Main > POLYMERS > Poly(Ethylene) > Production > Catalyst > Nickel Catalyst > Ar-N=C(Het)-C(Het)=N-Ar. Complex

Product USA. E

PATENT ASSIGNEE'S COUNTRY USA
UPDATE 08.00
PATENT NUMBER This data is not available for free
PATENT GRANT DATE 15.08.00
PATENT TITLE Olefin polymerization catalysts containing group 8-10 transition metals, processes employing such catalysts and polymers obtained therefrom

PATENT ABSTRACT Methods for preparing olefin polymers, and catalysts for preparing olefin polymers are disclosed. The polymers can be prepared by contacting the corresponding monomers with a Group 8-10 transition metal catalyst. The polymers are suitable for processing in conventional extrusion processes, and can be formed into high barrier sheets or films, or low molecular weight resins for use in synthetic waxes in wax coatings or as emulsions.

PATENT INVENTORS This data is not available for free
PATENT ASSIGNEE This data is not available for free
PATENT FILE DATE 22.10.98
PATENT REFERENCES CITED W. Marginggele, Zeitschrift Fur Naturforschung, vol. 40b, No. 2, Feb., 1985, 277-281.
M. Doering, Zeitschrift Fur Anorganische und Allgemeine Chemie, vol. 620, No. 3, 1994, 551-560.
Dirk Lindauer et al, J. Prakt. Chem./Chem.-Ztg. (1995), 337(2), 143-52 Coden: JPCCEM; ISSN: 0941-1216.
L. K. Johnson, et al., J. Am. Chem. Soc., 1995, 117, No. 23, Jun. 14, 1995, 6414-6415.
G. F. Schmidt et al., J. Am. Chem. Soc. 1985, 107,1443.
M. Brookhart et al, Macromolecules 1995, 28, 5378.
M. Peuckert et al., Organomet. 1983, 2 (5), 594.
W. Keim et al., Angew. Chem. Int. Ed. Eng. 1981, 20, 116.
V. M. Mohring et al., Angew. Chem. Int. Ed. Eng. 1985, 24, 1001.
G. Wilke, Angew. Chem. Int. Ed. Engl. 1988, 27, 185.
K.A.O. Starzewski et al., Angew. Chem. Int. Ed. Engl. 1987, 26, 63.
W. Maringgele, Zeitschrift Fur Naturforschung, vol. 40b, No. 2, Feb., 1985, 277-281.
L. K. Johnson et al, Journal of the American Chemical Society, vol. 118, Oct. 10, 1996, 267-268.
Yasar Gok, Transition Metal Chemistry, vol. 20, No. 3, Jun. 1909, 225-319.

PATENT PARENT CASE TEXT This data is not available for free
PATENT CLAIMS We claim:

1. A composition comprising (a) a Group 8-10 transition metal M, (b) one or more Lewis acids, and (c) a binucleating or multinucleating compound of the formula X: ##STR67## wherein the Lewis acid or acids are bound to one or more heteroatoms which are .pi.-conjugated to the donor atom or atoms bound to the transition metal M;

R.sup.1 and R.sup.6 each, independently, represent sterically hindered aryl;

N represents nitrogen;

A and B are each, independently, a heteroatom connected mono-radical wherein the connected heteroatom is selected from Group 15 or 16; in addition, A and B may be linked by a bridging group.

2. The composition as in claim 1 wherein the transition metal is Ni(II), the Lewis acid is a boron or aluminum containing Lewis acid and the binucleating or multinucleating compound of formula X is selected from ##STR68## wherein R.sup.1 and R.sup.6 each, independently, represent sterically hindered aryl;

R.sup.2, R.sup.3, R.sup.4 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl; in addition, any two of R.sup.2, R.sup.3, R.sup.4, and R.sup.5 may collectively form a bridging group, provided that when the compound is of formula VI or IX, the bridging group is not a substituted sulfur atom or a substituted phosphorous atom; and

N represents nitrogen; O represents oxygen, and S represents sulfur.

3. A compound of the formula I: ##STR69## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl;

R.sup.2, R.sup.3, R.sup.4 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl; in addition, any two of R.sup.2, R.sup.3, R.sup.4, and R.sup.5 may collectively form a bridging group;

T represents a hydrogen or hydrocarbyl;

L represents a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;

M represents Ni(II), Pd(II), Co(II), or Fe(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

4. A compound of formula II: ##STR70## wherein R.sup.1 and R.sup.6 each independently, represent a sterically hindered aryl;

R.sup.2, R.sup.3, R.sup.4 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl; in addition, any two of R.sup.2, R.sup.3, R.sup.4, and R.sup.5 may collectively form a bridging group;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

N represents nitrogen; and

M represents Ni(II), Pd(II), Co(II), or Fe(II).

5. A compound of formula IV: ##STR71## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl;

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

T represents a hydrogen or hydrocarbyl;

L represents a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;

M represents Ni(II), Pd(II), Co(II), or Fe(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

6. A compound of formula V: ##STR72## wherein R.sup.1 and R.sup.6 each, independently, represent sterically hindered aryl;

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

N represents nitrogen; and

M represents Ni(II), Pd(II), Co(II), or Fe(II).

7. A compound of the formula VII: ##STR73## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl;

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

T represents a hydrogen or hydrocarbyl;

L represents a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;

M represents Ni(II), Pd(II), Co(II), or Fe(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

8. A compound of formula VIII: ##STR74## wherein R.sup.1 and R.sup.6 each, independently, represent a sterically hindered aryl;

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

N represents nitrogen; and

M represents Ni(II), Pd(II), Co(II), or Fe(II).

9. A compound of the formula XIII: ##STR75## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl;

R.sup.2, R.sup.3, and R.sup.4 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, any two of R.sup.2, R.sup.3, and R.sup.4 may collectively form a bridging group;

T represents a hydrogen or hydrocarbyl;

L represents a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;

M represents Ni(II), Pd(II), Co(II), or Fe(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

10. A compound of formula XV: ##STR76## wherein R.sup.1 and R.sup.6 each, independently, represent a sterically hindered aryl;

R.sup.2, R.sup.3, and R.sup.4 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, any two of R.sup.2, R.sup.3, and R.sup.4 may collectively form a bridging group;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

N represents nitrogen; and

M represents Ni(II), Pd(II), Co(II), or Fe(II).

