Support materials for use with polymerization catalysts

Abstract

The invention provides new olefin(s) polymerization catalyst systems, including polytetrafluoroethylene support. The invention also provides methods of preparing the catalyst system, and to the catalyst system's use in a gas or slurry polymerization process.

We claim:  
     
         1 . A catalyst system comprising a polytetrafluoroethylene support material, a catalyst compound, and an activator compound.  
     
     
         2 . The catalyst system of  claim 1 , wherein the polytetrafluoroethylene support material further comprises surface functionality.  
     
     
         3 . The catalyst system of  claim 2 , wherein the surface functionality is selected from the group consisting of amines, azides, alkylamines, thiols, alkylthiols, alcohols, diols, carboxylic acids, and combinations thereof.  
     
     
         4 . The catalyst system of  claim 1  wherein the catalyst compound is a bulky ligand metallocene catalyst compound.  
     
     
         5 . The catalyst system of  claim 1  wherein the catalyst compound is a Group 15 containing metal catalyst compound.  
     
     
         6 . The catalyst system of  claim 1  wherein the activator compound is selected from the group consisting of methylalumoxane, modified methylalumoxane, ethylalumoxane, isobutylalumoxane, and combinations thereof.  
     
     
         7 . The catalyst system of  claim 1  wherein the activator compound is a stoichiometric activator.  
     
     
         8 . A method of making a supported catalyst system, the method comprising the steps of: 
 a) combining a catalyst compound with an activator compound to form an activated catalyst compound; and    b) combining the activated catalyst compound with a polytetrafluoroethylene support material.    
     
     
         9 . The method of  claim 8  wherein the catalyst compound is selected from the group consisting of a bulky ligand metallocene catalyst compound, a Group 15 containing metal catalyst compound, and combinations thereof.  
     
     
         10 . The method of  claim 8  wherein the activator compound is selected from the group consisting of methylalumoxane, modified methylalumoxane, ethylalumoxane, isobutylalumoxane, a stoichiometric activator compound, and combinations thereof.