· United States Patent [II] Patent Number: Lai et al. 1451 Date of Patent: Dee. 21, 1993 Inventon: Shib-Yaw Lai, Sugar Laad; Jdra R Whm, Richwood; G~xw@? W. Knigi~t, Lake Jackson,

Case 1:05-cv-00737-JJF Document 158-7 Filed 09/03/2008 Page 1 of 47


United States Patent [II] Patent Number:

Lai et al. 1451 Date of Patent: Dee. 21, 1993

Inventon: Shib-Yaw Lai, Sugar Laad; Jdra R W h m , Richwood; G~xw@? W. Knigi~t, Lake Jackson, 1 1 of Tex.; JMKS C Stcray Midland, Mich.; P.k-Wing S. Cbrun, Lake Jackson, Tu.

Assignee: Tbe Dow aumicril Cornpiny, Midland, Mich.

A P ~ I . NO.: n6.130

Filed: Oct, 15,1991

~nt a.9 .................-. ~ I S F 210m. C O ~ F 21o/14 US. CI. ................................ 526/3485; 526/127;

526/160; 526/170. 526/348.2; 526/348.4; 526/348.6; M2/152

............... Field of S d 526/160, 170, 127, 348, 526/348.2, 348.4. 348.5, 348.6

i561 Ref- Cited US. PATENT DOCUMENTS

............................. h h r k d 260/88.2 Eluon.

....................... Moriu a d. 525/240 ...................... Miwa a d. 526/348.2

............................ Od. a d. 5?5/283 ......................... E w ~ a d. 502/113

................ Tominui CI al. 526/348.2 ......................... Ewen et .I. 526/1 14 ......................... Ewcn er d. 526/1 19

................. Monerol ct d. 52W348.4 ................................ Clnich 526/127 ................................ Clnich M2/1 17

...................... Stevens a d. 526/170 ................. A l b i i t i a d. 526/348.6

FOREIGN PATENT DOCUMENTS

041 68 l5A2 3/1991 Eumpun Pat. Oft . 9rX)hi4 4/1990 World lnt. Prop. 0.

OTHER PUBLICATIONS

Journal of Polymer Science. Part A, vol. 1, @p. 2869-2880 (1993)), "Long-Chain Branching Frequency in Polycthylcne" by J . E. Guillet. Polymer Preprints, Amer. Chem. Society, vol. 12, No. 1, pp. 277-281, (Mar. 1971). "Evidence of Long-Chain Branching in High Density Polyethylene" by E. E. Drott and R. A. Mendelson. Journal of the American Chemical Sociery, 98:7. pp.

1729-1742, (Mar. 31, 1976). "Structure and Chemistry of Bicyclopentodieny1)-MLn Complues" by Joseph W. h u h a and R d d Hoffrmn. h l y m e r Engineering and Science. vol. 16, No. 12, pp. 81 1-816. @tc. 1976). "Influence of Long-ChPin Branching on tbe Vircoelutic Propertics of Low-Den- nty Polyethylemr" by L. Wild. R. Rutguuth, and D. Knobcloch. Angew. CAHm Inr Ed EngL, pp. 630632, (1976). vol. 15, No. 10, "Halogen-Free Soluble Ziegla Catalysts for the Polymerization of Ethylene. Control of Molecu- lar Weight by Choice of Temperature" by Arne An- drexn d d. Advlrnccs in Orgclnometallic chemistry. pp. 99-148, vol. 18, (1980). 'Ziegla-Natt. Catalysis" by Hansjorg Sinn and Walter Kaminsky. Angew. Chem In& Ed. En& pp. 390-393, vol. 19, No. 5, (1980). "'Living Polymers' on Polymerization with Extremely Productive Ziegler CltalysiS" by Hansjorg S i , Walter Kaminsky, Hans-Jurgen Vollmer, and Rudiger Woldt. Polymer Bulletin, 9. pp. 464-469, (1983). "Halogen Free Soluble Ziegler Catalysts with Methyldumom as Cat- dyst" by Jens Henvig and Wdter Kaminsky.

(List continued on next page.)

Primary Exuminer-Joseph L. Schofer Assistant Examiner-David Wu Attorney. Agent, or Finn-Stephen P. Krupp; L. Wayne White

Substantially linear olefin polymm having a melt flow ratio, It&2, h5.63, a molecular weight distrilution, MJMn, defined by the equation: MV/MnI(I~o/Iz- )-4.63. and a critical shear stress at onset of groa melt fracture of greater than about 4 x 106 dyne /cd and their method of manufacture are disclosed. The substantially linear olefin polymers preferably have at least about 0.01 long chain brancha/1000 carbons and a molecular weight distribution from about 1.5 to about 2.5. q e new polymers have jPlPElPved -b'ility over conventional olefin polymen and are useful in producing fabricated articla such as fibers, f h s , and m o w parts.

38 Cinims, 5 Drrwing Sheets

EXHIBIT PAGE 000236


Page 2

OTHER PUBLICATIONS MakromoL Chem, Rapid Commun, 4, pp. 417-421, (1983). "Bir(cyclopentndieny1)lirkm-Vdmgungen und AluminounilP Ziegler-Katalysatoren fur die Polymerktion und Copolyrncrisation von Olefinen" by W d t a K.minsky et al. A m Rwedings, pp. 306-309, (1983), "Analysis of Long Chain Branching in High Dcnisty Polyethylene" by J. K. Hughes. MakmmoL Chem, Rapid Commun, (5). pp. 225-228, (1984). "Innueboc of Hydrogen on the Polymeriution of Ethylene with the Homogeneous Ziegla System Bis(cyc1opentadienyl)Zirco~umdi- choloridJAluminoxiane'* by Walter -sky et al. Journal of Po,lymer,&ience, Bolymer Chemistry Lidition. pp. 21 17-2133. (1985). vol. 23. "Homogemour Zie- gla-Natta Catalysis. 11. Ethylene Polymeriution by TVB T d o n Metal Complex#/Mcthyl Aluminox- ane Catalyst Systems" by E. Giannetti and R. Muzoc- chi. Journal of Applied Polymer Science, pp. 3751-3765, (1985). vol. 30, Wn the Effects of Very Low Levels of Long Chain Branching on Rheologicll Behavior in Polyethylene" by B. H. Bent&. Journal of PoIymer Science Polymer Cheminty Edition, pp. 2151-2164, (1985). vol. 23, "Ethylene Propylene Dime Terpolymus Produced with 8 H o m o g e ~ o w arid Highly Active Zirconium Catalyst" by Walter Klminalry et al. The Society of Rheology. pp. 337-357, (1986). vol. 30, "Wall Slip in Viscous Fluids and Influence of Materials of Construction" by A. V. Ramamurthy. Moknwnd Chem, MacrvmoL Symp, 4, pp. 103-118. (1986), "Elastomers by Atactic Linkage of a-01efins Using Soluble Ziegler Catalysts" by W. Kaminsky and M. Schlobohm. J o u m l of Rheolog~, 31(8), pp. 815-834, (1987). "Wall Slip and Extrudate Distortion in Linear Low-Density Polyethylene" by D. Kalika and M. Denn. MokrvmoL Chem. 190, pp. 515-526, (1989). "Copoly- merization of Cycloalkenes with Ethylene In Presence of Chiral Zirconocene Catalysts" by W. Kaminsky and R. Spiehl. J m m l of Mocromoleculor Science: Reviews in Macrvmo- lmrlor Chemisrry and Physics, C29(2&3), pp. 201-303, (1989). "A Review of High Resolution Liquid l%h-bon Nuclear Magnetic Resonance Characterizations of Eth ylene-Based Polymers". Journal of Non-Newtonian Fluid Mechanics 36, pp.

255-263, (1990). "'Additional Otrservations on The Sur- f ~ c e Melt Fracture Behavior of Lin&u L ~ w - D e o ~ i t ~ Polyethylene" by R. Moynihan, D. Baird, and R. Ruouuthan. M U M Cham Commun, pp. 89-94, (1990). 'TQ- polymers of Ethylene, Propcne and 1.5-Hurdieae Syn- thcrizdl with Zicmn~ccne/Mdhy~uminoMne" 6y W. Kuniruky and H. Dmgcrnuller. Journal of Rheology, 35(4), 3, (May, 1991). pp. 497-552, Wall Slip of Molten High Density Polyethylene. I. Sliding Plate Rhocmcter Studies" by S. G. Hat- zikirkkos lad J. M. Duly. Pnxudings of the 1991 IEEE P o w Engineering Societyt pp. 1E4-190, (Scp. 22-27,1991). "New Spectlty Linear Poiywrr (SLP) For P o w a Cables" by Moniu Hen- dewerk and Lawrence S p d e l . SocLry of Pfaric Engineen Arwwdingr. Polyolefins VII In-tionrl confer en^,. Feb. 24-27, 1991, "Struc- ture/Property Relationships in Exxpol m Polymers*', (pp. 45-66), by C. Speed, B. Trudell, A. Mehta, and F. Stehling. 1991 S ' l t y Au'plefins Confemncc Prclceedings T h e Msrketing Challenge Created by Single Site Catalysts in Polyolefms", Scp. 24, 1991, (pp. 41-45). by Michael P. Jeffries. High Polymen; voi. XX. "Crystalline Olefin Poiyrnm", P.ri I, pp. 495-501. 1991 fkdymers h m i ~ r i o n s & Cwtings Conference, TAPPI Proceedings, presented in Feb. 1991, pp. 289-296, "A New Family of Linuu Ethylene Polymm with Enhrmocd Scaling Performance" by D. Van der Sanden md R. W. Halle. Socirty of PIactic Engineers 1991 Specialty Polyolefins Conference ADCtwdings, pp. 41-55. ''The Marketing CWIenge Created by Single Site Catalysts in Polyole- fins" by M. Jeffuies, (Sep. 24, 1991). Adwnca In P o l p l e ~ by R B. Seymour and T. Cheng, (1987), pp. 373-380, "Crystallinity and Mor- phology of Ethylene a-Olefm Copolymm* by P. Schouterden, G. Groeninckx, and H. Reynaers. Adwnces In Polyolefinr. by R. B. Seymour and T. Cheng, (1987). "New Catalysis and Process for Ethyl- m e Polymerization", pp. 337-354, by F. Karol, 8. Wag- ner, I. M e , G. Goeke, and A. Noshay. Adwnca In Polplefins, by R. B. Seymour and T. Cheng, (1987), "Polymerization of Olefins with a Ho- mogeneous ZirconiWAlumorane Catalysts", pp. 361-371 by W. Kaminsky and H. Hahnsen. Derwent 90-23901 7/3 1.

EXHIBIT PAGE 000237


U.S. Patent Sheet 1 of 5

FIG. I

EXHIBIT PAGE 000238


FIG. 2

MWD MWD VS. I IO/I2 PLOT

4 CONVENTIONAL ZIEGLER POLYMERS

-8- SUBSTANTIALLY LINEAR POLYMERS OF THE INVENTION

EXHIBIT PAGE 000239


U.S.. Patent Sheet 3 of 5

Apparent Shear Rote ( I / sec. )

EXHIBIT PAGE 000240


FIG. 4 MELT FRACTURE STUDY

* COMPARATlVE EXAMPLE 9

-0- EXAMPLE 6

5Et05 IE+06 2E+06 3E+06 5E+06

APPA. SHEAR STRESS, DYNE/ CM2

EXHIBIT PAGE 000241


FIG. 5 HEAT SEAL PERFORMANCE COMPARISON

4 COMPARATIVE EXAMPLE I I

-+EXAMPLE 10 - - * - -COMPARATIVE

EXAMPLE 13 --@--EXAMPLE 12

180 190 195 205 215 225 235 HEAT SEAL TEMPERATURE, O F

EXHIBIT PAGE 000242


5,272,236 1 2

the same melt index. In a recent publication, Emon E M C SUBSL4NXLULY LINEAR O m Chemical Company has also taught that NMWD poly-

POLYMERS men made using a single site catslyst create the poten- tinl for melt ffsctwc ("New Speci.lty Linear Pdymers

FIELD O F THE INVENTION (SLP) For Power Cabks." by Monica Hcadewak and This invention relates to elastic substantially linear Lawrence Spcnad4 presented at IEEE m&g in

oldin polymers having improved promsabiity, c.g., Dallas, Tex., September, 1991). low suscqtiility to melt fracture, even under high Laown nurow moleculu weight W b u - s h a r stress extrusion conditions. Methods of manufkc- tion lint.r polymar djavantageously p- low Curing thac polymers u e also disclosed. shear d t i v i t y or low I l d 2 value. which limits the

BACKGROUND O F THE INVENTION extrudability of such polymers. Additionally, sucb p l y - men powrsed low melt cbtkity, causing probkms in

M d w h & t distrib~tion (MWD), or pol~dis- melt fab-hn film forming p- or blow pedty, is a wen known variable in polymers. The mo-

wdOht rn the 15 molding p- (c.g.. rurtlining 8 bubble in the

w+t a v m g e molec* weight (M,) n m - b l o w film Pro- 0' % the blow molding Process b a avmge mo1- weight (MJ (ip., MJMJ - be etc.)- F i d l ~ , such r h also a p e r i a & melt &e

musured diractly, cg., by gel permeation chromatog- p m m at dative'y low rates - .. . akphy techniquq'or more routinely. by measuring Ilo pdg l l l u c c e ~ ~ ~ ~ y - /I2 mtb, as descri'bed in ASTM D-1238. For linear polyolefins, arptciafly linear polyethylene. it is well

SUMMARY O F THE INVENTION

known that as M A o increws, I j d 2 also increases. We have now discovered a new frynilv of substan- John Dealy in "Melt Rhcology and Its Role in Plns- t i d y linear oldin mlymers which have mrmy am-

tics Pnxruingn (Van Nostrand Reinhold, 1990) page proved properties and a method of their rmnui.cturc. 597 discloses that ASTM D-1238 is employed with 25 The substnntially linear olefin polymers have (1) high diif-t l d t in order to obtain an estirrmte of the shear melt elasticity and, (2) ~fa t ive ly -ow m&& rate dependence of melt viscosity, which is sensitive to weight &"butions with erccpt id ly good process- weight average mokcular weight (M,) and number ibility while maintaining good pro6es average molecular weight w,). and (3) they do not melt fracture o v a 8 broad ~ g e of

Berstcd in Joumol of Applied Polymer Science Vol. 19, 30 ,hear st . . . These p r o p d e s u e W e d page 2167-2177 (1975) theorized the relationship be- - e h o u t w h ~ ~ f i c prOCeSring .ddidvCL nC

twan molecular weight distribution and steady shear new - be sUCCCLSfuily preprred in a melt viscosity for linear polymer systems. He dso h w c d tu t t)?e Ma MWD material a UOUS polymeriution praxis using mmC higher shear rate or shear stress dependency. 35 try catalyst technology, especially when polymerized

Ramunurthy in Journd of RhmIogy, 30(2). 337-357 soluti0n process ttchnology. (1986), md Moynih.n, Baird And *than in JOW- The improved properties of the polymenr include no1 of Non-Nrwtonion Fluid Mechonia, 36. 255-263 improved melt e l s t ic i t~ and P-%I~~Y in t head (1990). both disclose that the onset of sharkskin (LC., forming Pr- such oJ a t k o % blowing film, in- melt fracture) for linear low density polyethylene 40 jection moldin& and blowmolding. (LLDPE) occurs at an apparent shear stress of Substantially linear polymers made according to the 1-1.4X 106dynehn2, which was observed to be coinci- present invention have the following novel properties: dent with the change in slope of the flow curve. Rarna- a) a melt flow ratio. Ii&, Z5.63, murthy discloses that the onset of surface melt b) a molecular weight distribution, M a , , defined fracture or of gross melt fracture for high pressure low 45 by the quation: density polyethylene (HP-LDPE) occurs at an apparent shear stress of about 0.13 MPa (1.3X 106 dyna/cm2). MJMmW~d1z)-4.63. a d

K.lika and Dcnn in Journol of Rheology. 31, 815-834 (1987) confirmed the surface defects or sharkskin phe- c) 8 critical shear stress at onset of gross melt fracture nomena for LLDPE, but the results of their work deter- 50 of grenter than about 4 x 106 dyne/cm2. mined a critical shear stress of 2.3 X 106 dync/cm2, significantly higher than that found by Ramamurthy and BRIEF JESCRW'IION O F THE DRAWINGS Moynihan et al. FIG. 1 is a schematic representation of a polymniza-

Inteflllltional Patent Application (Publication No. tion process suitable for making polymers of the WO 90/03414) published Apr. 5, 1990, discloses linear 55 present

i n t e r ~ l ~ e r with narrow n G . 2 plots data describing the relationship between weight distribution and narrow short chain branching distributions (SCBDS). The melt processibility of the 11dI2 and M a n for polymer Examples 5 and 6 of the

interpolymer blends is controlled by blending different inve"tion' and from comparative examples 7-9. molecular weight interpolymers having different nar- 60 plots the versus shear rate for

row molecular weight distributions and different and comparative example 79 described

SCBDs. herein. E~~~~ chemical company, in the preprints of poly- FIG. 4 plots the shear stress versus shear rate for

olefins VII International Conference, page 45-66, Feb. Example 6 and comparative example 9, d a d x d 24-27 1991, disclose that the narrow molecular weight 65 herein. distribution (NMWD) rains produced by their EXX- FIG. 5 plots the heat seal strength versus heat seal POL TM technology have higher melt viscosity and temperature of film made from Examples 10 and 12, and lower melt strength than conventional Ziegler resins at comparative examples 1 1 and 13, described herein.

EXHIBIT PAGE 000243


DETAILED DESCRIPTION O F T H E "Melt tension" is measured by a specidly designed

INVENTION pulley transducer in conjunction with the melt indexer. Melt tension is the load that the extntdate o r filament

metfured in accordance with ASTM D-1238 (190/2.16); "110" k musured in accordance with ASM D - m a (im/io).

The melt tension of these new polymers is also surprisingly good, e.g., as high as about 2 grams or more, esptci.fly for polymers which have a very narrow molecular weight distribution (k., M J M h from h u t 1.5 to about 25).

The substantially linear polymers of the present invention can be homopolymers of C 2 - h o l e f w , such as ethylene, propylene. 4-methyl-1-pentme, etc., or they can be interpolymers of ethylene with at least one C3-Cm a-olefin and/or C2-Cm acctylenically unsaturated monomer and/or G-Clg dioldins. Tbe substantially linear polymers of the present invention can also be interpolymers of ethylene with at least one of the above C3-Cm a-olefm d i o l d i and/or acctylenically unsaturated monomers in combination with other unm- urated monomers.

Monomm usefully polymerized according to the present invention include, for example, ethylenically unsaturated monomers, acetylenic compounds, conjugated or nonconjugated dienes, polyenes, carbon mon- oxide, ctc. Preferred monomers include the C2-lo a b l e - fw especially ethylene, propylene, isobutylene, 1- buteae. 1-hexene, 4-methyl-1-pcntene, and I-octene. Other preferred monomers include styrene, halo- or &yl substituted styrenes, tetrafluoroethylene, vinylbenzocyclobutane, 1.4-hexadiene, and naphthenics (e.g., cyclo-pcntene, cyclo-hexene and cyclcmctenc).

The term "substantially linear" polymers means that the polymer backbone is either unsubstituted or substituted with up to 3 long chain branches/1000 carbons. Preferred polymers are substituted with about 0.01 long chain branchesA000 carbons to about 3 long chain branches/1000 carbons, more preferably from about 0.01 long chain branched1000 carbons to about 1 long chain branches/1000 carbons, and especially from about 0.3 long chain branches/1000 carbons to about 1 long chain branchcs/l000 carbons.

Long chain branching is defmed herein as a chain length of at least about 6 carbons, above which the length cannot be distinguished using l ) C nuclear magnetic resonance spectroscopy. The long chain branch can be as long as about the same length as the length of the polymer back-bone.