11. A compound of the formula XIV: ##STR77## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl;

R.sup.2 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl;

T represents a hydrogen or hydrocarbyl;

L represents a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;

M represents Ni(II), Pd(II), Co(II), or Fe(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

12. A compound of formula XVI: ##STR78## wherein R.sup.1 and R.sup.6 each, independently, represent a sterically hindered aryl;

R.sup.2 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

N represents nitrogen; and

M represents Ni(II), Pd(II), Co(II), or Fe(II).

13. A compound of the formula XIX: ##STR79## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl;

R.sup.2, R.sup.3, R.sup.4 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl; in addition, any two of R.sup.2, R.sup.3, R.sup.4, and R.sup.5 may collectively form a bridging group;

G is a .pi.-allyl or .pi.-benzyl group;

M represents Ni(II) or Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

14. A compound of formula XX: ##STR80## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl;

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

G is a .pi.-allyl or .pi.-benzyl;

M represents Ni(II), Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

15. A compound of the formula XXI: ##STR81## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl;

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

G is a .pi.-allyl or .pi.-benzyl;

M represents Ni(II), Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

16. A compound of the formula XXII: ##STR82## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl;

R.sup.2, R.sup.3, and R.sup.4 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging group;

G is a .pi.-allyl or .pi.-benzyl;

M represents Ni(II) or Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

17. A compound of the formula XXIII: ##STR83## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl;

R.sup.2 and R.sup.3 each independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl;

G is a .pi.-allyl or .pi.-benzyl;

M represents Ni(II), Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

18. A compound of formula XXIV, ##STR84## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl;

A and B are each, independently, a heteroatom connected mono-radical wherein the connected heteroatom is selected from Group 15 or 16; in addition, A and B may be linked by a bridging group;

T represents a hydrogen or a hydrocarbyl;

L represents a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;

M represents Ni(II) or Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

19. A compound of formula XXIX, ##STR85## wherein R.sup.1 and R.sup.6 each, independently, represent a sterically hindered aryl;

A and B are each, independently, a heteroatom connected mono-radical wherein the connected heteroatom is selected from Group 15 or 16; in addition, A and B may be linked by a bridging group;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

M represents Ni(II) or Pd(II); and

N represents nitrogen.

20. The compound of claim 5 having the formula XXV: ##STR86## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; and X.sup.- is a weakly coordinating anion.

21. The compound of claim 5 having the formula XXVI: ##STR87## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl; and X.sup.- is a weakly coordinating anion.

22. The compound of claim 6 having the formula XXVII, ##STR88## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl.

23. The compound of claim 6 having the formula XXVIII, ##STR89## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl.

24. The compound of claim 7 having the formula XXX, ##STR90## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; and X.sup.- is a weakly coordinating anion.

25. The compound of claim 7 having the formula XXXI, ##STR91## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl; and X.sup.- is a weakly coordinating anion.

26. The compound of claim 8 having the formula XXXII, ##STR92## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl.

27. The compound of claim 8 having the formula XXXIII, ##STR93## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl.

28. The compound of claim 7 having the formula XXXIV, ##STR94## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl; and X.sup.- is a weakly coordinating anion.

29. The compound of claim 5 having the formula XXXV, ##STR95## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl; and X.sup.- is a weakly coordinating anion.

30. The compound of claim 9 having the formula XXXVI, ##STR96## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; and X.sup.- is a weakly coordinating anion.

31. The compound of claim 9 having the formula XXXVII, ##STR97## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl; and X.sup.- is a weakly coordinating anion.

32. The compound of claim 10 having the formula XXXVIII, ##STR98## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl.

33. The compound of claim 10 having the formula XXXIX, ##STR99## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl.

34. The compound of claim 11 having the formula XL, ##STR100## wherein R.sup.1, R.sup.2, R.sup.5 and R.sup.6 are 2,6-dimethyl-4-methoxyphenyl;

and X.sup.- is a weakly coordinating anion.

35. The compound of claim 12 having the formula XLI, ##STR101## wherein R.sup.1, R.sup.2, R.sup.5 and R.sup.6 are 2,6-dimethyl-4-methoxyphenyl.

36. The compound of claim 4 wherein M is Ni(II).

37. A supported catalyst comprising the reaction product of a compound of formula V, VIII, or XV: ##STR102## wherein R.sup.1 and R.sup.6 each, independently, represent a sterically hindered aryl;

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

N represents nitrogen; and

M represents Ni(II), Pd(II), Co(II), or Fe(II);

with a solid support which has been pre-treated with a compound Y, wherein Y is selected from the group consisting of a neutral Lewis acid capable of abstracting Q.sup.- or W.sup.- to form a weakly coordinating anion, a cationic Lewis acid whose counterion is a weakly coordinating anion, and a Bronsted acid whose conjugate base is a weakly coordinating anion.

38. The supported catalyst of claim 37, wherein the compound of formula V, VII, or XV is selected from the group consisting of ##STR103## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; ##STR104## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl; ##STR105## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; ##STR106## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl; ##STR107## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; and ##STR108## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl.

39. The supported catalyst of claim 37 comprising the reaction product of a compound of the formula XXVII, ##STR109## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; with silica which has been pre-treated with methylaluminoxane.

40. The supported catalyst of claim 37 comprising the reaction product of a compound of the formula XXXII, ##STR110## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; with silica which has been pre-treated with methylaluminoxane.

41. A supported catalyst formed by the reaction of

(a) a compound of formula V, VIII, or XV: ##STR111## wherein R.sup.1 and R.sup.6 each, independently, represent a sterically hindered aryl;

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

N represents nitrogen; and

M represents Ni(II), Pd(II), Co(II), or Fe(II);

(b) a solid support; and

(c) a compound Y, wherein Y is selected from the group consisting of a neutral Lewis acid capable of abstracting Q.sup.- or W.sup.- to form a weakly coordinating anion, a cationic Lewis acid whose counterion is a weakly coordinating anion, and a Bronsted acid whose conjugate base is a weakly coordinating anion.

42. The catalyst of claim 41, wherein the solid support is selected from the group consisting of talcs, silicas, titania, silica/chromia, silica/chromia/titania, silica/alumina, zirconia, aluminum phosphate gels, silanized silica, silica hydrogels, silica xerogels, silica aerogels, silica co-gels, montmorillonite clay and Y is a compound selected from the group consisting of methylaluminoxane and other aluminum sesquioxides having the formulas R.sup.7.sub.3 Al, R.sup.7.sub.2 AlCl, and R.sup.7 AlCl.sub.2, wherein R.sup.7 is alkyl.

43. The supported catalyst of claim 41, wherein the compound of formula V, VIII, or XV is selected from the group consisting of: ##STR112## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; ##STR113## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl; ##STR114## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; ##STR115## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl; ##STR116## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; and ##STR117## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl.

