Polypropylene

The present invention relates to a propylene homopolymer, a propylene copolymer and a propylene elastomer, all having a high triad tacticity of the propylene units chain, and low in an amount of inversely inserted propylene units.

Propylene polymers have been applied to various uses such as industrial parts, containers, films and nonwoven fabrics, because of their excellent rigidity, surface hardness, heat resistance, glossiness and transparency.

However, the conventional propylene homopolymer is not always sufficient in transparency, impact resistance, etc. for some uses, and therefore the advent of a propylene polymer excellent in rigidity, heat resistance, surface hardness, glossiness, transparency and impact strength is desired.

Moreover, the physical properties of the copolymers of propylene and an α-olefin other than propylene vary depending on composition thereof, and hence the copolymers are generally distinguishable from each other bordering the monomer content derived from the α-olefin other than propylene of 5% by mol.

Propylene copolymers containing monomer units derived from α-olefin other than propylene in an amount of less than 5% by mol have been applied to various uses such as containers and packaging materials (e.g., films), because of their excellent rigidity, surface hardness, heat resistance, transparency and heat-sealing property. However, when the copolymer is used as a film, the resulting film is not always sufficient in transparency, heat-sealing property, anti-blocking property, anti-bleedout property and impact strength. Therefore, a propylene copolymer further improved in transparency, rigidity, surface hardness, heat resistance and heat-sealing property, and having excellent anti-blocking property, anti-bleedout property and impact strength is desired.

In contrast, propylene copolymers containing monomer units derived from α-olefin other than propylene in an amount of more than 5% by mol have been applied to various uses such as films, heat-sealing layers of laminated films, and modifiers for improving impact resistance and anti-heat-sealing property of thermoplastic resins, because of their excellent transparency, heat-sealing property at low temperature, environmental aging property and impact absorbing capacity. However, the conventional propylene copolymer is not always sufficient in transparency, heat-sealing properties at low temperature, anti-blocking properties, bleedout resistance, impact strength, etc. for some uses, and the modifiers therefrom are not always sufficient in effect of improving heat-sealing property at low temperature and impact strength. Therefore, there has been demanded a propylene copolymer further improved in transparency, environmental aging property and impact strength, and having excellent in effect of improving heat-sealing property at low temperature and impact strength.

In the light of such circumstances as described above, the present inventors have further studied, and as a result, they have found that a propylene/ethylene random copolymer containing a small amount of ethylene units is excellent in transparency, rigidity, surface hardness, heat resistance, and hence it is used for films, containers etc.

Heretofore, there is known some methods for preparation of the propylene/ethylene random copolymer containing a small amount of ethylene units, such as a method using a titanium catalyst system comprising a titanium compound and an organoaluminum compound and a method using a metallocene catalyst system comprising a metallocene compound (e.g., zirconocene and hafnocene) and an alkylaluminoxane or ionic compound.

However, the propylene/ethylene random copolymer obtained by using a titanium catalyst system is not always sufficient in heat-sealing property for some uses, and also insufficient in anti-blocking property, bleedout property and impact strength. <patcit id="pcit0001" dnum="EP0115940A"><text>EP-A-0 115 940</text></patcit> relates to such a propylene copolymer containing from 0.1 to 2.0 mole % of ethylene based on the total amount of ethylene and propylene. The copolymer of <patcit id="pcit0002" dnum="EP0115940A"><text>EP-A-0 115 940</text></patcit> is described as having an isotactic value (Iso) in the range represented by the following formula (1) or (2), <ul id="ul0001" list-style="none" compact="compact"><li>(i) when 0.1≤Ec≤0.3,         Iso≥-5Ec+96.3(%)     (1), and</li><li>(ii) when 0.3&lt;Ec≤2.0,         Iso≥-0.67Ec+95.0(%)     (2) wherein Ec represents the numerical value of the ethylene content in mole %.</li></ul>

On the other hand, the propylene/ethylene random copolymer obtained by using a metallocene catalyst system is not always sufficient in rigidity, surface hardness and heat resistance. Therefore, the advent of the propylene/ethylene random copolymer having advantages of the both, and excellent in balance' of properties is demanded.

In the light of such circumstances as described above, the present inventors have further studied, and as a result, they have found that a propylene copolymer containing a specific amount of ethylene unit, having a high triad tacticity, as measured by ¹³C-NMR, of the propylene chain consisting of head-to-tail bonds, a specific proportion of inversely inserted propylene units and a specific intrinsic viscosity is excellent in transparency, rigidity, surface hardness, heat-sealing property, anti-blocking property, anti-bleedout property and impact strength.

Further, the propylene elastomer is excellent in impact absorbing capacity, heat resistance and heat-sealing property, it is singly used for films, and also is used for modifier for thermoplastic resin.

However, when the conventional propylene elastomer is singly used for films, the resulting films are not always sufficient in heat-sealing property, anti-blocking property and heat resistance. When the elastomer is used for modifier, the effect of improving impact strength is not always sufficient. Therefore, the advent of the propylene elastomer having excellent impact strength, and effective in improving heat resistance, transparency, heat-sealing property, anti-blocking resistance and impact resistance is demanded.

In the light of such circumstances as described above, the present inventors have further studied, and as a result, they have found that a propylene elastomer containing a specific amount of ethylene unit, having a high triad tacticity, as measured by ¹³C-NMR, of the propylene chain consisting of head-to-tail bonds, a specific proportion of inversely inserted propylene units and a specific intrinsic viscosity is excellent in above mentioned properties, and hence accomplished the present invention.

It is the object of the present invention to provide a propylene copolymer having excellent impact strength and transparency, and a propylene elastomer having excellent impact strength and transparency.

The propylene copolymer according to the invention has such properties that: <ul id="ul0002" list-style="none" compact="compact"><li>(i) said copolymer contains propylene units in an amount of 95 to 99.5 % by mol and ethylene units in an amount of 0.5 to 5 % by mol;</li><li>(ii) a triad tacticity of propylene units chain consisting of head-to-tail bonds, as measured by ¹³C-NMR, is not less than 95.0 %;</li><li>(iii) a proportion of inversely inserted propylene units based on 2,1-insertion of a propylene monomer in all propylene insertions, as measured by ¹³C-NMR, of 0.05 to 0.5 %, and</li><li>(iv) an intrinsic viscosity, as measured in decahydronaphthalene at 135 °C, is in the range of 0.1 to 12 dl/g.</li></ul>

The propylene copolymer of the present invention is excellent in rigidity, surface hardness, heat resistance, transparency, heat-sealing property, anti-blocking property and anti-bleedout property.

The propylene elastomer according to the invention has such properties that: <ul id="ul0003" list-style="none" compact="compact"><li>(i) said elastomer contains propylene units in an amount of 50 to 95 % by mol and ethylene units in an amount of 5 to 50 % by mol;</li><li>(ii) a triad tacticity of propylene units chain consisting of head-to-tail bonds, as measured by ¹³C-NMR, is not less than 90.0 %;</li><li>(iii) a proportion of inversely inserted propylene units based on 2,1-insertion of a propylene monomer in all propylene insertions, as measured by ¹³C-NMR, of 0.05 to 0.5 %; and</li><li>(iv) an intrinsic viscosity, as measured in decahydronaphthalene at 135 °C, is in the range of 0.1 to 12 dl/g.</li></ul>

The propylene elastomer of the present invention is excellent in heat resistance, impact absorbing capacity, transparency, heat-sealing properties and anti-blocking properties.

The propylene copolymer and the propylene elastomer, according to the invention, will be described in detail hereinafter.

The propylene copolymer according to the present invention contains propylene units in an amount of 95 to 99.5 % by mol, preferably 95 to 99 % by mol, more preferably 95 to 98 % by mol, and ethylene units in an amount of 0.5 to 5 % by mol, preferably 1 to 5 % by mol, more preferably 2 to 5 % by mol.

The propylene copolymer may contain constituent .units derived from other olefins than propylene and ethylene in an amount of not more than 5 % by mol.

The propylene copolymer according to the invention has a triad tacticity of not less than 95.0 %, preferably not less than 96.0 %, more preferably not less than 97.0 %. It is also desirably that the proportion of inversely inserted units based on 2,1-insertion of propylene monomer is in the range of 0.05 to 0.5 %, preferably 0.05 to 0.4 %, more preferably 0.05 to 0.3 %, and the intrinsic viscosity [η], as measured in decahydronaphthalene at 135 °C, is in the range of 0.1 to 12 dl/g, preferably 0.5 to 12 dl/g, more preferably 1 to 12 dl/g,

In the propylene copolymer of the invention, thea proportion of inversely inserted units based on 1,3-insertion of propylene monomer is desirably not more than 0.05 %.

The propylene copolymer according to the present invention can be prepared by copolymerizing ethylene and propylene in the presence of an olefin polymerization catalyst, for example, a catalyst comprising : <ul id="ul0004" list-style="none" compact="compact"><li>(A) a transition metal compound represented by the following formula (Ia) ;</li><li>(B) at least one compound selected from the group consisting of <ul id="ul0005" list-style="none" compact="compact"><li>(B-1) an organoaluminum oxy-compound, and</li><li>(B-2) a compound which reacts with the transition metal compound to form an ion pair; and optionally,</li></ul></li><li>(C) an organoaluminum compound.</li></ul>

The transition metal compound used in the preparation of the third propylene copolymer according to the present invention is a transition metal compound represented by the following formula (Ia). <chemistry id="chem0001" num="0001"><img file="EP0629632B2_D0001.tif" /></chemistry>

In the formula (Ia), M is a transition metal of Group IVa, Group Va or Group VIa of the periodic table. Examples of the transition metals include titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum and tungsten. Of these, titanium, zirconium and hafnium are preferred, and zirconium is particularly preferred.

R^a is a hydrogen atom, a halogen atom, a hydrocarbon group of 1 to 20 carbon atoms, a halogenated hydrocarbon group of 1 to 20 carbon atoms, a silicon-containing group, an oxygen-containing group, a sulfur-containing group, a nitrogen-containing croup or a phosphorus-containing group. Examples of the halogen atoms include fluorine, chlorine, bromine or iodine.

Examples of the hydrocarbon groups of 1 to 20 carbon atoms include an alkyl group such as methyl, ethyl, propyl, butyl, hexyl, cyclohexyl, octyl, nonyl, dodecyl, icosyl, norbornyl and adamantyl; an alkenyl group such as vinyl, propenyl and cyclohexenyl; arylalkyl group such as benzyl, phenylethyl and phenylpropyl; and an aryl group such as phenyl, tolyl, dimethylphenyl, trimethylphenyl, ethylphenyl, propylphenyl, biphenyl, naphthyl, methylnaphthyl, anthracenyl and phenanthryl.

Examples of the halogenated hydrocarbon groups of 1 to 20 carbon atoms include the halogenated groups of the above mentioned hydrocarbon group of 1 to 20 carbon atoms.

Examples of the silicon-containing groups include monohydrocarbon-substituted silyl such as methylsilyl and phenylsilyl; dihydrocarbon-substituted silyl such as dimethylsilyl and diphenylsilyl; trihydrocarbon-substituted silyl such as trimethylsilyl, triethylsilyl, tripropylsilyl, tricyclohexylsilyl, triphenylsilyl, dimethylphenylsilyl, methyldiphenylsilyl, tritolylsilyl and trinaphthylsilyl; silyl ether of hydrocarbon-substituted silyl such as trimethylsilyl ether; silicon-substituted alkyl group such as trimethylsilylmethyl; and silicon-substituted aryl group such as trimethylphenyl.

Examples of the oxygen-containing groups include a hydroxy group; an alkoxy group such as methoxy, ethoxy, propoxy and butoxy; an allyloxy group such as phenoxy, methylphenoxy, dimethylphenoxy and naphthoxy; and an arylalkoxy group such as phenylmethoxy and phenylethoxy.

Examples of the sulfur-containing groups include groups obtained by substituting sulfur for oxygen in the above-mentioned oxygen-containing groups.

Examples of the nitrogen-containing groups include an amino group; an alkylamino group such as methylamino, dimethylamino, diethylamino, dipropylamino, dibutylamino and dicyclohexylamino; an arylamino group such as phenylamino, diphenylamino, ditolylamino, dinaphthylamino and methylphenylamino; and an alkylarylamino group.

Examples of the phosphorus-containing groups include a phosphino group such as dimethylphosphino and diphenylphosphino.

Of these, R^a is preferably a hydrocarbon group, particularly a hydrocarbon group of 1 to 4 carbon atoms such as methyl, ethyl, propyl and butyl.

R^b is aryl group of 6 to 16 carbon atoms. Examples of the aryl group of 6 to 16 carbon atoms include phenyl, α-naphthyl, β-naphthyl, anthracenyl, phenanthryl, pyrenyl, acenaphthyl, phenalenyl, aceanthrenyl, tetrahydronaphthyl, indanyl and biphenylyl. Of these, preferred is phenyl, naphthyl, anthracenyl or phenanthryl.

These aryl groups may be substituted with a halogen atom such as fluorine, chlorine, bromine or iodine; <ul id="ul0006" list-style="none" compact="compact"><li>a hydrocarbon group of 1 to 20 carbon atoms, for example an alkyl group such as methyl, ethyl, propyl, butyl, hexyl, cyclohexyl, octyl, nonyl, dodecyl, icosyl, norbornyl and adamantyl; an alkenyl group such as vinyl, propenyl and cyclohexenyl; arylalkyl group such as benzyl, phenylethyl and phenylpropyl; and an aryl group such as phenyl, tolyl, dimethylphenyl, trimethylphenyl, ethylphenyl, propylphenyl, biphenyl, naphthyl, methylnaphthyl, anthracenyl and phenanthryl; or</li><li>an organo-silyl group such as trimethylsilyl, triethylsilyl and triphenylsilyl.</li></ul>

The aryl groups may be substituted with a halogen atom, a hydrocarbon group of 1 to 20 carbon atoms or a halogenated hydrocarbon group of 1 to 20 carbon atoms, as same as the aforementioned R^a.

X¹ and X² are each a hydrogen atom, a halogen atom, a hydrocarbon group of 1 to 20 carbon atoms, a halogenated hydrocarbon group of 1 to 20 carbon atoms, an oxygen-containing group or a sulfur-containing group. Examples of those atoms and groups include the halogen atoms and the hydrocarbon groups of 1 to 20 carbon atoms as exemplified above. Examples of the halogenated hydrocarbon groups of 1 to 20 carbon atoms include the halogenated groups of the above mentioned hydrocarbon group of 1 to 20 carbon atoms.

Examples of the oxygen-containing groups include a hydroxy group; an alkoxy group such as methoxy, ethoxy, propoxy and butoxy; an aryloxy group such as phenoxy, methylphenoxy, dimethylphenoxy and naphthoxy; and an arylalkoxy group such as phenylmethoxy and phenylethoxy.

Examples of the sulfur-containing groups include groups obtained by substituting sulfur for oxygen in the above-mentioned oxygen-containing groups. As the sulfur-containing group, there can be also mentioned a sulfonato group such as methylsulfonato, trifluoromethanesulfonato, phenylsulfonato, benzylsulfonato, p-toluenesulfonato, trimethylbenzenesulfonato, triisobutylbenzenesulfonato, p-chlorobenzenesulfonato and pentafluorobenzenesulfonato; and a sulfinato group such as methylsulfinato, phenylsulfinato, benzenesulfinato, p-toluenesulfinato, trimethylbenzenesulfinato and pentafluorobenzenesulfinato.

Y¹ is a divalent hydrocarbon group of 1 to 20 carbon atoms, a divalent halogenated hydrocarbon group of 1 to 20 carbon atoms, a divalent silicon-containing group, a divalent germanium-containing group, a divalent tin-containing group, -O-, -CO-, -S-, -SO-, -SO₂-, -NR³-, -P(R³)-, -P(O)(R³)-, -BR³- or -AlR³- (R³ is a hydrogen atom, a halogen atom, a hydrocarbon group of 1 to 20 carbon atoms or a halogenated hydrocarbon group of 1 to 20 carbon atoms).

Examples of the divalent hydrocarbon groups of 1 to 20 carbon atoms include an alkylene group such as methylene, dimethylmethylene, 1,2-ethylene, dimethyl-1,2-ethylene, 1,3-trimethylene, 1,4-tetramethylene; a cycloalkylene group such as 1,2-cyclohexylene and 1,4-cyclohexylene; and an arylalkylene group such as diphenylmethylene and diphenyl-1,2-ethylene.

Examples of the divalent halogenated hydrocarbon groups include groups obtained by halogenating the above-mentioned hydrocarbon groups of 1 to 20 carbon atoms, such as chloromethylene.