Long chain branching a determined by using I3C nuclear magnetic resonance (NMR) spectroscopy and is quantified usrng the method of Randall (Rev. Macromol Chem Phyr, C29 (2&3), p 285-297), the dtsclosure of which is incorporated herein by reference

Co. (1982) on page 97, both publi t ions of which incorporated by r e f e r a ~ x herein in thcir entirety. All GER experiments are performed at a tanperatwe of

20 190. C, at nitrogen pressures between 5250 t o p psig wing a 0.02% inch d i e t e r , 20.1 yD die An apparent shear stress vs. a ~ ~ a r e n t shear rate lot is med to identify the melt frrrdthe p b e n o r m p ~ According to Rama- murthy in Journal of RheoJogy, 30(2), 337-357, 1986, above a certain critical flow rate, the observed extrudate irregularities may be broadly clurifted into two main types: surface melt fracture and gross melt fracture.

Surface melt fracture occurs under apparently steady flow conditions and ranges in detail from loss of specu- lar gloss to the more revere form of "sharkskin". Gross melt fracture ~ % u r s at unsteady flow conditions and ranges in detail from regular (alternating rough and smooth, helical, ctc.) to random distordonc For arm- m a d acceptability, (e.g., in blown film products), surface defects should be minimit, if not absent. The critical shear rate at onset of nuface melt hrcrute (OSMF) and onxt of gross melt fracture (OGMF) will be used herein based on the ciungcs of surface roughness and configurations of tbc urt;ud.ta extruded by 3 GER. Preferablv. the critical shear stress at the OGMF

the critical*&+ s t r w at the OSMF for the substantidly linear ethylene polymers described herein is greater than about 4 X 106 dyne/cm2 and greater than about 2.8 X 106 dync /cd , respectively.

For the polymers described herein, the PI is the apparent viscosity (in Kpoix) of a material measured by GER at a temperature of 190' C., at nitrogen pressure of 2500 psig using a 0.0296 inch diameter, 20:l I JD die, o r corresponding apparent shew stress of 2.15X I d dyne/cm2. The novel polymers described herein prcfcra- bly have a PI in the range of about 0.01 kpoise to about 50 kpoise, preferably about 15 kpoisc o r less.

The SCBDI (Shon Chain Branch Distribution Index) or CDBl (Composition Distribution Branch Index) is defined as the weight percent of the polymer molaules having a comonomer content within 50 percent of the median total molar comonomcr content. The CDBI of an polymer is readily calculated from data obtained from techniques known in the art, such as, for example, temperature rising elution fractionation (abbreviated herein as "TREF') as described, for example, in Wild et al, Journal oJPolymer Science. Poly. Phyr Ed.. Vol. 20, p. 441 (1982), or in U S . Pat. No 4,798,081, both d ~ x l o - s u m of which are incorporated herean by reference. The SCBDI or CDBI for the new polymers of the present mventron IS preferably greater than about 30 percent, espec~ally greater than about 50 percent.

EXHIBIT PAGE 000244


EXHIBIT PAGE 000245


Cp* is a cyclopentadienyl or substituted cyclopentadienyl group bound in an $bonding mode to M;

Z is a moiety comprising boron, o r a member of group 14 of the Periodic Table of the Elements, and optionally sulfur or oxygen, raid moiety h v i n g up to 20 non-hydrogen atoms, and optionally Cp* and Z together form a fused ring system;

X indepcadently u c h occurrence is an anionic ligand group or neutral Lewis base ligand group having up to 10 30 non-hydrogen atwns;

nisO,1 .2 .3 .o r4andis2 lm than thevalenceofM; and

Y is an anionic o r nonanio~c ligand group bonded to Z and 51 comprising nitrogen, phorpho& oxygen or 1s sulfur and having up to 20 non-hydrogen atoms, option- d l y Y and Z tog& form a fused ring system.

More preferably still, such complexes comspond to the formula: ,

20

wherein R' each occurrence is independently selected from the group consisting of hydrogen, alkyl, aryl, silyl,

M

germyl. cyano, halo and combinations thereof having up to 20 non-hydrogen atoms;

X each occurrence independently is selected from the group consisting of hydride, halo, alkyl, aryl, silyl, ger- 35 myl, uyloxy, alkoxy, amide, siloxy, neutral Lewis base ligands and combinations thereof having up to 20 non- hydrogen atoms;

Y is -a. -S-, -NRm-. -PRm-, or a neutral two electron donor ligand selected from the group 40 consisting of OR*, SR*, NRm2, or PRm2;

M is a previously defined; and -, Z is SiRm2, CRm2. SiRm2SiR*2, CRm2CR*2,

CRm==CR*. CRm2SiR*2, GeRm2, BR*, BRm2; wherein: 45 R* each occurrence is independently selected from

the group consisting of hydrogen, alkyl, aryl, silyl, halogenated alkyl, halogmated aryl groups having up to 20

.non-hydrogen atoms, and mixtures thereof, or two or more R* groups from Y, Z, o r both Y and Z form a U)

fused ring system; and n is 1 or 2. It should be noted that whereas formula I and the

following formulas indicate a cyclic structure for the catalysts, when Y is a neutral two electron donor li- 55 gand, the bond between M and Y is more accurately referred to as a coordinatecovalent bond. Also, it should be noted that the complex may exist as a dimcr or higher oligomer.

Further preferably, at least one of R', Z, or R* is an 60

electron donating moiety. Thus, highly preferably Y is a nitrogen or phosphorus containing group corrapond- ing to the formula -N(RW-- or -P(Rr')-, wherein R" is Cl.loalkyl or aryl, i.e. an amido or phosphido group. 65

Most highly preferred complex compounds are amidosilane- or amidoalkanediyl- compounds corresponding to the formula:

wherein: M is titanium, zirconium or hafnium. bound in an q 5

bonding mode to the cyclopcntlldienyl group; R' u c h o c c m is independently delectcd from

the group consisting of hydrogen, silyl, dkyl, u y l and combinations thereof having up to 10 carbon or &con atoms;

E is silicon or carbon, X independently each occurrence is hydride, halo,

alkyl aryl, aryloxy or alkoxy of up to 10 carbons; m i s l o r 2 ; m d n is 1 or 2. Examples of the above most highly prefemd metal

coordination compounds include compounds wherein the R' on the m i d o group is methyl, ethyl, propyl. butyl, pentyl, hexyl, (including isomers), norbornyl. benryl, phenyl, etc.; the cyclopcntlldienyl group is cyclopentadienyl, indenyl, tetrahydroindenyl, fluorenyl, octahydrofluorenyl, etc.; R' on the foregoing cyclopcntadienyl groups each occurrence is hydrogen, methyl, ethyl, propyl, butyl, pentyl, hexyl. (including isomers), norbornyl, bemyl, phenyl, etc.; and X is chloro, bromo, iodo, methyl, ethyl, propyl, butyl, pentyl, hexyl, (i- cluding isomers), norbornyl. bcnzyl, phenyl, etc. Spe- cific compounds include: (ten-butylamidoXtctrameth- yl-q5cyc1opentadieny1)- 1.2-eth~edi~izirconium dichloride, (tut-butyIamidoXtetra-methyl-qkyclopen- tadicny1)- 1 .2tthanediyltitnnium dichloridc, (methylamido)(tctramethyl-q5cyclopcntadienyl1.2- ethanediylzirconium dichloride, (methylamido) (tctramethyl-q5cycl~ritlldienyl>1.2ctb.nediyltitanium dichloride. (ethyfamido)(tctnunethyl-qkyclopen- tadienv1)-methvlenetitanium dichloro. (tert- buty&do)didenzyl(tetramethyl-q5cyclo~~i&yl) silanezirconium dibenzyl, (benzylamido)dimethyl(tet- . - rmethyl-rl~cyclopenta&enyl)s'daneti& dichloride, (phenylphosphido)dimethyl(tetramethyl-75- cyclopentadienyl)silanezirconium dibenzyl, (tcrt- butylamido)dimethyl(tetrarnethyl-q5cyclopen- tadienyl)silanetitanium dimethyl, and the like.

The complexes may be prepared by contacting a derivative of a metal, M, and a group I metal derivative or Grignard derivative of the cyclopentadienyl compound in a solvent and separating the salt byproduct. Suitable solvents for use in preparing the metal complexes are aliphatic or aromatic liquids such as cyclo- hexanc, mcthylcyclohexane, pcntane, hexane, heptane. tetrahydrofuran, diethyl ether, benzene, toluene, xy- lene, ethylbenzene, etc., or mixtures thenof.

In a preferred embodiment, the metal compound is MX,+ 1, i.e. M is in a lower oxidation state than in the corresponding compound, MXn+2 and the oxidation state of M in the desired final complex. A noninterfering oxidizing agent may thereafter be employed to raise the oxidation state of the metal. The oxidation is accomplished merely by contacting the reactants utilizing solvents and reaction conditions used in the preparation of the complex itself. By the term "nonintcrfering oxidizing agent" is meant a compound having an oxidation

EXHIBIT PAGE 000246


to the formula:

wherein: M is a metal of group 3-10, or the Lanthanide ser ia 35

of the Periodic Table of the Elements; Cp* is a cyclopentadienyl or substituted cyclopenta-

dienyl group bound in an l5 bonding mode to M; Z is a moiety comprising boron, or a member of

group 14 of the Periodic Table of the Elements and * o p t i d l y sulfur or oxygen, said moiety having up to 20 non-hydrogen atoms, and optionally Cp* and Z together form a fused ring system;

X independently each occurrence is an anionic ligand 45 p u p or neutral Lewis base ligand group having up to 30 non-hydrogen atoms;

n is 0, I ,2.3, or 4 and is 2 less than the valence of M; and

A- is a noncoordinating, compatible anion. 50 One method of making the ionic catalyst species

which can be utilized to make the polymers of the p r a - ent invention involve combining:

a) at least one fmt component which is a mono(cy- clopmtadimyl) derivative of a metal of Group 3-10 or 55 the h t h a n i d e Series of the Periodic Table of the Ele- ments containing at least one substituent which will combine with the cation of a second component (described hereinafter) which first component is capable of forming a cation formally having a coordination num- 60 ber that is one l a s than its valence, and

b) at least one second component which is a salt of a Bronsted acid and a noncoordinating, compatible anion.

More particularly the noncoordinating, compatible anion of the Bronsted acid salt may comprise a single 65 coordination complex comprising a charge-beanng metal or metalloid core, which anion is both bulky and non-nucleoph'ilic. The recitation "metalloid", as used

of the substituted cyclopentadienyl group such as a cyclopentadienyl-alkuiediyl, cyclopentadienyl-diane arnide, or cyclopentadienyl-phosphide compound. The reaction is wnducted in an inert liquid such as tetrahydrofuran, Cslo alkanes, toluene. ctc. utilizing conventional synthetic procedures. Additionally, the first components may be prepared by reaction of a group I1 derivative of the cyclopmtadienyl compound in a solvent and separating the salt by-product. Magne- sium derivatives of the cyclopentadienyl compounds are preferred. The reaction may be conducted in an inert solvent such as cyclohexane, pentane, tetrahydrofuran, diethyl ether, benzene, toluene, o r mixtuns of the like. The resulting metal cyclopantadienyl balide com- plexa may be alkylated using a variety of techniques. Generally, the metal cyclopentadienyl alkyl o r aryl wmplexa may be prepared by alkylation of the metal cyclopentadienyl halide complexes with dkyl or aryl derivatives of group I or group I1 metals. Preferred alkylating agents are alkyl lithium and Grignard derivatives using conventional synthetic technique. The reaction may be conducted in an inert wlvent such as cyclo- hexanc, pentane, tetrahydrofuran, diethyt ether, benzene, toluene, o r mixtures of the like. A preferred solvent is a mixture of toluene and tetrahydrofuran.

Compounds useful as a second wmponent in the preparation of the ionic catalysts w f u l in this invention will comprise a cation, which is a Bronsted acid capable of donating a proton, and a compatible noncoordinating anion. Preferred anions are those containing a single coordination complex comprising a charge-bearing metal or metalloid core which anion is relatively large (bulky), capable of stabilizing the active catalyst species (the Group 3- 10 or Lanthanide Series cation) which is formed when the two components are wmbiied and sufficiently labile to be displaced by olefinic, diolefinic and acetylenically unsaturated substrates or other neutral Lewis bases such as ethers, nitrilcs and the like. Suitable metals, then, include, but are Rot limited to. aluminum, gold, platinum and the like. Suitable metal- loids include. but are not limited to, boron, phosphorus, silicon and the like. Compounds containirtg anions

EXHIBIT PAGE 000247


5,272,236 11

which comprise coordination complexes containing a single metal o r metalloid atom arc, of coune, well known and many, particularly such compounds containing 8 single boron atom in the anion portion, u e

27' CpLM+ XA*-

aMil.bk comwrcially. In £i&t of this, salts contduning 5 \ m.-I

miom comgriaing a amdimt ion complex containing a single boron atom an prcfmed. wherein:

H k h f ~ pre fed ly* the second component w f u l in M iL a met.l of group %lo, o r the h t h m i d e -6 the ~ r e p ~ r , * of the of this invention a Y be of the p * d j able of the Elements; rtprrroted by the following general formula: lo Cp* is a cyclopcatadienyl o r substituted cyclopenta-

dienyl group bouod in an $ bonding mode to M; (L-H)+W Z is a moiety comprising boron, or a member of

wharin: group 14 of the Periodic Table of the Efema14 and

LisaMnrtrrlLewi0b.K; o p t i o d l y sulfur or oxygen, said moiety having up to 20 '' non-hydrogen atoms, and optionally Cp* and Z to-

(L-H)+ is a Bronaed acid; and g a b e r form a fwtd ring system; [A]- is 8 compatibk, noncoordinating mion. X independently each occurrence is an anionic ligand More H e r a b l y [A]- corresponds to the formula: p u p or w u t d Lewis bPse l i e d group having up to

WQ.1- 30 non-hydrogen atoms;

n is 0, I, 2.3, o r 4 and is 2 less than the valence of M; and

wherein: M' is a metal or metalloid selected from Groups 5-1 5 J U * - is -XB(C&)3.

of the Periodic Table of the Elcmmts; and Q independently each occurrence is seiectod from the 25 This cl.sr of cationic complexes may be

Group consisting of hydridc, d i a l k ~ h i d o , halide, dk- prepirrd by contacting a metal compound conspond- oxide, ~ryloxide, hydrourbyl. .od substituted-hydro- ing to the fornub: carbyl radicals of up to 20 cubons with the proviso that in not more thm one occurrence is Q halide and

q is one more than the valence of M'. M Second components comprising boron which are

77 CpL-M

particularly w f u l in the preparation of catalysts of this \ invention may be represented by the following general 00.

formula: j5 wherein:

&-HI+ Ieq4l Cp, M, and n are as previously defined, with tris(pentlnuoropheny1)borne cocatalyst under

wherein: conditions to cause abstraction of X and formation of L is 8 neutral Lewis bast; the d o n -XB(C&5)3. &-HI+ is a Bronsted acid; Preferably X in the foregoing ionic catalyst is CI-CIO B is boron in a valence state of 3; and hydroarbyl, most preferably methyl. Q is as previously defined. The p r d i n g formula is referred to .s the limiting, ~ l l ~ ~ ~ ~ t i ~ ~ but not limiting, exampla of boron charge separated structure. ow ever. it is to be under-

may be - = a -nd in stood that, particularly in solid form, the catalyst may

the preparation of the improved catalysu of this inven- 45 be vrated. That is* the X v0Up may tion a ~ i a f k ~ l ~ ~ b ~ t i t ~ t e d ammonium such as a ~artiaf covalent bond to the metal atom, M. triethylammonium tetraphenylborate, tripropylam- Thw the catdysts may be depicted as monium tetraphenylborate, tri(n-buty1)ammonium tet- the raphenylborate, trimethylammonium tctra(pto1ylbo- rate), tributylammonium tctrakis-pcntafluorophmylbo- 50 Z-Y rate, tripropylnmmonium tctr~~2,4-dimethylphmYl- / /

CpLM X.. A borate. tributvlammonium tetrakis-3.5dimethvlohenvl- \

borate, tricth&mmonium tetrakis<3,5di-trifi;orome- 09.- I

thy1phmyl)borate and the like. Also suitable are N,N- dialkyl anilinium salts such as N,Ndimethylanilinium 55 The Catalysts arc preferably prepared by contacting tctraphenylborate, N,Ndiethylanilinium tctraphenyl- the derivative of a Group 4 or Lanthanide metal with borate, N,N-2,4,6-pentamethylanilinium tetraphenylbo- the tris@tntafluorophenyl)borpnc in ur inert diiuent rate and the like; dialkyl ammonium salts such as di-(i- such organic liquid. propy1)ammonium tetrakispentafluorophenylborate, Tr%wntafluorphmyl)boranc is a commonly avail- dicyclohexylammonium tctraphenylborate and the like; @ d ~ l e Lewis acid that may be readly prepared a ~ ~ ~ d i n g and triaryl phosphonium salts such as triphenylphos- to known technique. The compound is disclosed in phonium tetraphenylborate, tri(methy1phcnyl)phos- Marks, et 81- J. Am. Chem. Sot. 1991. 113,3623-3625 for phonium tetrakis-pentafluorophenylborate, tri(dime- in alkyl abstraction of zirconwena. thylpheny1)phosphonium tetraphenylborate and the All reference to the Periodic Table of the Elements like. 65 herein shall refer to the Periodic Table of the Elements,

Preferred ionic catalysts are those having a limiting published and copyrighted by CRC Press, lnc., 1989. charge separated structure corresponding to the for- A1501 any reference to a Group or Groups shall be to mula: the Group or Groups as reflected in this Periodic Table

EXHIBIT PAGE 000248


c~nrti&t atoms of the cycbpcnt.d'iyi or substituted PO~W disclosed as at Oae c o m ~ e n t cyclq~otadienyl group need not be equivdmt. -t is, -p*g at a portion of the fiber's nuf.ce)*

the wt.l my f y m m c ~ l y or mymmctr i~ly 15 spunbond fibers or melt blown fibers (using, eg., sys- =-bound to the cyclopentadimyl or m ~ t u M cy- tems as disclosed in U.S. Pat. No. 4,434563. U.S. Pat. ckgx!udienyl group. No. 4,663,220, U.S. Pat. No. 4,668,566, or U.S. Pat. No.

of the dve ,,,d dte hr further de- 4,322,027. #I of which are incorporated h& by refa-

fined .s follows. me centroid of the cyGlopcnt.dienyl tact). spun fiben (e& the s y t i a n d h c b d in or subaituted cyclopeotsdienyl grbup my be defined 20 U.S. Pat. No. 4.413.1 10, incorporated herria by refer-

= avmge of the rCSpective X. y, & h m t e s =e)X both woven 8nd onw woven fdxh (e.g.. wun-

of the atomic forming the cyclopentadienyl or laced fabrics disclosed in U.S. Pat. No. 3,485.706, incor-

substituted cyclopentadienyl group. The angle, 8, by m f ~ ) Or - such fibers (iicluding, e.g., blends of these fikn with

formed the the of the U otha fibers, e.g., PET or cotton) md molded &a cyclopcntadienyl or substituted cyclopentadiayl group -h o*ff ligaad of the metPf complex may be (e'~'S made using an in*tion molding p w a

moldiig process or a rotomolding procm). The new eusil~ calcul.ted techniques of rinde cw polymen d-w be- uc also wN for wire tal Epch Of these lnda my cable coating omtiow as wdl as in *& ex&On or decrease depending on the molecular structure of the for vrcuum forming constrained geometry metal complex. T h e complexes useful compositions u e dso suimbly ~ r rpa r td wherein one or more of the angles, 8, is less than in a

prising the lintar Flymen of he prrsent dmil.r, comparative complex differing only in the fact invention and lean one ohr D1m synthetic that the --bdu&g ~ ~ t ~ t is qld by pol-. &fared o tba pofymm m&& & a m o p b

have camrained geometry for purposcr of 35 tics such as styrene-butadiene block copolymers, p l y - the praent invention. Preferably one or more of the styrene cmcluding high impact polyrtyrrne), dy lenc above m g l e ~ 8, d m e m by at l a t 5 Percent, more vinyl dcohol copofymerr, &ylae .crylic .cid oopoly- preferably 7.5 percent, compared to the comparative mera, other olefin c o p o l p u s (specially polyahylene complu. Highly pref-bly, the avmge value of all copolymers) and homopolymerr (e.g., those made using bond 8* is llso less in - v t i v e 40 conventional heterogeneous catalysts). Examples in- complex. clude polymm made by the proms of U.S. Pat. No.