44. The supported catalyst of claim 41 comprising the reaction product of a compound of the formula XXVII, ##STR118## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; with silica and with methylaluminoxane.

45. The supported catalyst of claim 41 comprising the reaction product of a compound of the formula XXXII, ##STR119## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; with silica and with methylaluminoxane.
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PATENT DESCRIPTION FIELD OF THE INVENTION

The present invention is directed to Group 8-10 transition metal-containing complexes, their use in olefin polymerizations, and to novel olefin polymers produced thereby.

BACKGROUND OF THE INVENTION

Olefin polymers are used in a wide variety of products, from sheathing for wire and cable to film. Olefin polymers are used, for instance, in injection or compression molding applications, in extruded films or sheeting, as extrusion coatings on paper, for example photographic paper and digital recording paper, and the like. Improvements in catalysts have made it possible to better control polymerization processes, and, thus, influence the properties of the bulk material. Increasingly, efforts are being made to tune the physical properties of plastics for lightness, strength, resistance to corrosion, permeability, optical properties, and the like, for particular uses. Chain length, polymer branching and functionality have a significant impact on the physical properties of the polymer. Accordingly, novel catalysts are constantly being sought in attempts to obtain a catalytic process for polymerizing olefins which permits more efficient and better controlled polymerization of olefins.

Conventional polyolefins are prepared by a variety of polymerization techniques, including homogeneous liquid phase, gas phase, and slurry polymerization. Certain transition metal catalysts, such as those based on titanium compounds (e.g. TiCl.sub.3 or TiCl.sub.4) in combination with organoaluminum cocatalysts, are used to make linear and linear low density polyethylenes as well as poly-.alpha.-olefins such as polypropylene. These so-called "Ziegler-Natta" catalysts are quite sensitive to oxygen and are ineffective for the copolymerization of nonpolar and polar monomers.

Recent advances in non-Ziegler-Natta olefin polymerization catalysis include the following.

L. K. Johnson et al., WO Patent Application 96/23010, disclose the polymerization of olefins using cationic nickel, palladium, iron, and cobalt complexes containing diimine and bisoxazoline ligands. This document also describes the polymerization of ethylene, acyclic olefins, and/or selected cyclic olefins and optionally selected unsaturated acids or esters such as acrylic acid or alkyl acrylates to provide olefin homopolymers or copolymers.

European Patent Application Serial No. 381,495 describes the polymerization of olefins using palladium and nickel catalysts which contain selected bidentate phosphorous containing ligands.

L. K. Johnson et al., J. Am. Chem. Soc., 1995, 117, 6414, describe the polymerization of olefins such as ethylene propylene, and 1-hexene using cationic .alpha.-diimine-based nickel and palladium complexes. These catalysts have been described to polymerize ethylene to high molecular weight branched polyethylene. In addition to ethylene, Pd complexes act as catalysts for the polymerization and copolymerization of olefins and methyl acrylate.

G. F. Schmidt et al., J. Am. Chem. Soc. 1985, 107, 1443, describe a cobalt(III) cyclopentadienyl catalytic system having the structure [C.sub.5 Me.sub.5 (L)CoCH.sub.2 CH.sub.2 --.parallel.--H].sup.+, which provides for the "living" polymerization of ethylene.

M. Brookhart et al., Macromolecules 1995, 28, 5378, disclose using such "living" catalysts in the synthesis of end-functionalized polyethylene homopolymers.

U. Klabunde, U.S. Pat. Nos. 4,906,754, 4,716,205, 5,030,606, and 5,175,326, describes the conversion of ethylene to polyethylene using anionic phosphorous, oxygen donors ligated to Ni(II). The polymerization reactions were run between 25 and 100.degree. C. with modest yields, producing linear polyethylene having a weight-average molecular weight ranging between 8 K and 350 K. In addition, Klabunde describes the preparation of copolymers of ethylene and functional group containing monomers.

M. Peuckert et al., Organomet. 1983, 2(5), 594, disclose the oligomerization of ethylene using phosphine, carboxylate donors ligated to Ni(II), which showed modest catalytic activity (0.14 to 1.83 TO/s). The oligomerizations were carried out at 60 to 95.degree. C. and 10 to 80 bar ethylene in toluene, to produce .alpha.-olefins.

R. E. Murray, U.S. Pat. Nos. 4,689,437 and 4,716,138, describes the oligomerization of ethylene using phosphine, sulfonate donors ligated to Ni(II). These complexes show catalyst activities approximately 15 times greater than those reported with phosphine, carboxylate analogs.

W. Keim et al., Angew. Chem. Int. Ed. Eng. 1981, 20,116, and V. M. Mohring, et al. Angew. Chem. Int. Ed. Eng. 1985, 24,1001. disclose the polymerization of ethylene and the oligomerization of .alpha.-olefins with aminobis(imino)phosphorane nickel catalysts; G. Wilke, Angew. Chem. Int. Ed. Engl. 1988, 27, 185, describes a nickel allyl phosphine complex for the polymerization of ethylene.

K. A. O. Starzewski et al., Angew. Chem. Int. Ed. Engl. 1987, 26, 63, and U.S. Pat. No. 4,691,036, describe a series of bis(ylide) nickel complexes, used to polymerize ethylene to provide high molecular weight linear polyethylene.

WO Patent Application 97/02298 discloses the polymerization of olefins using a variety of neutral N, 0, P, or S donor ligands, in combination with a nickel(0) compound and an acid.

Brown et al., WO 97/17380, describes the use of Pd .alpha.-diimine catalysts for the polymerization of olefins including ethylene in the presence of air and moisture.

Fink et al., U.S. Pat. No. 4,724,273, have described the polymerization of .alpha.-olefins using aminobis(imino)phosphorane nickel catalysts and the compositions of the resulting poly(.alpha.-olefins).

Recently Vaughan et al. WO 9748736, Denton et al. WO 9748742, and Sugimura et al. WO 9738024 have described the polymerization of ethylene using silica supported .alpha.-diimine nickel catalysts.

Additional recent developments are described by Sugimura et al., in JP96-84344, JP96-84343, by Yorisue et al., in JP96-70332, by Canich et al. WO 9748735, McLain et al. WO 9803559, Weinberg et al. WO 9803521 and by Matsunaga et al. WO 9748737.

