Catalyst composition and methods for its preparation and use in a polymerization process

Abstract

The present invention relates to a catalyst composition and a method for making the catalyst composition of a polymerization catalyst and a carboxylate metal salt. The invention is also directed to the use of the catalyst composition in the polymerization of olefin(s). In particular, the polymerization catalyst system is supported on a carrier. More particularly, the polymerization catalyst comprises a bulky ligand metallocene-type catalyst system.

1 . A catalyst composition comprising, in combination, a polymerization catalyst and a carboxylate metal salt. 
     
     
         2 . The catalyst composition of  claim 1  wherein the polymerization catalyst comprises a conventional-type transition metal catalyst compound. 
     
     
         3 . The catalyst composition of  claim 1  wherein the polymerization catalyst comprises a bulky ligand metallocene-type catalyst compound. 
     
     
         4 . The catalyst composition of a  claim 1  wherein the carboxylate metal salt is represented by the formula:
   MQ X (OOCR) y      
       where M is a metal from the Periodic Table of Elements; Q is halogen, or a hydroxy, alkyl, alkoxy, aryloxy, siloxy, silane or sulfonate group; R is a hydrocarbyl radical having from 2 to 100 carbon atoms; x is an integer from 0 to 3; y is an integer from 1 to 4; and the sum of x and y is equal to the valence of the metal M. 
     
     
         5 . The catalyst composition of  claim 4  wherein M is a metal from Groups 1 to 7 and Groups 13 to 16; Q is halogen or a hydroxy group; and R is a hydrocarbyl radical having from 4 to 24 carbon atoms. 
     
     
         6 . The catalyst composition of  claim 4  wherein y is either 1 or 2, M is a Group 2 or 13 metal, Q is a hydroxy group, and R is a hydrocarbyl radical having greater than 12 carbon atoms. 
     
     
         7 . The catalyst composition of  claim 1  wherein the carboxylate metal salt is selected from the group consisting of aluminum mono-stearate, aluminum di-stearate and aluminum tri-stearate or a combination thereof. 
     
     
         8 . The catalyst composition of  claim 1  wherein the polymerization catalyst comprises a carrier.