Examples of the divalent silicon-containing groups include an alkylsilylene group, an alkylarylsilylene group and an arylsilylene group, such as methylsilylene, dimethylsilylene, diethylsilylene, di(n-propyl)silylene, di(i-propyl)silylene, di(cyclohexyl)silylene, methylphenylsilylene, diphenylsilylene, di(p-tolyl)silylene and di(p-chlorophenyl)silylene; and an alkyldisilyl group, an alkylaryldisilyl group and an aryldisilyl group, such as tetramethyl-1,2-disilyl and tetraphenyl-1,2-disilyl.

Examples of the divalent germanium-containing groups include groups obtained by substituting germanium for silicon in the above-mentioned divalent silicon-containing groups.

Examples of the divalent tin-containing groups include groups obtained by substituting tin for silicon in the above-mentioned divalent silicon-containing groups.

Examples of the atoms and the groups indicated by R³ include the halogen atoms, the hydrocarbon groups of 1 to 20 carbon atoms and the halogenated hydrocarbon groups of 1 to 20 carbon atoms exemplified above.

Of these, preferred are a divalent silicon-containing group, a divalent germanium-containing group and a divalent tin-containing group. More preferred is a divalent silicon-containing group. Of the silicon-containing groups, alkylsilylene, alkylarylsilylene and arylsilylene are particularly preferred.

Listed below are examples of the transition metal compounds represented by the above formula (Ia). <ul id="ul0007" list-style="none" compact="compact"><li>rac-Dimethylsilyl-bis{1-(4-phenylindenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(α-naphthyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(β-naphthyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethyisilyl-bis{1-(2-methyl-4-(1-anthracenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(2-anthracenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(9-anthracenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(9-phenanthryl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(p-fluorophenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(pentafluorophenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(p-chlorophenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(m-chlorophenyl)indenyl)} zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(o-chlorophenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(o,p-dichlorophenyl)phenyl-1-indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(p-bromophenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(p-tolyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(m-tolyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(o-tolyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(o,o'-dimethylphenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(p-ethylphenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(p-i-propylphenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(p-benzylphenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(p-biphenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(m-biphenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(p-trimethylsilylphenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-methyl-4-(m-trimethylsilylphenyl)indenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-ethyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-Diphenylsilyl-bis{1-(2-ethyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-phenyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-Dimethylsilyl-bis{1-(2-n-propyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-Diethylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-Di-(i-propyl)silyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-Di-(n-butyl)silyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-Dicyclohexylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-methylphenylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-diphenylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-di(p-tolyl)silyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-di(p-chlorophenyl)silyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-methylene-bis{1-(2-methyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-ethylene-bis{1-(2-methyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-dimethylgermyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-dimethylstanyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium dichloride,</li><li>rac-dimethylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium dibromide,</li><li>rac-dimethylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium dimethyl,</li><li>rac-dimethylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium methylchloride,</li><li>rac-dimethylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium monochloride mono(trifluoromethanesulfonato),</li><li>rac-dimethylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium di(trifluoromethanesulfonato),</li><li>rac-dimethylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium di(p-toluenesulfonato),</li><li>rac-dimethylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium di(methylsulfonato),</li><li>rac-dimethylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium di(trifluoromethanesulfinato),</li><li>rac-dimethylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium di(trifluoroacetato),</li><li>rac-dimethylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium monochloride(n-butoxide),</li><li>rac-dimethylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium di(n-butoxide), and</li><li>rac-dimethylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium monochloride(phenoxide).</li></ul>

There may also be used the transition metal compounds obtained by substituting titanium metal, hafnium metal, vanadium metal, niobium metal, tantalum metal, chromium metal, molybdenum metal or tungsten metal for zirconium metal in the above-exemplified compounds.

The transition metal compounds which may be used to produce the present invention can be prepared in accordance with the methods described in <nplcit id="ncit0001" npl-type="s"><text>Journal of Organometallic Chem. 288 (1985), pages 63 to 67</text></nplcit>, European Patent Publication No. <patcit id="pcit0003" dnum="EP0320762A"><text>0,320,762</text></patcit> specification and Examples thereof, for instance, by the following manner. <chemistry id="chem0002" num="0002"><img file="EP0629632B2_D0002.tif" /></chemistry> wherein, Z represents Cl, Br, I or o-tosyl group, and H₂R represents <chemistry id="chem0003" num="0003"><img file="EP0629632B2_D0003.tif" /></chemistry>

The transition metal compound which may be used to produce the present invention can be used as an olefin polymerization catalyst in combination with an organoaluminum oxy-compound.

The transition metal compound is used as an olefin polymerization catalyst component in the form of csually a racemic modification, but the R configuration or the S configuration can be also used.

Next, olefin polymerization catalysts containing the above-mentioned transition metal compound (Ia) as its catalyst component are described.

The meaning of the term "polymerization" used herein is not limited to "homopolymerization" but may comprehend "copolymerization". Also, the meaning of the term "polymer" used herein is not limited to "homopolymer" but may comprehend "copolymer".

The first and the second olefin polymerization catalysts which may be used to produce the invention are described below.

The first olefin polymerization catalyst which may be used to produce the invention is formed from: <ul id="ul0008" list-style="none" compact="compact"><li>(A) a transition metal compound represented by the above formula (Ia) (sometimes referred to as "component (A)" hereinafter); and</li><li>(B) at least one compound selected from the group consisting of <ul id="ul0009" list-style="none" compact="compact"><li>(B-1) an organoaluminum oxy-compound, and</li><li>(B-2) a compound which reacts with the transition metal compound to form an ion pair.</li></ul></li></ul>

The second olefin polymerization catalyst which may be used to produce the invention is formed from: <ul id="ul0010" list-style="none" compact="compact"><li>(A) a transition metal compound represented by the above formula (Ia);</li><li>(B) at least one compound selected from the group consisting of <ul id="ul0011" list-style="none" compact="compact"><li>(B-1) an organoaluminum oxy-compound, and</li><li>(B-2) a compound which reacts with the transition metal compound to form an ion pair; and</li></ul></li><li>(C) an organoaluminum compound.</li></ul>

The organoaluminum oxy-compound (B-1) (hereinafter sometimes referred to as "component (B-1)") used for the first and the second olefin polymerization catalysts may be a conventionally known aluminoxane or may be a benzene-insoluble organoaluminum oxy-compound as described in Japanese Patent Laid-Open Publication No. <patcit id="pcit0004" dnum="JP2078687A"><text>78687/1990</text></patcit>.

The conventionally known aluminoxane can be prepared, for example, by the following processes. <ul id="ul0012" list-style="none" compact="compact"><li>(1) A process comprising allowing an organoaluminum compound such as trialkylaluminum to react with a suspension of a compound having adsorbed water or a salt containing water of crystallization, for example, hydrate of magnesium chloride, copper sulfate, aluminum sulfate, nickel sulfate or cerous chloride in a hydrocarbon solvent.</li><li>(2) A process comprising allowing water, ice or water vapor to directly react with an organoaluminum compound such as trialkylaluminum in a solvent such as benzene, toluene, ethyl ether and tetrahydrofuran.</li><li>(3) A process comprising allowing an organotin oxide such as dimethyltin oxide and dibutyltin oxide to react with an organoaluminum compound such as trialkylaluminum in a solvent such as decane, benzene and toluene.</li></ul>

The aluminoxane may contain a small amount of an organometallic component. Moreover, the solvent or the unreacted organoaluminum compound may be distilled off from the recovered solution of aluminoxane described above, and the resultant product may be dissolved again in a solvent.

Examples of the organoaluminum compounds used for preparing aluminoxane include: <ul id="ul0013" list-style="none" compact="compact"><li>trialkylaluminums, such as trimethylaluminum, triethylaluminum, tripropylaluminum, triisopropylaluminum, tri-n-butylaluminum, triisobutylaluminum, tri-sec-butylaluminum, tri-tert-butylaluminum, tripentylaluminum, trihexylaluminum, trioctylaluminum and tridecylaluminum;</li><li>tricycloalkylaluminums, such as tricyclohexylaluminum and tricyclooctylaluminum;</li><li>dialkylaluminum halides, such as dimethylaluminum chloride, diethylaluminum chloride, diethylaluminum bromide and diisobutylaluminum chloride;</li><li>dialkylaluminum hydrides, such as diethylaluminum hydride and diisobutylaluminum hydride;</li><li>dialkylaluminum alkoxides, such as dimethylaluminum methoxide and diethylaluminum ethoxide; and</li><li>dialkylaluminum aryloxides, such as diethylaluminum phenoxide.</li></ul>

Of the organoaluminum compounds, trialkylaluminum and tricycloalkylaluminum are particularly preferred.

Further, there may be also used, as the organoaluminum compound for preparing aluminoxane, isoprenylaluminum represented by the following formula (II):         (i-C₄H₉)_xAl_y(C₅H₁₀)_z     (II) wherein x, y and z are each a positive number, and z ≥ 2x.

The organoaluminum compounds mentioned above may be used singly or in combination.

Solvents used for preparing aluminoxane include aromatic hydrocarbons such as benzene, toluene, xylene, cumene and cymene; aliphatic hydrocarbons such as pentane, hexane, heptane, octane, decane, dodecane, hexadecane and octadecane; alicyclic hydrocarbons such as cyclopentane, cyclohexane, cyclooctane and methylcyclopentane; petroleum fractions such as gasoline, kerosine and gas oil; and halides of the above-mentioned aromatic, aliphatic and alicyclic hydrocarbons, particularly chlorides and bromides thereof. In addition thereto, ethers such as ethyl ether and tetrahydrofuran may be also used. Of these solvents, particularly preferred are aromatic hydrocarbons.

Examples of the compounds which react with the transition metal compound (A) to form an ion pair (hereinafter sometimes referred to as "component (B-2)"), which are used for the first and the second olefin polymerization catalysts, include Lewis acid, ionic compounds, borane compounds and carborane compounds, as described in National Publications of International Patent No. <patcit id="pcit0005" dnum="WO5019501989A"><text>501950/1989</text></patcit> and No.<patcit id="pcit0006" dnum="WO5020361989A"><text> 502036/1989</text></patcit>, Japanese Patent Laid-Open Publications No. <patcit id="pcit0007" dnum="JP4179005A"><text>179005/1992</text></patcit>, No. <patcit id="pcit0008" dnum="JP4179006A"><text>179006/1992</text></patcit>, No. <patcit id="pcit0009" dnum="JP4207703A"><text>207703/1992</text></patcit> and No. <patcit id="pcit0010" dnum="JP4207704A"><text>207704/1992</text></patcit>, and <patcit id="pcit0011" dnum="US547718A"><text>U.S. Patent No. 547718</text></patcit>.

The Lewis acid includes Mg-containing Lewis acid, Al-containing Lewis acid and B-containing Lewis acid. Of these, B-containing Lewis acid is preferred.

The Lewis acid containing a boron atom (B-containing Lewis acid) is, for example, a compound represented by the following formula:         BR⁶R⁷R⁸ wherein R⁶, R⁷ and R⁸ are each independently a phenyl group which may have a substituent such as a fluorine atom, a methyl group and a trifluoromethyl group, or a fluorine atom.

Examples of the compounds represented by the above formula include trifluoroboron, triphenylboron, tris(4-fluorophenyl)boron, tris(3,5-difluorophenyl)boron, tris (4-fluoromethylphenyl)boron, tris(pentafluorophenyl)boron, tris(p-tolyl)boron, tris(o-tolyl)boron and tris(3,5-dimethylphenyl)boron. Of these, tris(pentafluorophenyl)boron is particularly preferred.

The ionic compound used in the catalysts which may be used to produce the invention is a salt comprising a cationic compound and an anionic compound. An anion reacts with the transition metal compound (A) to make the transition metal compound (A) cationic and to form an ion pair so as to stabilize the transition metal cation seed. Examples of such anions include organoboron compound anion and organoarsenic compound anion, organoaluminum compound anion. Preferred is such anion as is relatively bulky and stabilizes the transition metal cation seed. Examples of cations include metallic cation, organometallic cation, carbonium cation, tripium cation, oxonium cation, sulfonium cation, phosphonium cation and ammonium cation. More specifically, there can be mentioned triphenylcarbenium cation, tributylammonium cation, N,N-dimethylammonium cation and ferrocenium cation.

Of these, preferred are ionic compounds containing a boron compound as anion. More specifically, examples of trialkyl-substituted ammonium salts include <ul id="ul0014" list-style="none" compact="compact"><li>triethylammoniumtetra(phenyl)boron,</li><li>tripropylammoniumtetra(phenyl)boron,</li><li>tri(n-butyl)ammoniumtetra(phenyl)boron,</li><li>trimethylammoniumtetra(p-tolyl)boron,</li><li>trimethylammoniumtetra(o-tolyl)boron,</li><li>tributylammoniumtetra(pentafluorophenyl)boron,</li><li>tripropylammoniumtetra(o,p-dimethylphenyl)boron,</li><li>tributylammoniumtetra(m,m-dimethylphenyl)boron,</li><li>tributylammoniumtetra(p-trifluoromethylphenyl)boron,</li><li>tri(n-butyl)ammoniumtetra(o-tolyl)boron and</li><li>tri(n-butyl)ammoniumtetra(4-fluorophenyl)boron.</li></ul>

Examples of N,N-dialkylanilinium salts include <ul id="ul0015" list-style="none" compact="compact"><li>N,N-dimethylaniliniumtetra(phenyl)boron,</li><li>N,N-diethylaniliniumtetra(phenyl)boron and</li><li>N,N-2,4,6-pentamethylaniliniumtetra(phenyl)boron.</li></ul>

Examples of dialkylammonium salts include di (n-propyl)ammoniumtetra (pentafluorophenyl)boron and dicyclohexylammoniumtetra(phenyl)boron.

Examples of triarylphosphonium salts include <ul id="ul0016" list-style="none" compact="compact"><li>triphenylphosphoniumtetra(phenyl)boron,</li><li>tri(methylphenyl)phosphoniumtetra(phenyl)boron and</li><li>tri(dimethylphenyl)phosphoniumtetra(phenyl)boron.</li></ul>

Also employable as the ionic compound containing a boron atom are <ul id="ul0017" list-style="none" compact="compact"><li>triphenylcarbeniumtetrakis-(pentafluorophenyl)borate,</li><li>N,N-dimethylaniliniumtetrakis(pentafluorophenyl)borate and ferroceniumtetrakis(pentafluorophenyl)borate.</li></ul>

Further, the following compounds can be also employed. (In the ionic compounds enumerated below, the counter ion is tri(n-butyl)ammonium, but the counter ion is in no way limited thereto.)

That is, there can be mentioned salts of anion, for example, bis{tri(n-butyl)ammonium}nonaborate, <ul id="ul0018" list-style="none" compact="compact"><li>bis{tri(n-butyl)ammonium}decaborate,</li><li>bis{tri(n-butyl)ammonium}undecaborate,</li><li>bis{tri(n-butyl)ammonium}dodecaborate,</li><li>bis{tri(n-butyl)ammonium)decachlorodecaborate,</li><li>bis{tri(n-butyl)ammonium)dodecachlorododecaborate,</li><li>tri(n-butyl)ammonium-1-carbadecaborate,</li><li>tri(n-butyl)ammonium-1-carbaundecaborate,</li><li>tri(n-bucyl)ammonium-1-carbadodecaborate,</li><li>tri(n-butyl)ammonium-1-trimethylsilyl-1-carbadecaborate and</li><li>tri (n-butyl) ammoniumbromo-1-carbadecaborate.</li></ul>

Moreover, borane compounds and carborane compounds can be also employed. These compounds are employed as the Lewis acid or the ionic compounds.

Examples of the borane compounds and the carborane compounds include: <ul id="ul0019" list-style="none" compact="compact"><li>borane and carborane complex compounds and salts of carborane anion, for example,</li><li>decaborane(number of hydrogen = 14),</li><li>7,8-dicarbaundecaborane(13),</li><li>2,7-dicarbaundecaborane (13),</li><li>undecahydride-7,8-dimethyl-7,8-dicarbaundecaborane,</li><li>dodecahydride-11-methyl-2,7-dicarbaundecaborane,</li><li>tri (n-butyl) ammonium-6-carbadecaborate (14),</li><li>tri(n-butyl)ammonium-6-carbadecaborate(12),</li><li>tri(n-butyl)ammonium-7-carbaundecaborate(13),</li><li>tri(n-butyl)ammonium-7,8-dicarbaundecaborate(12),</li><li>tri(n-butyl)ammonium-2,9-dicarbaundecaborate(12),</li><li>tri(n-butyl)ammoniumdodecahydride-8-methyl-7,9-dicarbaundecaborate,</li><li>tri(n-butyl)ammoniumundecahydride-8-ethyl-7,9-dicarbaundecaborate,</li><li>tri(n-butyl)ammoniumundecahydride-8-butyl-7,9-dicarbundecaborate,</li><li>tri(n-butyl)ammoniumundecahydride-8-allyl-7,9-dicarbaundecaborate,</li><li>tri(n-butyl)ammoniumundecahydride-9-trimethylsilyl-7,8-dicarbaundecaborate and</li><li>tri(n-butyl)ammoniumundecahydride-4,6-dibromo-7-carbaundecaborate; and</li><li>carborane and salts of carborane, for example, 4-carbanonaborane(14), 1,3-dicarbanonaborane(13), 6,9-dicarbadecaborane(14),</li><li>dodecahydride-1-phenyl-1,3-dicarbanonaborane,</li><li>dodecahydride-1-methyl-1,3-dicarbanonaborane and</li><li>undecahydride-1,3-dimethyl-1,3-dicarbanonaborane.</li></ul>

Furthermore, the following compounds can be also employed. (In the ionic compounds enumerated below, the counter ion is tri(n-butyl)ammonium, but the counter ion is in no way limited thereto.)