Notwithstanding these advances in non-Ziegler-Natta catalysis, there remains a need for efficient and effective Group 8-10 transition metal catalysts for effecting polymerization of olefins. In addition, there is a need for novel methods of polymerizing olefins employing such effective Group 8-10 transition metal catalysts. In particular, there remains a need for Group 8-10 transition metal olefin polymerization catalysts with both improved temperature stability and functional group compatibility. Further, there remains a need for a method of polymerizing olefins utilizing effective Group 8-10 transition metal catalysts in combination with a Lewis acid so as to obtain a catalyst that is more active and more selective.

SUMMARY OF THE INVENTION

The present invention is directed to novel Group 8-10 transition metal catalysts, to batch or continuous olefin polymerizations using these catalysts, and to the polymers produced thereby.

The process of the present invention comprises contacting one or more olefin monomers of the formula LI:

RCH.dbd.CHR.sup.8

LI

wherein R.sup.1 and R.sup.8 each, independently, represent a hydrogen, a hydrocarbyl or a fluoroalkyl, and may be linked to form a cyclic olefin;

with a Group 8-10 transition metal having coordinated thereto a bidentate ligand having the formula X: ##STR1## wherein R.sup.1 and R.sup.6 are each, independently, hydrocarbyl, substituted hydrocarbyl, or silyl, preferably sterically hindered aryl;

A and B are each, independently, a heteroatom connected mono-radical wherein the connected heteroatom is selected from Group 15 or 16, preferably N, O, S, and wherein A and B may be linked by a bridging group;

and, optionally, a Bronsted or Lewis acid; and polymerization is carried out to obtain a polymer comprising units of the aforementioned olefin monomer.

In the above process, it should be appreciated that the Group 8-10 transition metal has coordinated thereto a bidentate ligand having the formula X and that the Bronsted or Lewis acid is optionally reacted with this metal-ligand complex. In addition, the Bronsted or Lewis acid may be optionally combined with the ligand X prior to complexation to the Group 8-10 transition metal.

In addition, the process of the present invention comprises contacting one or more monomers of the aforementioned formula LI with a catalyst of the present invention having the following formula XI: ##STR2## wherein R.sup.1, R.sup.6, A, and B are as in formula (X) above; T represents a hydrogen or a hydrocarbyl;

L represents a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;

M represents a Group 8-10 transition metal, preferably Ni(II), Pd(II), Co(II) or Fe(II), more preferably Ni(II) or Pd(II);

and X.sup.- is a weakly coordinating anion; and polymerization is carried out to obtain a polymer comprising units of the aforementioned olefin monomer.

We believe that when T is hydrogen or hydrocarbyl and L is ethylene or a mono-olefin in formula XI above, then XI is the catalytically active specie. This active specie can be prepared by a number of different methodologies, including reaction of a zero-valent metal complex with a ligand of formula X and a Bronsted acid in the presence of ethylene or a mono-olefin. An example of this methodology includes the reaction of bis(1,5-cyclooctadiene)Ni(0) with a bidentate ligand of formula X and the ether solvate of hydrogen tetrakis[3,5-bis(trifluoromethyl)phenyl]borate in the presence of ethylene or a mono-olefin to generate an active catalyst of formula XI.

Further, the process of the present invention comprises contacting an olefin monomer of formula LI with a catalyst of the present invention, formed by combining a compound of formula (XII): ##STR3## with a compound Y, selected from the group consisting of a neutral Lewis acid capable of abstracting Q.sup.- or W.sup.- to form a weakly coordinating anion, a cationic Lewis acid whose counterion is a weakly coordinating anion, or a Bronsted acid whose conjugate base is a weakly coordinating anion,

wherein R.sup.1, R.sup.6, A, and B are as in formula X above;

Q represents an alkyl, chloride, iodide or bromide;

W represents an alkyl, chloride, iodide or bromide;

M represents a Group 8-10 transition metal, preferably Ni(II), Pd(II), Co(II), or Fe(II); and polymerization is carried out to obtain a polymer comprising units of the aforementioned olefin monomer.

The catalysts used in the processes of the present invention readily convert ethylene and .alpha.-olefins to high molecular weight polymers, and allow for olefin polymerizations under various conditions, including ambient temperature and pressure, and in solution.

The polymers of the present invention include homopolymers of olefins, such as polyethylene, polypropylene, and the like, and olefin copolymers, including functional-group containing copolymers. As an example, ethylene homopolymers can be prepared with strictly linear to highly branched structures by variation of the catalyst structure, cocatalyst composition, and reaction conditions, including pressure and temperature. The effect these parameters have on polymer structure is described herein. These polymers and copolymers have a wide variety of applications, including use as packaging material and in adhesives.

Accordingly, it is an object of the present invention to provide novel catalysts capable of polymerizing olefins, including functional group-containing olefins.

It is another object of the invention to set forth catalyst systems for olefin polymerizations.

It is a further object of the invention to describe olefin polymerizations under mild conditions.

It is yet another object of the invention to provide novel catalysts and processes for homogeneous olefin catalysis.

It is yet another object of the invention to provide novel catalysts and processes for heterogeneous gas or slurry phase olefin polymerization.

It is still a further object of the invention to provide novel polyolefins.

It is yet still another object of the invention to describe methods of varying catalyst structure and polymerization reaction conditions to vary the structure of the resultant polyolefin.

These and other objects, features, and advantages of the invention will become apparent as reference is made to the following detailed description and preferred embodiments.

DETAILED DESCRIPTION OF THE INVENTION

In this disclosure certain chemical groups or compounds are described by certain terms and symbols. These terms are defined as follows:

Symbols ordinarily used to denote elements in the Periodic Table take their ordinary meaning, unless otherwise specified. Thus, N, O, S, P, and Si stand for nitrogen, oxygen, sulfur, phosphorus, and silicon, respectively.

Examples of neutral Lewis acids include, but are not limited to, methylaluminoxane (hereinafter MAO) and other aluminum sesquioxides, R.sup.7.sub.3 Al, R.sup.7.sub.2 AlCl, R.sup.7 AlCl.sub.2 (where R.sup.7 is alkyl), organoboron compounds, boron halides. B(C.sub.6 F.sub.5).sub.3. BPh.sub.3, and B(3,5-(CF.sub.3)C.sub.6 H.sub.3).sub.3. Examples of ionic compounds comprising a cationic Lewis acid include: R.sup.9.sub.3 Sn[BF.sub.4 ], (where R.sup.9 is hydrocarbyl), MgCl.sub.2, and H.sup.+ X.sup.-, where X.sup.- is a weakly coordinating anion.