Prrfmbl~v monoc~clo~entadim~f maaf coordina- 4,076,698, incorporated heicin by reference, o t h a lin- tion complexes of group 4 or lanthanide metals accord- ,or substantially lin, p l y m m ofthe pr-t bvm- mg to the present invention have constrained geometry tion, and mixturts thermf. other bear such that the smallest angle, 8, is less than 115'. more 45 polymers of the pr-t invention and conventional ~ ~ f m b l ~ less than 110'. most preferably less than 105'. HDPE and/or LLDPE are preferred for w in the

Other compounds which are useful in the catalyst themoplsstic compositions. compositions of this invention, especially compounds Compositions comprising the olefin polymers - containing other Group 4 or Lanthanide metals, will, of dx, be formed into fabricated articles such as those course, be apparent to those skilled in the art. 50 previously mentioned using conventional polyolefm

In E P e d the polymerization according to the P r e processing techniques which arc well known to those ent invention may be accomplished at conditions well skilled in the art of polyolefm processing. known in the prior art for Ziegler-Natta or Kaminsky- All procedures were perfomed under an inert atmo- S h type polymerization action^ that tempera- sphere or nitrogen or argon. Solvent choices were often tures from O' to 250' C. and pressures from atmospheric 55 optional, for exsmplc, in most cases either pentane or to 1000 atmospheres (100 MPa). Susprnsion, solution, 30-60 petroleum ether can be interchanged. Amincs, slurry, gas phax or other process conditions may be silans, lithium reagents, and Grignard reagents were employed if desired. A support may be m p l o ~ d but purchased from Aldrich Chemical Company. Published preferably the catalysts are used in a homogeneous methods for preparing tetramethylcyclopentadiene (C5 manner. It will, of course, be appreciated that the active 60 MyH2) and lithium tetramethylcyclopentadienide catalyst system, especially nonionic catalysts, form in (Li(C5 MyH)) include C. M. Fendrick et al. Orgonome- situ if the catalyst and the cocatalyst components tallicr 3. 819 (1984). Lithiated substituted cyclopenut- thereof are added directly to the polymerization process dienyl compounds may bc typically prepared from the and a suitable solvent or diluent, including condensed corresponding cyclopentadiene and a lithium reagent monomer, is used in said polymerization process. It is, 65 such as n-butyl lithium. Titanium trichloride (TiC13) however, preferred to form the active catalyst in a was purchased from Aldrich Chemical Company. The separate step in a suitable solvent prior to adding the tetrahydrofuran adduct of titanium trichloride, same to the polymerization mixture. TiCl3(THF)3, was prepared by refluxing Tic13 in THF

EXHIBIT PAGE 000249


overnight, cooling, and isolating the blue d i d product. according to the procedure of L. E Manzer, Inorg. Syn.. 21, 135 (1982).

EXAMPLES 1-4

The metal wmplex solution for Ehmple 1 is prepared as follows:

Put 1: Prep of Li(CM4H) In the drybox, a 3 L fnecked flask was charged with

18.34 g of CsMJ.Iz, 800 mL of pcntane, and XX) mL of ether. The flask was topped with a reflux condenser, a mechanical rtirrrr, and constant addition funnel con- tainer 63 mL of 2 - 9 4 n-BuLi 4Ln hexanc Tbe BuLi was added dropwise over several hours. A very thick precipitate formed: approx. 1000 mL of a d d i t i d pen- W e M to be added over the course of the reaction to allow stirring to continue. Afta the addition was unn- plete, the mixture was stirred overnight. The next day, the rrmterid was Ntered, and the d i d was dhoroughly washed with pmtanc and t h b dried under reduced pressure. 14.89 g of Li(CMJI) was obtained (78 percent). Part 2: Prep of CsMyHSiMc2CI In the drybox 30.0 g of Li(C5Md-I) was p l d in a

XX) m L Schlcnk flask with 250 mL of THF and a h g e magnetic stir bar. A syringe was charged with 30 mL of MqSiCIz and the flask and syringe were removed from the drybox. On the Schfenk line under a flow of argon, the h k was cooled to -78' C., and the MqSiCll added in one rapid addition. The reaction was allowed to slowly warm to room temperature and stirred ovcr- night. The next morning the volatile materials were m o v e d under reduced pressure, and the flask was taken into the d m x . The oily material was cxtncted with pentane, filtered, and the pcntane was removed under reduced pressure to leave the CsMyHSiMqCl as a clear yellow liquid (46.83 g; 92.9 percent). Part 3: Prep of CjMyHSiMe2NH'Bu In the drybox. a 3-necked 2 L flask was charged with

37.4 g of t-butylamine and 210 mL of THF. CsMJH- SiMe2Cl (25.47 8) was slowly dripped into the solution o v a 3-4 hours. The solution turned cloudy and yellow. The mixture was stirred overnight and the volatile materials removed under reduced pressure. The residue was extracted with diethyl ether, the solution was filtered, and the ether removed under reduced pressure to leave the C ~ M J H S ~ M Q N H ~ B U as a clear yellow liquid (26.96 g; 90.8 percent). Part 4: Prep ~ ~ C ~ ] ~ [ M ~ C ~ S M ~ ~ N ' B U ] ( T H F ) ~ In the drybox, 14.0 mL of 2.OM isopropylmagnesium

chloride in ether was syringed into a 250 mL flask. The ether was rcmoved under reduced pressure to leave a colorless 03. 50 mL of a 4: 1 (by volume) to1uene:THF mixture was addcd followed by 3.50 g of M d C - ~SiMe2NH'BU. The solution was heated to rcflux. After refluxing for 2 days, the solution was cooled and the volatile materials rcmoved under reduced pressure. The white solid residue was slurried in pentane and filtered to leavc a white powder, which was washed with pentane and dried under reduced pressure. The white powder was identified as [MgCllz[MqC~SiMezN- rBu](THF), (yield: 6.7 g).

Part 5: Prep of [C5Mu(SiMe2N'Bu)]TiC12 In the drybox, 0.50 g of TiC13(THF)3 was suspended

in 10 mL of THF. 0.69 g of solid [MgC1I2[Me4C- 5SiMe2N'Bu](THF), was added, resulting in a color change from pale blue to deep purple. After I5 minutes, 0.35 g of AgCl was added to the solution. The color

immediately began to lighten to a pale green-yellow. After 1) hours, the T H F was removed under ruiuced pressure to leave a yellow-green solid. Tolutne (20 mL) was added, the wiution was fdtcrad. and the toluene

5 was removed under reduced pressure to leave a yellow- green solid, 0.51 g (quantitative yield) identified by 1H NMR as [CsMq(SiMc2N'Bu)]TiC12. Part 6: Preparation of [CsMe*(SiMc2N'Bu)ricrl In an inert atmosphere glove box, 9.031 g of

10 [C+la(MqSiNrBu)]TiC12 is charged into 250 ml flask and diaolved into 100 ml of THF. This wlution is cooled to &out -2Y C. by placement in the glove box freezer for 15 rninuta To the cooled solution b added 35 ml of a 1.4M McMgBr solution in tolulume/THF (75/25). The reaction mixture is stirred for 20 to 25 minutes followed by removal of the folvent under vrcuum. The resulting wlid is dried under vacuum for -4 hours. The product is extracted with pentane (4x50 ml) and filtered. The filtrate is combincd and the pcntane removed under vacuum giving the atat-t as a straw yellow wlid.

The metal complex. [CsMy(SiMezN'Bu)]TiMez, wlution for Examples 2 and 3 is prepared as follows:

In an inert atmosphere glovc box 10.6769 g of a tetra- 25 hydrofuran adduct of titanium trichloridc, TiCl3(THF

)j, is loaded into a 1 1 flask and slurried into = 30 ml of THF. T o this slurry. at room temperature, n added 17.402 g of (MgCIJzfN'BuSiMe~sMyJ ox rs a solid. An additional 200 ml of T H F is used to help wash

XI this solid into the reaction !lask. This addition resulted in an immediate reaction giving a deep purple solution. After stirring for 5 minutes 9.23 d of a 1.56M solution of C H a 2 in T H F is added giving a quick color change ,:, to dark yellow. This stage of the reaction is allowed to stir for about 20 to 30 minutes. Next, 61.8 m 1 of a 1.4M MeMgBr wlution in t o l u e n e ~ ( 7 S L 2 5 ) is added via syringe. After about 20 to 30 rninuta stirring tame the solvent is rcmoved under vacuum and the solid dried. The product is extracted with pmtane (8 ~ 5 0 ml) and filtered. The filtrate is combined and the Dentant removed under vacuum giving the metal complex as a tan solid.

The metal wmplex, [C5Me*(SiMezNfBu)]TiMe2, solution for Example 4 is prepared as follows:

In an inert atmosphere glove box 4.8108 g of TiCl,(thf)s is placed in a HX) ml flask and slurried into 130 ml of THF. In a separate flask 8.000 g of ~ ~ C I ] ~ ~ N ' B U S ~ M ~ C , M Y ] ~ F ) ~ is dissolved into 150 ml of THF. These flasks are rcmoved from the glovc box and attached to a vacuum line and the contents cooled to -30' C. The T H F solution of [MgCl]z~'BuSiM~2CsMer]cIlIF)~ is transferred (over a IS minute period) via cannula to the flask containing the TiC13(THF)3 slurry. This reaction is allowed to stir for 1.5 hours over which time the temperature warmed to 0' C. and the solution color turned deep purple. The reaction mixture is cooled back to -30' C. and 4.16 ml of a 1.56M CHzC12 solution in THF is added. This stage of the reaction is stirred for an additional 1.5 hours and the temperature warmed to - 10' C. Next, the reaction mixture is again cooled to -40' C. and 27.81 ml of a 1.4M McMgBr solution in tolucne/THF (75/25) was added via syringe and the reaction is now allowed to warm slowly to room temperature over 3 hours. After this time the solvent is removed under vacuum and the solid dried. At this point the reaction flask is brought back into the glove box where the product is extracted

EXHIBIT PAGE 000250


5,272,236 17 18

with pcntane (4x50 ml) and Ntered. The filtrate is TABLE I-wntinued combined and the pentane removed under vacuum giving the catalyst as a tan solid. The metal complex is then Eumpk I 2 3 4

disolved into a mixture of Ct-Clo w ~ t e d hydmcar- lbv - boar (e-g. . ISOF @ E, made by ~ u a n ) and ready for 5 zz? o 001 0.001 0.002 0 . m use in polymerization. -YMIO~

Polymerization The polymer products of Examples 1-4 llrc produced Emf 2.9 1.3 6 11.9

in a solution polymerization proc*u using a continu- (&-) ourly' stirred reactor. Additives (e.g., antioxidants, pig- ur 114 160 160 200

m a t s , etc.) can be incorporated into the interpolymer -paamre products either d u ~ g the pelletiutioo step or after ztkCrmc. 2.65 3 0.86 1.98 msnufilaun, with a subsequent rcextrusion. Examples tbc - 1-4 are etch stabilized with 1250 ppm Ollcium Stcarate, 15 - 200 ppm IRGANOX 1010, and 1600 ppm irgafos 168. (-1 -1)

I r g a f o s ~ ~ 168 is a phwpbitc stabiiizcr and IR- z0M2uta) 1.22 0.96 1.18 0.25 GANOX TM 1010 is a hindered polyphenof stabilizer RafDa - o 903 0.954 0.954 0953 (e.g., tetrakis [methylene W3.Mitert.butyl4bydrory- y,) phrnylpropionate)]methanc. Both are trademarks of 20 Wua 1 1 4 2 6.5 7.4 11.8 16 1 and made by CibaGcigy Corporation. A representative 1.86 1.9 2.09 2.07 schematic for the polymerization process is shown in M A "

FIG. 1. *FutynlJa1-4.L&Colammer/(WcCm~ot~ddiiacbcpcreea~md.r Ruo or ( f l ~ t a o r + nbuhr))

The ethylene (4) and the hydrogen u e combined into one, a r u m (15) before being introduced into the dib- 25 m e 1% NMR spectrum of E-ple 3 (ethylene eat mixture (3). ~ypically, the dilucnt mixture corn- homopolymer) shows pealrs which cnn be migned to pr- a mixture of Cs-Clo saturated hyd1-m (1). the as+, @6+, d m&e m h n s e t e d with a (c.o.* @ made by Exxon) and the ~ ~ m m o - long chain branch. Long chain bmching is determined meds) (2). For e u m p l a 1-4, the Wmonomer is 1- using the method of k d P U dcscribad rul ier in this octene. The reactor fted mixture (6) is continuously U) dizlOSurg he s t a t 6 that of thse inwed into the reactor (9). The metal ~ m p l e x O) and reso-ccs in high-density polyethylena where no the m t a l ~ s t (8) tthe m a y s t is trisipentafluw* I-olefms were a d d 4 during the polymerization should ~ h e n ~ f ) b o m for -PI= her& which forms be m g l y indiative of the pr-ce of long chain the ionic walyst am combined into l single branchg: using the equation 141 from -1 (p. stream and also continuously injected into the reactor. 35 292): Sufficient residence time is d o w e d for the metal complex and coclltalyst to met to the desired extent for use ~lsnebcs pa IQ~OO c u t m = [ i d ~ ~ ~ ) ] x 1 0 1 . in the polymerization reactions, at least about 10 see- onds. For the polymerization reactions of Ewnples wherein a x t h e average intensity of a carbon from a 1-4. the reactor pressure is held constant at about 490 branch ( a s + ) carbon and T~,,,=the total carbon inten- psig. Ethylene content of the reactor, after reaching sity, steady state, is maintained below about 8 percent. the number of long chain branches in this sample is

After polymerization, the reactor exit stream (14) is determined to be 3.4 per 10,000 carbon atoms, or 0.34 introduced into a separator (10) where the molten poly- 45 long chain brancha/1000 carbon atoms. m n is separated from the unreacted comonomcr(s), unreacted ethylene, unreacted hydrogen, and diluent EXAMPLES 5.6 and COMPARATIVE

mixture sueam (13). The molten polymer is subse- EXAMPLES 7-9 quently strand chopped or pelletin& and, after being Exampla 5.6 and comparison examples 7-9 with the cooled in a water bath or pelletizer (1 I), the solid pellets same melt index arc tested for rheology comparison. arc collected (12). Table I d m b a the polymerization Examples 5 pnd 6 are the substantially linear polyethyl- conditions and the resultant polymer properties: cnes produced by the constrained geometry catalyst

TABLE I technology, as described in Examples 1-4. Examples 5 and 6 are stablized as Examples 1-4.

b p l c I 2 3 4 55 Comparison examples 7, 8 and 9 are conventional Ethykne i d 3.2 3.8 3.8 3.8 heterogeneous Ziegler polymerization blown film resins rate owhour)

Jhwlex @ 2545A. Attane @ 4201, and Attane @ 4403, Comawacr/ 12.3 o o o respectively, all of which are ethylene/l-octene copoly- W m . ntio mers made by The J h w Chemical Company. Compara- ( ~ O I C %) 60 tive elrample 7 is stsblized with 200 ppm IRGANOX @ Hydrogen/ 0.054 Ethylenc ratio

O.OE3 1010, and 1600 pprn Irgafos @ 168 while comparative (mole %) examples 8 and 9 are stablized with 200 ppm IR- Dilumc/ 9.5 7.4 8.7 8.7 GANOX @ 1010 and 800 ppm PEPQ @. PEPQ @ is a Ethyiene ratio trademark of Sandoz Chemical, the primary ingredient (weight bans) 65 of which is believed to be tctrakis-(2,rkii-tertbutyl- mcul wmplca 0.00025 0.0005 0.001 0.001 concmtralion phenyl)-4,4' biphenylphosphonite. (molar) A comparison of the physical properties of cach ex- mcul urmplcx 5.q 1.7 2 4 4.8 ample and comparative example is listed in Table 11.

EXHIBIT PAGE 000251


TABLE I1 Exunple Eumpk Complriron Comp.rbon Comparison

WY 5 6 Exunpk 7 F.sunpIc 8 Example 9

12 1 I I I 0.76 dcariry .92 .!?€a .92 912 .9M w 2 9.45 7.61 7 .84 1.2 8.7 M d m 1.97 2.09 3.5-3.8 3.8 3.64.0

10 TABLE N

-Y E v m p k 6 u r m p k 9

Surprisingly. even though the molecular weight dis- I W I O ntinula) I 0.76 h d 2 7.61 8.7

tnbution of Examples 5 and 6 is narrow (i.e.. M&, is PI (L;poiu) 14 15 low) , the 110/12 values u e higher in complrison with I5 ~ d c T- (11 1.46 1.39 c u m v t i v e examples 7-9. A compuiwn of the rela- ootic M O ~ U I U ~ 14-w 1921 tiomhip between l i d 2 W. M a n for ~ o m e of the Bpat nd/=

novel polymers described herein and conventionnl het- ( d y o J d ) O O M P . criW 1186 652

erogeneous Ziegler polymers is given in FIG. 2. The .bar n t c (I/WC) _ ,I . I I ~ Z value for the novel polymers of the present inven- 20 OOMP. cr i ta 0.43 I 0.323

tion is asentially independent of the molecular weight .bar - ( M W O S M P * , aitial -764, -402

distribution, Mv/Mn. which is not true for conventional .bar n t e (~ /wc. ) Ziegkr polymenied m s k OSMP.. cnuui 0.366 0180

Example 5 and comparison example 7 with cimiiar .bar amr (Mpa) . .

melt index and density (Table 11) u e a h extruded via 25 - d h M d F-

a Gas Extrusion Rheometer (GER) at 190' C. usinn r Fnaorr

0.0296" diameter, 20 WD die. The procasing in&x (P.I.) is measured at an apparent shear stress of 2-15 X 106 d y n e / c d as described previously. The onset of gross melt fracture can easily be identified from the sheu stress vs. shear rate plot shown in FIG. 3 where a sudden jump of shear rate occurs. A compuison of the s h u r stresses and corresponding shear rates before the onset of gross melt fracturc is listed in Table 111. It is particularly interesting that the PI of Example 5 is more than WO lower than the PI of comparative example 7 and that the onset of melt fracturc o r sharkskin for Example 5 is also at a significantly higher shear stress and shear rate in comparison with the comparativc w n p l e 7. Furthermore, the Melt Tension (MT) as well as Elastic Modulus of Example 5 are higher than that of comparative example 7.

TABLE I11

The onset of gross melt fracture can &y be identi- iicd from the shear stress vs. shear rate plot shown in FIG. 4 where a sudden increase of shear rate occm at an apparent shear stress of about 3.23 X 106 d y n e h 2 (0.323 Mpa). A comparison of the shear stresses and corresponding shear rates before the onset of gross w l t fracture is listed in Table W. The PI of Example 6 is surprisingly about the rune as comparative example 9. even though the Il0/12 is lower for Exampie 6. The onset of melt fracturc or sharkskin for Example 6 is also at a significantly higher shear stress and shear rate in comparison with the comparative example 9. Further- more, it is .Ix, unexpected that the Melt Tendon (MT3 of Example 6 is higher than that of comparative example 9. even though the melt index for Example 6 is slightly higher and the 11a/12 is slightly lower than that of comparative example 9.