That is, there can be mentioned salts of metallic carborane and metallic borane anion, for example, <ul id="ul0020" list-style="none" compact="compact"><li>tri(n-butyl) ammoniumbis (nonahydride-1,3-dicarbononaborate)cobaltate (III),</li><li>tri(n-butyl)ammoniumbis(undecahydride-7,8-dicarbaundecaborate)ferrate(III),</li><li>tri (n-butyl)ammoniumbis (undecahydride-7,8-dicarbaundecaborate)cobaltate(III),</li><li>tri (n-butyl) ammoniumbis(undecahydride-7,8-dicarbaundecaborate)nickelate(III),</li><li>tri(n-butyl)ammoniumbis(undecahydride-7,8-dicarbaundecaborate)cuprate(III),</li><li>tri(n-butyl) ammoniumbis (undecahydride-7,8-dicarbaundecaborate)aurate(III),</li><li>tri(n-butyl)ammoniumbis(nonahydride-7,8-dimethyl-7,8-dicarbaundecaborate)ferrate(III),</li><li>tri(n-butyl)ammoniumbis(nonahydride-7,8-dimethyl-7,8-dicarbaundecaborate)chromate (III),</li><li>tri(n-butyl)ammoniumbis(tribromooctahydride-7,8-dicarbaundecaborate)cobaltate(III),</li><li>tri(n-butyl)ammoniumbis(dodecahydridedicarbadodecaborate)cobaltate(III),</li><li>bis{tri(n-butyl)ammonium}bis(dodecahydridedodecaborate)nickelate(III),</li><li>tris{tri(n-butyl)ammonium}bis(undecahydride-7-carbaundecaborate)chromate(III),</li><li>bis{tri(n-butyl)ammonium}bis(undecahydride-7-carbaundecaborate)manganate(IV),</li><li>bis{tri(n-butyl)ammonium}bis(undecahydride-7-carbaundecaborate)cobaltate(III) and</li><li>bis{tri(n-butyl)ammonium}bis(undecahydride-7-carbaundecaborate)nickelate(IV).</li></ul>

The compounds (B-2) which react with the transition metal compound (A) to form an ion pair can be used in combination of two or more kinds.

The organoaluminum compound (C) (hereinafter sometimes referred to as "component (C)") used for the second olefin polymerization catalyst is, for example, an organoaluminum compound represented by the following formula (III):         R⁹ _nAlX_3-n     (III) wherein R⁹ is a hydrocarbon group of 1 to 12 carbon atoms, X is a halogen atom or a hydrogen atom, and n is 1 to 3.

In the above formula (III), R⁹ is a hydrocarbon group of 1 to 12 carbon atoms, e.g., an alkyl group, a cycloalkyl group or an aryl group. Particular examples thereof include methyl, ethyl, n-propyl, isopropyl, isobutyl, pentyl, hexyl, octyl, cyclopentyl, cyclohexyl, phenyl and tolyl.

Examples of such organoaluminum compounds (C) include: <ul id="ul0021" list-style="none" compact="compact"><li>trialkylaluminums, such as trimethylaluminum,</li><li>triethylaluminum, triisopropylaluminum,</li><li>triisobutylaluminum, trioctylaluminum and tri(2-ethylhexyl)aluminum;</li><li>alkenylaluminums, such as isoprenylaluminum,</li><li>dialkylaluminum halides, such as dimethylaluminum chloride, diethylaluminum chloride, diisopropylaluminum chloride, diisobutylaluminum chloride and dimethylaluminum bromide;</li><li>alkylaluminum sesquihalides, such as methylaluminum sesquichloride, ethylaluminum sesquichloride, isopropylaluminum sesquichloride, butylaluminum sesquichloride and ethylaluminum sesquibromide;</li><li>alkylaluminum dihalides, such as methylaluminum dichloride, ethylaluminum dichloride, isopropylaluminum dichloride and ethylaluminum dibromide; and</li><li>alkylaluminum hydrides, such as diethylaluminum hydride and diisobutylaluminum hydride.</li></ul>

Also employable as the organoaluminum compound (C) is a compound represented by the following formula (IV):         R⁹ _nAlL_3-n     (IV) wherein R⁹ is the same hydrocarbon as in the above formula (III); L is -OR¹⁰ group, -OSiR¹¹₃ group, -OAlR¹²₂ group,-NR¹³₂ group, -SiR¹⁴₃ group or -N(R¹⁵)AlR¹⁶₂ group; n is 1 to 2; R¹⁰, R¹¹, R¹² and R¹⁶ are each methyl, ethyl, isopropyl, isobutyl, cyclohexyl, phenyl or the like; R¹³ is hydrogen, methyl, ethyl, isopropyl, phenyl, trimethylsilyl or the like; and R¹⁴ and R¹⁵ are each methyl, ethyl or the like.

Examples of such organoaluminum compounds (C) include: <ul id="ul0022" list-style="none" compact="compact"><li>(1) compounds represented by the formula R⁹_nAl(OR¹⁰)_3-n, for example, dimethylaluminum methoxide, diethylaluminum ethoxide and diisobutylaluminum methoxide;</li><li>(2) compounds represented by the formula R⁹_nAl (OSiR¹¹₃)_3-n, for example, Et₂Al(OSiMe₃), (iso-Bu)₂Al(OSiMe₃) and (iso-Bu)₂Al(OSiEt₃);</li><li>(3) compounds represented by the formula R⁹_nAl (OAlR¹²₂)_3-n, for example, Et₂AlOAlEt₂ and (iso-Bu)₂AlOAl(iso-Bu)₂;</li><li>(4) compounds represented by the formula R⁹_nAl(NR¹³₂)_3-n, for example, Me₂AlNEt₂, Et₂AlNHMe, Me₂AlNHEt, Et₂AlN (SiMe₃)₂ and (iso-Bu)₂AlN(SiMe₃)₂;</li><li>(5) compounds represented by the formula R⁹_nAl(SiR¹⁴₃)_3-n, for example, (iso-Bu)₂AlSiMe₃; and</li><li>(6) compounds represented by the formula R⁹_nAl(N(R¹⁵)AlR¹⁶₂)_3-n, for example, Et₂AlN(Me)AlEt₂ and (iso-Bu)₂AlN(Et)Al(iso-Bu)₂.</li></ul>

Of the organoaluminum compounds represented by the formulas (III) and (IV), the compounds represented by the formulas R⁹₃Al, R⁹_nAl (OR¹⁰)_3-n and R⁹_nAl(OAlR¹²₂)_3-n, are preferred, and the compounds having these formulas wherein R is an isoalkyl group and n is 2 are particularly preferred.

Water may be used as a catalyst component in addition to the component (A), the component (B-1), the component(B-2) and the component (C). As the water employable in the catalysis, there can be mentioned water dissolved in a polymerization solvent described later, and adsorbed water or water of crystallization contained in a compound or a salt used for preparing the component (B-1).

The first olefin polymerization catalyst which may be used to produce the invention can be prepared by mixing the component (A) and the component (B-1) (or the component (B-2)), and if desired water (as a catalyst component), in an inert hydrocarbon medium (solvent) or an olefin medium (solvent).

There is no specific limitation on the order of mixing those components, but it is preferred that the component (B-1) (or the component (B-2)) is mixed with water, followed by mixing with the component (A).

The second olefin polymerization catalyst which may be used to produce the invention can be prepared by mixing the component (A), the component (B-1) (or the component (B-2)) and the component (C), and if desired water (as a catalyst component), in an inert hydrocarbon medium (solvent) or an olefin medium (solvent).

There is no specific limitation on the order of mixing those components. However, when the component (B-1) is used, it is preferred that the component (B-1) is mixed with the component (C), followed by mixing with the component (A). When the component (B-2) is used, it is preferred that the component (C) is mixed with the component (A), followed by mixing with the component (B-2).

In the mixing of each components, an atomic ratio (Al/transition metal) of aluminum in the component (B-1) to the transition metal in the component (A) is in the range of usually 10 to 10,000, preferably 20 to 5,000; and a concentration of the component (A) is in the range of about 10^-8 to 10^-1 mol/liter-medium, preferably 10^- to 5 × 10^-2 mol/liter-medium.

When the component (B-2) is used, a molar ratio (component (A)/component (B-2)) of the component (A) to the component (B-2) is in the range of usually 0.01 to 10, preferably 0.1 to 5; and a concentration of the component (A) is in the range of about 10^-8 to 10^-1 mol/liter-medium, preferably 10^-7 to 5 × 10^-2 mol/liter-medium.

In the preparation of the second olefin polymerization catalyst, an atomic ratio (Al_C/Al_B-1) of the aluminum atom (Al_C) in the component (C) to the aluminum atom (Al_B-1) in the component (B-1) is in the range of usually 0.02 to 20, preferably 0.2 to 10.

When water is used as a catalyst component, a molar ratio (Al_B-1/H₂O) of the aluminum atom (Al_B-1) in the component (B-1) to water (H₂O) is in the range of 0.5 to 50, preferably 1 to 40.

The above-mentioned each components may be mixed in a polymerizer, or a mixture of those components beforehand prepared may be fed to a polymerizer.

If the components are beforehand mixed, the mixing temperature is in the range of usually -50 to 150 °C, preferably -20 to 120 °C; and the contact time is in the range of 1 to 1,000 minutes, preferably 5 to 600 minutes. The mixing temperature may be varied while the components are mixed and contacted with each other.

Examples of the media (solvents) used for preparing the olefin polymerization catalyst the invention include; <ul id="ul0023" list-style="none" compact="compact"><li>aliphatic hydrocarbons, such as propane, butane, pentane, hexane, heptane, octane, decane, dodecane and kerosine;</li><li>alicyclic hydrocarbons, such as cyclopentane, cyclohexane and methylcyclopentane;</li><li>aromatic hydrocarbons, such as benzene, toluene and xylene;</li><li>halogenated hydrocarbons, such as ethylene chloride, chlorobenzene and dichcloromethane; and</li><li>mixtures of these hydrocarbons.</li></ul>

Next, the third and the fourth olefin polymerization catalysts which may be used to produce the invention are described.

The third olefin polymerization catalyst which may be used to produce the invention comprises: a fine particle carrier; <ul id="ul0024" list-style="none" compact="compact"><li>(A) a transition metal compound represented by the above formula (Ia); and</li><li>(B) at least one compound selected from the group consisting of <ul id="ul0025" list-style="none" compact="compact"><li>(B-1) an organoaluminum oxy-compound, and</li><li>(B-2) a compound which reacts with the transition metal compound to form an ion pair;</li></ul> said transition metal compound (A) and said at least one compound (B) being supported on the fine particle carrier.</li></ul>

The fourth olefin polymerization catalyst which may be used to produce the invention comprises: a solid catalyst component comprising: <ul id="ul0026" list-style="none" compact="compact"><li>a fine particle carrier, <ul id="ul0027" list-style="none" compact="compact"><li>(A) a transition metal compound represented by the above formula (Ia), and</li><li>(B) at least one compound selected from the group consisting of <ul id="ul0028" list-style="none" compact="compact"><li>(B-1) an organoaluminum oxy-compound, and</li><li>(B-2) a compound which reacts with the transition metal compound to form an ion pair,</li></ul> said transition metal compound (A) and said at least one compound (B) being supported on the fine particle carrier; and</li><li>(C) an organoaluminum compound.</li></ul></li></ul>

The transition metal compound (A) used for the third and the fourth olefin polymerization catalysts is the same as that for the aforesaid first and second olefin polymerization catalysts, and is represented by the above formula (Ia).

Examples of the organoaluminum oxy-compounds (B-1) used for the third and the fourth olefin polymerization catalysts are the same as those used for the first and the second olefin polymerization catalysts.

Examples of the compounds (B-2) which react with the transition metal compound (A) to form an ion pair and used for the third and the fourth olefin polymerization catalysts are the same as those used for the first and the second olefin polymerization catalysts.

Examples of the organoaluminum compounds (C) used for the fourth olefin polymerization catalyst are the same as those used for the second olefin polymerization catalyst.

The fine particle carrier used for the third and the fourth olefin polymerization catalysts is an inorganic or organic compound, and is a particulate or granular solid having a particle diameter of 10 to 300 µm, preferably 20 to 200 µm.

The inorganic carrier is preferably porous oxide, and examples thereof include SiO₂, Al₂O₃, MgO, ZrO₂, TiO₂, B₂O₃, CaO, ZnO, BaO, ThO₂, and mixtures thereof such as SiO₂-MgO, SiO₂-Al₂O₃, SiO₂-TiO₂, SiO₂-V₂O₅, SiO₂-Cr₂O₃ and SiO₂-TiO₂-MgO. Of these, preferred is a carrier containing SiO₂ and/or Al₂O₃ as its major component.

The above-mentioned inorganic oxides may contain carbonates, sulfates, nitrates and oxides, such as Na₂CO₃, K₂CO₃, CaCO₃, MgCO₃, Na₂SO₄, Al₂(SO₄)₃, BaSO₄, KNO₃, Mg(NO₃)₂, Al(NO₃)₂, Na₂O, K₂O and Li₂O, in a small amount.

The fine particle carrier is varied in its properties depending on the kind and the process for the preparation thereof, but preferably used is a carrier having a specific surface area of 50 to 1,000 m²/g, preferably 100 to 700 m²/g, and a pore volume of 0.3 to 2.5 cm³/g. The fine particle carrier is used after calcined at 100 to 1,000 °C, preferably 150 to 700 °C, if necessary.

Also employable as the fine particle carrier in'the invention is a granular or particulate solid of an organic compound having a particle diameter of 10 to 300 µm. Examples of the organic compounds include (co)polymers prepared mainly from α-olefins of 2 to 14 carbon atoms such as ethylene, propylene, 1-butene and 4-methyl-1-pentene, and (co)polymers prepared mainly from vinylcyclohexane or styrene.

The fine particle carrier may contain a surface hydroxyl group or water. In this case, the surface hydroxyl group is contained in an amount of not less than 1.0 % by weight, preferably 1.5 to 4.0 % by weight, more preferably 2.0 to 3.5 % by weight; and water is contained in an amount of not less than 1.0 % by weight, preferably 1.2 to 20 % by weight, more preferably 1.4 to 15 % by weight. The water contained in the fine particle carrier means water which is adsorbed on the surface of the fine particle carrier.

The amount (% by weight) of the adsorbed water and the amount (% by weight) of the surface hydroxyl group in the fine particle carrier can be determined in the following manner.

Amount of adsorbed water

The weight reduction of the fine particle carrier after drying at 200 °C under ordinary pressure for 4 hours in a stream of nitrogen is measured, and a percentage of the weight after the drying to the weight before the drying is calculated.

Amount of surface hydroxyl group

The weight of the fine particle carrier after drying at 200 °C under ordinary pressure for 4 hours in a stream of nitrogen is taken as X (g). The carrier is calcined at 1,000 °C for 20 hours to obtain a calcined product containing no surface hydroxyl group. The weight of the calcined product thus obtained is taken as Y (g). The amount (% by weight) of the surface hydroxyl group is calculated from the following formula. <maths id="math0001" num=""><math display="block"><mi>Amount</mi><mfenced separators=""><mi mathvariant="normal">w</mi><mo>⁢</mo><mi mathvariant="normal">t</mi><mn mathvariant="normal">.</mn><mo>%</mo></mfenced><mo>⁢</mo><mspace width="1em" /><mi mathvariant="normal">o</mi><mo>⁢</mo><mi mathvariant="normal">f</mi><mspace width="1em" /><mi>surface</mi><mspace width="1em" /><mi>hydroxyl</mi><mspace width="1em" /><mi>grou</mi><mi mathvariant="normal">p</mi><mo>=</mo><mfenced open="{" close="}" separators=""><mfenced separators=""><mi mathvariant="normal">X</mi><mo>+</mo><mi mathvariant="normal">Y</mi></mfenced><mo>/</mo><mi mathvariant="normal">X</mi></mfenced><mo>×</mo><mn mathvariant="normal">100</mn></math><img file="EP0629632B2_D0004.tif" /></maths>

Further, in the third and the fourth olefin polymerization catalysts which may be used to produce the invention, such water as described in the first and the second olefin polymerization catalysts may be used as a catalyst component.