The term "weakly coordinating anion" is well-known in the art per se and generally refers to a large bulky anion capable of delocalization of the negative charge of the anion. Suitable weakly coordinating anions include, but are not limited to, PF.sub.6.sup.-, BF.sub.4.sup.-, SbF.sub.6.sup.-, (Ph).sub.4 B.sup.- wherein Ph=phenyl, .sup.- BAr.sub.4 wherein .sup.- BAr.sub.4 =tetrakis[3,5-bis(trifluoromethyl)phenyl]borate. The coordinating ability of such anions is known and described in the literature (Strauss. S. et al., Chem. Rev. 1993, 93, 927).

Examples of neutral Lewis bases include, but are not limited to, (i) ethers, for example, diethyl ether or tetrahydrofuran, (ii) organic nitriles, for example acetonitrile, (iii) organic sulfides, for example dimethylsulfide, or (iv) monoolefins, for example, ethylene, hexene or cyclopentene.

A "hydrocarbyl" group means a monovalent or divalent, linear, branched or cyclic group which contains only carbon and hydrogen atoms. Examples of monovalent hydrocarbyls include the following: C.sub.1 -C.sub.20 alkyl; C.sub.1 -C.sub.20 alkyl substituted with one or more groups selected from C.sub.1 -C.sub.20 alkyl, C.sub.3 -C.sub.8 cycloalkyl or aryl; C.sub.3 -C.sub.8 cycloalkyl; C.sub.3 -C.sub.8 cycloalkyl substituted with one or more groups selected from C.sub.1 -C.sub.20 alkyl, C.sub.3 -C.sub.8 cycloalkyl or aryl; C.sub.6 -C.sub.14 aryl; and C.sub.6 -C.sub.14 aryl substituted with one or more groups selected from C.sub.1 -C.sub.20 alkyl, C.sub.3 -C.sub.8 cycloalkyl or aryl; where the term "aryl" preferably denotes a phenyl, napthyl, or anthracenyl group. Examples of divalent (bridging) hydrocarbyls include: --CH.sub.2 --, --CH.sub.2 CH.sub.2 --, --CH.sub.2 CH.sub.2 CH.sub.2 --, and 1,2-phenylene.

A "silyl" group refers to a SiR.sub.3 group wherein Si is silicon and R is hydrocarbyl or substituted hydrocarbyl or silyl, as in Si(SiR.sub.3).sub.3.

A "heteroatom" refers to an atom other than carbon or hydrogen. Preferred heteroatoms include oxygen, nitrogen, phosphorus, sulfur, selenium, arsenic, chlorine, bromine, silicon and fluorine.

A "substituted hydrocarbyl" refers to a monovalent or divalent hydrocarbyl substituted with one or more heteroatoms. Examples of monovalent substituted hydrocarbyls include: 2,6-dimethyl-4-methoxyphenyl, 2,6-diisopropyl-4-methoxyphenyl, 4-cyano-2,6-dimethylphenyl, 2,6-dimethyl-4-nitrophenyl, 2,6-difluorophenyl, 2,6-dibromophenyl, 2,6-dichlorophenyl, 4-methoxycarbonyl-2,6-dimethylphenyl, 2-tert-butyl-6-chlorophenyl, 2,6-dimethyl-4-phenylsulfonylphenyl, 2,6-dimethyl-4-trifluoromethylphenyl, 2,6-dimethyl-4-trimethylammoniumphenyl (associated with a weakly coordinated anion), 2,6-dimethyl-4-hydroxyphenyl, 9-hydroxyanthr-10-yl, 2-chloronapth-1-yl, 4-methoxyphenyl, 4-nitrophenyl, 9-nitroanthr-10-yl, --CH.sub.2 0CH.sub.3, cyano, trifluoromethyl, or fluoroalkyl. Examples of divalent (bridging) substituted hydrocarbyls include: 4-methoxy-1,2-phenylene, 1-methoxymethyl-1,2-ethanediyl, 1,2-bis(benzyloxymethyl)-1,2-ethanediyl, or 1-(4-methoxyphenyl)-1,2-ethanediyl.

A "sterically hindered aryl" means (i) a phenyl ring with hydrocarbyl, substituted hydrocarbyl, F, Cl, Br or silyl substituents at both the 2- and 6-positions, optionally substituted elsewhere with hydrocarbyl, substituted hydrocarbyl, F, Cl, Br, silyl, hydroxy, methoxy, nitro, cyano, phenylsulfonyl, CO.sub.2 Me, CO.sub.2 H, C(O)CH.sub.3, CF.sub.3, or fluoroalkyl substituents, (ii) a 2-substituted napth-1-yl ring, optionally substituted elsewhere with hydrocarbyl, substituted hydrocarbyl, F, Cl, Br, silyl, hydroxy, methoxy, nitro, cyano, phenylsulfonyl, CO.sub.2 Me, CO.sub.2 H, C(O)CH.sub.3, CF.sub.3, or fluoroalkyl substituents, (iii) an 9-anthracenyl or 1,2,3,4,5,6,7,8-octahydro-9-anthracenyl ring, optionally substituted elsewhere with hydrocarbyl, substituted hydrocarbyl, F, Cl, Br, silyl, hydroxy, methoxy, nitro, cyano, phenylsulfonyl, CO.sub.2 Me, CO.sub.2 H, C(O)CH.sub.3, CF.sub.3, or fluoroalkyl substituents, or (iv) an aromatic substituted hydrocarbyl with steric properties functionally equivalent (in the context of this invention) to one or more of the following sterically hindered aryls; 2,6-dimethylphenyl, 2,4,6-trimethylphenyl, 2,6-diisopropylphenyl, 2,6-dimethyl-4-nitrophenyl, 2,6-dimethyl4-phenylsulfonylphenyl, 2-isopropyl-6-methylphenyl, 2,6-bis(trifluoromethyl)phenyl, 2,6-dimethyl-4-methoxyphenyl, 2-methyl napth-1-yl, 9-anthracenyl, 1,2,3,4,5,6,7,8-octahydro-9-anthracenyl, 2,6-diclorophenyl, 2,6-dibromophenyl, 2-tert-butyl-6-methylphenyl, 2-trimethylsilylnapth-1-yl, 2-chloro-6-methylphenyl, 4-cyano-2,6-dimethylphenyl, 2,6-diisopropyl-4-methoxyphenyl, 2,4,6-tri-tert-butylphenyl, and 2-chloro-6-tert-butylphenyl.