Compukn 45 WY Eumplc 5 eumpk 7 EXAMPLE 10 A N D COMPARATIVE EXAMPLE

12 1 I 11

1 1 d z 9.45 7.8-8 Blown film is fabricated from two novel cthylene/l- PI, kpoiv 1 1 15 Me11 Tension 1.89 1.21 octene polymm made in accordance with the present Ekuic Modulus 2425 682.6 M invention and from two comparative conventional pol- @.I nd/u~. ymers made according to conventional Zieglcr cataly- tdyoJrm2) sis. The blown films ;are tested for physical properties, O O M P , critical > 1556 936 rhcu Rle (I/rcc) (W -a including heat seal strength versus heat seal tempera- OOMF., oitiul ,452 .W ture (shown in F I G . 5 for Examples I0 and 12 and .bar ruar WP.) 55 comparative examples 11 and 13). machine WD) and OSMF*.. criliul > 1566 -628 cross direction (CD) properties (e.g., tensile yield and sbar n t c (I/=.) (not observed) OSMP'. criliul -0.452 -0.25

break, elongation at break and Young's modulus). Other sbar .trerr (UP.) film properties such as dart, puncture, tear, clarity,

.Opul dGraa Meh F ~ w r . haze, 20 degree gloss and block are also tested. *-o~me d M~CC ~ e h ~ntlur. 60 Blown Film Fabrication Conditions

The improved processing substantially linear pol y - Example 6 and comparison example 9 have similar mers of the prexnt invention produced via the proce-

. melt index and density. but example 6 has lower 11612 dure described earlier, as well as two comparative res- (Table IV). These polymers are extruded via a Gas ins are fabricated on an Egan blown film line using the Extrusion Rheorneter (GER) at 190' C. using a 0.0296 65 following fabrication conditions: inch diameter, 20: 1 L/D die. The processing index (PI) 2 inch extruder is measured at an apparent shear stress of 2 . 1 5 ~ 106 3 inch die dyne/cm' as described previously. 30 mil die gap

EXHIBIT PAGE 000252


5,272,236 21 22

25 RPM extruder specd ing efficiency than comparative example 11 (LC.. more 460' F. melt tcmpcrature polymer goes through per turn of the screw). 1 mii gauge Aa FIG. 5 shows, the h a t seal properties of polymers 2.7:l Blow up ratio (125 inches byflat) of tbe present invention ue improved, as evidenced by 1x5 i n c h frost l k height 5 lower b a t seal inidtion t e m p e r r t u r ~ ~ a d h i e b a t Tbe melt tempmature is kept constant by changing d ~ e n g t h s at a given tempcrrtm, as armwed with

the urtnda tempmature profile. Frost line height is conventiod h e t c r o g c 1 ~ 0 ~ ~ polymers at about thc same maintained at 1 2 5 inches by adjusting the air flow. The melt iodu .nd d d ~ . .

utnda output sate, bick prrrnue m d power am- What h cl.imed is: wnption in .mps mopitored throughout & 10 1. A substantidly linear olefin polymer c- ment. The polymers of the present invention .nd the as h*g: compurtivc polymers uc ilf e t h y l e n e / l - o c t ~ ~ co- a) a melt flow ratio, I t d I 2 , h5.63, polymar ~ ~ b l ~ VI l- ~ h y r i c l l of b) a mokcula~ weight distribution, M A , d e f d thc two polymers of the invention m d for the two com- - by the equation: plrrtive-polymers: 1s

Y"/hf.S(xt~2)-4.63. md TABLE VI

~ ~ c o m p n t i v c E u m p l c Compntive c) a critical shear Nesr at onset of gross melt fracture w 10 cvmplc11 12 aun* 13 of g m t e r than rbout 4~ 106 dyne/cm2, 11 1 I I 0.8 20 w h a d n the olcfin polymer is further characterized as a W l O copolymer of ethylene with a C3-Cm alpha-okfin. nria~m) 2. The polymer of claim 1 wherein the MJM, is l e n Dcndty 0.92 0.92 a902 0 . ~ 5 w-1 than about 3.5. 1 1 d 2 9.45 - 8 7.61 11.7 3. The polymer of claim 1 wherein the MJM. is from M J M . 2 -5 2 - 5 25 about 1.5 to about 2-5.

4. The polymer of claim 1 wherein the polymer has

Tabla VII m d VlII summuire the film pmperties about o.oi to about 3 long chain b m n c h s / l o cutxms measured for blown film made from two of these four along polymer backbone.

polymers: 5. The polymer of claim 4 having at least about 0.1 30 long chain bmches/1000 carbons dong the polyma

TABLE VII backbone. BIOWII fiim propcnm 6. The polymer of claim 4 having at least ribout 0.3

Evmplc cunpruivr long chain branched1000 carbons dong the polymer 10 uumpk 11 backbone.

+Y MD CD MD 35 7. A composition comprising a substantidly linear ~rorikywld 1391 1340 1% 1593 olefin polymer, w h n d n the polymer is chu;rctcriztd .s W) having: Tanikbruk 7194 5661 6698 6854 a) a melt flow ratio, 11O/I2. Z5.63. W) *- 650 668 63 1 723

b) a molecutar weight distribution, MJM,. defined (prmr0 40 by the equation: Young's 18990 19997 23086 23524 Modulus MJM.SOtdi2)-4.63. and ( 3 4 P F T Tur 5.9 6.8 6.4 6.5 (PI

c) a critical shear stress at onset of gross melt fracture

*R8aorrRoppc*aTcp 45 of g ra te r than about 4X 106 dync/cm2.

and at least one other natural o r synthetic polymer, wherein the substantially linear olefin polymer is fur-

TABLE VIII ther characterized as a copolyma of ethylene with a ~ w n p k ~ o m p u ~ u v e C 3 - C m alpha-olefin.

R o p m y 10 -pk 11 M 8. The composition of claim 7 wherein the substan- 472 454 tially linear olefin polymer has a I10/12 up to about 20.

F'lmmuc (gnmr) 235 275 9. The composition of claim 7 wherein the substan- M a @a-~ 7 1 68 tially linear olefin polymer has a M a . less than about Hue 3.1 6.4 m' @o+r 1 14 81

3.5.

croft (b"rm) 148 I u 55 10. The composition of claim 7 wherein the substantially linenr olefin polymer has a MJh4,from about 1.5

During the blown film fabrication, it is noticed that at the same screw speed (25 rpm) and at the same ternpera- ture profile. the extruder back pressure is about 3500 psi 60 at about 58 amps power consumption for comparative example 11 and about 2550 psi at about 48 amps power consumption for example 10, thus showing the novel polymer of examplc 10 to havc improved proccssability over that of a conventional heterogeneous Zieglcr poly- 65 merized polymer. The throughput is also higher for Example 10 than for comparative example 1 1 at the samc screw speed. Thus, example 10 has higher pump-

to about 2.5. 11. The composition of claim 7 wherein the synthetic

polymer is a conventional ethylene homopolymer or copolymer.

12. A substantially lincar olcfin polymer having a melt flow ratio. I l d 2 , S5.63, and a molecular weight distribution, Mw/h4,, defincd by the quation:

produced by continuously contac:ing cthylenc and a C3-Czo alpha-olcfin with a catalyst composition under

EXHIBIT PAGE 000253


* . . * - . .. 5,272,236 - . -

23 24 polymerization conditions, wherein E G ~ catalyst corn- 26. The wmposition of claim 7, wherein the substan- position is char;lctcrizcd as: tially linear olefm polymer is a copolymer of ethylene

a) a metal coordination complex comprising a metal and 1-hexene. atom of p p s 3-10 or the L P n t M d e series of the 27- The wmposition of claim 7, wherein tbe tubstan- Paiodic Tabk of the Elements and a d e l a 5 w y linear olef i polymer is a c o p ~ f ~ m u of ethylene --bonded moiety subhtitutcd with a constrain in- .nd I-butene. ducing moiety. 28. The composition of claim 7, wherein the substan-

raid complex having a constrk~ed geometry about t a l y linear olefin polymer is a ~ ~ ~ l y m u of ethylene

tbe metal atom such that the an& at the metal ~ m e t h y l - l - ~ e n ~ e - atom hecn the centroid of the d e l o c . l d , .ut,- 29. The cnbtantidy l inar olefin polymer of claim d t u d --bonded m&y & the of ku;t 13, wherein the polymer is a c o ~ l ~ ~ e ~ o f e t h ~ l e n e m d one remaining rubstituent is less than such angle in 'atme. a a COmP1ex con*g a mu rr-bonded 30. The ~ubs-tidly .okfu! pol= of c h b moiety io such constrain-inducing rubstit,,- 13, wheran the polymer is a w'pofymu of ethylene and

car, 1-bucne. 31. The substantially linear olafm polyma of claim

provided that for such annplexes 13, wherein the polymer is w p l y m e r of ethylene m d prising mow than one deloulired, substituted w- I-butenc. 3 bmded Only One for metd 32. The substantially linear 0Lfi.l polymer of claim atom of the complex is a cyclic, d e l o c d d , substi- 13, where,, the poiymcr is a copole.er of e;hylcne md tuted n-bonded moiety, and 20 Cmethyl-I-pentme.

b) an activating cocptalyrt. 33. The substantially linear o l e f i polymer of claim 13- A subst.nttfb' linear olefin polymer 17, wherein the polymer is a copolymer of ethylenc and

ired as having: l-octme. a ) a melt flow ratio, IIO/I~, L7. 34. The substantially linear oldin polymer of claim b) a molecular weight distribution, M A n , of from 2s 17, wherein the polymer is a copolymer of ethylene and

about 1.5 to about 2.5, 1-hexme. wherein the rubstantially linear olefin polymer is fur- 35. he substantially linear olefin polymer of claim ther ~ w a i . z . d a wpolymer of ethylene with a 17, wherein the polymer is a copdfymer of ethylene and C3-C2o dpha-olefm. 1-butme. 14. The polymer of claim 13 wherein the l 1 d I 2 is at 30 36. The substantially linear olefin polymer of claim

least about 8. 17, wherein the polymer is a wpolymer of ethylene and 15. The polymer of claim 13 wherein the I l d I 2 is at Cmethyl-1-pentene.

least about 9. 37. A composition comprising: 16. The polymer of claim 13 wherein the substantially (i) a substantially linear olefm polymer. wherdn the

linear olefin polymer is an ethylene/dpha-olefin co- 35 substantially linear olefin polymer is characterized polymer. Ils having: 17. A substantially linear olefin polymer having: a) from about 0.01 to about 3 long chain bran- (a) from about 0.01 to about 3 long chain branches/1000 carbons along the polymer backbone

ches/1000 carbons along the polymer backbone and and 40 b) a critical shear stress at onset of g r o ~ melt f m -

@) a critical shear stress ht onset of gross melt fracture of greater than about 4X 1G6dyne/cm2, and ture of greater than about 4 X 106 dync/cm2. (ii) at least one other natural or synthetic polymer,

wherein the substantially linear olcfin polymer is fur- wherein the substantially linear olefin polymer is

ther characterized as a copolymer of ethylene with a funher characterized as a copolymer of ethylme

C3-Clo alphaalefin. 45 with a CJ-CZO alpha-olefin. The of claim having at least about O, 38. The substantially linear olefin polymer of claim 12

long chain brancha/1000 carbons along the polymcr whercin (a) is an amidosilane- or arnidoalkanediyl- com-

backbone. pound corresponding to the formula:

19. The polymer of claim 17 having at least about 0.3 long chain branched1030 carbons dong the polymer M backbone.

20. The polymer of claim 17 wherein the polymer has R.@:7N-R' a I1& of at least about 16.

21. The substantially linear olefin polymer of claim 1, (xh wherein the polymer is a copdymer of ethylene and 55 R' I-ocrene.

22. The substantially linear oltfin polyma of claim 1, whcrcin: wherein the polymer is a copdymer of ethylene and M is titanium, zirconium or hafnium, bound in an 115 1 -hexene. bonding mode to the cyclopentadienyl group;

23. The substantially linear olefin polymer oiclaim 1, 60 R' tach -umcnce is independently select4 from wherein the polymer is a copolymer of ethylene and the group consisting of hydrogen. silyl, alkyl, aryl I -butcne. and combinations thereof having up to 10 carbon

24. The substantially linear olefin polymer of claim 1, or silicon atoms; wherein the polymer is 4 copolymer of ethylene and E is silicon or carbon; 4-mctl~yl-1 -pentcne. 65 X independently each occurrencc is hydride. halo,

25. The composition of claim 7, wherein the substan- alkyl, or aryl, of up to 2C carbons; and tially linear olefin polymer is a copolymer of ethylene m is 1 or 2. and I-octene. 8 1 1 1

EXHIBIT PAGE 000254


CERTIFICATE OF CORRECTION

PATENT NO. : 5,272,236

DATED : December 21, 1993 INVENTOR(S) : $&i,h-yav Lai et al.

Page 1 of 5

It is certified that error appears in the above-indentified patent and that said Letters Patent is hereby corrected as shown below:

On t h e cover p a g e , under Other P u b l i c a t i o n s , a f t e r pp. 2869-2880, " ( 1 9 9 3 ) ) , " s h o u l d r e a d --(1963)),.:-.

On page 2 , under O t h e r P u b l i c a t i o n s , f i r s t column, Makromol. Chem. Rapid Comun, , i n t h e t i t l e , "Aluminoxiane" " shou ld read --A1uminoxane"--.

On page 2 , under O t h e r P u b l i c a t i o n s , f i r s t column, J o u r n a l o f Polymer S c i e n c e , i n t h e t i t l e "Transac t ion" shou ld be - -Transi t ion-- .

On page 2 , under O t h e r P u b l i c a t i o n s , ' s e c o n d column, Makromol. Chem. Comun., i n t h e t i t l e "Zicronocene" shou ld r e a d --Zirconocene--,

On drawing sheet I n F ig .5 , t h e "dashed l i n e " d e s c r i b i n g p e e l s t r e n g t h between 215OF and 225°F f o r Comparat ive Example 11 shou ld be a --sol id l i n e - - .

EXHIBIT PAGE 000255


UNITED STATES PATENT AND TRADEMARK OFFICE


PATENT NO. : 5,272,236

DATED : December 21, 1993

INVENTOR(S) : Shih-Yaw L a i et al.

Page 2 of 5

It is certified that error appears in the above-indentifid patent and that said Letters Patent is hereby corrected as shown below:

Cdumn 4, li ne.59, "an" should read -- a --.

Cd urnn 5, line 35, " (R)" should. read - 2 - .

' Column 7, line 42, "a" should read - as - .

Column 7, line 64, *-N(R"-" should read - -N(R")- -- .

Column 7, line 15, "51" should read -- M -- .

t d u m n 8, line 40, 'ramethyl-rl~-cyd4X?ritadienyl)-1,2- ethanediyltitanium" shatld read - - ramethyl-$- cydopentadieny1)-1,2-ethanediyltitanium - - . p-

Column 10, line 65, " Rot"'shou1d read - not - .

Column 11, line 11, "(L-H)f [A]" should read -- (L-H)+[A- -- .

Column 12, line 59, "~Tris(pmtafluorphenyl)baneN should read -- Tris(pentafl uorapheny1)brane -- .

. -

EXHIBIT PAGE 000256



CERTIFICATE OF CORRECTION PATENT NO. : 5,272,236

DATED : Dectraaber 21, 1993

INVENTOR(S) : Shlh-Yaw Lai et al,

Page 3 of 5


Gdurnn 13, line 11, "q-bonding" shculd read - n-bnding - .

Cdumn 14, line 12, "include-nu" should read -- including - .

Cdumn 14, ltne 54 (1st Instance), "mu should read - of - .

Cdumn 15, line 13, "tainer" shmld read - tainfng --.

EXHIBIT PAGE 000257




PATENT NO. : 5,272,236

DATED : December 21, 1993

INVENTOR(S) : Shih-Yav Lai et al.

Page 4 of 5


Cdumn 15, iine 13, "4Ln" should read -- in - .

Cdumn 15, line 49, "Prep [ M ~ Q JdMe4Cssi M~N~%U](TI - IF )~ '~ should read - Prep d [M~~J~[M~QS~M~~N~BU](THF)X--.

Cdumn 15, line 55, in the fonnul a " BU" should read - Bu -.

Cdumn 16, line 36, "m 1" shcxlld read -- ml -.

Cdumn 16, line 47, " Tia3( thf)3" should read -- TiCQ(THF& --.

Cdumn 17, line 14, "Calcium Stearate" should read - caldum stearate - .

Column 17, 1ln.e 34, "tnsltu" should read -- 1i7 dfu--.

Column 18, line 15, "exit stearn" should read - exit stream --.

Cdumn 20, line 32, "(0.323 Mpa)" should read -- (0.323 MPa) --.

Cdumn 20, line 55, "examples 11 and 13)." should read -- examples 11 and 131, -- .

EXHIBIT PAGE 000258


UNITED STATE3 PATENT AND TRADEMARK OFFICE


PATENT NO. : 5,272,236 Page 5 of 5 I

DATED : December 21, 1993 INVENJOR(S) : Sfby= et al-

It is certified that error appears in the above-indentitied patent and that said Letters Patent is hereby corrected as shown below:

Cdurnn 22, line 62, "i;" shwld read -- 2 - . --

Column 16, line 37, "tame" should read - time -.

Column 17, line 15, "1600 ppm Irgafcls 168," should read -- 1600 ppm Irgafas 168. -.

Column 17, line 25, "one, stream" should read - one stream --.

Signed and Sealed this

Twenty-ninth Day of November, 1994

Anesring Oficer

BRUCE LEHMAN

Commissioner of Par rnrs a n d Trademark$

EXHIBIT PAGE 000259


USOO5278272A

United States Patent PI 11 11 Patent Number: 5,278,272 Lai et al. [4s] Date of Patent: Jan. 11, 1994

ELASnC SUBSTANTIALY LINEAR OLEFIN POLYMERS

Inventors:

Assignee:

Appl. No.:

Filed:

Shib-Yaw LA, Sugar Land; John R. Wilson, Richwood; George W. Knight, Lake Jackson, all of Tex.; James C. Stevens, Midland, Mich.

Tbe Dow Chemical Company, Midland, Mich.

Sep. 2,1992

Related US. Application Data

Continuation-in-part of Ser. No. 776,130. Oa. 15. 1991.

..................... Int. ( 3 . 5 C08F 10/04, CO8F 210/02; C08F 210/14

................................. US. (3. 526/348.5; 526/348; 526/348.1; 526/348.2; 526/348.3; 526/348.4;

526/348.6; 526/348.7 ..................... Field of Search 526/170, 348. 348.2,

526/348.3, 348.4, 348.5, 348.6, 348.7, 348.1

References Cited

U.S. PATENT DOCUMENTS

............................. 3,491,073 ]/I970 Marinak 26W88.2 3,645,992 2/1972 Elston .

....................... 4,205,021 5/1980 Morita el al. 525/240 ...................... 4,405,774 9/1983 Miwa et at. 526/348.2

............................ 4,510,303 4/1985 Oda et al. 526/283 ......................... 4,530,914 7/1985 Ewen et a]. 502/113

................ 4,668,752 5/1987 Tominari et al. 526/348.2 ......................... 4,935,474 6/1990 Ewen et al. 526/114 ......................... 4,937,299 6/1990 Ewen et al. 526/1 19

................. 4,987,212 ]/I991 Moneroi et at. 526/348.4 ................................ 5,026,798 6/1991 Canich 526/121 ................................ 5,055,438 10/1991 Canich 502/117

................. 5,084,540 1/1992 Albizzati et al. 526/348.6

FOREIGK PATENT DOCUMENTS

0416815A2 3/1991 European Pat. Off. . 9003414 4/1990 World Int. Prop. 0. .

OTHER PUBLICATIONS

Journal of Polymer Science. Pan A, vol. 1, (pp. L-.

2869-2880 (1963)), "Long-Chain Branching Frequency in Polyethylene" by J. E. Guillet. Polymer Preprintr. Amer. Chem. Society, vol. 12, No. 1, pp. 277-281 (Mar. 1971). "Evidenu of Long-Chain Branching in High Density Polyethylene" by E E Drott and R. A. Mendelson. Journal of the American Chemical Society. 98.7, pp. 1729-1742 (Mar. 3 1,1976). "Structure and Chemistry of Bis(cyclopcntadienyl>-MLn Complexes" by Joseph W. Lauher and Roald Hoffman. Polymer Engineering and Science, vol. 16, No. 12, pp. 8 1 1-8 16 @ec. 1976), "Influence of Long-Chain Branching on the Viscoelastic Properties of Low-Den- sity Polyethylenes" by L. Wild, R. Ranganath, and D. Knobeloch. Angew. Chem Int. Ed. Engl. pp. 630632 (1976) wL 15. No. 10 "Halogen-Free Soluble Ziegler Catalysts for the Polymerization of Ethylene. Control of Molecular Weight by Choice of Ternpemture" by Arne Andresen ct a1 Admnces in Organometallic Chemistry, pp. 99-148, vol. 18, (1980) "Ziegler-Natta Catalysis" by Hansjorg Sinn and Walter Kaminsky.

(List continued on next page.)

Pninary Examiner-Joxph L. Schofer Assistant Examiner-David Wu Attorney, Agent, or Finn-Stephen P. Kmpp; L. Wayne White

Elastic substantially linear olefin polymers are disclosed which have very good processability, including processing indices (PI'S) less than or equal to 70 percent of those of a comparative linear olefin polymer and a critical shear rate at onset of surface melt fracture of at least 50 percent greater than the critical shear rate at the OnKt of surface melt fracture of a traditional h e a r olefin polymer at about the same I2 and MJM,. The novel polymers have higher low/zero shear viscosity and lower high shear viscosity than comparative linear olefin polymers.