The third olefin polymerization catalyst which may be used to produce the invention (i.e., solid catalyst component) can be prepared by mixing the fine particle carrier, the component (A) and the component (B-1) (or the component (B-2)), and if desired water (catalyst component), in an inert hydrocarbon medium (solvent) or an olefin medium (solvent). In the mixing of those components, the component (C) can be further added.

There is no specific limitation on the order of mixing those components.

However, preferred processes are: <ul id="ul0029" list-style="none" compact="compact"><li>a process in which the fine particle carrier is mixed and contacted with the component (B-1) (or the component (B-2), and then with the component (A), followed by mixing with water if desired;</li><li>a process in which a mixture of the component (B-1) (or the component (B-2)) and the component (A) is mixed and contacted with the fine particle carrier, followed by mixing with water if desired; and</li><li>a process in which the fine particle carrier is mixed and contacted with the component (B-1) (or the component (B-2)) and water, followed by mixing with the component (A).</li></ul>

In the mixing of each components, the component (A) is used in an amount of usually 10^-6 to 5 × 10^-3 mol, preferably 3 × 10^-6 to 10^-3 mol, per 1 g of the fine particle carrier; and a concentration of the component (A) is in the range of about 5 × 10^-6 to 2 × 10^-2 mol/liter-medium, preferably 2 × 10^-5 to 10^-2 mol/liter-medium. An atomic ratio (Al/transition metal) of aluminum in the component (B-1) to the transition metal in the component (A) is in the range of usually 10 to 3,000, preferably 20 to 2,000. When the component (B-2) is used, a molar ratio (component (A)/component (B-2)) of the component (A) to the component (B-2) is in the range of usually 0.01 to 10, preferably 0.1 to 5.

When water is used as a catalyst component, a molar ratio (Al_B-1/H₂O) of the aluminum atom (Al_B-1) in the component (B-1) to water (H₂O) is in the range of 0.5 to 50, preferably 1 to 40.

The temperature for mixing the components is in the range of usually -50 to 150 °C, preferably -20 to 120 °C; and the contact time is in the range of 1 to 1,000 minutes, preferably 5 to 600 minutes. The mixing temperature may be varied while the components are mixed and contacted with each other.

The fourth olefin polymerization catalyst which may be used to produce the invention is formed from the above-mentioned third olefin polymerization catalyst (solid catalyst component) and the organoaluminum compound (C). The component (C) is used in an amount of not more than 500 mol, preferably 5 to 200 mol, per 1 g of the transition metal atom in the component (A) contained in the solid catalyst component.

The third and the fourth olefin polymerization catalysts may contain other components useful for the olefin polymerization than the above-described components.

Examples of the inert hydrocarbon media (solvents) used for preparing the third and the fourth olefin polymerization catalysts of the invention are the same as those used for the first and the second olefin polymerization catalysts.

Next, the fifth and the sixth olefin polymerization catalysts which may be used to produce the invention are described.

The fifth olefin polymerization catalyst which may be used to produce the invention comprises: a fine particle carrier; <ul id="ul0030" list-style="none" compact="compact"><li>(A) a transition metal compound represented by the above formula (Ia);</li><li>(B) at least one compound selected from the group consisting of <ul id="ul0031" list-style="none" compact="compact"><li>(B-1) an organoaluminum oxy-compound, and</li><li>(B-2) a compound which reacts with the transition metal compound to form an ion pair; and</li></ul> a prepolymerized olefin polymer produced by prepolymerization.</li></ul>

The sixth olefin polymerization catalyst which may be used to produce the invention comprises: a fine particle carrier; <ul id="ul0032" list-style="none" compact="compact"><li>(A) a transition metal compound represented by the above formula (Ia);</li><li>(B) at least one compound selected from the group consisting of <ul id="ul0033" list-style="none" compact="compact"><li>(B-1) an organoaluminum oxy-compound, and</li><li>(B-2) a compound which reacts with the transition metal compound to form an ion pair;</li></ul></li><li>(C) an organoaluminum compound; and</li></ul> a prepolymerized olefin polymer produced by prepolymerization.

Examples of the fine particle carrier used for the fifth and the sixth olefin polymerization catalysts are the same as those for the aforesaid third and fourth olefin polymerization catalysts.

The transition metal compound (A) used for the fifth and the sixth olefin polymerization catalysts is the same as that for the aforesaid first and second olefin polymerization catalysts, and is represented by the above formula (Ia).

Examples of the organoaluminum oxy-compounds (B-1) used for the fifth and the sixth olefin polymerization catalysts are the same as those used for the first and the second olefin polymerization catalysts.

Examples of the compounds (B-2) which react with the transition metal compound (A) to form an ion pair and used for the fifth and the sixth olefin polymerization catalysts are the same as those used for the first and the second olefin polymerization catalysts.

Examples of the organoaluminum compounds (C) used for the sixth olefin polymerization catalyst are the same as those used for the second olefin polymerization catalyst.

Further, in the fifth and the sixth olefin polymerization catalysts, such water as described in the first and the second olefin polymerization catalysts may be used as a catalyst component.

The fifth olefin polymerization catalyst can be prepared by prepolymerizing a small amount of an olefin to the solid catalyst component. The solid catalyst component is obtained by mixing the fine particle carrier, the component (A) and the component (B-1) (or the component (B-2)), and if desired water, in an inert hydrocarbon medium (solvent) or an olefin medium (solvent). In the mixing of those components, the component (C) can be further added.

There is no specific limitation on the order of mixing those components.

However, preferred processes are: <ul id="ul0034" list-style="none" compact="compact"><li>a process in which the fine particle carrier is mixed and contacted with the component (B-1) (or the component (B-2)), and then with the component (A), followed by mixing with water if desired</li><li>a process in which a mixture of the component (B-1) (or the component (B-2)) and the component (A) is mixed and contacted with the fine particle carrier, followed by mixing with water if desired; and</li><li>a process in which the fine particle carrier is mixed and contacted with the component (B-1) (or the component (B-2)) and water, followed by mixing with the component (A).</li></ul>

The mixing of the components is desirably carried out with stirring.

In the mixing of each components, the component (A) is used in an amount of usually 10^-6 to 5 × 10^-3 mol, preferably 3 × 10^-6 to 10^-3 mol, per 1 g of the fine particle carrier; and a concentration of the component (A) is in the range of about 5 × 10^-6 to 2 × 10^-2 mol/liter-medium, preferably 10^-5 to 10^-2 mol/liter-medium. An atomic weight ratio (Al/transition metal) of aluminum in the component (B-1) to the transition metal in the component (A) is in the range of usually 10 to 3,000, preferably 20 to 2,000. When the component (B-2) is used, a molar ratio (component (A)/component (B-2)) of the component (A) to the component (B-2) is in the range of usually 0.01 to 10, preferably 0.1 to 5.

When water is used as a catalyst component, a molar ratio (Al_B-1/H₂O) of the aluminum atom (Al_B-1) in the component (B-1) to water (H₂O) is in the range of 0.5 to 50, preferably 1 to 40.

The temperature for mixing the components is in the range of usually -50 to 150 °C, preferably -20 to 120 °C; and the contact time is in the range of 1 to 1,000 minutes, preferably 5 to 600 minutes. The mixing temperature may be varied while the components are mixed and contacted with each other.

The fifth olefin polymerization catalyst can be prepared by prepolymerizing an olefin in the presence of the above-mentioned components. The prepolymerization can be carried out by introducing an olefin into an inert hydrocarbon medium (solvent) in the presence of the components and if necessary the component (C) .

In the prepolymerization, the component (A) is used in an amount of usually 10^-5 to 2 × 10^-2 mol/liter, preferably 5 × 10^-5 to 10^-2 mol/liter. The prepolymerization temperature is in the range of -20 to 80 °C, preferably 0 to 50 °C; and the prepolymerization time is 0.5 to 100 hours, preferably about 1 to 50 hours.

The olefin used for the prepolymerization is selected from olefins which are used for polymerization, and it is preferable to use the same monomer as used in the polymerization or a mixture of the same monomer as used in the polymerization and an α-olefin.

In the olefin polymerization catalyst which may be used to produce the invention obtained as above, it is desired that the transition metal atom is supported in an amount of about 10^-6 to 10^-3 g·atom, preferably 2 × 10^-6 to 3 × 10^-4 g·atom, per 1 g of the fine particle carrier; and the aluminum atom is supported in an amount of about 10^-3 to 10^-1 g·atom, preferably 2 × 10^-3 to 5 × 10^-2 g·atom, per 1 g of the fine particle carrier. Further, it is also desired that the component (B-2) is supported in an amount of 5 × 10^-7 to 0.1 g·atom, preferably 2 × 10^-7 to 3 × 10^-2 g·atom, in terms of the boron atom contained in the component (B-2).

The amount of the prepolymerized polymer prepared by the prepolymerization is desired to be in the range of about 0.1 to 500 g, preferably 0.3 to 300 g, particularly preferably 1 to 100 g, per 1 g of the fine particle carrier.

The sixth olefin polymerization catalyst which may be used to produce the invention is formed from the above-mentioned fifth olefin polymerization catalyst (component) and the organoaluminum compound (C). The organoaluminum compound (C) is used in an amount of not more than 500 mol, preferably 5 to 200 mol, per 1 g·atom of the transition metal atom in the component (A).

The fifth and the sixth olefin polymerization catalysts may contain other components useful for the olefin polymerization than the above-described components.

Examples of the inert hydrocarbon solvents used for the fifth and the sixth olefin polymerization catalysts are the same as those used for preparing the aforesaid first and second olefin polymerization catalysts.

The propylene copolymer of the invention can be prepared by copolymerizing propylene and ethylene in the presence of, for example, the aforesaid olefin polymerization catalysts. The copolymer can be carried out by a liquid phase polymerization (e.g., a suspension polymerization and a solution polymerization) or a gas phase polymerization.

In the liquid phase polymerization, the same inert hydrocarbon solvent as used for preparing the aforesaid catalyst can be used, and propylene and/or ethylene can be also used as a solvent.

In the suspension polymerization, the temperature for copolymerizing propylene and ethylene is in the range of usually -50 to 100 °C, preferably 0 to 90 °C. In the solution polymerization, the temperature is in the range of usually 0 to 250 °C, preferably 20 to 200 °C. In the gas phase polymerization, the temperature is in the range of usually 0 to 120 °C, preferably 20 to 100 °C. The copolymerization pressure is in the range of usually atmospheric pressure to 100 kg/cm², preferably atmospheric pressure to 50 kg/cm². The copolymerization reaction can be carried out either batchwise, semicontinuously or continuously. Further, the copolymerization can be carried out in two or more stages having different reaction conditions.

The molecular weight of the resultant propylene copolymer can be regulated by allowing hydrogen to exist in the copolymerization system or by varying the copolymerization temperature and the copolymerization pressure.

The propylene elastomer of the invention is a propylene/ethylene random copolymer containing propylene units in an amount of 50 to 95 % by mol, preferably 60 to 93 % by mol, more preferably 70 to 90 % by mol, and containing ethylene units in an amount of 5 to 50 % by mol, preferably 7 to 40 % by mol, more preferably 10 to 30 % by mol.

The propylene elastomer may contain constituent units derived from other olefins than propylene and ethylene in an amount of not more than 10 % by mol.

In the propylene elastomer of the invention, it is desirably that the triad tacticity is not less than 90.0 %, preferably not less than 93.0 %, more preferably not less than 96.0 %, a proportion of inversely inserted units based on 2,1-insertion of propylene monomer is 0.05 to 0.5 %, preferably 0.05 to 0.4 %, more preferably 0.05 to 0.3 %, and an intrinsic viscosity [η], as measured in decahydronaphthalene at 135 °C, is 0.1 to 12 dl/g, preferably 0.5 to 12 dl/g, more preferably 1 to 12 dl/g.

Moreover, in the propylene elastomer according to the present invention, a proportion of inversely inserted units based on 1,3-insertion of propylene monomer is desirably not more than 0.05 %, preferably not more than 0.03.

The propylene elastomer of the invention can be prepared by copolymerizing propylene and ethylene in the presence of, for example, the aforesaid olefin polymerization catalyst used in the preparation of the propylene copolymer of the invention. The copolymerization can be carried out by a liquid phase polymerization (e.g., a suspension polymerization and a solution polymerization) or a gas phase polymerization.

In the liquid phase polymerization, the same inert hydrocarbon solvent as used for preparing the aforesaid catalyst can be used, and propylene and/or ethylene can be also used as a solvent.

In the suspension polymerization, the temperature for copolymerizing propylene and ethylene is in the range of usually -50 to 100 °C, preferably 0 to 90 °C. In the solution polymerization, the temperature is in the range of usually 0 to 250 °C, preferably 20 to 200 °C. In the gas phase polymerization, the temperature is in the range of usually 0 to 120 °C, preferably 20 to 100 °C. The copolymerization pressure is in the range of usually atmospheric pressure to 100 kg/cm², preferably atmospheric pressure to 50 kg/cm². The copolymerization reaction can be carried out either batchwise, semicontinuously or continuously. Further, the copolymerization can be carried out in two or more stages having different reaction conditions.

The molecular weight of the resultant propylene copolymer can be regulated by allowing hydrogen to exist in the copolymerization system or by varying the copolymerization temperature and the copolymerization pressure.

In the present invention, the molecular weight distribution (Mw/Mn), the triad tacticity (mm fraction), the proportion of inversely inserted units based on 2,1-insertion of propylene monomer, and the proportion of inversely inserted units based on 1,3-insertion of propylene monomer are determined by the following manner.

Molecular Weight Distribution (Mw/Mn)

The Mw/Mn was determined from a chromatograph measured using Gel permeation chromatography (GPC) (150-ALC/GPC™, manufactured by Waters Co.). The measurement was conducted at temperature of 140 °C by using column of GMH-HT and GMH-HLT type (both manufactured by Toyo Soda K.K), and o-dichlorobenzene as an eluting solvent. From the chromatograph, a number average molecular weight (Mn) and a weight average molecular weight (Mw), both in terms of polypropylene by universal method (with the proviso that when the comonomer content is not less than 10 % by mol, polystyrene standard was used) were calculated to obtain Mw/Mn.

Triad Tacticity (mm fraction)

Triad tacticity (mm fraction) of the propylene copolymer is determined by defining as a proportion of such chains of three propylene units that directions of methyl branches in the propylene chain are the same as each other and each propylene units bonded to each other with head-to-tail bonds, when the main chains are represented by plane-zigzag structure. The triad tacticity (mm fraction) of the propylene copolymer can be determined from a ¹³C-NMR spectrum of the propylene copolymer and the following formula:<maths id="math0002" num=""><math display="block"><mi>Triad</mi><mo>⁢</mo><mspace width="1em" /><mi>tacticity</mi><mspace width="1em" /><mfenced><mo>%</mo></mfenced><mo>=</mo><mfrac><mrow><mi mathvariant="normal">P</mi><mo>⁢</mo><mi mathvariant="normal">P</mi><mo>⁢</mo><mi mathvariant="normal">P</mi><mfenced separators=""><mi mathvariant="normal">m</mi><mo>⁢</mo><mi mathvariant="normal">m</mi></mfenced></mrow><mrow><mi mathvariant="normal">P</mi><mo>⁢</mo><mi mathvariant="normal">P</mi><mo>⁢</mo><mi mathvariant="normal">P</mi><mfenced separators=""><mi mathvariant="normal">m</mi><mo>⁢</mo><mi mathvariant="normal">m</mi></mfenced><mo>+</mo><mi mathvariant="normal">P</mi><mo>⁢</mo><mi mathvariant="normal">P</mi><mo>⁢</mo><mi mathvariant="normal">P</mi><mfenced separators=""><mi mathvariant="normal">m</mi><mo>⁢</mo><mi mathvariant="normal">r</mi></mfenced><mo>+</mo><mi mathvariant="normal">P</mi><mo>⁢</mo><mi mathvariant="normal">P</mi><mo>⁢</mo><mi mathvariant="normal">P</mi><mfenced separators=""><mi mathvariant="normal">r</mi><mo>⁢</mo><mi mathvariant="normal">r</mi></mfenced></mrow></mfrac><mo>×</mo><mn>100</mn></math><img file="EP0629632B2_D0005.tif" /></maths> wherein PPP(mm), PPP(mr) and PPP(rr) denote peak areas derived from the methyl groups of the second units in the following three propylene units chain consisting of head-to-tail bonds, respectively: <chemistry id="chem0004" num="0004"><img file="EP0629632B2_D0006.tif" /></chemistry><chemistry id="chem0005" num="0005"><img file="EP0629632B2_D0007.tif" /></chemistry><chemistry id="chem0006" num="0006"><img file="EP0629632B2_D0008.tif" /></chemistry>

The ¹³C-NMR spectrum is measured in the following manner. A sample is completely dissolved in a mixed solvent containing about 0.5 ml of hexachlorobutadiene, o-dichlorobenzene or 1,2,4-trichlorobenzene and about 0.05 ml of deuterated benzene (i.e., lock solvent) in an NMR sample tube (diameter: 5 mm), and then subjected to a proton perfect decoupling method at 120 °C to measure the ¹³C-NMR spectrum. The measurement is conducted under the conditions of a flip angle of 45° and a pulse interval of not less than 3.4 T₁ (T₁ is a maximum value with respect to a spin-lattice relaxation time of the methyl group). In the polypropylene, T₁ of the methylene group and T₁ of the methine group are each shorter than that of the methyl group, and hence the magnetization recovery of all carbons under these conditions is not less than 99 %. With respect to the chemical shift, the methyl group of the third unit in the five propylene units chain consisting of head-to-tail bonds is set to 21.593 ppm, and the chemical shift of other carbon peak is determined by using the above-mentioned value as a reference.