A "heteroatom connected mono-radical" refers to a mono-radical group in which a heteroatom serves as the point of attachment. Examples include: NH(2,6-dimethylphenyl) and SPh, where Ph is phenyl. Numerous other examples are given herein.

A "substituted silicon atom" refers to a --SiR.sup.9.sub.2 --group, wherein R.sup.9 is a hydrocarbyl or substituted hydrocarbyl.

A "substituted phosphorous atom" refers to a --P(O)(OR.sup.9)--group, wherein R.sup.9 is a hydrocarbyl or substituted hydrocarbyl.

A "substituted sulfur atom" refers to a --S(O)--, --SO.sub.2 --, or --S(NR.sup.9).sub.2 --group, wherein R.sup.9 is a hydrocarbyl or substituted hydrocarbyl.

A "bridging group" refers to a divalent hydrocarbyl, divalent substituted hydrocarbyl, --C(O)--, --C(S)--, substituted silicon atom, substituted sulfur atom, substituted phosphorous atom, --CH.sub.2 C(O)--, --C(O)C(O)--, or 3,4,5,6-tetrafluoro-1,2-phenylene.

In certain cases, the bridging group, together with groups A and B, may collectively form a divalent heteroatom substituted heterocycle; examples include: ##STR4##

A "mono-olefin" refers to a hydrocarbon containing one carbon-carbon double bond.

A "suitable metal precursor" refers to a Group 8-10 transition metal compound, preferably Ni, Co, Pd, and Fe compounds, which may be combined with compound X (preferably, compound III, VI, IX, XVII or XVIII, described below), and optionally a Lewis or Bronsted acid, to form an active olefin polymerization catalyst. Examples include: (1,2-dimethoxyethane)nickel(II) dibromide, bis[(.mu.-chloro)(1,2,3-.eta..sup.3 -2-propenyl)nickel(II)], bis[(.mu.-chloro)(1,2,3-.eta..sup.3 -2-propenyl)palladium(II)], bis[(.mu.-chloro)(1,2,3-.eta..sup.3 -1-trimethylsilyloxy-2-propenyl)nickel(II)], CoBr.sub.2, FeBr.sub.2, bis(acetylacetonate)Ni(II), and [tetrakis(acetonitrile)Pd(II)][BF.sub.4 ].

A "suitable nickel precursor" refers to a suitable metal precursor wherein the metal is nickel.

A "suitable nickel(0) precursor" refers to a suitable metal precursor which is a zerovalent nickel compound.

The term "fluoroalkyl" as used herein refers to a C.sub.1 -C.sub.20 alkyl group substituted by one or more fluorine atoms.

The term "polymer" as used herein is meant a species comprised of monomer units and having a degree of polymerization (DP) of ten or higher.

The term ".alpha.-olefin" as used herein is a 1-alkene with from 3 to 40 carbon atoms.

A ".pi.-allyl" group refers to a monoanionic group with three sp.sup.2 carbon atoms bound to a metal center in a .eta..sup.3 -fashion. Any of the three sp.sup.2 carbon atoms may be substituted with a hydrocarbyl, substituted hydrocarbyl, heteroatom connected hydrocarbyl, heteroatom connected substituted hydrocarbyl, or O-silyl group. Examples of .pi.-allyl groups include: ##STR5##

The term .pi.-benzyl group denotes an .pi.-allyl group where two of the sp.sup.2 carbon atoms are part of an aromatic ring. Examples of .pi.-benzyl groups include: ##STR6##

A polymer with a "broad composition distribution" refers to a polymer that comprises a plurality of compositions (preferably >5) having varying levels of branching. The polymers can be fractionated and the fractions have levels of branching/1000 carbons that range from about 0 to about 100 branches/1000 carbons.

A "free flowing polymer" refers to a non-tacky polymer that can be transported without significant agglomeration. In this context, this lack of significant agglomeration refers to polymer products which are useful under commercial gas phase reactor conditions.

As used herein, the terms "monomer" and "olefin monomer" refer to the olefin or other monomer compound before it has been polymerized; the term "monomer units" refers to the moieties of a polymer that correspond to the monomers after they have been polymerized.

In some cases, a compound Y is required as a cocatalyst. Suitable compounds Y include a neutral Lewis acid capable of abstracting Q.sup.- or W.sup.- to form a weakly coordinating anion, a cationic Lewis acid whose counterion is a weakly coordinating anion, or a Bronsted acid whose conjugate base is a weakly coordinating anion. Preferred compounds Y include: methylaluminoxane (hereinafter MAO) and other aluminum sesquioxides. R.sup.7.sub.3 Al, R.sup.7.sub.2 AlCl, R.sup.7 AlCl.sub.2 (wherein R.sup.7 is alkyl), organoboron compounds, boron halides, B(C.sub.6 F.sub.5).sub.3, R.sup.9.sub.3 Sn[BF.sub.4 ] (wherein R.sup.9 hydrocarbyl), MgCl.sub.2, and H.sup.+ X.sup.-, wherein X.sup.- is a weakly coordinating anion. Examples of H.sup.+ X.sup.- are the ether solvate of hydrogen tetrakis[3,5-bis(trifluoromethyl)phenyl]borate and montmorillinite clay.

Examples of "solid support" include inorganic oxide support materials, such as: talcs, silicas, titania, silica/chromia, silica/chromia/titania, silica/alumina, zirconia, aluminum phosphate gels, silanized silica, silica hydrogels, silica xerogels, silica aerogels, montmorillonite clay and silica co-gels as well as organic solid supports such as polystyrene and functionalized polystyrene. (See, for example, Roscoe, S. B.; Frechet, J. M. J.; Walzer, J. F.; Dias, A. J.; "Polyolefin Spheres from Metallocenes Supported on Non-Interacting Polystyrene", 1998, Science, 280, 270-273 (1998).) An especially preferred solid support is one which has been pre-treated with Y compounds as described herein, most preferably with MAO. Thus, in a preferred embodiment, the catalysts of the present invention are attached to a solid support (by "attached to a solid support" is meant ion paired with a component on the surface, adsorbed to the surface or covalently attached to the surface) which has been pretreated with a compound Y. Alternatively, the catalyst, the compound Y, and the solid support can be combined in any order, and any number of Y compounds can be utilized; in addition, the supported catalyst thus formed, may be treated with additional quantities of compound(s) Y. In an especially preferred embodiment, the compounds of the present invention are attached to silica which has been pre-treated with MAO. Such supported catalysts are prepared by contacting the transition metal compound, in a substantially inert solvent--by which is meant a solvent which is either unreactive under the conditions of catalyst preparation, or if reactive, acts to usefully modify the catalyst activity or selectivity--with MAO treated silica for a sufficient period of time to generate the supported catalysts. Examples of substantially inert solvents include toluene, mineral spirits, hexane. CH.sub.2 Cl.sub.2 and CHCl.sub.3.

