Process for production of trialkoxyhalosilanes, process for production of alkoxy (dialkylamino) silanes, catalysts for (co)polymerization of a-olefins, catalyst components therefor, and processes for polymerization of a-olefins with the catalysts

Abstract

A process for the production of trialkoxyhalosilanes which comprises reacting a tetrahalosilane [37] with a tetra-alkoxysilane [38] in the presence of an alcohol whose alkoxy group is the same as those of the tetraalkoxysilane to thereby obtain a trialkoxyhalosilane [39], characterized in that the alcohol is used in an amount of 5 to 50% by mole based on the total amount of Si of the tetrahalosilane and the tetraalkoxysilane: SiX 4 [37] (wherein X is halogeno) Si(OR 1 ) 4 [38] (wherein R 1 is a hydrocarbon group having 1 to 6 carbon atoms) XSi(OR 1 ) 3 [39] (wherein X and R 1 are each as defined above).

1 - 22 . (canceled)  
   
   
       23 . A process for production of trialkoxyhalosilanes, which comprises reacting a tetrahalosilane represented by Formula 1 with a tetraalkoxysilane represented by Formula 2 in the mixture of an alcohol composed of the same alkoxy group as that of the tetraalkoxysilane to yield a trialkoxyhalosilane represented by Formula 3, wherein the alcohol is used in an amount of 5-50% by mol based on a total amount of Si in the tetrahalosilane and the tetraalkoxysilane:  
       SiX 4   [Formula 1] 
     (where X denotes halogen)  
       Si(OR 1 ) 4   [Formula 2] 
     (where R 1  denotes a hydrocarbon group having 1-6 carbon atoms)  
       XSi(OR 1 ) 3   [Formula 3] 
     (where X denotes halogen; and R 1  a hydrocarbon group having 1-6 carbon atoms).  
   
   
       24 . The process for production of trialkoxyhalosilanes according to  claim 23 , wherein a molar quantity of the tetraalkoxysilane in use is more than three times the molar quantity of the tetrahalosilane in use.  
   
   
       25 . The process for production of trialkoxyhalosilanes according to  claim 23 , wherein X is chlor and R 1  is ethyl in the compound represented by Formulae 1-3.  
   
   
       26 . The process for production of trialkoxyhalosilanes according to  claim 24 , wherein X is chlor and R 1  is ethyl in the compound represented by Formulae 1-3.  
   
   
       27 . A process for production of trialkoxyhalosilanes, which comprises reacting a tetrahalosilane represented by Formula 4 with an alcohol represented by Formula 5 at a controlled temperature of 40° C. or below to yield a trialkoxyhalosilane represented by Formula 6:  
       SiX 4   [Formula 4] 
     (where X denotes halogen)  
       R 1 OH  [Formula 5] 
     (where R 1  denotes a hydrocarbon group having 1-6 carbon atoms)  
       XSi(OR 1 ) 3   [Formula 6] 
     (where X denotes halogen; and R 1  a hydrocarbon group having 1-6 carbon atoms).  
   
   
       28 . The process for production of trialkoxyhalosilanes according to  claim 27 , wherein the reaction of the tetrahalosilane with the alcohol is performed in the presence of an acid catalyst.  
   
   
       29 . The process for production of trialkoxyhalosilanes according to  claim 28 , wherein the acid catalyst is a hydrogen halide secondarily produced in the reaction.  
   
   
       30 . The process for production of trialkoxyhalosilanes according to  claim 27 , wherein X is chlor and R 1  is ethyl in the compound represented by Formulae 4-6.  
   
   
       31 . The process for production of trialkoxyhalosilanes according to  claim 28 , wherein X is chlor and R 1  is ethyl in the compound represented by Formulae 4-6.  
   
   
       32 . The process for production of trialkoxyhalosilanes according to  claim 29 , wherein X is chlor and R 1  is ethyl in the compound represented by Formulae 4-6.  
   
   
       33 . A process for production of trialkoxy(dialkylamino) silanes, which comprises a first step including the process for production of trialkoxyhalosilanes according to  claim 23;  and a second step of reacting the trialkoxy halosilane obtained in the first step with a dialkylamine represented by Formula 7 to yield a trialkoxy(dialkylamino) silane represented by Formula 8:  
       R 2 R 3 NH  [Formula 7] 
     (where R 2  denotes a hydrocarbon group having 1-12 carbon atoms; and R 3  a hydrocarbon group having 1-12 carbon atoms)  
       R 2 R 3 NSi(OR 1 ) 3   [Formula 8] 
     (where R 1  denotes a hydrocarbon group having 1-6 carbon atoms; R 2  a hydrocarbon group having 1-12 carbon atoms; and R 3  a hydrocarbon group having 1-12 carbon atoms).  
   
   
       34 . The process for production of trialkoxy(dialkylamino) silanes according to  claim 33 , wherein the reacted mixture obtained in the first step is reacted with the dialkylamine represented by Formula 7, without subjecting to isolation/purification.  
   
   
       35 . The process for production of trialkoxy(dialkylamino) silanes according to  claim 33 , wherein X is chlor and R 1 , R 2  and R 3  are ethyl in the compound represented by Formulae 1-8.  
   
