Aminosilane compounds, catalyst components and catalysts for olefin polymerization, and process for production of olefin polymers with the same

Abstract

A catalyst for polymerization of olefins formed from (A) a solid catalyst component containing magnesium, titanium, halogen, and an electron donor compound, (B) an organoaluminum compound shown by the formula, R 6 p AlQ 3-p , and (C) an aminosilane compound shown by the formula, R 3 n Si(NR 4 R 5 ) 4-n ; and a process for producing a catalyst for polymerization of olefins in the presence of the catalyst are provided. A novel aminosilane compound, a catalyst component for polymerization of olefins having a high catalytic activity, capable of producing polymers with high stereoregularity in a high yield, and exhibiting an excellent hydrogen response, a catalyst, and a process for producing olefin polymers using the catalyst are provided.

1 . An aminosilane compound represented by the following formula (1),
   R 1   2 Si(NHR 2 ) 2   (1)   
     wherein R 1  represents a linear or branched alkyl group having 3 to 5 carbon atoms or a cyclopentyl group, two R 1 s being either the same or different, and R 2  represents an ethyl group. 
   
   
       2 . The aminosilane compound according to  claim 1 , which is bis(ethylamino)dicylcopentylsilane, or bis(ethylamino)diisopropylsilane. 
   
   
       3 . A catalyst component for polymerization of olefins represented by the following formula (2),
   R 3   n Si(NR 4 R 5 ) 4-n   (2)   
     wherein R 3  represents a linear or branched alkyl group having 1 to 20 carbon atoms, a cycloalkyl group or a derivative thereof, a vinyl group, an aryl group, or an aralkyl group, two or more R 3 s which may be present being either the same or different; R 4  represents a hydrogen atom, a linear or branched alkyl group having 1 to 20 carbon atoms, a cycloalkyl group or a derivative thereof, a vinyl group, an aryl group, or an aralkyl group, two or more R 4 s which may be present being either the same or different; R 5  represents a linear or branched alkyl group having 1 to 20 carbon atoms, a cycloalkyl group or a derivative thereof, a vinyl group, an aryl group, or an aralkyl group, two or more R 5 s which may be present being either the same or different; R 4  and R 5  may bond to form a ring; n is 0 or an integer from 1 to 3; and at least one of the NR 4 R 5  groups is a secondary amino group. 
   
   
       4 . The catalyst component for polymerization of olefins according to  claim 3 , wherein, in the formula (2), n is 2; R 3  is a linear or branched alkyl group having 1 to 12 carbon atoms or a cycloalkyl group, two or more R 3 s which may be present being either the same or different; R 4  is a hydrogen atom; and R 5  is a linear or branched alkyl group having 1 to 3 carbon atoms. 
   
   
       5 . The catalyst component for polymerization of olefins according to  claim 3 , wherein, in the formula (2), n is 1; R 3  is a linear or branched alkyl group having 1 to 12 carbon atoms or a cycloalkyl group, two or more R 3 s which may be present being either the same or different; R 4  is a hydrogen atom; and R 5  is a linear or branched alkyl group having 1 to 3 carbon atoms. 
   
   
       6 . The catalyst component for polymerization of olefins according to  claim 3 , wherein, in the formula (2), n is 0; two out of the four NR 4 R 5  groups are perhydroquinolino groups or perhydroisoquinolino groups, or one out of the four NR 4 R 5  groups is a secondary amino group wherein the R 4  is a hydrogen atom. 
   
   
       7 . A catalyst for polymerization of olefins formed from an aminosilane compound as an essential component, which is represented by the following formula (2),
   R 3   n Si(NR 4 R 5 ) 4-n   (2)   
     wherein R 3  represents a linear or branched alkyl group having 1 to 20 carbon atoms, a cycloalkyl group or a derivative thereof, a vinyl group, an aryl group, or an aralkyl group, two or more R 3 s which may be present being either the same or different; R 4  represents a hydrogen atom, a linear or branched alkyl group having 1 to 20 carbon atoms, a cycloalkyl group or a derivative thereof, a vinyl group, an aryl group, or an aralkyl group, two or more R 4 s which may be present being either the same or different; R 5  represents a linear or branched alkyl group having 1 to 20 carbon atoms, a cycloalkyl group or a derivative thereof, a vinyl group, an aryl group, or an aralkyl group, two or more R 5 s which may be present being either the same or different; R 4  and R 5  may bond to form a ring; n is 0 or an integer from 1 to 3; and at least one of the NR 4 R 5  groups is a secondary amino group. 
   
   
       8 . A catalyst for polymerization of olefins formed from (A) a solid catalyst component comprising magnesium, titanium, halogen, and an electron donor compound; (B) an organoaluminum compound represented by the following formula (3),
   R 6   p AlQ 3-p   (3)   
     wherein R 6  represents an alkyl group having 1 to 4 carbon atoms, Q represents a hydrogen atom or a halogen atom, and p represents a real number satisfying the formula 0≦p≦3 and (C) a catalyst component according to  claim 3 . 
   
   
       9 . The catalyst for polymerization of olefins according to  claim 8 , wherein the solid catalyst component (A) is prepared by contacting (a) a magnesium compound, (b) a tetravalent titanium halide compound, and (c) an electron donor compound. 
   
   
       10 . A process for producing an olefin polymer comprising polymerizing olefins in the presence of the catalyst for polymerization of olefins according to  claim 8 . 
   
   
       11 . The process for producing olefin polymer according to  claim 10 , wherein the olefins are propylene.