37 Claims, 1 Drawing Sheet

EXHIBIT PAGE 000260


Page 2

OTHER PUBLICATIONS

Angew. Chem In& Ed. EngL. pp. 390-393, vol. 19 No. 5 (1980) "Living Polymers on Polymerization with Ex- termely Productive Ziegler Catalysis" by Hansjorg Sinn, Walter Karninsky, Hans-Jurgen Vollmer, and Rudiger Woldt. Polymer Bulletin. 9, pp. 464-469 (1983) "Halogen Free Soluble Ziegler Catalysts with Methylalumoxan as Cat- alyst" by Jens Herwig and Walter Kaminsky. Maknomol Chem. Rapid Commun.. 4, pp. 417-421 (1983) *'Bis(cyclopcntadi~nyl)zirkon-Verbingungen und Aluminoxan aIs Ziegler-Katalysatoren fur die Polymerisation und Copolymerisation von Olefinen" by Walter Kmninsky et al. ANTEC Arrceedings, pp. 306-309 (1983). "Analysis of Long Chain Branching in High Density Polyethylene" by J. K. Hugha. Maknomol. Chem. Rapid Commun, (5) pp. 225-228 (1984) "Influence of hydrogen on the pol ymerizaton of ethylene with the homogeneous Ziegler system bis(cyclopcntadienyl)zirwniumdichloridc/aluminoxane" by Walter Kaminsky et a1. Journal of Polymer Science. Polymer Chemistry Edition pp. 21 17-2133 (1985) vol. 23, "Homogeneous Ziegler Natta Catalysis 11 Ethylene Polymerization by IVB Transition Metal Complexes/Methyl Aluminoxane Cat- alyst Systems" by E. Giannetti and R. Mazzocchi. Journal of Applied Polymer Science. pp. 375 1-3765 (1 985) vol. 30, "On the Effects of Very Low Levels of Long Chain Branching on Rhwlogical Behavior in Polyeth- ylene" by B. H. Basted. Journal of Polymer Science: Polymer Chemistry Edition. pp. 2151-2164 (1985) vol. 23, "Ethylene Propylene Dime Terpolymers Produced with a Homogeneous and Highly Active Zirconium Catalyst" by Walter Kaminsky et al. 77te Society of Rheology. pp. 337-357 (1986) vol. 30, "Wall Slip in Viscous Fluids and Influence of Materials of Construction" by A. V. Ramamurthy. Makromol. Chem., Macromol. Symp. 4, pp. 103-1 18 (1986) "Elastomers by Atactic Linkage of a-Olefins Using Soluble Ziegler Catalysts" by W. Kaminsky and M. Schlobohrn. Journal of Rheology. 31 (8) pp. 815-834 (1987) "Wall Slip and Extrudate Distortion in Linear Low Density Polyethylene" by D. Kalika and M. Denn. Makmmol. Chem., 190, pp. 515-526 (1989) "Copoly- merization of Cycloalkenes with Ethylene in Presence of Chiral Zirconocene Catalysts" by W. Kaminsky and R. Spiehl.

Journal of Macromolecular Science: Reviews in Macnomo- lecular Chemistry and Physics. C29 (2 & 3), pp. 201 303 (1989) "A Review of High Resolution Liquid Warbon Nuclear Magnetic Resonance Characterizations of Eth- y lene Based Polymers". Journal of Non-Newtonian Fluid Mechanics, 36, pp. 255-263 (1990) "Additional Observations on the Sur- face Melt Fracture Behavior of Linear Low-Density Polyethylene" by R. Moynihan, D. Baird, and R Ramanathan. MakmmoL Chem Rapid Comrnun, pp. 89-94 (1990) "Terpolymers of Ethylene, Propene and 1.5-Hexadiene Synthesized with Zirwnoctne/Methylaluminome" by W. Kaminsky and H. Drogemuller. Journal of Rheology. 35 (4, 3 (May 1991) pp. 497-552. "Wall Sl+ of Molten High &miry Polyethylene I. Sliding Plate Rheometer Studies" by S. G. Hatzikinbkos and J. M. Dealy. Proreedings of the 1991 IEEE Power Engineering Society, pp. 184- I90 (Sep. 22-27, 199 1). "New Specialty Linear Polyemrs (SLP) for Power Cables" by Monica Hen- dewerk and Lawrence Smnadel. Swiery of Plastic ~ n ~ i n e e k Proreedings Polyolefins VII International Conference, Feb. 24-27, 1991. "Struc- ture/Property Relationships in Exxpol m Polymers" (pp. 45-66) by C. Speed, B. Turdell, A. Mehta, and F. Stehling. High Polymers vol. X X , "Crystalline Olefin Polymers" Part 1, pp. 495-501. 1991 Polymers, Laminations & Coozings Conference. TAPPI Proceedings. presented in Feb.. 1991, p. 289-296, "A New Family of Linear Ethylene Polymers wtih Enhanced Sealing Performance" by D. Van der Sanden and R. W. Halle. Society of Plastic Engineers 1991 Specialty Polyolefins Conference Proceedings, pp. 41-55, "The Marketing Challenge Created by Single Site Catalysts in Polyole- fins" by M. Jefferies (Sep. 24, 1991. Adwnces in Polyolefins by R. B. Seymour and jl: Cheng,. (1987), pp. 373-380 "Crystallinity and Morphology of Ezhyelene a-Olefin Copolymers" by P. Schouterden, G. Groeninckr. and H. Reynaers Advances in Polyolefins, R. B. Seymour and T. Cheng, (1987) "New Catalysis and Process or Ethylene Polyer- ization," pp. 337-354, by F. Karol, B. Wagner, I. Le- vine, G. Goeke, and A. Noshay. Advances in Polyolefins, by R. B. Seymour and T. Cheng, (1987), "Polymerization of Olefins with a HO- mogeneous Zirconium/Alumoxane Catalyst", pp. 361-371 by W. Karninsky and G. Hahnsen. Derwent 90-23901 7/3 1.

EXHIBIT PAGE 000261


U.S. Patent Jan. 11, 1994

m N - Dyna V ~ s c o s ~ t y poise

EXHIBIT PAGE 000262


chain branching distributions (SCBDs). The melt pro- U S T I C SUBSTANTIALY LINEAR OLEFIN cessibility of the interpolymer blends is controlled by

POLYMERS blending different molecular weight interpolymers having different narrow molecular weight distributions and

CROSS-REFERENCE TO RELATED 5 different SCBDs. APPLICATIONS Exxon Chemical Company, in the Preprints of Poly-

l h i s application is a continuation in pan of pending ~ k f i ~ VII International Conference, page 45-66, ~ e b . application Ser. No. 07/776.130, fied Oct. 15, 1991, 24-27 1991, disclose that the narrow molecular weight peading the disclosure of which is incorporated herein distribution (NMWD) resins produced by their EXX- by reference. lo POLTM technology have higher melt viscosity and

FIELD O F THE INVENTION lower melt strength than conventional Ziegler &ins at the same melt index. In a recent publication. Exxon

This invcltion relates to elastic substantially linear Chemical Company has also taughtthat NMWD poly- okfm polymers having improved processsbiiity, e.g., mers made using a single site catalyst create the poten- low susccptibiity to melt fracture, even under high IS tial for melt fracture ("New Specialty Linear P o l p m s b u r st- conditions. Such substantially linear ethyl- (SLP) For Power Cabla," by Monica Hendewmk and au polymers have a critical shear rate at the onset of Lawrence Spenadel, presented at IEEE meeting in surface melt fracture substantidly higher than, and a Dallas. Tex., September, 1991). processing index substantially less than, that of a linear Previously known narrow molecular weight distribu- polyethylene at the same molecular weight distribution z0 tion linear polymers disadvantageously p o d low and melt index. shear sensitivity or low I l d z value, which limits the

BACKGROUND O F THE INVENTION

Molecular weight distribution (MWD), or polydis- pcrsity, is a well known variable in polymers. The molecular weight distribution, sometimes described as the ratio of weight average molecular weight (M,) to number average molecular weight (M,) (i.e., Mw/Mn) can be measured directly, e.g.. by gel permeation chromatog- r a ~ h v techniques, or more routinely, bv measurina Itn

extrudability of such polymers. Additionally, such polymen possessed low melt elasticity, causing problems in melt fabrication such as film forming processes or blow molding processes (e.g.. sustaining a bubble in the blown film process, or sag in the blow molding process etc.). Finally, such resins also experienced melt fracture surface properties at relatively low extrusion rates thereby processing unacceptably.

A; ratio, as described in ASTM D-i238. For &tear SUMMARY O F THE INVENTION polyolefins. especially linear polyethylene, it is well -,,,,, that as M w / M n increases. Elastic substantially linear olefin polymers have now

John Dealy in "Melt Rhtology and Its Role in PIas- been discovered which have unusual properti* includ- tiCS ~ocesSing-v pan ~~~~~~~d ~ ~ i ~ f t ~ l d , 1990) page 35 ing an unusual combination of properti=, which leads 597 discloses that ASTM D-1238 is employed with 10 enhat~ced processability of the novel polymers. The different loads in order to obtain an estimate of the shear subsfantially linear olefin polymers have the

rate dependence of melt vixlosity, which is to ability similar to highly branched low density polyeth- ! weight average molefular weight (M,) and number ~ l ene , but the strength in toughness of linear low den- ' average molecular weight ma) . 40 sity polyethylene. The substantially linear olefm poly-

Bersted in Journal of Applied Polymer science Val. mer are characterized as having a critical shear rate at 19, page 2167-2177 (1975) theorized the relationship Onset of surface melt fracture of at least 50 Percent between molecular weight distribution and steady shear greater than the critical shear rate at the onset of surface i melt viscosity for linear polymer systems. He also melt fracture of a linear olefin polymer having about the showed that the broader MWD material exhibits a 45 same 12 and Mw/Mn. higher shear rate or shear stress dependency. ??le elastic substantially linear olefin polymers also

Ramamurthy in Journal of Rheology, 30(2), 337-357 have a processing index (PI) less than or equal to about (1986), and Moynihan, Baird and Ramanathan in Jour- 70% of the P1 of a comparative linear olefin polymer at nal of Non-Newtonian Fluid Mechanics, 36, 255-263 about the same I2 and Mw/Mn. (1990). both disclose that the onset of sharkskin (i.e., 50 The elastic substantially Smear olefin polymers also melt fracture) for linear low density polyethylene have a melt flow ratio, llofl2,Z5.63, and a molecular (LLDPE) occurs at an apparent shear stress of weight distribution, M,/M,, defined by the equation: 1-1.4X 106 dyne/cm2, which was observed to be coin- cident with the change in slope of the flow curve. M f l , 5 0 1 d 1 2 ) - 4 . 6 3 .

Ramamurthy also discloses that the onset of surface 55 melt fracture or of gross melt fracture for high pressure Compositions comprising the substantially linear ole- low density polyethylene (HP-LDPE) occurs at an fin polymer and at least one other natural or synthetic apparent shear stress of about 0.13 MPa ( 1 . 3 ~ 106 dy- polymer are also within the scope of the invention. nes/cm2). Elastic substantially linear olefin polymers compris-

Kalika and Denn in Journol of Rheology. 31, 815-834 60 ing ethylene homopolymers or an interpolymer of eth- (1987) confirmed the surface defects or sharkskin phe- ylene with at least one C3-C2o a-olefin copolymers are nomena for LLDPE, but the results of their work deter- especially preferred. mined a critical shear stress of 2.3X 106 dyne/cm', significantly higher than that found by Ramamunhy and BRIEF DESCRIPTION O F THE DRAWINGS

~ o ~ n i h a n eial. International Patent Application (Pub- 65 FIG. 1 graphically displays dynamic shear viscosity lication No. WO 90/03414) published Apr. 5 . 1990. data for an elastic substantially Itnear olefin polymer of discloses linear ethylene interpolymer blends with nar- the present invention and for a comparative linear poly- row molecular weight distribution and narrow short mer made using single site catalyst technology. -

EXHIBIT PAGE 000263


DETAILED DESCRIPTION OF THE INVENTION

Other properties of the substantially linear polymers clude: a) a density from about 0.85 grams/cubic centimeter

(g/cm3) to about 0.97 g/cm3. and b) a melt index, 12, from about 0.01 grams/lO minutes

to about 1OOO gram/lO minutes. Preferably the melt flow ratio, I l d l o is from about 7

to about 20. The molecular weight distniution (Mu/M.) is prefer-

ably less than about 5, especially from about 1.5 to about 2.5, and most prder.bly from about 1.7 to .bout 2.3. I

Throughout this diilosurt. "melt index" or "12" is measured in accordance with ASTM D-1238 (190' C.R.16 kg); Tlo" is measured ii~ accordance with ASlM D-1238 (190' C A O kg). . . ~

The melt tension of these new polymers is also surprisingly good, e.& as high as about 2 grams or more, especially for polymers which have a very narrow molecular weight distribution (i.c.. M f l n from about 1.5 to about 2.5).

The substantially linear polymers of the present invention can be homopolymers of CpC20a-oIefis, such as ethylene, propylene, 4-methyl-I-pentcne, etc., or they can be interpolymers of ethylene with at least one CpCta-olefin and/or C2-Cz0 acetylenically unsaturated monomer and/or G-Cls diolefins. The substantially linear polymers of the present invention can also be interpolymers of ethylme with at least one of the above CJ-Czo a-olcfins, diolefins and/or acetylenically unsaturated monomers in combination with other unsaturated monomers.

Monomers usefully polymerized according to the present invention include, for example, ethylenically unsaturated monomers, acetylenic compounds, conjugated or nonconjugated dienes, polyenes, carbon mon- oxide, etc. Preferred monomers include the C r C l o a-olefins especially ethylene, I-propene, isobutylene, I-butene, 1 hexene, Cmethyl-I-pentene, and Isctene. Other preferred monomers include styrene, halo- or alkyt substituted styrenes, tctrafluoroethylene, vinylbenzocyclobutane, 1,6hexadiene, and naphthenics (e.g., cyclo pentene, cyclo-hexene and cyclooctene).

Other unsaturated monomers usefully polymerized according to the present invention include, for example, ethylenically unsaturated monomers, conjugated or nonconjugated dienes, polyenes, etc. Preferred monomers include the Cz-Clo a-olefins especially ethylene, 1-propene, isobutylene, 1-butene, I-hexene, Cmethyl-l- pentene, and I-octene. Other preferred monomers include styrene, halo- or alkyl substituted styrenes, tetra- fluorwthylene, vinylbenzocyclobutane, l,Chexadiene, and naphthenics (e.g., cyclopentene, cyclohexene and cyclooctene).

The term "substantially linear" polymers means that the polymer backbone is substituted with about 0.01 long chain branches/1000 carbons to about 3 long chain branches/1000 carbons, more preferably from about 0.01 long chain branches/1000 carbons to about I long chain branched1000 carbons, and especially from about 0.05 long chain branches/1000 carbons to about 1 long chain branches/IW carbons.

The term "linear olefin polymers" means that the olefin polymer does not have long chain branching That is: the linear olefin polymer has an absence of long chain branching, as for example the traditional linear

low density polyethylene polymers or linear high density p~lyethylene polymus made using Ziegler polymerization procesvs (e.g., U.S. Pat. No. 4,076,698 or U.S. Pat. No. 3,645,992, the disclosures of which are incorporated herein by reference). The term "liiear olefin polymers" does not refer to high pressure branched polyethylene, ethylene/vinyl acetate copoty- men, or ethylene/vinyl alcohol wpo lymm which arc known to those skilled in the art to have numerous long chain branches.

Long chain branching is defied herein as a chain length of at least about 6 carbons above which the length cannot be distinguished using 1% nuclear magnetic resonance spectroscopy. The long cbain brnnch can be as long as about the mw length as the length of the polymer back-bone.

Long chain branching is determined by using 13C - nuclear mametic resonance (NMR) s~ctrosco~y and is quantified &ing the method of ~ ~ d a i l (Rev. ~ o > m m o ~ Chem Ph-. C29 (2&3), p. 285-297), the disclosure of which is incorporated herein by reference.

"Melt tension" is measured by a specially designed pulley transducer in conjunction with the melt indexer. Melt tension is the load that the cxtrudate or fiarnent exerts while passing over the pulley at the standard speed of 30 rpm. The melt tension measurement is similar to the "Melt Tension Tester" made by Toyoseiki and is d e s c n i by John Dealy in "Rheometers for Molten Plastics", published by Van Nostrand Reinhold Co. (1982) on page 250-251.

The SCBDI (Short Chain Branch Ditniution Index) or CDBI (Composition Distribution Branch Index) is defied as the weight percent of the polymer molecules having a comonomer content within 50 percent of the median total molar comonomer content. The CDBI of a polymer is readily calculated from data obtained from techniques known in the art, such a& for example, tcm- perature rising elution fractionation (abbreviated herein as "TREF') as described, for exampIe, in Wild et al, Journal of Polymer Science. Poly. Phyr Ed., Vol. 20, p. 441 (1982). or in U.S. Pat. No. 4.798.081. both disclosures of which are incorporated herein by reference. The SCBDI or CDBI for the new polymers of the present invention is preferably greater than about 30 percent, especially greater than about 50 percent.

A unique characteristic of the presently claimed polymers is a highly unexpected flow property where the I IO/I~ value is essentially independent of polydispersity index (i.e. Md.). l h i s is contrasted with wnven- tional polyethylene resins having rhcological properties such that as the polydispersity index increases, the 1 lo. A2 value also increases.

The density of the ethylene or ethylene/a-olefin substantially linear olefin polymers in the present invention is measured in accordance with ASTM D-792 and is generally from about 0.85 g/cm3 to about 0.97 g/cm3, preferably from about 0.85 g/cm3 to about 0.9 g/cm3, and especially from about 0.85 g/cm3 to about 0.88 g/cm3.

The molecular weight of the ethylene or ethylene/a- olefin substantially linear olefin polymers in the present invention is conveniently indicated using a melt index measurement according to ASTM D-1238, Condition 190" Cl2.16 kg (formally known as "Condition (E)"

I and also known as 12). Melt index is inversely propor- tional to the molecular weight of the polymer. Thus, the higher the molecular weight, the lower the melr index, although the relationship is not linear. The melt index

EXHIBIT PAGE 000264


5,278,272 5 6

for the ethylene or ethylene/a-olefin substantially tin- The molecular weight determination is deduced by ear olcfin polymers used herein is generally from about using narrow molecular weight distribution polystyrene 0.01 grms/lO minutes W 1 0 min) to about 1000 g/10 standards (from Polymer Laboratories) in conjunction mixi, preferably from about 0.01 g/10 min to about 100 with their elution volumes. The equivalent polyethyl- g/10 min, and especially from about 0.01 g/10 min to 5 ene molecular weights are determined by using appro- .boot 10 g/10 min. priate Mark-Houwink coeficients for polyethylene and

Additives such as antioxidants (e.g., hindered pheno- polystyrene (as described by Wdlims and word in lies (e& %anox@ 1010)~ ~h-phi ta (e.g., lrgafm@ Jounut~ofPolymerSrience. PolymerLetterr Vol. 6, (621) 168)). cling additives (e.g., PIB), antiblock additives, 1968, incorporated herein by reference) to derive the pigments, and the like can also be included in the p l y - 10 following equation: etbylene compositions, to the extent that they do not Interfere with the enhanced properties discovered by ~pa3n~+=@(~prprwP. Applicants.