The spectrum is classified into the first region (21.1 - 21.9 ppm), the second region (20.3 - 21.0 ppm) and the third region (19.5 - 20.3 ppm).

In the first region, the methyl group of the second unit in the three propylene units chain represented by PPP(mm) resonates.

In the second region, the methyl group of the second unit in the three propylene units chain represented by PPP(mr) resonates and the methyl group (PPE-methyl group) of a propylene unit whose adjacent units are a propylene unit and an ethylene unit resonate.

In the third region, the methyl group of the second unit in the three propylene units chain represented by PPP(rr) resonates and the methyl group (EPE-methyl group) of a propylene unit whose adjacent units are ethylene units resonate.

Further, the propylene copolymer has the following structures (i), (ii) and (iii) containing an inversely inserted unit. <chemistry id="chem0007" num="0007"><img file="EP0629632B2_D0009.tif" /></chemistry><chemistry id="chem0008" num="0008"><img file="EP0629632B2_D0010.tif" /></chemistry><chemistry id="chem0009" num="0009"><img file="EP0629632B2_D0011.tif" /></chemistry>

Among the peaks derived from the structures (i), (ii) and (iii), peaks of the carbon A and the carbon B do not appear in the first to third regions, because the carbon A resonates at 17.3 ppm and the carbon 3 resonates at 17.0 ppm. Further, the carbon A and the carbon B do not relate to the three propylene units chain, and hence it is not necessary to take these carbons into consideration of calculation of triad tacticity.

Peaks of the carbon C, carbon D and carbon D' appear in the second region; and peaks of the carbon E and carbon E' appear in the third region.

Of the peaks in the first to third regions as described above, peaks which are not based on the three propylene units chain consisting of head-to-tail bonds are peaks based on the PPE-methyl group (resonance in the vicinity of 20.7 ppm), the EPE-methyl group (resonance in the vicinity of 19.8 ppm), the carbon C, the carbon D, the carbon D', the carbon E and the carbon E'.

The peak area based on the PPE-methyl group can be evaluated by the peak area of the PPE-methine group (resonance in the vicinity of 30.6 ppm), and the peak area based on the EPE-methyl group can be evaluated by the peak area of the EPE-methine group (resonance in the vicinity of 32.9 ppm). The peak area based on the carbon C can be evaluated by the peak area of the adjacent methine group (resonance in the vicinity of 31.3 ppm), the peak area based on the carbon D can be evaluated by 1/2 as much as the sum of the peak areas of the αβ methylene carbons of the structure (ii) (resonance in the vicinity of 34.3 ppm and resonance in the vicinity of 34.5 ppm, respectively), and the peak area based on the carbon D' can be evaluated by the peak area of the adjacent methine group of the methyl group of the carbon E' of the aforementioned structure (iii) (resonance in the vicinity of 33.3 ppm), the peak area based on the carbon E can be evaluated by the peak area of the adjacent methane group (resonance in the vicinity of 33.7 ppm) and the peak area based on the carbon E' can be evaluated by the peak area of the adjacent methine group (resonance in the vicinity of 33.3 ppm).

Accordingly, by subtracting these peak areas from the total peak areas of the second region and the third region, the peak areas based on the three propylene units chain (PPP(mr) and PPP(rr)) consisting of head-to-tail bonds can be obtained.

Thus, the peak areas of PPP(mm), PPP(mr) and PPP(rr) can be evaluated, and hence the triad tacticity of the propylene units chain consisting of head-to tail bonds can be determined.

Triad tacticity (mm fraction) of the propylene homopolymer is also determined by defining as a proportion of such chains of three propylene units that directions of methyl branches in the propylene chain are the same as each other and each propylene units bonded to each other with head-to-tail bonds, when the main chains are represented by plane-zigzag structure. The triad tacticity (mm fraction) of the propylene homopolymer can be determined from a ¹³C-NMR spectrum of the propylene copolymer and the following formula:<maths id="math0003" num=""><math display="block"><mi>Triad</mi><mspace width="1em" /><mo>⁢</mo><mi>tacticity</mi><mspace width="1em" /><mfenced><mo>%</mo></mfenced><mo>=</mo><mfrac><mrow><mi mathvariant="normal">P</mi><mo>⁢</mo><mi mathvariant="normal">P</mi><mo>⁢</mo><mi mathvariant="normal">P</mi><mfenced separators=""><mi mathvariant="normal">m</mi><mo>⁢</mo><mi mathvariant="normal">m</mi></mfenced></mrow><msub><mi mathvariant="normal">Σ</mi><msub><mrow><mi mathvariant="normal">I</mi><mo>⁢</mo><mi mathvariant="normal">C</mi><mo>⁢</mo><mi mathvariant="normal">H</mi></mrow><mn mathvariant="normal">3</mn></msub></msub></mfrac><mo>×</mo><mn mathvariant="normal">100</mn></math><img file="EP0629632B2_D0012.tif" /></maths> wherein PPP(mm) has the same meanings defined above, and ΣI_{CH<sub2>3</sub2>} denotes the total areas of all peaks derived from the methyl groups.

With respect to the chemical shift, the methyl group of the third unit in the five propylene units chain consisting of head-to-tail bonds is set to 21.593 ppm, and the chemical shift of other carbon peak is determined by using the above-mentioned value as a reference.

In this standard, the peak of the methyl group of the second unit in the three propylene units chain represented by PPP(mm) appears in the range of 21.1 to 21.9 ppm, the peak of the methyl group of the second unit in the three propylene units chain represented by PPP(mr) appears in the range of 20.3 to 21.0 ppm and the peak of the methyl group of the second unit in the three propylene units chain represented by PPP(rr) appears in the range of 19.5 to 20.3 ppm.

Here, the propylene homopolymer contains a small amount of partial structure comprising inversely inserted units based on the 2,1-insertion represented by the aforementioned structure (i), in addition to the regular structure consisting of head-to-tail bonds of propylene units.

In the irregular structure represented by the aforementioned structure (i), the aforementioned definition of PPP(mm) is not applied to the carbon A, the carbon B and the carbon C. However, the carbon A and the carbon B resonate in the region of 16.5 to 17.5 ppm, and the carbon C resonates in the vicinity of 20.7 ppm (PPP(mr) region). In the partial structure containing inversely inserted units, not only the peak of the methyl group but also the peaks of the adjacent methylene and methine group must be confirmed. Therefore, the carbon A, the carbon B and the carbon C are not included in the region of PPP(mm).

Thus, the triad tacticity (mm fraction) of the propylene homopolymer can be calculated from the aforementioned formula.

Proportion of inversely inserted units based on 2,1-insertion of propylene monomer

In the polymerization, the 1,2-insertion (methylene side is bonded to the catalyst) of the propylene monomer mainly takes place, but the 2,1-insertion insertion thereof sometimes takes place. Therefore, the propylene copolymer and the propylene elastomer contain the inversely inserted units based on the 2,1-insertion represented by the aforementioned structures (i), (ii) and (iii). The proportion of the inversely inserted units based on the 2,1-insertion was calculated from the following formula by using ¹³C-NMR.<maths id="math0004" num=""><math display="block"><mi>Proportion</mi><mspace width="1em" /><mi mathvariant="normal">o</mi><mo>⁢</mo><mi mathvariant="normal">f</mi><mspace width="1em" /><mi>inversely</mi><mo>⁢</mo><mspace width="1em" /><mi>inserted</mi><mo>⁢</mo><mspace width="1em" /><mi>units</mi><mspace width="1em" /><mo>⁢</mo><mi>based</mi><mo>⁢</mo><mspace width="1em" /><mi mathvariant="normal">o</mi><mo>⁢</mo><mi mathvariant="normal">n</mi><mo>⁢</mo><mspace width="1em" /><mn mathvariant="normal">2</mn><mo>,</mo><mn mathvariant="normal">1</mn><mo>-</mo><mi>insertion</mi><mspace width="1em" /><mfenced><mo>%</mo></mfenced><mo>=</mo><mfrac><mrow><mn mathvariant="normal">0.5</mn><mo>+</mo><mn mathvariant="normal">0.25</mn><mspace width="1em" /><mi mathvariant="normal">B</mi></mrow><mrow><mi mathvariant="normal">C</mi><mo>+</mo><mi mathvariant="normal">D</mi><mo>+</mo><mn mathvariant="normal">0.5</mn><mspace width="1em" /><mi mathvariant="normal">E</mi></mrow></mfrac><mo>×</mo><mn mathvariant="normal">100</mn></math><img file="EP0629632B2_D0013.tif" /></maths><dl id="dl0001" compact="compact"><dt>A:</dt><dd>Iαβ [structures (i) and (iii)]</dd><dt>B:</dt><dd>Iαβ [structure (ii)]</dd><dt>C:</dt><dd>Iαα</dd><dt>D:</dt><dd>Iαβ [structures (i) and (iii)]</dd><dt>E:</dt><dd>Iαγ + Iαβ [structure (ii)] + Iαδ</dd></dl>

Naming of these peaks was made in accordance with the method by <nplcit id="ncit0002" npl-type="s"><text>Carman, et al. (Rubber Chem. Tachnol., 44, 781 (1971</text></nplcit>)). Iαβ and the like indicate the peak areas of αβ-peak and the like.

Homopolymer of propylene contains the inversely inverted units based on the 2,1-insertion. The proportion of the 2,1-propylene monomer insertions to the all propylene insertions was calculated from the following formula. <maths id="math0005" num=""><math display="block"><mi>Proportion</mi><mo>⁢</mo><mspace width="1em" /><mi mathvariant="normal">o</mi><mo>⁢</mo><mi mathvariant="normal">f</mi><mspace width="1em" /><mo>⁢</mo><mi>inversely</mi><mo>⁢</mo><mspace width="1em" /><mi>inserted</mi><mo>⁢</mo><mspace width="1em" /><mi>units</mi><mo>⁢</mo><mspace width="1em" /><mi>based</mi><mo>⁢</mo><mspace width="1em" /><mi mathvariant="normal">o</mi><mo>⁢</mo><mi mathvariant="normal">n</mi><mo>⁢</mo><mspace width="1em" /><mn mathvariant="normal">2</mn><mo>,</mo><mn mathvariant="normal">1</mn><mo>-</mo><mi>insertion</mi><mspace width="1em" /><mfenced><mo>%</mo></mfenced><mo>=</mo><mfrac><mrow><mn mathvariant="normal">0.5</mn><mo>×</mo><mfenced open="{" close="}" separators=""><mi>area</mi><mspace width="1em" /><mi mathvariant="normal">o</mi><mo>⁢</mo><mi mathvariant="normal">f</mi><mspace width="1em" /><mi>methyl</mi><mspace width="1em" /><mi>group</mi><mspace width="1em" /><mi>resonated</mi><mo>⁢</mo><mspace width="1em" /><mi mathvariant="normal">a</mi><mo>⁢</mo><mi mathvariant="normal">t</mi><mspace width="1em" /><mn mathvariant="normal">16.5</mn><mo>-</mo><mn mathvariant="normal">17.5</mn><mo>⁢</mo><mi mathvariant="normal">p</mi><mo>⁢</mo><mi mathvariant="normal">p</mi><mo>⁢</mo><mi mathvariant="normal">m</mi></mfenced></mrow><msub><mrow><mi mathvariant="normal">Σ</mi><mo>⁢</mo><mi mathvariant="normal">I</mi></mrow><msub><mrow><mi mathvariant="normal">C</mi><mo>⁢</mo><mi mathvariant="normal">H</mi></mrow><mn mathvariant="normal">3</mn></msub></msub></mfrac><mo>×</mo><mn mathvariant="normal">100</mn></math><img file="EP0629632B2_D0014.tif" /></maths> wherein, ΣI_{CH<sub2>3</sub2>} is the same as those mentioned before.

Proportion of inversely inserted units based on 1,3-insertion of propylene monomer

In the propylene copolymer and the propylene elastomer, the amount of three units chain based on the 1,3-insertion of propylene is determined from βγ-peak (resonance in the vicinity of 27.4 ppm).

The propylene copolymer according to the invention is excellent in rigidity, surface hardness, heat resistance, transparency, heat-sealing property, anti-blocking property and anti-bleedout property, and suitable for films, sheets, containers, stretched yarns, nonwoven fabrics, etc.

The propylene elastomer according the invention is excellent in heat resistance, impact absorbing properties, transparency, heat-sealing properties and anti-blocking properties. Hence, it can be singly used for films, sheets, etc., and moreover it can be suitably used as a modifier of a thermoplastic resin.

EXAMPLES

The present invention is described in more detail with reference to the following examples, but it should be construed that the invention is in no way limited to those examples.

In the present invention, an intrinsic viscosity [η] and the composition of a copolymer are determined by the following methods.

Further, in some examples, a heat seal-starting temperature and a heat seal-starting temperature after heat treatment, a melting point (Tm), a melt flow rate (MFR), an izod impact strength (IZ) and a film impact strength are measured by the following method.

Intrinsic viscosity [η]

The intrinsic viscosity [η] was determined in decahydronaphthalene at 135 °C, and expressed by dl/g.

Composition of copolymer

The composition of a propylene copolymer is measured by ¹³C-NMR.

Heat seal-starting temperature and heat seal-starting temperature after heat treatment

With respect to the T-die film having a width of 30 cm and a thickness of 50 µm prepared using a single screw extruder having a diameter of 30 mm under the conditions of a resin temperature of 210 °C (at a portion of dicer of extruder), a take-off speed of 3 m/min and a temperature of cooling roll of 25 °C, a heat seal of two films is carried out using a heat sealer by sealing at various seal bar temperatures under the conditions of a heat seal pressure of 2 kg/cm², a seal time of 1 second and a width of 5mm to prepare a sealed film having a width of 15 mm. The above-prepared sealed film was allowed to stand overnight.

The heat seal-staring temperature is defined as a temperature of the heat sealer when the peeling resistance of the sealed film becomes 300 g/25 mm, under such conditions that the sealed film is peeled off at 23 °C, a peeling speed of 200 mm/min and a peeling angle of 180 °.

Separately, another sealed film was subjected to heat treatment at 50 °C for 7 days. The heat seal-starting temperature after heat treatment was measured using the heat treated specimen.

Melting point (Tm)

The melting point was determined from an endothermic curve given by heating about 5 mg of a sample charged in an aluminum pan to 200 °C at a rate of 10 °C/min, keeping it at 200 °C for 5 minutes, then cooling it to room temperature at a rate of 20 °C/min and heating it again at a rate of 10 °C/min. The measurement was conducted using a DSC-7 type apparatus produced by Perkin Elmer Co.

Melt flow rate (MFR)

The MFR is measured in accordance with ASTM D 1238 under a load of 2.16 kg at 230 °C.

Izod impact strength (IZ)

The IZ is measured in accordance with ASTM D 256 at 23 °C using a notched specimen of 12.7 mm (width) x 6.4 mm (thickness) X 64 mm (length).

The specimen is prepared by injection molding at a resin temperature of 200 °C and a molding temperature of 40 °C using a polypropylene composition obtained by dry-blending 20 % by weight of a polymer according to the present invention and 80 % by weight of a polypropylene (HIPOL™, grade J 700, melt flow rate: 11 g/10 min (at 230 °C), density: 0.91, manufactured by Mitsui Petrochemical Industries, Ltd.), and melt-kneading at 200 °C using a twin-screw extruder.

Film impact strength

The film impact strength is measured using a film impact tester (manufactured by Toyo Seiki K.K., diameter of impact head bulb: 1/2 inch (12.7 mm φ)).