   
       36 . The process for production of trialkoxy(dialkylamino) silanes according to  claim 34 , wherein X is chlor and R 1 , R 2  and R 3  are ethyl in the compound represented by Formulae 1-8.  
   
   
       37 . A catalyst component for polymerization or copolymerization catalysts of α-olefins, which comprises a mixture of silane compounds represented by Formulae 9 and 10:  
       Si(OR 1 ) 3 R 2   [Formula 9] 
     (where R 1  denotes a hydrocarbon group having 2-6 carbon atoms; and R 2  a hydrocarbon group having 1-12 carbon atoms, an amino group including a hydrogen atom and a hydrocarbon group having 1-12 carbon atoms, which are bonded on a N atom, or an amino group including two hydrocarbon groups each having 1-12 carbon atoms, which are bonded on a N atom (the two hydrocarbon groups may be the same or different from each other))  
       SiR 3   4   [Formula 10] 
     (where R 3  denotes an alkoxy group having 1-6 carbon atoms, a hydrocarbon group having 1-12 carbon atoms, an amino group including a hydrogen atom and a hydrocarbon group having 1-12 carbon atoms, which are bonded on a N atom, or an amino group including two hydrocarbon groups each having 1-12 carbon atoms, which are bonded on a N atom (the two hydrocarbon groups may be the same or different from each other). Each R 3  may be the same as or different from another. Formulae 9 and 10 do not represent the same compound).  
   
   
       38 . A catalyst component for polymerization or copolymerization catalysts of α-olefins, which comprises a mixture of silane compounds represented by Formulae 11 and 12:  
       Si(OR 1 ) 3 (NR 4 R 5 )  [Formula 11] 
     (where R 1  denotes a hydrocarbon group having 2-6 carbon atoms; R 4  a hydrocarbon group having 1-12 carbon atoms, or a hydrogen atom; and R 5  a hydrocarbon group having 1-12 carbon atoms)  
       Si(R 6 ) n (NR 7 R 8 ) 4-n   [Formula 12] 
     (where R 6  denotes a hydrocarbon group having 1-12 carbon atoms or an alkoxy group having 1-6 carbon atoms (each R 6  may be the same as or different from another); R 7  a hydrocarbon group having 1-12 carbon atoms; R 8  a hydrocarbon group having 1-12 carbon atoms; and n is equal to 1-2 or 4).  
   
   
       39 . The catalyst component for polymerization or copolymerization catalysts of α-olefins according to  claim 37 , wherein the silane compound represented by Formulae 9-12 is obtained by reacting a tetrahalosilane represented by Formula 13 with a tetraalkoxysilane represented by Formula 14 to yield a trialkoxyhalosilane represented by Formula 15, which is then reacted with a dialkylamine represented by Formula 16:  
       SiX 4   [Formula 13] 
     (where X denotes halogen)  
       Si(OR 1 ) 4   [Formula 14] 
     (where R 1  denotes a hydrocarbon group having 2-6 carbon atoms)  
       XSi(OR 1 ) 3   [Formula 15] 
     (where X denotes halogen; and R 1  a hydrocarbon group having 2-6 carbon atoms)  
       R 2 R 3 NH  [Formula 16] 
     (where R 2  denotes a hydrocarbon group having 1-12 carbon atoms; and R 3  a hydrocarbon group having 1-12 carbon atoms).  
   
   
       40 . The catalyst component for polymerization or copolymerization catalysts of α-olefins according to  claim 38 , wherein the silane compound represented by Formulae 9-12 is obtained by reacting a tetrahalosilane represented by Formula 13 with a tetraalkoxysilane represented by Formula 14 to yield a trialkoxyhalosilane represented by Formula 15, which is then reacted with a dialkylamine represented by Formula 16:  
       SiX 4   [Formula 13] 
     (where X denotes halogen)  
       Si(OR 1 ) 4   [Formula 14] 
     (where R 1  denotes a hydrocarbon group having 2-6 carbon atoms)  
       XSi(OR 1 ) 3   [Formula 15] 
     (where X denotes halogen; and R 1  a hydrocarbon group having 2-6 carbon atoms)  
       R 2 R 3 NH  [Formula 16] 
     (where R 2  denotes a hydrocarbon group having 1-12 carbon atoms; and R 3  a hydrocarbon group having 1-12 carbon atoms).  
   
   
       41 . A catalyst component for polymerization or copolymerization catalysts of α-olefins, which comprises a mixture of a diethylaminotriethoxysilane and a bis(diethylamino)diethoxysilane.  
   
   
       42 . A polymerization or copolymerization catalyst of α-olefins, which includes the catalyst component according to  claim 37 .  
   
   
       43 . A polymerization or copolymerization catalyst of α-olefins, which includes the catalyst component according to  claim 38 .  
   
   
       44 . A polymerization or copolymerization catalyst of α-olefins, which includes the catalyst component according to  claim 39 .  
   
   
       45 . A polymerization or copolymerization catalyst of α-olefins, which includes the catalyst component according to  claim 40 .  
   