The compositions comprising the substantially linear In this equation, a=0.4316 and b= 1.0. Weight avenge oMin polymers are famed by any convenient method, 1s molecular weight, M,,, is calculated in the usual manner including dry blending the individual components and according to the following formula: M,=R w,*Mi, ~ u ~ u e n t l y melt mixing, either dircctly in the extruder where wiand Miare the weight fraction and molauiar 4 to make the finished article (e.g.. fW, or by pre- weight, respectively, of the id fraction eluting from the d t mixing in a separate extruder. The polyethylesse*- - 'GPC column. ampositions may also be prepared by multiple reactor 20 polymaization techniques. For example. one reactor Processing Index Determination mY polymerire the constrained geometry catalyzed The rheological processing index (PI) is measured by p d ~ e t h ~ l e n e and another reactor polymerize the hew- a gas extrusion rheometer (GER). The GER is de- ogeneous cstalyzed polyethylene, either in series or in scribed by M. Shida, R. N. Shroff and L. V. Cancio in parallel operation. 25 Polym. Eng. Sci., Vol. 17, no. 1 1, p. 770 (1977). and in

The improved melt elasticity and processibility of the - ~ h ~ ~ ~ ~ t ~ for ~ ~ l t ~ ~ plastiM* by john ~ ~ ~ l ~ , pub- wbtant ia l l~ fincar polymers according to the P r m t lished by Van Nostrand Reinhold CQ. (1982) on page invention result, it is believed, from their method of 97-99, the disclosures of both ofwhich Ire incorporated production. The poiYmers be produced via a con- herein by reference. The processing index is measured h ~ ~ u s (as o p p o ~ d to a batch) controfled polymerim- 30 at a temperature of 190' C., at nitrogen pressure of 2MO tion Pr- using at one reactor, but can also be psig using 0.0296 inch diameter, 20:1 L/D die having an produced using multiple reactors (c.g., using a multiple entrance of 180'. me GER index is reactor configuration as described in U.S. Pat. No. calculated in millipoiK units from the fouowing 3.914.342) at a polymerization temperature and pressure tion: suff~cient to produce the interpolymers having the de- 35 sired properties. According to one embodiment of the P I - 2 . 1 5 ~ lo6 dyna/cm2/(lm0xrheu rrte), present proms, the polymers are produced in a continuous process, as o p p o d to a batch process. Preferably, where: 2 . 1 5 ~ 106 dynes/cmZ is the shear stress at 2M0 the plymerimtion temperature is from about 20' C. to psi, and the shear rate is the shear rate at the wall as about 250' C., using constrain~d geometry catalyst s0 represented by the following equation: technology. If a narrow molecular weight distribution polymer (MJM, of from about 1.5 to about 2.5) having 32 Q./ ( 6 a . - / m i n X 0 . 7 4 ~ ~ ~ ~ m c t ~ x 2 . n d i n ) ) , . . a higher I lf l2 ratio (e.g. Itofl;~ of about 7 or more, whcrc:

preferably at least about 8, especially at least about 9) is desired, the ethylene concentration in the reactor is 45 Q' is the extrusion rate (gms/min), preferably not more than about 8 percent by weight of 0.745 is the melt density of ~ l ~ e t h ~ l e n e &m/cm3), the reactor contents, especially not more than about 4 and percent by weight of the reactor contents. Preferably, Diameter is the orifice diameter of the capillar~ th polymerization is in a solution polymeri- (inches). The PI is the apparent viscosity of a material ution process. Generally, manipulation of Iifli, while 50 measured at apparent shear stress of 2.15X 106 dy- holding M J M , relatively low for producing the novel ne/cm2. polymers described herein is a function of reactor tern- For the substantially linear olefin polymers disclosed pcrature and/or ethylene concentration. Reduced eth- herein, the Pi is less than or equal to 70 percent of that ykne concentration and higher temperature generally of a comparative linear olefin polymer at about the same produces higher 1 10/12. 55 I2 and MdM,. An apparent shear stress vs. apparent

shear rate plot is used to identify the melt fracture phe- Molecular Weight Distribution Determination nomena. According to Ramamurthy in Journol of Rhe-

The whole interpolymer product samples and the ology. 30(2), 337-357, 1986, above a certain critical flow individual interpolymer samples are analyzed by gel rate, the observed extrudate irregularities may be permeation chromatography (GPC) on a Waters 150" M) broadly classified into two main t y : surface melt C. high temperature chromatographic unit equipped fracture and gross melt fracture. with three mixed porosity columns (Polymer Laborato- Surface melt fracture occurs under apparently steady r i a 103, 104, 105, and 106). operating at a system temper- flow conditions and ranges in detail from loss of specu- ature of 140' C. The solvent is 1,2,4-trichlorobenzene, lar gloss to the more severe form of "sharkskin". In this from which 0.3 percent by weight solutions of the Sam- 65 disclosure, the onset of surface melt fracture is charac- ples are prepared for injection. The flow rate IS 1.0 terized at the beginning of losing extrudate gloss at millil~ters/m~nute and the injection size is 2M) microlr- which the surface roughness of extrudate can only be ~ers. detected by 40X magnification. The critical shear rate

EXHIBIT PAGE 000265


5,278,272 7 8

at onset of surface melt fracture for the substantially n is 0, 1,2, 3, or 4 and is 2 less than the valence of M; linear olcfm polymers is at least 50 percent greater than and the critical shear rate at the onset of surface melt frac- Y is an anionic or nonanionic ligand group bonded to ture of a linear olefin polymer having about the same 1z Z and M comprising nitrogen, phosphorus, oxygen or and MJM.. 5 sulfur and having up to 20 non-hydrogen atoms, option-

Gross melt fracture occurs at unsteady flow condi- ally Y and Z together form a fused ring system. tions and ranges in detail from regular (alternating More preferably still, such complexes correspond to rough and smooth, helical, etc.) to random distortions. For commercial acceptability. (e.g., in blown film products), surface defects should be minimal, if not absent. The critical shear rate at onset of surface melt fracture (OSMF) and onset of gross melt fracture (OGMF) will be usad herein based on the changes of surface roughness and configurations of the extrudates extruded by a GER.

The Constrained Geometry Catalyst

Suitable constrained geometry catalysts for use herein preferably include constrained geometry catalysts as disclosed in U.S. application Ser. Nos.: 545,403, fded Jul. 3, 1990, Ser. No. 758.654, filed Sep. 12, 1991; Ser. No. 758,660, filed Sep. 12, 1991; and Ser. No. 720,041, filed Jun. 24, 1991, the teachings of all of which are incorporated herein by reference. The monocyclopentadienyl transition metal ofefin polymerization catalysts taught in U.S. Pat. No. 5,026,798, the teachings of which are incorporated herein by reference, are also suitable for use in preparing the polymen of the present invention.

The foregoing catalysts may bc further described as comprising a metal coordination complex comprising a metal of groups 3-10 or the Lanthanide series

of the Periodic Table of the Elements and a delocalized s-bonded moiety substituted with a constrain- inducing moiety, said complex having a constrained geometry about the metal atom such that the angle at the metal between the centroid of the delocalized, substituted r-bonded moiety and the center of at least one remaining substituent is less than such angle in a similar complex containing a similar n-bonded moiety lacking in such constrain-inducing substituent, ,and provided further that for such complexes comprising more than one delocalized, substituted x-bonded moiety, only one thereof for each metal atom of the complex is a cyclic, detocaiued, substituted r-bonded moiety. The catalyst further comprises an activating cocatalyst.

Preferred catalyst complexes correspond to the formula:

wherein: M is a metal of group 3-10, or the Lanthanide series

of the Periodic Table of the Elements; Cp* is a cyclopentadienyl or substituted cyclopenta-

dienyl group bound in an q5 bonding mode to M; Z is a moiety comprising boron, or a member of

group 14 of the Periodic Table of the Elements, and optionally sulfur or oxygen, said moiety having up to 20 non-hydrogen atoms, and optionally Cp* and Z together form a fused ring system;

X independently each occurrence is an anionic ligand group or neutral Lewis base hgand group hax-ing up to 30 non-hydrogen atoms;

the formula:

wherein: R' each occurrence is independently selected from

20 the group consisting of hydrogen, alkyl, aryl, silyl, ger- my], cyano, halo and combinations thereof having up to 20 non-hydrogen atoms;

X each occurrence independently is selected from the group consisting of hydride, halo, alkyl, aryl, silyl, ger-

25 my], aryloxy, alkoxy, amide. siloxy, neutral Lewis bast ligands and combinations thereof having up to 20 non- hydrogen atoms;

Y is -4-, -S-. -NRa--, -PRe-, or a neutral two electron donor ligand selected from the group

30 consisting of OR*, SR*, NR*z or PR.2; M is as previously defined; and Z is SiRez, C R * t SiR*2SiRa2, CR*2CRe2.

CRe=CR*, CRezSiR*z, GeR.2, BR*, BRe2; wherein

35 R* each occurrence is independently selected from the group consisting of hydrogen, alkyl, aryl, silyl, halogenated alkyl, halogenated aryl groups having up to 20 non-hydrogen atoms, and mixtures thereof, or two or more Re groups from Y, Z, or both Y and Z form a

40 fused ring system; and n is 1 or 2. It should be noted that whereas formula I and the

following formulas indicate a cyclic structure for the catalysts, when Y is a neutral two electron donor ligand, the bond between M and Y is more accurately

45 referred to as a coordinatecovalent bond. Also, it should be noted that the complex may exist as a dimer or higher oligomer.

Further preferably, at least one of R', 2, or R* is an electron donattng moiety. Thus, highly preferably Y is

50 a nitrogen or phosphorus containing group wrrapond- ina to the formula -N(R")- or -P(R"h. wherein - . . . , . R" is Cl-10 alkyl or aryl, i.e., an amido or phosphido group.

Most highly preferred complex compounds are amidosilane- or amidoalkanediyl- compounds corresponding to the formula:

R

65 wherein:

M is titanium. zirconium or hafnium, bound in an ~ ) 5

bonding mode to the cyclopentadienyl group;

EXHIBIT PAGE 000266


5,278,272 9 10

R' each occurrcnce is independently selected from nation Complex (I)", filed in the names of Peter Nickas the group consisting of hydrogen, silyl, alkyl, aryl and and David Wilson, on Oct. IS, 1991 and the copending combinations thereof having up to 10 carbon or silicon application Ser. No. 778,432 entitled: "Preparation of atoms; Metal Coordination Complex (11)". filed in the names of

E is silicon or carbon; 5 Peter Nickias and David Devore, on Oct. IS, 1991, the X independently each occurrence is hydride, halo, teachings of which are incorporated herein by reference

nlkyl, aryl, aryloxy or alkoxy of up to 10 carbons; thereto. m is 1 o r 2; and Suitable cocatalysts for use herein include polymeric n is 1 o r 2. or oligomeric aluminoxanes, especially methyl alumi- Exampla of the above most highly preferred metal 10 noxane, as well as inert. compatible, noncoordiiting,

coordination compounds inciude compounds wherein ion forming compounds. -fled modifid methyl the R' on the amid0 F o u P is methyl, ethyl, P ~ O P Y ~ , aluminoxane (MMAO) is dx, suitable for use as a cocat- butyl, psntyl, huyl , Cmcluding isomers), n o h r n ~ l , l p t . One technique for preparing such modified dumi- h z y f . p h m ~ l , etc.; the c ~ c l o ~ e n m d i e n ~ l F o u P CY- noxane is disclosed in U.S. Pat. NO. 5.04f.584, the teach- clopentadienyl, indenyl. ~uahydro indmyl , fluorenyl. 15 ings of which are incorporated herein by refnmce. ~ctah~drofluorenyl , ttc.; R' on the foregoing c~c lopen- Aluminoxan& can dso be made as disclosed in U.S. Pat. t ad ien~l F o W s each ~ccurrence is hydrogen* methyl* Nos. 5,542,199; 4,544,762; 5,015,749; and 5,041,585, the ethyl, propyi, butyl, pentyl, hexyl. (including i.Wmers)+ entire specification of each of which is incorporated.

,

e o h r n y l , benzyl, phenyl, etc.; and X is chloro, bromo, herein by reference. Preferred cocatnlysts are inert, iodo, methyl, ethyl, propyl, butyk pentyl, h e x ~ l , (in- 20 non-rdinating, boron compounds. cluding isomers), norborn~l, bcnzyl, ~ h e n ~ l , Ctc. S F - Ionic catalyst species which be used to cific compounds includc: (ten-butylamidoXtetrameth- po~ymek the polymers desc-jbed herein yl-q5cyclopentadieny1>1,2-~thanediylzirconium di- lo the formula: chloride, (ten-butylamido~tetramethyl-q%yclopenta- dienyl) 1,2-~thanediyltitanium dichloride, (me- 25 thylamidoXtetramethy1-qkyclopcntadieny1)-1.2- 2-Y ethanediyizirconium dichloride, (methylamidoXtet- / /

Cp'-M + A- ramethyl-qJ cyclopentadieny1)-1.2-ethanediyltitanium \ dichloride, (ethylamidoXtetramethyI-q5-cyclopen- CXb- I tadicnvll.methvlmehtanium dichloro, (terl- 30 . . - ., butylamido)dibenzyl(tctramethyl-q~-cyclopentadienyl) dlanuirconium dibenzyl, (benzylamido)dimethyI(tetramethyl-q~cyclopentadienyl)silanetitanium dichloride, (phenylphosphido)dimethyl(tetramethyl q5- cyclopentadicny1)silanezirconium dibenzyl, (tertbutylamido)dimethyl(tetramcthyl-qkyclopen- tadieny1)silanetitanium dimethyl, and the like.

The complexes may be prepared by contacting a derivative of a metal, M, and a group I metal derivative o r Grignard derivative of the cyclopentadienyl compound in a solvent and separating the salt byproduct. Suitable solvents for use in preparing the metal complexes are aliphatic or aromatic liquids such as cyclohexane. methvlcvclohexane. Dentane, hexane, heptane,

wherein: M is a metal of group 3-10, o r the Lanthanidc series

of the Periodic Table of the Elements; Cp* is a cyclopentadienyl o r substituted cyclopenta-

dienyl group bbund in an r)s bonding mode to M; Z is a moiety comprising boron, o r a member of

group 14 of the Periodic Table of the Elements, and 20 optionally sulfur o r oxygen, said moiety having up to 20 non-hydrogen atoms, and optionally Cp* and Z together form a fused ring system;

X independently each occurrence is an anionic ligand group or neutral Lewis base ligand group having up to 30 non-hydrogen atoms;

n is 0, I, 2, 3, or 4 and is 2 less than the valence of M; . . tetrahydrofuran, diethyl ethkr, benzene, toluene, xy- 45 and lene, ethylbenzene, etc., or mixtures thereof. A- is a noncoordinating, compatible anion.

In a preferred embodiment, the metal compound is 0 ° C method of making the ionic catalyst MX,+,, i.e., M is in a lower oxidation state than in the which can be utilized to make the polymers of the P r a - corresponding compound, MX,+* and the oxidation Cnt invention involve combining: state of M in the desired final complex. A noninterfering M a) af kast one first component which is a mono(c~- oxidizing agent may thereafter be employed to raise the clopenfadienyl) derivative of a metal of Group 3-10 or oxidation state of the metal. The oxidation is acmm- the Lanthanide Series of the Periodic Table of the Ele- plished merely by contacting the reactants utilizing ments containing at least one substituent which will solvents and reaction conditions used in the preparation combine with the cation of a second component (de- of the complex itself. By the term "noninterfering oxi- 55 scribed hereinafter) which first component is capable of &zing agent" is meant a compound having an oxidation forming a cation formally having a coordination num- potential sufficient to raise the metal oxidation state ber that is one less than its valence, and without interfering with the desired complex formation b) at least one second component which is a salt of a o r subsequent polymerization processes. A particularly Bronsted acid and a noncoordinating, compatible anion. suitable noninterfering oxidizing agent is AgCl or an 60 More panicularly, the noncoordinating, compatible organic halide such as methylene chloride. The forego- anion of the Bronsted acid salt may comprise a single ing techniques are disclosed in U S . Ser. Nos.: 545,403, coordination complex comprising a charge-bearing filed Jul. 3, 1990 and Ser. No. 702.475, filed May 20, metal or metalloid core, which anion is both bulky and 1991, the teachings of both of which are incorporated non-nucleophilic. The recitation "metalloid", as used herein by reference. 65 herein, includes non metals such as boron, phosphorus

Additionally the complexes may be prepared accord- and the like which exhibit semi-metallic characteristics. ing to the teachings of the copending application serial illustrative, but not limiting examples of monocy- number 778,433 entitled: "Preparation of Metal Coordi- clopentadienyl metal components (first components)

EXHIBIT PAGE 000267


5,278,272 11 12

which may be used in the preparation of cationic com- available commercially. In light of this, salts containing plexes are derivatives of titanium, zirconium. vanadium, anions comprising a coordination complex a hafnium, chromium, lanthanum, etc. Preferred compo- Single boron atom preferred.

are titanium Or zirconium compounds. Highly preferably, the second component useful in of monocyclopentadienyl metal compounds are the preparation of the catalysts of this invention may be h~drocarb~l-substituted monoc~clopentad ien~~ metal represented by the following formula: compounds such as (ten-butylamido)(tetramethyl-$- cyclopmtadienyl~l.2~hanediylzirconium dimethyl,

0--H)+ [A]- (tertbutyIamidoXtetramethy1-q5-cyclo~nyI 1,2- ethancdiyltitaniurn dimethyl, (mcthylamido)(tetrameth- 10 yl-r)~eyclopenudienyl~l,2~thanediylzirc diben- wherein: zyl. (methylunido~tetramethy1-r)51yc10pmtadieny1~ is a Lewis -; 1.2-ah.ncdiyItitanium dimethyl. (ethylamidoXtet- (L-H)+ a Bronsted acid; and m e t h y l r)5cyclopentadienyl)metfiylenetitanium di- [A]-- is a compatible, n o n m r d i m t i n g anion. mahyl, (tertbutylamido)dibenzyl(tetrme(hyl-q5- 1s More preferably [A]-corresponds to the formula: cyclopentadieoyl) silanezimnium dibmzyl. (ben- zylmido)dmethyl(tetramethyl-qseyclopenMienylb W'W- silanctitanium diphenyl, @henylphosphido)dimethyl(- % *: - - .- '

tarmethyl-q~1yclopentadieny1)silanezirium di- wherein: benzyl, and the like. 20 M' is a metal o r metalloid selected from Groups 5-13

Such WmponmB are readily prepared by combining of the Periodic Table of the Elements; and the corresponding metal chloride with a dilithium d t

Q each occurrence is xlected from the of the substituted c ~ c l o ~ n t a d i e n ~ l group such as a Group consisting ofhydride, dia]kylamido, halide, &- c~clopmtadien~l-~kanedi~l. cyclopentadienyl-~;lane oxide, ary]ofide, hydrocsrbyl, and substituted-hydro- amide, o r cyclopentadienyl-phosphidc compound. 25 The reaction is conducted in an inert liquid such as carby1 radicals of UP to 20 carbons with the proviso that

tetrahydrofuran, Cs-$0 alkanes, toluene, etc. utilizing in more lhan One occurrence is Q and conventional synthetic procedures. Additionally, the q is One more than the vaknce of M'. first components may be prepared by reaction of a Second components comprising boron which are group 11 derivative of the cyclopentadienyl compound 30 particularly useful in the preparation of catalysts of this in r solvent and separating the salt by-product. Magne- invention may be represented by the following general sium derivatives of the cyclopentadienyl compounds formula: are preferred. The reaction may be'conducted in an inert solvent such as cyclohexane, pentane, tetrahydro- &-HI+ IrrQ41- furan, diethyl ether, benzene, toluene, o r mixtures of the 35 like. The resulting metal cyclopentadienyl halide corn- wherein: plena may be alkylated using a variety of techniques. L is a neutral h,,,is bax; Generally, the metal cyclopentadienyl alkyl o r aryl l L - ~ ~ + is a ~~~~~~~d acid; complexes may be prepared by alkylation of the metal is boron in a valence state of 3; and cyclopentadienyl halide complexes with alkyl o r aryl N

is as previously defined+ derivatives of group I or group I1 metals. Preferred alkylating agents are alky] lithium and Grignard deriva- ~l~ustrat ive, but not limiting, examples of boron com-

tives using conventional synthetic techniques. The reac- pounds which may b~ used as a component in

tion may be conducted in an inen solvent such as cyc]o- the preparation of the improved catalysts of this invcn- hexane, pentane, tetrahydrofuran, diethyl ether, ben- 45 tion are trialkyl-substituted ammonium salts such as zene, toluene, o r mixtures of the like. A preferred sol- triethylammonium tetraphenylborate, tripropylam- vent is a mixture of toluene and tetrahydrofuran. monium tetraphenylborate, tris(n-buty1)arnmonium tet-

Compounds useful as a second component in the raphenylborate, trimethylammonium tetrakis@toiyl)- preparation of the ionic catalysts usefuf in this invention borate, tributylammonium tetrakis@entafluorophenyl> will comprise a cation, which is a Bronsted acid capable 54 borate, tr~propy~ammonium tetr&is(2,4ctjmethy]- of donating a proton, and a compatible noncoordinating phenyl)borate, tributylammonium tetr&(3,5-dimc- anion. Preferred anions are those containing a single thylphenyl)borate, triethylammonium tetralis(3,5-di- coordination complex comprising a charge-bearing metal o r metalloid core which anion is relatively large trifluoromethylpheny1)borate and the like. Also suitable @ulky), capable of stabilizing the active catalyst species 55 are NJJ-diaJkyl anilinium salts such as NN-dimethyl- (the G~~~~ 3-10 or ~ ~ ~ ~ h ~ ~ i ~ ~ series cation) which is aniliniumtetraphenylborate, N,Ndiethylanilinium tet- formed when the two components are combined and raphenylborate, N.N-2.4.6-pentamethylanilinium tetra- sufiiciently labile to be displaced by olefinic, diolefinic phenylborate and the like; dialk~l-onium s&-~ such and acetylenically unsaturated substrates or other neu- as di-(i-propyl)ammonium tetrakisfpentafluorophenyl)- tral Lewis bases such as ethers, nitriles and the like. 60 borate, dicyclohexylammonium tetraphenylborate and Suitable metals, then, include, but are not limited to, the like; and triaryl phosphonium salts such as tri- aluminum, gold, platinum and the like. Suitable metal- phenylphosphonium tetraphenylborate, tri(methyl- loids include, but are not limited to, boron. phosphorus, pheny~)phosphonium tetrakispentafluorophenylborate. silicon and the like. Compounds containing anions t~(dime~hylphenyl)phosphonium tetraphenylborate which comprise coordination complexes containing a 65 and the like. single metal or metalloid atom are, of course, well Preferred ionic catalysts are those having a limiting known and many, particularly such compounds containing a single boron atom in the anion porrion, are charge separated structure corresponding to the for-

mula.