Example 1

Synthesis of rac-dimethylsilyl-bis{1-(2-ethyl-4-phenylindenyl)}zirconium dichloride

Synthesis of 3-(2-biphenylyl)-2-ethylpropionic acid

A 500-ml four-necked round flask equipped with a stirrer, a Dimroth condenser, a dropping funnel and a thermometer was charged with 13.46 g (120 mmol) of potassium t-butoxide, 100 ml of toluene and 20 ml of N-methylpyrrolidone. To the mixture was dropwise added a solution containing 20.7 g (110 mmol) of diethyl ethylmalonate dissolved in 50 ml of toluene under nitrogen atmosphere while warming at 60°C. After the addition was completed, the reaction mixture was stirred for 1 hour at this temperature. Then, to the resulting mixture was dropwise added a solution containing 20.27 g (100 mmol) of 2-phenylbenzylbromide dissolved in 30 ml of toluene. After the addition was completed, the temperature was elevated and the resulting mixture was stirred under reflux for 2 hours. The reaction mixture was poured onto 200 ml of water and the resulting mixture was adjusted with addition of 2N HCl to pH 1. The organic phase was separated and the aqueous phase was further extracted with 100 ml of toluene three times. The combined organic phase was washed with a saturated aqueous solution of sodium chloride until the resulting material was neutralized, followed by drying over anhydrous Na₂SO₄. The solvent was concentrated under reduced pressure to obtain 36.7 g of a yellow-orange liquid.

A 1-liter four-necked round flask equipped with a stirrer, a Dimroth condenser, a dropping funnel and a thermometer was charged with 67.3 g (1.02 mol) of potassium hydoxide and 160 ml of an aqueous solution of methanol (methanol/water=4/1(v/v)). To the mixture was dropwise added a solution containing the above-obtained concentrate dissolved in 50 ml of an aqueous solution of methanol (methanol/water=4/1(v/v)) at room temperature under a nitrogen atmosphere. After the addition was completed, the temperature was elevated and the resulting mixture was stirred under reflux for 4 hours. Thereafter, the temperature was cooled to room temperature and the resultant precipitated solid was filtered. The residue was dissolved in water and acidified with addition of sulfuric acid to pH 1. The resulting solution was extracted with 100 ml of methylene chloride five times. The combined organic phase was dried over anhydrous Na₂SO₄. The solvent was concentrated under reduced pressure to obtain 24.2 g of a white solid.

Then, a 300-ml three-necked round flask equipped with a stirring bar, a Dimroth condenser, a thermometer was charged with 24.2 g of the above-obtained white solid, 56 ml of acetic acid, 37 ml of water and 13.1 ml of concentrated sulfuric acid, and the mixture was stirred under reflux for 6 hours under a nitrogen atmosphere. After the reaction was completed, the acetic acid was evaporated under reduced pressure. To the resulting material was added 50 ml of water, which was then extracted with 50 ml of methylene chloride three times. The combined organic phase was washed with 50 ml of a saturated aqueous solution of sodium chloride, followed by drying over anhydrous Na₂SO₄. The solvent was evaporated under reduced pressure. The residue was chromatographed on silica gel (eluting with hexane/ethyl acetate (2/1), and hexane/ethyl acetate (1/1), parts by volume) to obtain 13.7 g of the desired product as a white solid (yield: 54%). <dl id="dl0002" compact="compact"><dt>FD-MS</dt><dd>: 254 (M⁺)</dd><dt>mp.</dt><dd>: 91.2-94.0 °C</dd><dt>NMR (CDCl₃, 90Hz) :</dt><dd>δ= 0.71(t, J=7.2Hz, 3H, CH₃); <ul id="ul0035" list-style="none" compact="compact"><li>1.16-1.58 (m, 2H); <chemistry id="chem0010" num="0010"><img file="EP0629632B2_D0015.tif" /></chemistry></li><li>2.61-2.99 (m, 2H);</li><li>6.89-7.47 (m, 9H).</li></ul></dd><dt>IR (Kbr disk)</dt><dd>: 1696cm^-1 (ν_c=o)</dd></dl>

Synthesis of 3-(2-biphenylyl)-2-ethylpropionyl chloride

A 100-ml three-necked round flask equipped with a stirring bar, a Dimroth condenser, a thermometer and a NaOH trap was charged with 13.3 g (52.4 mmol) of 3-(2-biphenylyl)-2-ethylpropionic acid and 25.9 ml (355 mmol) of thionyl chloride, and the resulting mixture was stirred under reflux for 2.5 hours under a nitrogen atmosphere. After the reaction was completed, the unreacted thionyl chloride was distilled off under reduced pressure to obtain 15.2 g of a crude product as a yellow-orange liquid. The thus obtained acid chloride was used in the next reaction without further purification. <dl id="dl0003" compact="compact"><dt>IR (Neat)</dt><dd>: 1786 cm^-1 (ν_c=o)</dd></dl>

Synthesis of 4-ethyl-2-phenyl-1-indanone

A 200-ml three-necked round flask equipped with a stirring bar, a Dimroth condenser, a dropping funnel, a thermometer and a NaOH trap was charged with 8.04 g (60.3 mmol) of anhydrous aluminum chloride and 50 ml of carbon disulfide. To the mixture was dropwise added a solution containing 15.2 g (52.4 mmol) of the above-obtained 3-(2-biphenylyl)-2-ethyl propionyl chloride under a nitrogen atmosphere at 0 °C. After the addition was completed, the temperature in the flask was elevated to room temperature and the reaction mixture was stirred for 1 hour. The reaction mixture was poured onto 200 ml of ice-water and extracted with 100 ml of ether two times. The combined organic phase was washed with 100 ml of a saturated aqueous solution of NaHCO₃ and further 100 ml of a saturated aqueous solution of sodium chloride, followed by drying over anhydrous Na₂SO₄. The solvent was evaporated under reduced pressure. The residue was chromatographed on silica gel (eluting with hexane/ethyl acetate (10/1), parts by volume) to obtain 10.8 g of the desired product as a yellow solid (yield: 88%). <dl id="dl0004" compact="compact"><dt>NMR (CDCl₃, 90 MHz) :</dt><dd>δ=0.98(t, J= 7.2Hz, 3H, CH₃); <ul id="ul0036" list-style="none" compact="compact"><li>1.60-2.20(m, 2H);</li><li><chemistry id="chem0011" num="0011"><img file="EP0629632B2_D0016.tif" /></chemistry></li><li>2.80(dd, J=3.8Hz, 16.5Hz, 1H);</li><li>3.36(dd, J=7.6Hz, 16.5Hz, 1H);</li><li>7.09-7.91(m, 8H).</li></ul></dd><dt>IR (Neat)</dt><dd>: 1705 cm^-1(ν_c=o)</dd></dl>

Synthesis of 2-ethyl-1-hydroxy-4-phenylindene

A 200-ml three-necked round flask equipped with a stirring bar, a Dimroth condenser, a dropping funnel and a thermometer was charged with 0.85 g (22.6 mmol) of sodium borohydride and 28 ml of ethanol. To the mixture was dropwise added a solution containing 10.6 g (45.1 mmol) of the above-obtained 2-ethyl-4 2-ethyl-4-phenyl-1-indanone dissolved in 20 ml of ethanol at room temperature under a nitrogen atmosphere. After the addition was completed, the temperature of was elevated to 50 °C, and the reaction mixture was stirred for 3.5 hours. After the reaction was completed, the unreacted sodium borohydride was decomposed by acetone. Then, the reaction mixture was concentrated under reduced pressure, and then dissolved in 50 mi of water and extracted with 50 ml of ether. After the organic phase was separated, the aqueous phase was extracted with 50 ml of ether two times. The combined organic phase was washed with 100 ml of a saturated aqueous solution of sodium chloride, followed by drying over anhydrous Na₂SO₄. The solvent was evaporated under reduced pressure to obtain 10.67 g of the desired product as a pasty pale yellow liquid (mixture of two kinds of isomers) (yield: 99%). <dl id="dl0005" compact="compact"><dt>NMR (CDCl₃, 90 MHz) :</dt><dd>δ=1.02(t, J=7.1Hz, 3H, CH₃); <ul id="ul0037" list-style="none" compact="compact"><li>1.31-3.25(m, 5H) ;</li><li>4.86, 5.03( each d, each <chemistry id="chem0012" num="0012"><img file="EP0629632B2_D0017.tif" /></chemistry><chemistry id="chem0013" num="0013"><img file="EP0629632B2_D0018.tif" /></chemistry> 7.10-7.66(m, 8H).</li></ul></dd><dt>IR (Neat)</dt><dd>: 3340 cm^-1(ν_c=o)</dd></dl>

Synthesis of 2-ethyl-4-phenylindene

A 300-ml four-necked round flask equipped with a stirring bar, a dropping funnel and a thermometer was charged with 9.78 g (41.3 mmol) of 2-ethyl-1-hydroxy-4-phenylindane, 17.2 ml (123.8 mmol) of triethylamine, 0.25 g (2.1 mmol) of 4-dimethylaminopyridine and 98 ml of methylene chloride. To the mixture was dropwise added a solution containing 6.4 ml (82.5 mmol) of methanesulfonyl chloride dissolved in 6.5 ml of methylene chloride under a nitrogen atmosphere at 0 °C. After the addition was completed, the reaction mixture was stirred for 3.5 hours at this temperature. The reaction mixture was poured onto 250 ml of ice-water. Then, the organic phase was separated and the aqueous phase was further extracted with 50 ml of methylene chloride two times. The combined organic phase was washed with a saturated aqueous solution of NaHCO₃, and then a saturated aqueous solution of sodium chloride, followed by drying over anhydrous Na₂SO₄. The solvent was evaporated under reduced pressure. The residue was chromatographed on silica gel (eluting with hexane) to obtain 6.56 g of the desired product as a pale yellow liquid (mixture of two kinds of isomers) (yield: 73%). <dl id="dl0006" compact="compact"><dt>NMR (CDCl₃, 90 MHz) :</dt><dd>δ=1.20(t, J=7.6Hz, 3H, CH₃); <ul id="ul0038" list-style="none" compact="compact"><li>2.49(q, J=7.6Hz, 2H);</li><li>3.41(s, 2H);</li><li>6.61, 6.72(each bs, total 1H);</li><li>7.09-8.01(m, 8H).</li></ul></dd></dl>

Synthesis of dimethylsilyl-bis(2-ethyl-4-phenylindene)

A 200-ml three-necked round flask equipped with a stirring bar, a Dimroth condenser, a dropping funnel and a thermometer was charged with 5.0 g (22.8 mmol) of 2-ethyl-4-phenylindene, 80 mg (0.63 mmol) of copper thiocyanate and 50 ml of anhydrous ether. To the mixture was gradually dropwise added 15.7 ml (25.1 mmol) of a 1.6 M solution of n-butyl lithium in hexane under a nitrogen atmosphere at 0 °C. After the addition was completed, the temperature was elevated to room temperature, the reaction mixture was stirred for 1 hour. Then, to the reaction mixture was gradually dropwise added a solution containing 1.52 ml (12.6 mmol) of dimethyldichlorosilane dissolved in 4.5 ml of anhydrous ether. After the addition was completed, the reaction mixture was stirred for 12 hours at room temperature. The reaction mixture was filtered through Celite, and the filtrate was poured onto 50 ml of a saturated aqueous solution of ammonium chloride. After the organic phase was separated, the aqueous phase was extracted with 50 ml of ether. The combined organic phase was washed with a saturated aqueous solution of sodium chloride, followed by drying over anhydrous Na₂SO₄. The solvent was evaporated under reduced pressure. The residue was chromatographed on silica gel (eluting with hexane, and hexane/methylene chloride (20/1), parts by volume) to obtain 4.5 g of the desired product (mixture of two kinds of isomers) as a pale yellow solid (yield: 80%). <dl id="dl0007" compact="compact"><dt>NMR (CDCl₃, 90MHz) :</dt><dd>δ=-0.23, -0.17(each s, total 6H, <ul id="ul0039" list-style="none" compact="compact"><li>Si-CH₃);</li><li>1.12, 1.19(each t, each J=7.4</li><li>Hz, 6H, CH₃);</li><li>2.44 (bq, J=7.4Hz, 4H);</li><li><chemistry id="chem0014" num="0014"><img file="EP0629632B2_D0019.tif" /></chemistry></li><li>6.75(bs, 2H, 3-H-Ind);</li><li>6.88-7.74 (m, 16H).</li></ul></dd></dl>

Synthesis of rac-dimethylsilyl-bis{1-(2-ethyl-4-phenylindenyl)}zirconium dichloride

A 50-ml three-necked round flask equipped with a stirring bar, a condenser, a dropping funnel and a thermometer was charged with 0.84 g (1.69 mmol) of dimethylsilyl-bis(2-ethyl-4-phenylindene) and 17 ml of anhydrous ether. To the mixture was gradually dropwise added 2.25 ml (3.56 mmol) of a 1.58 M solution of n-butyl lithium in hexane at room temperature. After the addition was completed, the reaction mixture was stirred for 13.5 hours. To the resulting solution was gradually added 0.395 g (1.69 mmol) of ZrCl₄ at -70 °C. After the addition was completed, the mixture was allowed to warm to room temperature overnight. Then, the solvent was evaporated at room temperature under reduced pressure. To the resulting material was added 30 ml of methylene chloride. Then, the insoluble material was filtered off and the filtrate was concentrated and crystallized at room temperature. After the precipitates were filtered, the residue was washed with 3 ml of anhydrous ether two times, followed by drying under reduced pressure to obtain 0.17 g of the desired product as an orange-yellow solid (yield: 15 %). <dl id="dl0008" compact="compact"><dt>NMR (CDCl₃, 90 MHz) :</dt><dd>δ=1.09(t, J=7.3Hz, 6H, CH₃); <ul id="ul0040" list-style="none" compact="compact"><li>1.34 (s, 6H, Si-CH₃);</li><li>2.46 (quin, J=7.3Hz, 2H)</li><li>2.73 (quin, J=7.3Hz, 2H)</li><li>6.96 (s, 2H, 3-H-Ind);</li><li>6.99-7.88 (m, 16H).</li></ul></dd></dl>

Example 2

A 500-ml gas through type-glass reactor thoroughly purged with nitrogen was charged with 250 ml of toluene. The reactor was cooled to 0°C, and the reaction system was sufficiently saturated by passing through propylene at a flow rate of 160 liters/hr and ethylene at a flow rate of 40 liters/hr. Then, to the reactor were added 0.25 mmol of triisobutylaluminum, 0.5 mmol (in terms of Al atom) of methylaluminoxane and 0.001 mmol (in terms of Zr atom) of rac-dimethylsilyl-bis{1-(2-ethyl-4-phenylindenyl)}zirconium dichloride. While maintaining the temperature of the reaction system at C°C, the polymerization was carried out for 10 minutes. The polymerization was stopped by the addition of a small amount of methanol. The polymerization suspension was poured onto 2 liters of methanol containing a small amount of hydrochloric acid, which was then sufficiently stirred and filtered. The resulting polymer was washed with a large amount of methanol and dried at 80°C for 10 hours.

The amount of the thus obtained polymer was 5.62 g. The polymerization activity was 33.7 kg-polymer/mmol-Zr·hr. The ethylene content was 3.9 % by mol, the intrinsic viscosity [η] was 1.80 dl/g, Mw/Mn was 2.15, and Tm was 126 °C. In the polymer, the triad tacticity was 99.3 %, the proportion of the inversely inserted units based on the 2,1-insertion of the propylene monomer was 0.12 %, and the proportion of the inversely inserted units based on the 1,3-insertion propylene monomer was less than the detectable lower limit (less than 0.03 %).

The results are shown in Table 1 (I) and (II).

The film of the polymer had a heat seal-starting temperature of 129 °C and a heat seal-starting temperature after heat treatment of 132 °C.

The results are shown in Table 2.

Example 3

The polymerization was carried out in the same manner as in Example 2 except that the reaction system was sufficiently saturated by passing through propylene at a flow rate of 140 liters/hr and ethylene at a flow rate of 60 liters/hr, respectively. The thus obtained polymer solution was poured onto 2 liters of methanol containing a small amount of hydrochloric acid to precipitate a polymer. The methanol was sufficiently removed, and the resulting polymer was dried at 130 °C for 10 hours.

The amount of the thus obtained polymer was 6.63 g and the polymerization activity was 39.8 kg-polymer/mmol-Zr·hr. The ethylene content was 8.7 % by mol, the intrinsic viscosity [η] was 1.66 dl/g, Mw/Mn was 2.46, and Tm was 105 °C. In the polymer, the triad tacticity was 99.2 %, the proportion of the inversely inserted units based on the 2,1-insertion of the propylene monomer was 0.12 %, and the proportion of the inversely inserted units based on the 1,3-insertion of the propylene monomer was less than the detectable lower limit (less than 0.03 %).

The results are shown in Table 1 (I) and (II).

The film of the polymer had a heat seal-starting temperature of 106 °C and a heat seal-starting temperature after heat treatment of 109 °C.

The results are shown in Table 2.

Example 4

The polymerization reaction was carried out in the same manner as in Example 2 except that the reaction system was sufficiently saturated by passing through propylene at a flow rate of 100 liters/hr and ethylene at a flow rate of 100 liters/hr, respectively. The thus obtained polymer solution was poured onto 2 liters of methanol containing a small amount of hydrochloric acid to precipitate a polymer. The methanol was sufficiently removed and the resulting polymer was dried at 130°C for 10 hours.