In one embodiment, the present invention provides a batch or continuous process for the polymerization of olefins, comprising contacting one or more monomers selected from compounds of the formula RCH.dbd.CHR.sup.8 with a catalyst comprising (a) a suitable metal precursor and (b) a ligand of the formula X, and optionally (c) a Bronsted or Lewis acid, ##STR7## wherein R and R.sup.8 each, independently, represent a hydrogen, a hydrocarbyl, or a fluoroalkyl, and may be linked to form a cyclic olefin;

R.sup.1 and R.sup.6 are each, independently, hydrocarbyl, substituted hydrocarbyl, or silyl, preferably sterically hindered aryl; N represents nitrogen;

A and B are each, independently, a heteroatom connected mono-radical wherein the connected heteroatom is selected from Group 15 or 16; in addition, A and B may be linked by a bridging group.

In a further aspect of the invention, there is provided a composition comprising (a) a Group 8-10 transition metal M, (b) one or more Lewis acids, and (c) a binucleating or multinucleating compound of the formula X: ##STR8## wherein the Lewis acid or acids are bound to one or more heteroatoms which are .pi.-conjugated to the donor atom or atoms bound to the transition metal M;

R.sup.1 and R.sup.6 are each, independently, hydrocarbyl, substituted hydrocarbyl, or silyl, preferably sterically hindered aryl;

N represents nitrogen;

A and B are each, independently, a heteroatom connected mono-radical wherein the connected heteroatom is selected from Group 15 or 16; in addition, A and B may be linked by a bridging group.

Preferred Group 8-10 transition metals are Ni, Pd, Fe, and Co, more preferably Ni and Pd.

Preferred ligands X are those given below: ##STR9## wherein R.sup.1 and R.sup.6 are as defined above; R.sup.2, R.sup.3, R.sup.4 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl; in addition, any two of R.sup.2, R.sup.3, R.sup.4, or R.sup.5 may collectively form a bridging group, provided that when the ligand is of formula VI or IX, the bridging group is not a substituted sulfur atom or a substituted phosphorous atom;

Synthesis of ligands of the formula X in general is based on a modification of methods previously described, and is detailed in the examples given below.

The Group 8-10 transition metal complex having coordinated thereto the bidentate ligand of formula X, above, may also have coordinated to it one or more additional ligands depending, for example, on whether the complex is the active catalyst, a precursor thereto, or the resting state of the catalyst.

In a preferred embodiment of the process of the present invention, one or more olefin monomers of the aforementioned formula LI is contacted with

(i) a suitable nickel(0) precursor, preferably bis(1,5-cyclooctadiene)nickel(0);

(ii) a Bronsted acid whose conjugate base is a weakly coordinating anion; and

(iii) a compound of the aforementioned formula X, preferably a compound of the formula III, VI, IX, XVII, or XVIII, described above; and polymerization is carried out to obtain a polymer comprising units of the aforementioned olefin monomer.

In another preferred embodiment of the process of the invention, there is provided a batch or continuous process for the polymerization of olefins, comprising contacting one or more monomers of the formula RCH.dbd.CHR.sup.8 with a catalyst of formula XI: ##STR10## wherein R and R.sup.8 each, independently, represent a hydrogen, a hydrocarbyl, or a fluoroalkyl, and may be linked to form a cyclic olefin;

R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably sterically hindered aryl;

A and B are each, independently, a heteroatom connected mono-radical wherein the connected heteroatom is selected from Group 15 or 16; in addition, A and B may be linked by a bridging group;

T represents a hydrogen or a hydrocarbyl;

L represents a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;

M represents Ni(II), Pd(II), Co(II), or Fe(II), preferably Ni(II) or Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

In a preferred embodiment, compound XI is selected from compounds having the following formulas: ##STR11## wherein R.sup.1, R.sup.2, R.sup.3, R.sup.4, R.sup.5, R.sup.6, T, L, and M are as defined above.

It is understood that, in the above formulas, when T represents the growing polymer chain or hydrogen, and L is a mono-olefin, the formulas represent the chain propagating species. T and L may collectively represent a .pi.-allyl or .pi.-benzyl complex, represented by the symbol G in the formula below, which is coordinated to M. Thus, in still another preferred embodiment of the process of the present invention, at least one olefin monomer LI is contacted with a catalyst selected from the following formulas: ##STR12## wherein R.sup.1 -R.sup.6, and X.sup.- are as defined above; G is a .pi.-allyl or .pi.-benzyl group,

M is a Group 8-10 transition metal, preferably Pd(II), Ni(II), Fe(II), or Co(II) more preferably Ni(II) or Pd(II);

and polymerization is carried out to obtain a polymer comprising units of the aforementioned olefin monomer.

As a further embodiment of the invention, there is provided a batch or continuous process for the polymerization of olefins, comprising contacting one or more monomers of the formula RCH.dbd.CHR.sup.8 with a catalyst formed by combining a compound of formula XII: ##STR13## with a compound Y, wherein R and R.sup.8 each, independently, represent a hydrogen, a hydrocarbyl, or a fluoroalkyl, and may be linked to form a cyclic olefin;

R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably sterically hindered aryl;

A and B are each, independently, a heteroatom connected mono-radical wherein the connected heteroatom is selected from Group 15 or 16, in addition, A and B may be linked by a bridging group;

Q represents an alkyl, chloride, iodide or bromide;

W represents an alkyl, chloride, iodide or bromide;

N represents nitrogen;

M represents Ni(II), Pd(II), Co(II), or Fe(II), preferably Ni(II) or Pd(II);

and Y is selected from the group consisting of a neutral Lewis acid capable of abstracting Q.sup.- or W.sup.- to form a weakly coordinating anion, a cationic Lewis acid whose counterion is a weakly coordinating anion, and a Bronsted acid whose conjugate base is a weakly coordinating anion.