EXHIBIT PAGE 000268


5,278,272 14

It is believed that in the constrained geometry cata-

2-Y t lysts used herein the metal atom is forced to greater / / exposure of the active metal site because one or more

CpW-M + XA0- \

substituents on the single cyclopentadienyl or substi-

(Xh-1 5 tuted metal is both bonded to an adjacent covalent moiety and held in association with the cyclopentadie-

wherein: nyl group through an $or other *-bonding interaction. M a metal of group 3-10, or the ~ ~ ~ ~ h ~ i d ~ It is understood that each respective bond between the

of the Puiodic Table of the Elements; metal atom and the constituent atoms oftbecyclopcnta- cp* is a cycbpentadienyl or substituted cyclopcnta- 10 d icn~ l or substituted c~clooentadien~l moue need not

dienyl group bound in an q5 bonding mode to M; Z is a moiety comprising boron, o r a member of

m u e 14 of the Periodic Table of the Elements. and optidnally sulfur or oxygen, said moiety having up to 20 non-hydrogen atoms, and optionally Cp* and Z to-

gether form a fused ring system; X independently each occurrence is an anionic ligand

group o r neutral Lewis base ligand group having up to 30 non-hydrogen atoms;

n is 0, 1,2,3, or 4 and is 2 less than the valence of M; 20 and

XA*- is -XB(C&5)3. This class of cationic complexes may be conveniently

prepared by contacting a metal compound corresponding to the formula: 25

/z/Y Cp* - M

'mr

wherein: Cp*. M, and n are as previously defined, with tris(-

pentafluorophenyl)borane cocatalyst under conditions 35 to cause abstraction of X and formation of the anion -

-XB(CaF5)3. Preferably X in the foregoing ionic catalyst is ClClo

hydrocarbyl, most preferably methyl. The preceding formula is referred to as the limiting,

charge separated structure. However, it is to be understood that, particularly in solid form, the catalyst may not be fully charge separated. That is, the X group may retain a partial covalent bond to the metal atom, M. Thus, the catalysts may be alternately depicted as pos- .,5 xssing the formula:

The catalysts are preferably prepared by contacting the derivative of a Group 4 or Lanthanide metal with the tris@entafluorophenyI)borane in an inert diluent 55 such as an organic liquid. Tris(pentafluorpheny1)borane is a commonly available Lewis acid that may be readily prepared according to known techniques. The compound is disclosed in Marks. et al. 3. Am. Chem. Soc. 1991, 113, 3623-3625 for use in alkyl abstraction of 60 zirconocenes.

All reference to the Periodic Table of the Elements herein shall refer to the Periodic Table of the Elements, publ~shed and copyrighted by CRC Press. lnc., 1989. Also, any reference to a Group or Groups shall be to 65 the Group or Groups as reflected in this Periodic Table of the Elements using the IUPAC system for numbering groups.

be &ivalent. That is, ihe metal may bcsynkctricafly or iansvmmetrically n-bound to the cycloventadienyl or - - substitked cyclo~ntadienyl group.

The geometry of the active metal site is further defined as follows. The centroid of the cyciopentrrdienyl or substituted cyclopentadienyl group may be defied as the average of the respective X, Y. and Z umrdinates of the atomic W n t m forming the cyclopentadienyl or substituted cyc lo~ tad ieny l group. The angle. 8, formed at the metal center between the centroid of the cyclopentadienyl or substituted cyclopentadienyl group and each other ligand of the metal complex may be easily calculated by standard techniques of single crys- tal X-ray diffraction. Each of these angles may increase or decrease depending on the molecular structure of the constrained geometry metal complex. Those complexes wherein one or more of the angles, 8, is less than in a similar, comparative complex differing only in the fact that the constrain inducing substituent is replaced by hydrogen, have constrained geometry for purposes of the present invention. Preferably one or more of the above angles, 8, decrease by at least 5 percent, more preferably 7.5 percent, compared to the comparative complex. Highly preferably, the average value of all bond angles, 8 i s also less than in the comparative complex.

Preferably, monocyclopcntadiayl metal mrdina- tion complexes of group 4 or lanthanide metals according to the present invention have constrained geometry such that the smallest angle, 8 between the centroid of the Cp* group and the Y substituent, is less than 115'. more preferably less than 110'. most preferably less than 105*, and especially less than 1W.

Other compounds which are useful in the catalyst compositions of this invention, especially compounds containing other Group 4 or Lanthanide metals, will, of course, be apparent to those skilled in the an.

Polymerization

The polymerization conditions for manufacturing the polymers of the prtxnt invention are generally those useful in the solution polymerization process, although the application of the present invention is not limited thereto. Slurry and gas phase polymerization processes are also believed to be uxful, provided the proper catalysts and polymerization conditions are employed.

Multiple reactor polymerization processes are also useful in the present invention, such as those disclosed in US. Pat. No. 3,914,342, incorporated herein by reference. The multiple reactors can be operated in series or in parallel, with at least one constrained geometry catalyst employed in at least one of the reactors.

In general, the continuous polymerization according to the present invention may be accomplished at conditions well known in the prior art for Ziegler-Natta or Karninsky-Sinn type polymerization reactions, that is, temperatures from 0" to 250" C. and pressures from atmospheric to 1OOO atmospheres (100 MPa). Suspen-

EXHIBIT PAGE 000269


15 sion, solution, slurry, gas phase or other process conditions may be employed if desired. A support may be employed but preferably the catalysts are used in a homogeneous (LC., soluble) manner. It will, of course, be appreciated that the active catalyst system, especially nonionic catalysts, form in situ if the catalyst and the cocatalyst components thereof are added directly to the polymerization process and a suitable solvent or diluent, including condensed monomer, is used in said polymerization process. It is, however, preferred to form the active catalyst in a separate step in a suitable wlvent prior to adding the same to the polymerization mixture.

The polymerization conditions for manufacturing the polymers of the present invention are generally those useful in the solution polymerization process, although the application of the present invention is not limited

16 All procedures were performed under an inen atmo-

sphere or nitrogen or argon. Solvent choices were often optional, for exampie, in most cam either pentane o r 30-60 petroleum ether can be interchanged. Amines,

5 silancs, lithium reagents, and Grignard reagents were purchased from Aldrich Chemical Company. Published methods for preparing tetmethylcyclopentadiene (C5Md2) and lithium tctramc*hyl~y~IopcnWienide (Li(C5Md)) include C. M. Fendrick et d. Ogonome-

10 rolfics 3, 819 ( 1984). Lithiated ~bst i tu ted cyclopcnta-

thereto. Gas phax poiymerization prr- are dm . believed to be useful, provided the proper catalysts and polymerization conditions are employed. 20

Fabricated articles made from the novel olefin polymen may be prepared using all of the conventional polyolefin proc cyiDn techniques. Useful articles in-

e. . w a ), ik%iEA:i r= Ec12h:duse-fin 25 polym&-disc1;Kcd herein as at kas t one component comprising at least a portion of the fiber's surface), spunbound fibers or melt blown fibers (using, e.g., systems as disclosed in U.S. Pat. No. 4,340,563, U.S. Pat. ,o No. 4,663,220, U.S. Pat. No. 4,668.566, or U.S. Pat. No. 4,322,027, all of which are incorporated herein by reference), and gel spun fibers (e.g., the system disclosed in US. Pat. No. 4,413,110, incorporated herein by reference)), both woven and nonwoven fabrics (e.g., spun- 35 laced fabrics disclosed in U.S. Pat. No. 3,485,706, incorporated herein by reference) or structures made from such fibers (including, e.g., blends of these fibers with other fibers, e.g., PET or cotton) and molded articles (cg., made using an injection molding process, a blow 40 m_oldina -moldina ~rocess). The new polymers described herein are also useful for wire and . - cable coating operations, impact modification, especially at low temperatures, of thermoplastic oiefins (e.g., polypropylene), as well as in sheet extrusion for 45

Useful compositions are also suitably prepared com-

thermoplaj&-ions. . Compositions comprising the olefin polymers can

also be formed into fabricated articles such as those 65

previously mentioned using conventional polyolefin processing techniques which are well known to those skilled in the a n of polyolefin processing.

dienyl compounds may be typically prepared from the corresponding cyclopcntadiene nnd a lithium -gent such as n-butyf lithium. Titanium trichloride (TicI3) was purchased from Aldrich Chemical Company. lire tetmhydrofiunn adduct of ticmiurn trichloride, TiC13(M[F)3, was prepared by refluxing Tic13 in THF overnight, cooling, and isolating the blue solid product. according to the procedure of L. E. bfuuer. Inorg. Syn. 21, 135 ( 1982).

EXAMPLES

The polymer products of Examples 1 and 3 are produced in a continuous solution polymerization pro- using a continuously stirred reactor, as dewxibad in copending application serial number O7/776,1M, filed Oct. 15. 1991. The metal complex [C5Mq(SiMe2N- rf)u)]TiMe2 is prepared as described in copending application Ser. No. 07/776,130 and the cocatalysts uscd are tris(pcntafluorophcny1) borane (B:Ti ratio of 2:l) and MMAO (A1:Ti ratio of 4:l). For Example 1 the ethylene concentration in the reactor is about 1.10% and for Example 3 the ethylene concentration in the reactor is about 1.02% (percentages based on the weight of the reactor contents). For each Example, the reactor is run without hydrogen.

Additives (e.g., antioxidants, pigments, etc.) can be incorporated into the interpolymer products either during the pelletization step or after manufacture, with a subsequent rc-cxtrusion. Examples 1 and 3 are each stabilized with 1250 ppm Calcium Stcarate, 200 ppm Irganox 1010, and 1600 ppm Irgafos 168. Irgafosni 168 is a phosphite stabilizer and Irganox TM 1010 is a hindered polyphenol stabilizer (e.g., tetrakis [methylene 3-(3,5ditert.butyl4hydroxyphenylpropionate)]me- thane. Both are trademarks of and made by Ciba-Geigy Corporation.

Example 1 and Comparative Example 2

Example 1 is an ethylene/l octene elastic substantially linear olefin polymer produced as described herein.

Comparative Example 2 is an ethylene/l-butene copolymer containing butylated hydroxy toluene (BHT) and I r g a n o x r ~ 1076 made by Exxon Chemical and trademarked Exact TM . Table 1 summarizes physical properties and rheological performance of these two polymers:

TABLE l Compararrvc

Propcny Example 1 Example 2

1: 3 3 3 58

EXHIBIT PAGE 000270


5,278,272 17 18

TABLE ltontinued made by single site catalyst technology at the melt processing shear rate region of commercial interest. In

Compuarwc Eumple l Lumple 2 addition, the novel elastic substantially linear olefin

b i - Y polymers have a higher low sheadzero shear viscosity UudE Modulus @ 87.7 8.3 0.1 ndks 5 than the Comparative linear polymer, thus dcmonstrat- (dyner/cm2) ing that the copolymers of the invention have higher OSMF*. c n w 660 2% "green strength" which is useful for forming and main- shear rate fuc- ') taining blended compositions such as t h o x used in the

-d.llrfaraelrlrnlm wire and cable coating industry, where the com-

lo pounded materials must maintain their integrity at low Even though and Comparative or zero shear without segregating the components.

have very similar molecular weight distributions (MJMA. 17 and density. E x a m ~ l e 1 has a much lower Example 3 and Comparative Example 4 . - . ., . - processing index (PI) (38% of ;he PI of Comparative Example 2). a much higher onset of surface melt fracture (264% incru~x in OSMF) and an elastic modulus an order of magnitude higher than Comparative Exam- ple 2, demonstrating that Example 1 has much better processnbility and higher melt elasticity than Compara- tive Example 2.

Elastic modulus is indicative of a polymer's melt stability, e.g., more stable bubbles when making blown

Example 3 is an ethylene/l-octene elastic substantially linear olefur polymer produced in a continuous solution polymerization process as d e s c n i herein.

Comparative Example 4 is an ethyleneA-propenc copolymer made by Mitsui PetroChcmical Corporation and trademarked Tafmer TM PW80. Table 3 summarizes physical properties and rheological performance of these two polymers:

film a i d I& neck-in. Resultant physical properties of TABLE 3 the finished film are also higher. h ~ . n r i v c

Onset of surface melt fracture is easily identified by 25 .fiopeny Example 3 . Eumplc 4 visually observing the surface extrudate and noting 1.01 1.1 when the extrudate starts losing gloss and small surface WIO I' minuter) roughness is detected by using 40 X magnification. -sirK 0.870 0.870

Dynamic shear viscosity of the polymers is also used (%on )

to show differences between the polymers and measures 3o l i d 2 7.62 6.06 M f i m 1.98 1.90

viscosity change versus shear rate. A Rheometrics Me- PI 7.9 27.4 chanical Spectrometer (Model RMS 800) is used to &Poise) measure viscosity as a function of shear rate. The RMS Elutic Modulus @ 964 567.7 800 is used at 190' C. at 15% strain and a frequency 0.1 nd/m

(dyner/cm2) sweep (i.e., from 0.1-100 rad/xc) under a nitrogen 35 OSMF., 781 105 purge. The parallel plates are positioned such thai they shear rate (m- I ) have a gap of about 1.5-2 mm. Data for Example I and .- rmure Comparative Example 2 are listed in Table 2 and graphically displayed in FIG. 1. Even though Example 3 and Comparative Example 4

TABLE 2 40 have similarly narrow molecular weight distributions Dynamic Dynamic Vtwosit) (MJM,,). 12, and density. Example 3 has a PI which is Viscosity (poise) 28% of that of Comparative Example 4, a 743% in-.

Shear Rate (poi=) for Cnmparativc crease in onset of surface melt fracture and a higher (rad/scc) for Exnmplc I Examplc 2 elastic modulus than Comparative Example 4, demon-

0.1 28290 18990 18870 45 strating that Example 3 has much better processability 0.1585 28070

0.2512 27630 18950 than Comparative Example 4. Onset of surface melt 0.3981 27140 18870 fracture is easily identified by visually observing the 0.63) 26450 18840 surface extrudate and notinn when the extrudate starts . - . . - - - - " I 25560 18800

24440 186W losing gloss and small surface roughness is detected by

1.505 2.512 23140 18540 SO using 40Xmagnification. 3.981 217W 18310 We claim: 6.31 20 170 17960 1. A substantiallv linear olefin wlymer characterized

Surprisingly, Example 1 shows a shear thinning behaviour. even though Example 1 has a narrow molecu- 60 lar weight distribution. In contrast, Comparative Exam- ple 2 shows the expected behaviour of a narrow molecular weight distribution polymer, with a flatter viscosity/shear rate curve.

Thus, elastic substantially linear olefin polymers 65 made in accordance with the present invention (e.g. Example 1) have lower melt viscosity than a typical narrow molecular weight distribution linear copolymer

. - as having:

a) a mett flow ratio, 1 1 d I z , S 5 . 6 3 , b) a molecular weight distribution. M,/M,, defined

by the equation:

c) a critical shear rate at onset of surface melt fracture of at least 50 percent greater than the critical shear rate at the onset of surface melt fracture of a linear olefin polymer having about the same I2 and M,/M,. and wherem the olefin polymer is further characterized as a copolymer of ethylene with a C,-C20 alpha-olefin.

2 The substantially linear olefin polymer of claim 1 wherein the MJM, is less than about 3.5.

EXHIBIT PAGE 000271


5,278,272 19 20

3. The substantially linear olefin polymer of claim 1 22 The composition of claim 17, wherein the substan- wherein the Mw/M. is from about 1.5 to about 2.5. tially linear olefin polymer 1s a copolymer of ethylene

4. The substantially linear olefin polymer of claim 3 and I-octene. wherein the Itdl2 is at least about 8. 23. The composition of claim 17. wherein the substan-

5. The substantially linear olefin polymer of claim 3 5 tlally llnear olefin polymer is a copolymer of ethylene wherein the I1&2 is at least about 9. and I-hexene.

6. The substantially linear olefin polymer of claim 1 24. The composition of claim 17, wherein the substan- wherein the polymer is a substantially linear ethylene tially linear olefin polymer is a copolymer of ethylene polymer having from about 0.01 to about 3 long chain and I-butene. brancha/1000 carbons d o n g the polymer backbone. 10 25. The composition of c lam 17, wherein the substan-

7. The substantially linear olefin polymer of claim 4 tially linear olefin polymer is a c o p o t ~ m e r of ethylene having at least about 0.05 long chain branches/1000 and rl-methyl-1-pentme. carbons d o n g the polymer backbone. 26. A substantially linear olefin polymer character-

8. The substantially linear olefin polymer of claim 4 ized as a copolymer of ethylme with a C3-Cn, alpha-

having at least about 0.3 long chain b r a n c h d l 0 0 0 car- 1s olefin and having: bans dong the polymer backbow. a) a melt flow ratio, I d I Z , ~ 5 . 6 3 ,

9. The substantially linear oiefin polymer of claim 1, b) a molecular weight distribution, Mm,, defined

wherein the polymer is a copolymer of ethylene and by the quation:

1 -octene. 10. The substantiallv linear olefin polymer of claim 1, 20 MdMns(i'dizt-4 63' md

wherein the polymer7is a copolym& of ethylene and I-hexene. c) a processing index (PI) less than o r equal to about

70% of rhe PI of a comparative linear olefin poly- 11. The substantially linear olefin pqlymer of claim 1. mer at about the same I* and M,/M,.

wherein the polymer is a ''polymer and 25 27. The ]inear olefin po]ymer of 1, I-butene. wherein the polymer is in pelletized form.

12. The substantially linear olefin polymer of claim 1, 28. The pelletized substantially linear olefin polymer wherein the polymer is a copolymer of ethylene and of 27, wherein the density of the polymer is from 4-methyl-I-pentene. about 0.85 g / c d to about 0.9 g/cm3.

13. The subtantialty linear olefin polymer of claim 1, 30 29. The pelletized linear olefin pofymcr wherein the polymer is a copolymer of ethylene and ofclaim 27, wherein the dmsity of the polymer is from I-octene. about 0.85 g/cm3 to about 0.88 g/cm3.