The amount of the thus obtained polymer was 8.95 g and the polymerization activity was 53.7 kg-polymer/mmol-Zr·hr. The ethylene content was 28.9 % by mol, the intrinsic viscosity [η] was 1.34 dl/g, and Mw/Mn was 1.95. In the polymer, the triad tacticity was 98.5 %, the proportion of the inversely inserted units based on the 2,1-insertion of the propylene monomer was 0.09 %, and the proportion of the inversely inserted units based on the 1,3-insertion of the propylene monomer was less than the detectable lower limit (less than 0.03 %).

The results are shown in Table 1 (I) and (II).

The copolymer had an izod impact strength of 28 kg·cm/cm and a film impact strength of 5300 kg·cm/cm.

The results are shown in Table 2.

Example 5

Synthesis of rac-dimethylsilyl-bis{1-(2-ethyl-4-(1-naphthyl)indenyl)}zirconium dichloride

Synthesis of 3-(2-bromophenylyl)-2-ethylpropionic acid

A 2-liter four-necked round flask equipped with a stirrer, a Dimroth condenser, a dropping funnel and a thermometer was charged with 44.2 g (394 mmol) of potassium t-butoxide, 392 ml of toluene and 30 ml of N-methylpyrrolidone. To the mixture was dropwise added a solution containing 61.2 g (325 mmol) of diethyl ethylmalonate dissolved in 61 ml of toluene under a nitrogen atmosphere at 60°C. After the addition was completed, the reaction mixture was stirred for 1 hour at this temperature. Then, to the resulting mixture was dropwise added a solution containing 75.4 g (302 mmol) of 2-bromobenzylbromide dissolved in 75 ml of toluene. After the addition was completed, the temperature was elevated and the resulting mixture was stirred under reflux for 5 hours. The reaction mixture was poured onto 300 ml of water and adjusted with 10 % sulfuric acid to pH 1. The organic phase was separated and the aqueous phase was extracted with 100 ml of ether three times. The combined organic phase was washed with 200 ml of a saturated aqueous solution of sodium bicarbonate and then 150 ml of a saturated aqueous solution of sodium chloride three times, followed by drying over anhydrous Na₂SO₄. The solvent was concentrated under reduced pressure to obtain 111.1 g of a concentrate as a yellow liquid.

A 2-liter four-necked round flask equipped with a stirrer, a Dimroth condenser, a dropping funnel and a thermometer was charged with 195 g (2.96 mol) of potassium hydoxide and 585 ml of an aqueous solution of methanol (methanol/water=4/1(v/v)). To the mixture was dropwise added the above-obtained concentrate at room temperature under a nitrogen atmosphere. After the addition was completed, the temperature was elevated and the resultant mixture was stirred under reflux for 3 hours. Thereafter, the temperature was cooled to room temperature and the precipitated white solid was filtered. The filtrate was concentrated and cooled to obtain a second crop. The same procedure was repeated as described above to obtain a third crop. The combined crops were slurried in hexane and filtered. The solid thus obtained was dried to obtain 101.5 g of a white powder. The white powder was dissolved in 400 ml of water and the resulting solution was acidified with addition of 50 % H₂SO₄ aq. to pH 1. The resulting mixture was extracted with 200 ml of methylene chloride five times. The combined organic phase was dried over anhydrous Na₂SO₄. The solvent was concentrated under reduced pressure to obtain 74.2 g of a hard white solid.

Then, a 300-ml three-necked round flask equipped with a stirring bar, a Dimroth condenser, a thermometer was charged with the above-obtained white solid. Then, the solid was heated to 200 °C and stirred for 5 hours under a nitrogen atmosphere. After the reaction was completed, the reaction product was cooled to room temperature to obtain 61.2 g of the desired product as a pale yellow-white solid (yield: 79%). <dl id="dl0009" compact="compact"><dt>FD-MS</dt><dd>: 256 (M⁺), 258 (M⁺ +2)</dd><dt>NMR (CDCl₃, 90 MHz) :</dt><dd>δ = 1.0(t, J=7.0Hz, 3H, CH₃); <ul id="ul0041" list-style="none" compact="compact"><li>1.40-1.85 (m, 2H);</li><li>2.53-3.12(m, 3H);</li><li>6.88, 7.66(m, 3H).</li></ul></dd></dl>

Synthesis of 3-(2-bromophenyl)-2-ethylpropionyl chloride

A 300-ml three-necked round flask equipped with a stirring bar, a Dimroth condenser, a thermometer and a NaOH trap was charged with 60.86 g (237 mmol) of 3-(2-bromphenylyl)-2-ethylpropionic acid, 40 ml of benzene and 120 ml of thionyl chloride, and the mixture was stirred under reflux for 1.5 hours under a nitrogen atmosphere. After the reaction was completed, the unreacted thionyl chloride was distilled off under reduced pressure to obtain the crude product as a yellow liquid. The thus obtained acid chloride was used in the next reaction without further purification.

Synthesis of 4-bromo-2-ethyl-1-indanone

A 1-liter three-necked round flask equipped with a stirring bar, a Dimroth condenser, a dropping funnel, a thermometer and a NaOH trap was charged with 36.3 g (272 mmol) of anhydrous aluminum chloride and 280 ml of carbon disulfide. To the mixture was dropwise added a solution containing the above obtained 3-(2-bromophenyl)-2-ethylpropionyl chloride dissolved in 50 ml of carbon disulfide under a nitrogen atmosphere at 0 °C. After the addition was completed, the temperature in the flask was elevated to room temperature and the reaction mixture was stirred for 1 hour. The reaction mixture was poured onto 1 liter of ice-water and extracted with 300 ml of ether two times. The combined organic phase was washed with a saturated aqueous solution of NaHCO₃, and then a saturated aqueous solution of sodium chloride, followed by drying over anhydrous Na₂SO₄. The solvent was evaporated under reduced pressure to obtain 56.9 g of the desired product as a slightly pasty red-brown liquid. The thus obtained ketone was used in the next reaction without further purification.

Synthesis of 4-bromo-2-ethyl-1-trimethylsilyloxyindane

A 500-ml three-necked round flask equipped with a stirring bar, a Dimroth condenser, a dropping funnel and a thermometer was charged with 4.97 g (118 mmol) of sodium borohydride and 200 ml of ethanol. To the mixture was dropwise added a solution containing 56.93 g of the above-obtained 4-bromo-2-ethyl-1-indanone dissolved in 85 ml of ethanol at room temperature under a nitrogen atmosphere. After the addition was completed, the reaction mixture was stirred for additonal 4 hours. After the reaction was completed, the reaction mixture was cooled and the unreacted sodium borohydride was decomposed by acetone. Then, the reaction mixture was concentrated under reduced pressure, and dissolved in 300 ml of water and extracted 300 ml of ether. After the organic phase was separated, the aqueous phase was extracted with 100 ml of ether three times. The combined organic phase was washed three times with 150 ml of a saturated aqueous solution of sodium chloride, followed by drying over anhydrous Na₂SO₄. The solvent was evaporated under reduced pressure to obtain 58.92 g of a flesh colored solid.

A 500-ml four-necked round flask equipped with a stirring bar, a Dimroth condenser, a dropping funnel and a thermometer was charged with 58.91 g (244 mmol) of the above-obtained solid, 43.3 ml (307 mmol) of triethylamine and 280 ml of methylene chloride. To the mixture was gradually dropwise added a solution containing 37.2 ml (293 mmol) of Me₃SiCl dissolved in 15 ml of methylene chloride under a nitrogen atmosphere at 0 °C. After the addition was completed, the temperature was elevated to room temperature, and the reaction mxitrure was stirred for additional 3.5 hours. The reaction mixture was poured onto 100 ml of water. Then, the organic phase was separated and the aqueous phase was extracted with 100 ml of methylene chloride two times. The combined organic phase was washed with 100 ml of water three times, followed by drying over anhydrous Na₂SO₄. The solvent was evaporated under reduced pressure. The residue was distilled under reduced pressure to obtain 69.9 g of the desired product (mixture of two isomers) as a colorless liquid (total yield: 95% from 3-(2-bromophenylyl)-2-ethylpropionic acid). <dl id="dl0010" compact="compact"><dt>mp.</dt><dd>: 133-135 °C/2mmHg</dd><dt>FD-MS</dt><dd>: 312 (M⁺), 314 (M⁺ +2)</dd><dt>NMR (CDCl₃, 90 MHz) :</dt><dd>δ=0.17, 0.24(each s, total 9H, Si-CH₃); <ul id="ul0042" list-style="none" compact="compact"><li>0.79-1.12(m, 3H);</li><li>1.16-3.31(m, 5H);</li><li>4.82, 5.10(each bd, each J=6.4</li><li>Hz, total 1H, -CH-O-);</li><li>6.91-7.46 (m, 3H).</li></ul></dd></dl>

Synthesis of 2-ethyl-4-(1-naphthyl)phenylindene

A 300-ml three-necked round flask equipped with a stirring bar, a Dimroth condenser, a dropping funnel and a thermometer was charged with 11.4 g (36.4 mmol) of 4-bromo-2-ethyl-1-trimetylsilyloxyindane, 0.13 g (0.18 mmol) of PdCl₂ (dppf) and 35 ml of anhydrous ether. To the resulting mixture was dropwise added 101 ml (72.8 mmol) of a 0.72 M solution of 1-naphthylmagnesiumbromide in ether/benzene at room temperature under a nitrogen atmosphere. After the addition was completed, the reaction mixture was stirred for 1 hour. Then, the temperature in the flask was elevated to 50 to 51 °C, and the reaction mixture was stirred for additional 5 hours. After the reaction was completed, to the reaction mixture was added 135 ml of 5 N hydrochloric acid at 0 °C to decompose the excess amount of Grignard reagent, and the resulting mixture was extracted with 100 ml of ether two times. The combined organic phase was washed with a saturated aqueous solution of sodium bicarbonate, and then a saturated aqueous solution of sodium chloride, followed by drying over anhydrous Na₂SO₄. The solvent was evaporated under reduced pressure to obtain 20.5 g of a product as a red-brown liquid.

Then, the above-obtained red-brown liquid was diluted with 20 ml of tetrahydrofuran. To the mixture was added 5 ml of 12 % hydrochloric acid and the reaction mixture was stirred at room temperature overnight. After the reaction was completed, to the reaction mixture was added 100 ml of ether and the organic phase was separated. The organic phase was washed with a saturated aqueous solution of sodium bicarbonate, and then a saturated aqueous solution of sodium chloride, followed by drying over anhydrous Na₂SO₄. The solvent was evaporated under reduced pressure. The residue was chromatographed on silica gel (Silica gel 60 from MERCK Co., 70-230 mesh, eluting with hexane, and then hexane/ethyl acetate (1/3, parts by volume)) to obtain 9.0 g of the desired product (mixture of two isomers) as a yellow solid (yield: 98 %). <dl id="dl0011" compact="compact"><dt>FD-MS</dt><dd>: 270 (M⁺)</dd><dt>NMR (CDCl₃, 90 MHz) :</dt><dd>δ=1.20(t, J=7.4Hz, 3H, CH₃); <ul id="ul0043" list-style="none" compact="compact"><li>2.38(bq, J=7.4Hz, 2H);</li><li>3.02, 3.42(each s, total 2H);</li><li>6.54(bs, 1H);</li><li>6.19-8.12(m, 10H)</li></ul></dd></dl>

Synthesis of dimethylsilyl-bis{1-(2-ethyl-4-(1-naphthyl)indene)}

A 200-ml three-necked round flask equipped with a stirring bar, a Dimroth condenser, a dropping funnel and a thermometer was charged with 4.97 g (18.4 mmol) of 2-ethyl-4-(1-naphthyl)indene, 50 mg (0.51 mmol) of copper cyanide and 53 ml of anhydrous ether. To the mixture was gradually dropwise added 12.8 ml (20.2 mmol) of a 1.58 M solution of n-butyl lithium in hexane under a nitrogen atmosphere at -10 °C. After the addition was completed, the temperature was elevated to room temperature and the reaction mixture was stirred for 4 hours. Then, to the reaction mixture was gradually dropwise added a solution containing 1.24 ml (10.1 mmol) of dimethyldichlorosilan dissolved in 5 ml of anhydrous ether. After the addition was completed, the reaction mixture was stirred for 15 hours at room temperature. The reaction mixture was poured onto 50 ml of a saturated aqueous solution of ammonium chloride and filtered through Celite. The organic phase was separated and the aqueous phase was extracted with 50 ml of ether. The combined organic phase was washed with a saturated aqueous solution of sodium chloride, followed by drying over anhydrous Na₂SO₄. The solvent was evaporated under reduced pressure. The residue was chromatographed on silica gel (eluting with hexane) to obtain 3.2 g of the desired product (mixture of two isomers) as a yellow solid (yield: 58 %). <dl id="dl0012" compact="compact"><dt>FD-MS</dt><dd>: 596 (M⁺)</dd><dt>NMR (CDCl₃, 90 MHz) :</dt><dd>δ=-0.20, -0.20(each s, total 6H, Si-CH₃); <ul id="ul0044" list-style="none" compact="compact"><li>0.82-1.41(m, 6H, CH₃);</li><li>2.23, 2.74(m, 4H);</li><li>3.84-4.10(m, 2H, -CH-Si);</li><li>6.20, 6.30(each bd, 2H);</li><li>6.98-8.14 (m, 20H)</li></ul></dd></dl>

Synthesis of rac-dimethylsilyl-bis{1-(2-ethyl-4-(1-naphthyl)indenyl)}zirconium dichloride

A 100-ml three-necked round flask equipped with a stirring bar, a condenser having beads, a dropping funnel and a thermometer was charged with 2.0 g (3.36 mmol) of dimethylsilyl-bis(2-ethyl-4-(1-naphthyl)indene and 40 ml of anhydrous ether under an argon atmosphere. To the mixture was gradually dropwise added 4.58 ml (7.06 mmol) of a 1.54 M solution of n-butyl lithium in hexane at room temperature. After the addition was completed, the reaction mixture was stirred for 17.5 hours. The resulting reaction solution was cooled to -75 °C. Then, to the solution was gradually added 0.83 g (3.56 mmol) of ZrCl₄. After the addition was completed, the mixture was allowed to warm to room temperature overnight.

The thus obtained red-yellow reaction slurry was filtered, and washed with 45 ml of anhydrous ether. To the residue were added 60 ml of methylene chloride and 40 ml of anhydrous ether, and then the insoluble material was filtered off. The filtrate was concentrated to dryness at room temperature. The residue was dissolved in 15 ml of methylene chloride and concentrated to about 1/3 of total volume of the mixture. Then, 2 ml of anhydrous ether to give the precipitate. The precipitate was filtered and washed with 2 ml of anhydrous ether, followed by drying under a reduced pressure to obtain 0.12 g of the desired product as a yellow-orange powder (yield: 5 %). <dl id="dl0013" compact="compact"><dt>NMR (CDCl₃, 90 MHz) :</dt><dd>δ=1.04(t, J=7.4Hz, 6H, CH₃); <ul id="ul0045" list-style="none" compact="compact"><li>1.38 (s, 6H, Si-CH₃);</li><li>2.12-3.02 (m, 4H);</li><li>6.53 (s, 2H, 3-H-Ind);</li><li>6.86-8.02 (m, 20H).</li></ul></dd></dl>

Example 6

The polymerization reaction was carried out in the same manner as in Example 3 except that the rac-dimethylsilyl-bis{1-(2-ethyl-4-(1-naphthyl)indenyl)}zirconium dichloride was used in place of the rac-dimethylsilyl-bis{1-(2-ethyl-4-phenylindenyl)}zirconium dichloride as a transition metal compound catalyst component.

The amount of the thus obtained polymer was 2.08 g and the polymerization activity was 12.5 kg-polymer/mmol-Zr·hr. The ethylene content was 7.9 % by mol, the intrinsic viscosity [η] was 1.39 dl/g, Mw/Mn was 2.33, and Tm was 109 °C. In the polymer, the triad tacticity was 99.2 %, the proportion of the inversely inserted units based on the 2,1-insertion of the propylene monomer was 0.10 %, and the proportion of the inversely inserted units based on the 1,3-insertion of the propylene monomer was less than the detectable lower limit (less than 0.03 %).

The results are shown in Table 1 (I) and (II).

The film of the polymer had a heat seal-starting temperature of 106 °C and a heat seal-starting temperature after heat treatment of 110 °C.

The results are shown in Table 2.

Example 7

A 200-ml reactor equipped with stirring blade throughly purged with nitrogen was charged with 80 liters of hexane, 80 mmol of triisobutylaluminum, 0.25 liter of hydrogen, 9 kg of ethylene and 0.3 kg of propylene, followed by elevating the temperature of the reactor to 70 °C. Then, to the reactor were added 18 mmol of methylaluminoxane and 0.06 mmol (in terms of Zr atom) of rac-dimethylsilyl-bis{1-(2-methyl-4-phenylindenyl)}zirconium dichloride to polymerize at 70 °C for 30 minutes. During the polymerization, 13.7 kg of propylene and 0.5 kg of ethylene were respectively fed to the reactor. After the polymerization, the autoclave was released, the resulting polymer was recovered in a large amount of methanol, and dried at 80 °C for 10 hours under reduced pressure.

