Catalyst system and its use in a polymerization process

Abstract

The present invention relates to a catalyst system of a Group 15 containing metal catalyst compound and a Lewis acid aluminum containing activator and to a supported catalyst system thereof and to a process for polymerizing olefin(s) utilizing them.

We claim:  
     
         1 . A process for polymerizing olefin(s) in the presence of a catalyst system comprising a Group 15 containing metal catalyst compound and a Lewis acid aluminum containing activator.  
     
     
         2 . The process of  claim 1  wherein the Group 15 containing metal catalyst compound is a Group 15 containing bidentate or tridentate ligated metal catalyst compound.  
     
     
         3 . The process of  claim 1  wherein the Group 15 containing metal catalyst compound is a metal atom bound to at least one substituted alkyl leaving group having 6 or greater carbon atoms and to at least two Group 15 atoms, where at least one of the at least two Group 15 atoms is bound to a Group 15 or 16 atom through a bridging group.  
     
     
         4 . The process of  claim 3  wherein the bridging group is selected from the group consisting of a C 1  to C 20  hydrocarbon group, a heteroatom containing group, silicon, germanium, tin, lead, and phosphorus.  
     
     
         5 . The process of  claim 4  wherein the Group 15 or 16 atom may also be bound to nothing, a hydrogen, a Group 14 atom containing group, a halogen, or a heteroatom containing group, and wherein each of the two Group 15 atoms are also bound to a cyclic group and may optionally be bound to hydrogen, a halogen, a heteroatom or a hydrocarbyl group, or a heteroatom containing group.  
     
     
         6 . The process of  claim 1  wherein the Group 15 containing metal compound is represented by the formulae:  
       
         
           
           
               
               
           
         
       
       wherein 
 M is metal;  
 each X is a leaving group;  
 y is 0 or 1;  
 n is the oxidation state of M;  
 m is the formal charge of the YZL or the YZL′ ligand;  
 L is a Group 15 or 16 element;  
 L′ is a Group 15 or 16 element or Group 14 containing group;  
 Y is a Group 15 element;  
 Z is a Group 15 element;  
 R 1  and R 2  are independently a C 1  to C 20  hydrocarbon group, a heteroatom containing group having up to twenty carbon atoms, silicon, germanium, tin, lead, or phosphorus;  
 R 3  is absent or a hydrocarbon group, hydrogen, a halogen, a heteroatom containing group;  
 R 4  and R 5  are independently an alkyl group, an aryl group, substituted aryl group, a cyclic alkyl group, a substituted cyclic alkyl group, a cyclic arylalkyl group, a substituted cyclic arylalkyl group or multiple ring system;  
 R 1  and R 2  may be interconnected to each other, and/or R 4  and R 5  may be interconnected to each other;  
 R 6  and R 7  are independently absent, or hydrogen, an alkyl group, halogen, heteroatom or a hydrocarbyl group; and  
 R* is absent, or is hydrogen, a Group 14 atom containing group, a halogen, a heteroatom containing group.  
 
     
     
         7 . The process of  claim 6  wherein R 4  and R 5  are represented by the formula:  
       
         
           
           
               
               
           
         
       
       wherein R 8  to R 12  are each independently hydrogen, a C 1  to C 40  alkyl group, a halide, a heteroatom, a heteroatom containing group containing up to 40 carbon atoms, preferably a C 1  to C 20  linear or branched alkyl group, preferably a methyl, ethyl, propyl or butyl group, any two R groups may form a cyclic group and/or a heterocyclic group. The cyclic groups may be aromatic.  
     
     
         8 . The process of  claim 7  wherein R 9 , R 10  and R 12  are independently a methyl, ethyl, propyl or butyl group and X is a substituted alkyl group having greater than 6 carbon atoms.  
     
     
         9 . The process of  claim 7  wherein R 9 , R 10  and R 12  are methyl groups, and R 8  and R 11  are hydrogen and X is a alkyl substituted with an aryl group.  
     
     
         10 . The process of  claim 6  wherein L, Y, and Z are independently nitrogen, R 1  and R 2  are a hydrocarbon radical, R 3  is hydrogen, and R 6  and R 7  are absent.  
     
     
         11 . The process of  claim 6  wherein L and Z are independently nitrogen, L′ is a hydrocarbyl radical, and R 6  and R 7  are absent.  
     
     
         12 . The process of  claim 1  wherein the catalyst system is supported on a carrier.  
     
     
         13 . The process of  claim 1  wherein the process is a continuous gas phase process.  
     
     
         14 . The process of  claim 1  wherein the process is a continuous slurry phase process.  
     
     
         15 . The process of  claim 1  wherein the olefin(s) is ethylene or propylene.  
     
     
         16 . The process of  claim 1  wherein the olefins are ethylene and at least one other monomer having from 3 to 20 carbon atoms.  
     
     
         17 . The process of  claim 1  wherein the catalysts system further comprises an activator.  
     
     
         18 . A supported catalyst system comprising: a Group 15 containing metal catalyst compound, an activator and a carrier.  
     
     
         19 . The supported catalyst system of  claim 18  wherein the Group 15 containing metal catalyst compound is a Group 15 containing bidentate or tridentate ligated metal catalyst compound having a substituted hydrocarbon leaving group.  
     
     
         20 . The supported catalyst system of  claim 18  wherein the Group 15 containing metal catalyst compound is contacted with the activator to form a reaction product that is then contacted with the carrier.