14. The substantially linear olefin polymer of claim 1, jg. The substantially linear olefin polymer of claim wherein the polymer is a copolymer of ethylene and wherein the winner is in wlletized form, l -hexene. 35 31. The peiletized subs&ntially linear olefin polymer IS. The substantially linear olefin polymer of claim 1, of claim jg, the dmsity of the polymer is from

wherein the polymer is a copolymer of ethylene and about 0.85 g/cm3 to about 0.9 g/cm3. I-butene. 32. The pelletized substantially linear olefin polymer

16. The substantially linear olefin polymer of claim 1, of claim 30, wherein the density of the poiymer is from wherein the polymer is a copolymer of ethylene and 40 about 0.85 g/cm3 to about 0.88 g/cm3. 4-methyl-I-pentene. 33. The substantially linear olefin polymer of claim 17. A composition comprising a substantially linear 26, wherein the poiymer is in form.

olefin polymer, wherein the polymer is characterized as 3q. ne pelletized subsbntially linear olefin polymer having: of claim 33, wherein the density of the polymer is from

a) a melt flow ratio, I IO/ I~ ,Z 5.63, 45 about 0.85 g/cm3 to about 0.9 g/cm3. b) a molecular weight distribution, Mw/Mn, defined 35. The pelletized substantially linear olefin polymer

by the equation: of claim 33, wherein the density of the polymer is from about 0.85 g/cm3 to about 0.88 g/cm3.

M,/M.Z(lidl~)-4.63. and 36. A film layer comprising a substantially linear 50 olefin polymer, wherein the substantially linear olefin

c) a critical shear rate at onset of surface melt fracture polymer is characterized as having: of at least 50 percent greater than the critical shear a) a melt now ratio, 1 , d 1 ~ , ~ 5 . 6 3 , rate at the onset of surface melt fracture of a linear b) a mo)ecular weight distribution, M,/M,, defined olefin polymer having about the same 12 and by the equation: M,/M,, and wherein the olefin polymer is further 55 characterized as a copolymer of ethylene with a M,/MnS(I~o/I~)-4.63. and

C3-C2oalpha-olefin and (b) at least one other natural or synthetic polymer. c) a critical shear rate at onset of surface melt fracture

18. The composition of claim 17 wherein the substan- at least 50 percent greater than the critical shear tialiy linear olefin polymer has a Ild12 up to about 20. 60 rate at the onset of surface melt fracture of a linear

19. The composition of claim 17 wherein the substan- olefin polymer having about the same 12 and tially linear olefin polymer has a M,/M,less than about Mw/Mn, and wherein the olefin polymer is further 3.5. charactenzed as a copolymer of ethylene with a

20. The composition of claim 17 wherein the subsran- C3-Czo alpha-olefin. tially linear olefin polymer has a MJM, from about 1.5 65 37. A film layer composition comprising a substan- to about 2.5. tlally linear olefin polymer, wherein the substantially

21. The composition of claim 17 wherelr? the syn- linear olefin polymer is characrerlzed as having: thetic polymer is a conventional olefin polymer. a) a melt flow ratio, IlO/I2,>= 5.63,

EXHIBIT PAGE 000272


5,278,272 21 22

b) a molecular weight distribution, Mw/Mn, of from olefin polymer at about the same Iz and Mw/Mn, 1.5 to 2.5, and and wherein the olefin polymer is further charac-

c) a critical shear rate at onset of surface melt fracture terized as a copolymer of ethylene with a C3-C20 of at least 50 percent greater than the critical shear alpha-olefin. rate at the onset of surface melt fracture of a linear 5 I * . . .

EXHIBIT PAGE 000273


USOO5374700A

United States Patent [I91 [ill Patent Number: 5,374,700 Tsutsui et aL [45] Date of Patent: Dec. 20, 1994

[54] COPOLYMER OTHER PUBLICATIONS

[75] Inventors:

[73] Assignee

[21] Appl. No.:

1221 Filed:

T o s h i ~ TsuW =en Yoshitsugu; Chien, et aL, "Mctallocenc-Mcthylaluminoxanc Cata- Tabhi Uedn, aXl of Kuga. Japan lysts For Ofefin Polymerization. I. Trimethylallrminum

Mitrui Petrochemical Indostries, as CoactivatoZ', J. Polymer Sdmart A: Polymer

Ltd.. Tokvo. Japan Chemistry. 26, No. 11, Oct. 1988. 3089-3102.

Primary Examiner-Fred Teskin Anorney, Agent, or F i r m S h e r m a n and Shalloway

Apr. 17,1991 191 ABSTRACT

[30] Foreign Appliution Priority Data

Apr. 18, 1990 [PI Japan .,.--...---.-.-.--. . 2-1021M) May 14, 1990 [JP] Japan ..... .................-.. 2-123858 Aug. 8, 1990 [JPl Japan -.----.---.-....---.. 2-211334

1511 Int. CI.5 ...........-..,..... CosF 210/16; CQ8F 4/602 (521 US, CL ...-................--.- 526/3483; 526/128;

526/129; 526/160; 526/348; 526D48.2; 526/348.5; 526B48.6; 526/904

[58] Field of Senrfh ..................... 526/160, 348, 348.5. 526/348.6, 348.2, 348.3, 904, 128

1561 References Cited U.S. PATENT DOCUMENTS

FOREIGN PATENT DOCUMENTS

0347128 12/1989 Europcan Pat Off. . 62-53313 3/1987 Japan ........................... S26/125 1-101315 4/1989 Japan . 3-074411 3/1991 Japan .

The present bvcntion provides an ethylene copolymer comprising constituent units (a) derived from ethyltnr: and constitncnt units @) duived from an a-olefin having 3 to 20 carbon atoms, the ethylene copolymer being characterized in that

(A) the ethylene copolymer has a density (d) of 0.86 to 0.95 g/cm;';

(B) the ethylene copolymer has a MFX of 0.001 to 50 g/10 min as measured at a temperature of 190' C. and a load of 2.16 kg;

(C) the melt tension (MT) and MFR of the ethylene copolymer satisfy the relation

log MD -0.66 log MFR+0.6; and

@) the temperature 0;) at which the exothermic curve of the ethylene copolymer measured by a diffamtial scanning dorimeta @SC) shows tbc highest peak and the density (d) satisfy the rdation

2 (Raims, 3 Drawing Sheets

EXHIBIT PAGE 000274


U.S. Patent Sheet 1 of 3

EXHIBIT PAGE 000275


US. Patent Dec. 20, 1994 Sheet 2 of 3

Absorption (%)

I * I I I I I I I

1500 1000 c m-' E peaks based on nujol

EXHIBIT PAGE 000276


U.S. Patent Dec. 20,1994 Sheet 3 of 3 5,374,700

Absorption (%) I

1

I

Y f

I 1 I I I I I I

1500 1000 crn-'

8 peaks based on nujol

EXHIBIT PAGE 000277


5,374,700 1 2

been proposed a proccss for the preparation of ImwLENE COPOLYMER ethylenda-olefin wpolymm using such a new type

=talyst FIELD OF THE INVENTION For example, Japanese Patent L-0-P No. 19309/1983

The present invention relates to a novel ethylene disc^ a P- for ~ lymer idng ethylene with one copolymu; more pvticululy to a novel ethylene co- Or two C N 1 2 aalefins at a ternpaam of polymer having ZURVW composition distnibah md -50. to 200' C, in the prcietlce of a cntalyrt c o m m m d m t melt Won compared with known ethy2. of 1 transition m a d compound represented by the for- ene copolymenr mula

Furthermore, the present invention relates to I pro- lo ccs for the preparation of an olefin polymer, cspccially (-cp.y1)1= R

an cthylcnc polymer, more particularly to a proccs for ribc prcparath of an ethylene polyma being excellent wherein R is c~dop~ntQdim~1. a]kylb$~halog~n, - in melt tension, and, m the mse of a copolymer, having Me is a t i a d o n metal and Hal is h.k,gC& and a hf%r a narrow composition distn'bution. 15 aluminoxam rep-ted by the foxmula

Still furthermore. the present invention relates to a solid catalvtt for olefin wlvmeniation and a orocm for ~ f i W ~ t - o L

procm for gas phase polymcriUtion, capable of pm- ducing, with high polymerization activities, a sphere olefin polymer u c d a r t in particle properties when applied to these polymerization processes with use of an organoaluminum oxycomponnd in a decreased 25

4A10--0+l amount, and excellent in melt tension, and a proccs for wh- R and n are as defined above olefin polymctizatjon using the catalyst Japanese Pateat L0-P No. 19309/1983 discloses an

BACKGROUND OF THE INVENTION invention relating to pmceses for preparing a linear alnminoxane represented by the fonnnh

Ethylene wpolymers have heretofore been molded by various molding methods, and used in many fields The requirement for the charactaistics of the ethylene copolymers Wer depending on the molding methods ant uss For example, when an inffation film is molded at a high speed, it is necmary to select an ethylene 35 R/ wpolymer having a high melt tension compared with its m o b d a r weight in order to stably conduct hi& whes~in n is a n ~ b e z of 2 to 40, nnd R is c,-cs +I, rpeod molding without 5uctoation Qr t c h g of bnb- and a cyclic alumimxane represented by the formula bles An ethylene copolymer is nquired to have similar characteristics m order to Drcvent sap: or tearine in blow 40 molding, or to suppress width shortaie to the &urn range in Tdie molding. -+z

A high-pressure lowdensj. polyethylene has a high m a t t-on -pard with an ethylme whndn n and R as d e f i above The ~ a m c P a t d prepared with a Ziegla type catalyst, md is used as a 45 Pubk&on also disdm a P- for the pol- material for fiIms and hollow containm The high-pres tion of 0- e g . a * Y s Vrpned by -& for sure low density polyethylene as d s c n i above has -pk d y 1 a l e - e prepand by the above low mechanical strength such 8s tensile strength, m~~ pr- a Wcyciopentadienyl) com- strmgth and impact strength, and in addition it has also pound of titanium or Zkoninm- h w heat resistance, low stress cracking resistance, etc. 50 Patent L4-P NO. 3KK)5/1985 discloxs a

On the other hand, Japanse Patent L6P Nos. P r o c s for preparing an olefin po lymht ion caMYsl, 90810/1981 and 106806/1985 pzopasc a method for wherein the Process amp* reacting an d ~ o x a n e improving the melt tension and blow ratio (die/swell W r m t e d by the f ~ r f d a ratio) of ethylene pol- obtained by wing Ziegler - type catalysts, especially a titanium type catalyst. 55

Thc ethylene polymers obtained by using a titanium R'

catalyst, howcvcr, apccially the low density ethylene \ ~ l - &-&Al/R' polymers generally have problems such as their broad

RO /

composition distribution and stickiness of their molded \RO articles such as fdms. 60

Accordingly, the advent of ethylene polymers having wherein R' is Ci-Clo *yl, and RO is R1 or RO repre- an excellent melt tension and a narrow composition sents -0- by tinkage, with a magnesium compound at distribution will industrially be of great value. first, then chlorinating the reaction product, and treat-

There has reccntly been developed a new Zicglcr ing with a compound of Ti V, Zr or Cr. trpc catalyst for oIefin polymerization comprising a 65 Japanese Patent L O P No. 35Cr)6/1985 discloser a zirconium compound and an aluminoxane, said catalyst catalyst composed of mono- di- or tkyclopentadienyl- being capable of producing ethylene/a-olefin copoly- transition metals (a) (transition metals beimg at least two mers with high polymerization activities. There has also different metals) or rheir derivatives and an alumoxane

EXHIBIT PAGE 000278


(aluminoxad in combhati& Euunde 1 of this Patent &liation &lasa that ethylene &d propylcnc KC polymeriztd to form a polyethylene in the presence of a ca9yst c0mcOmposc4 of biitamethylcyclopcn- tackeny1)zirConxum~ethyl and an aluminoxam= In 5 Exmn& 2 of this ~ & t pnblication, ethylene md propylenc are polymcrked to form a polymer blend of a pdyethyiene d an ethylmJpropylme wpolyma in the presence of P catalyst composed of b i i t a m e - ~ylcyclopentPdimyi)drconi~dichloride, biimethyl- 10 cydopcntadienyr);drconium dichloride and an alumox- me.

Japanese Patent GO-P No. 35007/1985 dirdoscs a procesr wherein &yIcne tkmc is polymcrbcd, 'or ethylene and an a-olefin of not less than 3 carbon atoms are 15 wpolymuized in the presence of metallorme, and a cyclic aluminoxme represented by the formula

,700 4

preparation of a composition composed of an ethylene polymer and a filler, which proces comprises polymer- idng ethylene or copolymerizing ethylene and a-olefin ia the presence of a produd prepared by contacting a highly activated catalyst component comprising a hy- dmcarbonaolublc tiraniam compound and/or P zirconium compound with a filler, an orgarrarluminum mm- pound and P fills having m .mnity for polyolcfrn

Japanese Patent LQ-P No. 31404/1986 discloses a process for plymaking ethylene or oopolymuiziug ethylene and an a-alcfin in thc preynu: of a catalyst mixture composed of a traodtion metal cumpound and a product obtained by t& reaction of txialkylaluminm and water in the prrrena of dliccm dioxide or aluminum oxide

Furthermore, Japanese Patent LO-P No. 276805/1986 discloses that okfin is pol- in the presence of a catalyst composed ofa drconinm compound and a reaction mixture obtained by reacting an duminosane with trialkylaluminum at first. and further

w h e r ~ ~ ~ u r ~ y i s m u P o f l ~ ~ ~ ~ m s . a n d b ~ ~ g f b e r ~ i r ~ o n ~ ~ ~ t h ~ h a n is an inwer of to aboot 24 or a kUIT aluminorane *org.nic o* having a hydroxide group on the sur-

reprcxoted by the formula fact as &a. 25 Still hthermore, Japanex Potent LOP Nos.

108610A986 and 296008A986 Moses a proms for polymaizing olefin in the presence of a catalyst m a4-&AlR2 which a transition mctd compound such as ~ O C Q ~ C

andmdrrminardnemesuppottedonacarriasnchas x an morganic oxide

wherein R and n are as defined above. Howeva, daring the polymuization or wpolymer- Japanese Patent GO-P No. 35008/1985 discloses a ization of oldin in a swpemion w gas phase by using

process for the prepandon of a polyethy1ene or a co- snch a solid catalyst component supported on a &cr polymer of ethylene and a C d i o a01& whack a as dcsraibcd in the abovc-mcntioned Patent publns, the

system camprSsing not less than two types of 35 catalyst COm.ponent conridtably lowaa the polymeri- metalloome and an alumoxane is used. zation activities compared with the abovedcscri i

Tho- the catalys~ formed from a tm.dti0~. metal solution plymerization, and the remlting polymers do oompound and aluminoxam proposed by the prior have a sathfactory b& d+. art are excellent in polymaization activities, especially ethylene polymerization activities compared with those 40 OBJECT OF THE MVENnON a t a l ~ s b having been known @or to the aPPearane of The pr-t invention fs intended to solve snch prob- these catalysts and formed from a transition metal com- lems m t d the prior ut tocw 16 do-

and = ~ g a n ~ ~ ~ ~ ~ a m p ~ a n d , of the - above, and an objact af the h ~ & * t~ pro- are * the and in - vide an ethylene aqm~ymer being e x d e n t in melt

cases the p v for the prepanrtkm are limited to a 4s and narnxv composition - rolutiOn P ~ Y ~ ~ ~ ~ vncm. In the Another objsn of prCSQlt invation ee lws h v e ~~~ a problem that the productivity of a a process for the preparation of ethylene polymer is lowered due to a marked increw in the being in tension, in the case of a viscosity of the polymercontaining reaction solution when ibe - & a e of a polymes hving a high mo- X, w~ol~mer , having a narrow c o m ~ t i o n lecalar weight is tried, that the polymer obtained by A still furthcr objcct of the i n v d o n is to provide

aftu:aftu:trrahnent of has a low bulL spc solid catalysts for olefrn polymerization capable of man- csc grav;ty, and that the of a sphere poly- ufacturing with high activities What olefin p o l ~ m

ma having =dent pdde propertis is dimcult excellent m particle prop& and melt tension even On the other hand, polymerization of olefin has been 55 when are to P ~ Y ~ ~ ~ ~ ~ ~ and

tried in a suspension polymerization system or a gas kW p h m pol~mekt ion with an organoaluminum phase polymerization system by -g catalysts in oxyampound used in a IarS quantity. and to W

which at least one of the transition metal compound out d e f i Pol~merization by using such catalysts having component and the aluminoxane component described gOOd p r o ~ d c s - above is supported on a porous inorganic oxide carrier 60 such as silica, alomina and silica-alumina.

SUMMARY OF THE INVENTION.

For example, Japanese Patent LO-P Nos. The ethylene copolymer according to the Prmnt 35006/1985, 3~@7/1985 and 35008/1985 described invention is an ethylene copolymer comprising constit- above disclose that there be used catalysts in which uent units (a) derived from ethylene and constituent a transition metal compound and an aluminoxane are 65 units @)derived from an (a-olefrn having 3 to 20 carbon supported on silica, alumina, silica-alumina, etc. atoms, and is characterized in that:

Fnrthermore, Japanese Patent GO-P Nos. (A) the ethylene copolymer has a density (d) of 0.86 106808/1985 and 106809/1985 disclose a process for the to 0.95 g/cm3;

EXHIBIT PAGE 000279


b g hlT>-Ol6 kxg MRIi-0.6 35

A first prepo1ymuized polyolefin-wutahhg solid catalyst (hmeinaftcr refer to ~epo iymuized solid a t . - lyst) for olefin polymtriution pccording to the prsent invention is characterized in that the solid d y s t is formed by prepolyrnerizing olefrn in a s+on or a 40 gas phase in the prescnce of a catalyst comprising

[A] a fine particle carrier, p] a transition metal armpound (designated as a

non-bridge type transition metal compound hereinafter) mmpris'ig ligaods having a cydopentadie- 45 nyl skeleton, the cydopentadknyl skeletons being not bonded mutually,

[i=] a transition metal wmpomnd (designated as a bridge type metal compound) comprising at least two ligands o c h having a cyclopcntadimyl skelo 2 ton, said at lcasr two ligands being bonded together through an alkylac group, a substituted alkylene group, a silylme group or a substituted dylene group, and

p] an organoaluminum oxycompound. 55 A second olefin polymerization catalyst according to

the present invention is characterized in that the o l e h polymerization catalyst is formed from the abovc- described c o m p e n t s [A], @I. [C] and [Dl, and [El an organaaluminum compound. 60

Furthermore, a stcond process for the preparation of oletin polymer accordmg to the present rnventlon com- pnses polymermug or copolymerizing olefin in the presence of the solid catalyst as described above.

BRIEF DESCRIPTION OF THE DRAWING 65

FIG. 1 shows an endothermic c w e obtained by measuring heat absorption of an ethylene copolymer

a diameter of 10 mm nuder the f o l l d g conditions: a measuring temperature of 1UT C, a measuring frequency of 25.05 MHz, a spcctmm width of 1500 Hz, a pulse repetition period of 4-2 see and a pulse width of 6 lLSec

Eramples of the a-olefin having 3 to 20 carbon atoms include propylenc, 1-butcnc, 1-pcntac, I-hcxenc, 4- methyl-1-pcntcnc, I-octene, l-decene, ldodecene, 1- tetradeanc, l ~ m n c , 1-octadmne and l z i m Sent

The ethylene copolyma according t o the present invention desirably has a MFR of awl to 50 g/10 min, preferably 0.01 to 20 9/10 min.

The determination of the MER is canied out in accordance with ASTM DlU8-65T. under the conditions af a temperature at 190' C and a load at 216 kg.

Furthemore, the melt tension (hfJJ and MFR of the ethylene copolymer of the invention satisfy the following relation:

1% M>-0.66 log MFR+0.7. more prcfenbly

tog m>-0.66 log hfFR+O.B.

As described above, the ethylene copolymer of the invention is excellent in melt tension (MT), and has good moldabiity. In addition, the melt tcnsion Ovrr) is dctcrmined by

measuring the strcss of a molten mpolymcr while the molten copolymcr is bei ig stretched at a constant rate. That is, a produced copolymer powder or a polymer obuined by once dissolving the copolymer powder in

EXHIBIT PAGE 000280


Documents

· United States Patent [II] Patent Number: Lai et al. 1451 Date of Patent: Dee. 21, 1993 Inventon: Shib-Yaw Lai, Sugar Laad; Jdra R Whm, Richwood; G~xw@? W. Knigi~t, Lake Jackson,