Catalysts

Abstract

The present invention relates to novel metallocene catalysts of formula I, which is defined herein. The present invention also provides processes for making these catalysts and their use in olefin polymerisation reactions.

What is claimed is: 
     
         1 . A compound of the formula I shown below 
       
         
           
           
               
               
           
         
         wherein: 
         R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11  and R 12  are each independently hydrocarbyl, carbocyclyl or heterocyclyl, each of which is optionally substituted by halo, amino, nitro, cyano, (1-6C)alkyl, (1-6C)alkoxy, (1-6C)alkylamino, [(1-6C)alkyl] 2 amino, or —S(O) r (1-6C)alkyl wherein r is 0, 1 or 2; 
         Q is a bridging group comprising 1, 2 or 3 bridging atoms; 
         X is zirconium, titanium or hafnium; and 
         each Y group is halo, hydride, a phosphonated or sulphonated anion, or a (1-6C)alkyl, (1-6C)alkoxy, aryl or aryloxy group which is optionally substituted with halo, nitro, amino, phenyl, (1-6C)alkoxy, or Si[(1-4C)alkyl] 3 . 
       
     
     
         2 . The compound according to  claim 1 , wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11  and R 12  are each independently (1-6C)alkyl or phenyl, each of which is optionally substituted by halo, amino, nitro, cyano, (1-6C)alkyl, (1-6C)alkoxy, (1-6C)alkylamino, [(1-6C)alkyl] 2 amino, or —S(O) r (1-6C)alkyl, wherein r is 0, 1 or 2. 
     
     
         3 . The compound according to  claim 2 , wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11  and R 12  are all methyl. 
     
     
         4 . The compound according to  claim 3 , wherein Q is a group of the formula —[C(R a R b )] n — wherein n is 2 or 3 and R a  and R b  are each independently hydrogen, (1-6C)alkyl or (1-6C)alkoxy. 
     
     
         5 . The compound according to  claim 4 , wherein Q is —CH 2 —CH 2 — or —CH 2 —CH 2 —CH 2 —. 
     
     
         6 . The compound according to  claim 5 , wherein Q is —CH 2 —CH 2 —. 
     
     
         7 . The compound according to  claim 1 , wherein X is zirconium or hafnium. 
     
     
         8 . The compound according to  claim 1 , wherein Y is halo, (1-6C)alkyl or phenyl, wherein the alkyl or phenyl group is optionally substituted with halo, nitro, amino, phenyl, (1-6C)alkoxy, or Si[(1-4C)alkyl] 3 . 
     
     
         9 . The compound according to  claim 8 , wherein Y is halo or a (1-2C)alkyl group which is optionally substituted with halo, phenyl, or Si[(1-4C)alkyl] 3 . 
     
     
         10 . The compound according to  claim 1 , wherein each Y group is the same. 
     
     
         11 . The compound according to  claim 1 , wherein the compound has the structural formula II shown below 
       
         
           
           
               
               
           
         
         and R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , X and Y are as defined in  claim 1 . 
       
     
     
         12 . The compound according to  claim 1 , wherein the compound has the structural formula IV shown below 
       
         
           
           
               
               
           
         
         and X and Y are as defined in  claim 1 . 
       
     
     
         13 . The compound according to  claim 1 , wherein the compound has the structural formula: 
       
         
           
           
               
               
           
         
       
     
     
         14 . A process of preparing a compound according to  claim 1 , comprising:
 reacting a compound of formula A:   
       
         
           
           
               
               
           
         
         wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , and R 12  are each as defined in  claim 1  and M is Li, Na or K; 
         with a compound of formula B:
   X(Y′) 4   B
 
 
         wherein X is as defined in  claim 1  and Y′ is halo; 
         in the presence of a suitable solvent to form a compound of formula Ia: 
       
       
         
           
           
               
               
           
         
         and optionally thereafter: 
         reacting the compound of formula Ia with MY″, wherein M is Li, Na or K and Y″ is a group Y as defined in  claim 1  other than halo, in the presence of a suitable solvent to form a compound of formula Ib shown below 
       
       
         
           
           
               
               
           
         
       
     
     
         15 . A pro-catalyst for the polymerisation of olefins comprising a compound of formula I prepared according to the process of  claim 14 . 
     
     
         16 . A process for forming a polyolefin which comprises reacting olefin monomers in the presence of a compound of formula I according to  claim 1  and a suitable activator. 
     
     
         17 . The process according to  claim 16 , wherein the activator is an aluminoxane or triethylaluminium. 
     
     
         18 . The process according to  claim 17 , wherein the polyolefin is polyethylene. 
     
     
         19 . The process of  claim 14 , wherein Y′ is chloro or bromo. 
     
     
         20 . The process of  claim 17 , wherein the aluminoxane is methylaluminoxane.