The amount of the polymer obtained was 7.0 kg. The polymerization activity was 117 kg-polymer/mmolZr·hr. The polymer had an ethylene content of 4.7 mol % and an intrinsic viscosity [η] of 2.7 dl/g. In the polymer, the triad tacticity of the propylene unit chain consisting of head-to-tail bonds was 97.5 %, the proportion of the inversely inserted units based on the 2,1-insertion of the propylene monomer was 0.22 %, and the proportion of the inversely inserted units based on the 1,3-insertion of the propylene monomer was not more than 0.05 %.

The results are shown in Table 1 (I) and (II).

The film of the copolymer had a heat seal-starting temperature of 120 °C and a heat seal-starting tempeature after heat treatment of 123 °C.

The results are shown in Table 2.

Example 8

A 2-liter autoclave throughly purged with nitrogen was charged with 900 ml of hexane. Then, to the autoclave was added 1 mmol of triisobutylaluminum. After elevating the temperature of the reaction system to 70 °C, ethylene was fed to the system to keep a pressure of 1.5 kg/cm²-G, and then propylene was fed to the system to keep a total pressure of 8 kg/cm²-G. To the autoclave were added 0.3 mmol of methylaluminoxane and 0.001 mmol (in terms of Zr atom) of rac-dimethylsilyl-bis{1-(2-dimethyl-4-phenylindenyl)}zirconium dichloride to polymerize the monomers for 7 minutes while propylene was continuously fed to keep the total pressure of 8 kg//cm²-G. After the polymerization, the autoclave was released, the resulting polymer was recovered in a large amount of methanol, and dried at 110 °C for 10 hours under reduced pressure.

The amount of the polymer obtained was 25.4 g. The polymerization activity was 25 kg-polymer/mmolZr·hr. The polymer had an ethylene content of 2.5 mol % and an intrinsic viscosity [η] of 3.1 dl/g. In the polymer, the triad tacticity of the propylene unit chain consisting of head-to-tail bonds was 97.6 %, the proportion of the inversely inserted units based on the 2,1-insertion of the propylene monomer was 0.22 %, and the proportion of the inversely inserted units based on the 1,3-insertion of the propylene monomer was not more than 0.05 %.

The results are shown in Table 1 (I) and (II).

The film of the copolymer had a heat seal-starting temperature of 134 °C and a heat seal-starting tempeature after heat treatment of 134 °C.

The results are shown in Table 2.

Example 9

A 17-liter autoclave throughly purged with nitrogen was charged with 8 liters of hexane. After the temperature of the reaction system was elevated to 60 °C, propylene and ethylene were continuously fed to the system at a flow rate of 250 liters/hr and a flow rate of 170 liters/hr, respectively, to elevate the pressure to 8 kg/cm²-G.

Then, to the autoclave were added 8 mmol of triisobutylaluminum, 1.8 mmol of methylaluminoxane and 0.006 mmol (in terms of Zr atom) of rac-dimethylsilyl-bis{1-(2-dimethyl-4-phenylindenyl)}zirconium dichloride to polymerize the monomers at 60 °C for 45 minutes while a mixed gas of propylene and ethylene (mol ratio: 60/40) were continuously fed to keep the pressure of 8 kg//cm²-G. After the polymerization, the autoclave was released, the resulting polymer was recovered in a large amount of methanol, and dried at 110 °C for 10 hours under reduced pressure.

The amount of the polymer obtained was 860 g. The polymerization activity was 143 kg-polymer/mmolZr·hr. The polymer had an ethylene content of 33.6 mol % and an intrinsic viscosity [η] of 1.4 dl/g. In the polymer, the triad tacticity of the propylene unit chain consisting of head-to-tail bonds was 97.5 %, the proportion of the inversely inserted units based on the 2,1-insertion of the propylene monomer was 0.27 %, and the proportion of the inversely inserted units based on the 1,3-insertion of the propylene monomer was not more than 0.03 %.

The results are shown in Table 1 (I) and (II).

The copolymer had an izod impact strength of 30 kg·cm/cm, a film impact strength of 5300 kg·cm/cm and MFR of 17.8 g/10 min.

The results are shown in Table 2.

Example 10

The polymerization was carried out in the same manner as in Example 9 except that the feed of ethylene was changed to 60 liters from 170 liters, and the mol ratio of propylene to ethylene in the mixed gas was changed to 81/19 from 60/40.

The amount of the polymer obtained was 900 g. The polymerization activity was 150 kg-polymer/mmolZr·hr. The polymer had an ethylene content of 15.4 mol % and an intrinsic viscosity [η] of 1.5 dl/g. In the polymer, the triad tacticity of the propylene unit chain consisting of head-to-tail bonds was 96.7 %, the proportion of the inversely inserted units based on the 2,1-insertion of the propylene monomer was 0.28 %, and the proportion of the inversely inserted units based on the 1,3-insertion of the propylene monomer was not more than 0.03 %.

The results are shown in Table 1 (I) and (II).

The film of the copolymer had a heat seal-starting temperature of 80 °C and a heat seal-starting temperature after heat treatment of 83 °C.

The results are shown in Table 2.

Example 11

A 17-liter autoclave throughly purged with nitrogen was charged with 8 liters of hexane and 40 ml of hydrogen. After the temperature of the reaction system was elevated to 70 °C, propylene and ethylene were continuously fed to the system at a flow rate of 253 liters/hr and a flow rate of 22 liters/hr, respectively, to elevate the pressure to 6.5 kg/cm²-G.

Then, to the autoclave were added 8 mmol of triisobutylaluminum, 1.8 mmol of methylaluminoxane and 0.006 mmol (in terms of Zr atom) of rac-dimethylsilyl-bis{1-(2-dimethyl-4-phenylindenyl)}zirconium dichloride to polymerize the monomers at 70 °C for 30 minuets while a mixed gas of propylene and ethylene (mol ratio: 92/8) was continuously fed to keep the pressure of 6.5 kg//cm²-G. After the polymerization, the autoclave was released, the resulting polymer was recovered in a large amount of methanol, and dried at 110 °C for 10 hours under reduced pressure.

The amount of the polymer obtained was 700 g. The polymerization activity was 117 kg-polymer/mmolZr·hr. The polymer had an ethylene content of 6.0 mol % and an intrinsic viscosity [η] of 2.0 dl/g. In the polymer, the triad tacticity of the propylene unit chain consisting of head-to-tail bonds was 97.5 %, the proportion of the inversely inserted units based on the 2,1-insertion of the propylene monomer was 0.18 %, and the proportion of the inversely inserted units based on the 1,3-insertion of the propylene monomer was not more than 0.03 %.

The results are shown in Table 1 (I) and (II).

The film of the copolymer had a heat seal-starting temperature of 112 °C and a heat seal-starting temperature after heat treatment of 115 °C.

The results are shown in Table 2. <tables id="tabl0001" num="0001"><table frame="all"><title>Table 1 (I)</title><tgroup cols="6"><colspec colnum="1" colname="col1" colwidth="14mm" /><colspec colnum="2" colname="col2" colwidth="18mm" colsep="0" /><colspec colnum="3" colname="col3" colwidth="22mm" /><colspec colnum="4" colname="col4" colwidth="13mm" /><colspec colnum="5" colname="col5" colwidth="37mm" /><colspec colnum="6" colname="col6" colwidth="14mm" /><thead><row rowsep="0"><entry valign="top" /><entry namest="col2" nameend="col3" align="left" valign="top">Comonomer</entry><entry align="center" valign="top">Yield</entry><entry align="center" valign="top">Polymerization Activity</entry><entry align="center" valign="top">[η]</entry></row><row><entry valign="top" /><entry valign="top">Kind</entry><entry align="right" valign="top">Content (%)</entry><entry align="center" valign="top">(g)</entry><entry align="center" valign="top">*1</entry><entry align="center" valign="top">(d1/g)</entry></row></thead><tbody><row rowsep="0"><entry>Ex. 2</entry><entry>ethylene</entry><entry align="right">3.9</entry><entry align="center">5.62</entry><entry align="center">33.7</entry><entry align="center">1.80</entry></row><row rowsep="0"><entry>Ex. 3</entry><entry>ethylene</entry><entry align="right">8.7</entry><entry align="center">6.63</entry><entry align="center">39.8</entry><entry align="center">1.66</entry></row><row><entry>Ex. 4</entry><entry>ethylene</entry><entry align="right">28.9</entry><entry align="center">8.95</entry><entry align="center">53.7</entry><entry align="center">1.34</entry></row><row><entry>Ex. 6</entry><entry>ethylene</entry><entry align="right">7.9</entry><entry align="center">2.08</entry><entry align="center">12.5</entry><entry align="center">1.39</entry></row><row rowsep="0"><entry>Ex. 7</entry><entry>ethylene</entry><entry align="right">4.7</entry><entry align="center">7000</entry><entry align="center">117</entry><entry align="center">2.7</entry></row><row><entry>Ex. 8</entry><entry>ethylene</entry><entry align="right">2.5</entry><entry align="center">25.4</entry><entry align="center">25</entry><entry align="center">3.1</entry></row><row rowsep="0"><entry>Ex. 9</entry><entry>ethylene</entry><entry align="right">33.6</entry><entry align="center">860</entry><entry align="center">143</entry><entry align="center">1.4</entry></row><row rowsep="0"><entry>Ex. 10</entry><entry>ethylene</entry><entry align="right">15.4</entry><entry align="center">900</entry><entry align="center">150</entry><entry align="center">1.5</entry></row><row><entry>Ex. 11</entry><entry>ethylene</entry><entry align="right">6.0</entry><entry align="center">700</entry><entry align="center">117</entry><entry align="center">2.0</entry></row></tbody></tgroup><tgroup cols="6" rowsep="0"><colspec colnum="1" colname="col1" colwidth="14mm" /><colspec colnum="2" colname="col2" colwidth="18mm" /><colspec colnum="3" colname="col3" colwidth="22mm" /><colspec colnum="4" colname="col4" colwidth="13mm" /><colspec colnum="5" colname="col5" colwidth="37mm" /><colspec colnum="6" colname="col6" colwidth="14mm" /><tbody><row><entry namest="col1" nameend="col6" align="justify">*1: kg-polymer/mmol-Zr·hr</entry></row></tbody></tgroup></table></tables><tables id="tabl0002" num="0002"><table frame="all"><title>Table 1 (II)</title><tgroup cols="5"><colspec colnum="1" colname="col1" colwidth="14mm" /><colspec colnum="2" colname="col2" colwidth="23mm" /><colspec colnum="3" colname="col3" colwidth="28mm" colsep="0" /><colspec colnum="4" colname="col4" colwidth="28mm" /><colspec colnum="5" colname="col5" colwidth="16mm" /><thead><row rowsep="0"><entry valign="middle" /><entry align="center" valign="middle">mm Fraction</entry><entry namest="col3" nameend="col4" align="center" valign="middle">Proportion of inversely inserted units</entry><entry align="center" valign="middle">Mw/Mn</entry></row><row><entry valign="middle" /><entry align="center" valign="middle" /><entry align="center" valign="middle">2,1-insertion (%)</entry><entry align="center" valign="middle">1,3-insertion (%)</entry><entry align="center" valign="middle" /></row></thead><tbody><row rowsep="0"><entry valign="middle">Ex. 2</entry><entry valign="middle" align="char" char=".">99.3</entry><entry valign="middle" align="char" char=".">0.12</entry><entry align="center" valign="middle">&lt;0.03</entry><entry align="center" valign="middle">2.15</entry></row><row rowsep="0"><entry valign="middle">Ex. 3</entry><entry valign="middle" align="char" char=".">99.2</entry><entry valign="middle" align="char" char=".">0.12</entry><entry align="center" valign="middle">&lt;0.03</entry><entry align="center" valign="middle">2.46</entry></row><row><entry valign="middle">Ex. 4</entry><entry valign="middle" align="char" char=".">98.5</entry><entry valign="middle" align="char" char=".">0.09</entry><entry align="center" valign="middle">&lt;0.03</entry><entry align="center" valign="middle">1.95</entry></row><row><entry valign="middle">Ex. 6</entry><entry valign="middle" align="char" char=".">99.2</entry><entry valign="middle" align="char" char=".">0.10</entry><entry align="center" valign="middle">&lt;0.03</entry><entry align="center" valign="middle">2.33</entry></row><row rowsep="0"><entry valign="middle">Ex. 7</entry><entry valign="middle" align="char" char=".">97.5</entry><entry valign="middle" align="char" char=".">0.22</entry><entry align="center" valign="middle">&lt;0.05</entry><entry align="center" valign="middle">-</entry></row><row><entry valign="middle">Ex. 8</entry><entry valign="middle" align="char" char=".">97.6</entry><entry valign="middle" align="char" char=".">0.22</entry><entry align="center" valign="middle">&lt;0.05</entry><entry align="center" valign="middle">-</entry></row><row rowsep="0"><entry valign="middle">Ex. 9</entry><entry valign="middle" align="char" char=".">97.5</entry><entry valign="middle" align="char" char=".">0.27</entry><entry align="center" valign="middle">&lt;0.03</entry><entry align="center" valign="middle">-</entry></row><row rowsep="0"><entry valign="middle">Ex. 10</entry><entry valign="middle" align="char" char=".">96.7</entry><entry valign="middle" align="char" char=".">0.28</entry><entry align="center" valign="middle">&lt;0.03</entry><entry align="center" valign="middle">-</entry></row><row><entry valign="middle">Ex. 11</entry><entry valign="middle" align="char" char=".">97.5</entry><entry valign="middle" align="char" char=".">0.18</entry><entry align="center" valign="middle">&lt;0.03</entry><entry align="center" valign="middle">-</entry></row></tbody></tgroup></table></tables><tables id="tabl0003" num="0003"><table frame="all"><title>Table 2</title><tgroup cols="7"><colspec colnum="1" colname="col1" colwidth="18mm" /><colspec colnum="2" colname="col2" colwidth="16mm" /><colspec colnum="3" colname="col3" colwidth="24mm" /><colspec colnum="4" colname="col4" colwidth="30mm" /><colspec colnum="5" colname="col5" colwidth="22mm" /><colspec colnum="6" colname="col6" colwidth="29mm" /><colspec colnum="7" colname="col7" colwidth="29mm" /><thead valign="top"><row><entry align="center">Example</entry><entry align="center">Melting point (°C)</entry><entry align="center">Heat seal-starting temperature (°C)</entry><entry align="center">Heat seal-starting temperature after heat treatment (°C)</entry><entry align="center">Film impact strength (kg·cm/cm)</entry><entry align="center">IZ of composition with polypropylene (kgf·cm/cm)</entry><entry align="center">MFR of composition with polypropylene (g/10 min)</entry></row></thead><tbody><row><entry>Ex. 2</entry><entry align="center">126</entry><entry align="center">129</entry><entry align="center">132</entry><entry align="center">-</entry><entry align="center">-</entry><entry align="center">-</entry></row><row><entry>Ex. 3</entry><entry align="center">105</entry><entry align="center">106</entry><entry align="center">109</entry><entry align="center">-</entry><entry align="center">-</entry><entry align="center">-</entry></row><row><entry>Ex. 4</entry><entry align="center">-</entry><entry align="center">-</entry><entry align="center">-</entry><entry align="center">5300</entry><entry align="center">28</entry><entry align="center">-</entry></row><row><entry>Ex. 6</entry><entry align="center">109</entry><entry align="center">106</entry><entry align="center">110</entry><entry align="center">-</entry><entry align="center">-</entry><entry align="center">-</entry></row><row><entry>Ex. 7</entry><entry align="center">123</entry><entry align="center">120</entry><entry align="center">123</entry><entry align="center">-</entry><entry align="center">-</entry><entry align="center">-</entry></row><row><entry>Ex. 8</entry><entry align="center">137</entry><entry align="center">134</entry><entry align="center">134</entry><entry align="center">-</entry><entry align="center">-</entry><entry align="center">-</entry></row><row><entry>Ex. 9</entry><entry align="center">-</entry><entry align="center">-</entry><entry align="center">-</entry><entry align="center">5300</entry><entry align="center">30</entry><entry align="center">17.8</entry></row><row><entry>Ex. 10</entry><entry align="center">78</entry><entry align="center">80</entry><entry align="center">83</entry><entry align="center">-</entry><entry align="center">-</entry><entry align="center">-</entry></row><row><entry>Ex. 11</entry><entry align="center">115</entry><entry align="center">112</entry><entry align="center">115</entry><entry align="center">-</entry><entry align="center">-</entry><entry align="center">-</entry></row></tbody></tgroup></table></tables>