionally a liquid diluent, and 
         a hydroxycarboxylate metal salt additive corresponding to the formula: 
       
       
         
           
           
               
               
           
         
         wherein R e  and R f  independently each occurrence are hydrogen, halogen, or C 1-6  alkyl. 
       
     
     
         7 . The polymeric composition according to  claim 6  wherein the catalyst compound is a π-bonded Group 4 metallocene.