   
       46 . A polymerization or copolymerization catalyst of α-olefins, which includes the catalyst component according to  claim 41 .  
   
   
       47 . A polymerization or copolymerization catalyst of α-olefins, which comprises [A] a solid catalyst component essentially including magnesium, titanium, a halogen element and an electron donor; [B] an organoaluminum compound component; and [C] the catalyst component according to  claim 37 .  
   
   
       48 . A polymerization or copolymerization catalyst of α-olefins, which comprises [A] a solid catalyst component essentially including magnesium, titanium, a halogen element and an electron donor; [B] an organoaluminum compound component; and [C] the catalyst component according to  claim 38 .  
   
   
       49 . A polymerization or copolymerization catalyst of α-olefins, which comprises [A] a solid catalyst component essentially including magnesium, titanium, a halogen element and an electron donor; [B] an organoaluminum compound component; and [C] the catalyst component according to  claim 39 .  
   
   
       50 . A polymerization or copolymerization catalyst of α-olefins, which comprises [A] a solid catalyst component essentially including magnesium, titanium, a halogen element and an electron donor; [B] an organoaluminum compound component; and [C] the catalyst component according to  claim 40 .  
   
   
       51 . A polymerization or copolymerization catalyst of α-olefins, which comprises [A] a solid catalyst component essentially including magnesium, titanium, a halogen element and an electron donor; [B] an organoaluminum compound component; and [C] the catalyst component according to  claim 41 .  
   
   
       52 . A process for polymerization of α-olefins, which comprises polymerizing or copolymerizing an α-olefin in the presence of the catalyst according to  claim 42 .  
   
   
       53 . A process for polymerization of α-olefins, which comprises polymerizing or copolymerizing an α-olefin in the presence of the catalyst according to  claim 43 .  
   
   
       54 . A process for polymerization of α-olefins, which comprises polymerizing or copolymerizing an α-olefin in the presence of the catalyst according to  claim 44 .  
   
   
       55 . A process for polymerization of α-olefins, which comprises polymerizing or copolymerizing an α-olefin in the presence of the catalyst according to  claim 45 .  
   
   
       56 . A process for polymerization of α-olefins, which comprises polymerizing or copolymerizing an α-olefin in the presence of the catalyst according to  claim 46 .  
   
   
       57 . A process for polymerization of α-olefins, which comprises polymerizing or copolymerizing an α-olefin in the presence of the catalyst according to  claim 47 .  
   
   
       58 . A process for polymerization of α-olefins, which comprises polymerizing or copolymerizing an α-olefin in the presence of the catalyst according to  claim 48 .  
   
   
       59 . A process for polymerization of α-olefins, which comprises polymerizing or copolymerizing an α-olefin in the presence of the catalyst according to  claim 49 .  
   
   
       60 . A process for polymerization of α-olefins, which comprises polymerizing or copolymerizing an α-olefin in the presence of the catalyst according to  claim 50 .  
   
   
       61 . A process for polymerization of α-olefins, which comprises polymerizing or copolymerizing an α-olefin in the presence of the catalyst according to  claim 51 .  
   
   
       62 . A catalyst component for polymerization or copolymerization catalysts of α-olefins, which comprises a reacted mixture of a trialkoxyhalosilane represented by Formula 17 with a dialkylamine represented by Formula 18:  
       XSi(OR 1 ) 3   [Formula 17] 
     (where X denotes halogen; and R 1  denotes a hydrocarbon group having 2-6 carbon atoms)  
       R 2 R 3 NH  [Formula 18] 
     (where R 2  denotes a hydrocarbon group having 1-12 carbon atoms; and R 3  a hydrocarbon group having 1-12 carbon atoms).  
   
   
       63 . A polymerization or copolymerization catalyst of α-olefins, which includes the catalyst component according to  claim 62 .  
   
   
       64 . A polymerization or copolymerization catalyst of α-olefins, which comprises [A] a solid catalyst component essentially including magnesium, titanium, a halogen element and an electron donor; [B] an organoaluminum compound component; and [C] the catalyst component according to  claim 62 .  
   
   
       65 . The polymerization or copolymerization catalyst of α-olefins according to  claim 63 , wherein the reacted mixture of the trialkoxyhalosilane represented by Formula 17 with the dialkylamine represented by Formula 18 is employed without subjecting to isolation/purification.  
   
   
       66 . The polymerization or copolymerization catalyst of α-olefins according to  claim 64 , wherein the reacted mixture of the trialkoxyhalosilane represented by Formula 17 with the dialkylamine represented by Formula 18 is employed without subjecting to isolation/purification.  
   
   
       67 . A process for polymerization of α-olefins, which comprises polymerizing or copolymerizing an α-olefin in the presence of the catalyst according to  claim 63 .  
   
   
       68 . A process for polymerization of α-olefins, which comprises polymerizing or copolymerizing an α-olefin in the presence of the catalyst according to  claim 64 .  
   
   
       69 . A process for polymerization of α-olefins, which comprises polymerizing or copolymerizing an α-olefin in the presence of the catalyst according to  claim 65.