In a further preferred embodiment, the compound of formula XII is attached to a solid support which has been pre-treated with a compound Y. Thus, as a further aspect of the invention, there is provided a process for the polymerization of olefins, comprising contacting one or more monomers of the formula RCH.dbd.CHR.sup.8 with a supported catalyst formed by combining a compound of formula XII: ##STR14## with a solid support which has been pre-treated with a compound Y, wherein R and R.sup.8 each, independently, represent a hydrogen, a hydrocarbyl, or a fluoroalkyl, and may be linked to form a cyclic olefin;

R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl;

A and B are each, independently, a heteroatom connected mono-radical wherein the connected heteroatom is selected from Group 15 or 16; in addition, A and B may be linked by a bridging group;

Q represents an alkyl, chloride, iodide or bromide;

W represents an alkyl, chloride, iodide or bromide;

N represents nitrogen;

M represents Ni(II), Pd(II), Co(II), or Fe(II);

and Y is selected from the group consisting of a neutral Lewis acid capable of abstracting W.sup.- or W.sup.- to form a weakly coordinating anion, a cationic Lewis acid whose counterion is a weakly coordinating anion, and a Bronsted acid whose conjugate base is a weakly coordinating anion.

In a more preferred embodiment, compounds of formula XII are those selected from the following formulas: ##STR15## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably sterically hindered aryl;

R.sup.2, R.sup.3, R.sup.4 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl; in addition, any two of R.sup.2, R.sup.3, R.sup.4, and R.sup.5 may be linked by a bridging group, provided that when the compound is of formula V or VIII, the bridging group is not a substituted sulfur atom or a substituted phosphorous atom;

Q represents an alkyl, chloride, iodide or bromide;

W represents an alkyl, chloride, iodide or bromide;

M represents Ni(II), Pd(II), Co(II) or Fe(II); and

N represents nitrogen, O represents oxygen; S represents sulfur.

As a further aspect of the invention, the compound of formula XII is a compound of formula V, VIII, or XV. In an especially preferred embodiment, such compounds are attached to a solid support which has been pretreated with a compound Y. Thus, as a further aspect of the invention, there is provided a supported catalyst comprising the reaction product of a compound of formula V, VIII, or XV: ##STR16## wherein R.sup.1 and R.sup.6 each, independently represent a sterically hindered aryl;

R.sup.2, R.sup.3 and R.sup.4 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition any two of R.sup.2, R.sup.3 and R.sup.4 may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

N represents nitrogen; and

M represents Ni(II), Pd(II), Co(II), or Fe(II);

with a solid support which has been pre-treated with a compound Y, wherein Y is selected from the group consisting of a neutral Lewis acid capable of abstracting Q.sup.- or W.sup.- to form a weakly coordinating anion, a cationic Lewis acid whose counterion is a weakly coordinating anion, and a Bronsted acid whose conjugate base is a weakly coordinating anion.

Also, as noted herein, the supported catalyst may be prepared by combining the catalyst, the solid support, and any number of compound(s) Y, in any order of addition; further, additional amounts of any number of compounds Y may be added after such preparation. Thus, the present invention provides a process for the preparation of supported catalysts, comprising contacting a compound of formula XII with a solid support which has been pretreated with a compound Y, or wherein said solid support is combined with a compound of formula XII and a compound Y in any sequence, ##STR17## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl;

A and B are each, independently, a heteroatom connected mono-radical wherein the connected heteroatom is selected from Group 15 or 16; in addition, A and B may be linked by a bridging group;

Q represents an alkyl, chloride, iodide or bromide;

W represents an alkyl, chloride, iodide or bromide;

N represents nitrogen;

M represents Ni(II), Pd(II), Co(II), or Fe(II);

and Y is selected from the group consisting of a neutral Lewis acid capable of abstracting Q.sup.- or W.sup.- to form a weakly coordinating anion, a cationic Lewis acid whose counterion is a weakly coordinating anion, and a Bronsted acid whose conjugate base is a weakly coordinating anion.

Likewise, in a further embodiment, there is provided a process for the polymerization of olefins, comprising contacting one or more monomers of the formula RCH.dbd.CHR.sup.8 with a supported catalyst formed by combining a compound of formula XII: ##STR18## with a solid support which has been pre-treated with a compound Y, or with a supported catalyst formed by combining a compound of formula XII, a solid support, and a compound Y, in any order,

wherein R and R.sup.8 each, independently, represent a hydrogen, a hydrocarbyl, or a fluoroalkyl, and may be linked to form a cyclic olefin;

R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl;

A and B are each, independently, a heteroatom connected mono-radical wherein the connected heteroatom is selected from Group 15 or 16; in addition, A and B may be linked by a bridging group;

Q represents an alkyl, chloride, iodide or bromide;

W represents an alkyl, chloride, iodide or bromide;

N represents nitrogen;

M represents Ni(II), Pd(II), Co(II), or Fe(II);

and Y is selected from the group consisting of a neutral Lewis acid capable of abstracting Q.sup.- or W.sup.- to form a weakly coordinating anion, a cationic Lewis acid whose counterion is a weakly coordinating anion, and a Bronsted acid whose conjugate base is a weakly coordinating anion.

The present invention also provides a process for the production of .alpha.-olefins, comprising contacting ethylene with (a) a suitable nickel precursor, (b) a compound of the formula: ##STR19## and, optionally (c) a Bronsted or Lewis acid, wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl or 4-methoxyphenyl;

R.sup.2, R.sup.3, R.sup.4 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl; in addition, any two of R.sup.2, R.sup.3, R.sup.4, and R.sup.5 may collectively form a bridging group;

N represents nitrogen; O represents oxygen; S represents sulfur.

As a further preferred aspect, there is provided a process for the production .alpha.-olefins, comprising contacting ethylene with a compound of the formula: ##STR20## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl or 4-methoxyphenyl,

R.sup.2, R.sup.3, R.sup.4 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl; in addition, any two of R.sup.2, R.sup.3, R.sup.4, and R.sup.5 may collectively form a bridging group, provided that when the compound is of formula IV or VII, the bridging group is not a substituted sulfur atom or a substituted phosphorous atom;

T represents a hydrogen or hydrocarbyl;

L represents a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;

M represents Ni(II);

N represents nitrogen; O represents oxygen; S represents sulfur; and

X.sup.- is a weakly coordinating anion.

As a further preferred aspect, there is provided a process for the production of .alpha.-olefins, comprising contacting ethylene with a catalyst formed by combining a complex of the formula: ##STR21## with a compound Y, wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl or 4-methoxyphenyl;

R.sup.2, R.sup.3, R.sup.4 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl; in addition, any two of R.sup.2, R.sup.3, R.sup.4, and R.sup.5 may collectively form bridging group, provided that when the complex is of formula V or VIII, the bridging group is not a substituted sulfur atom or a substituted phosphorous atom;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

M represents Ni(II);

N represents nitrogen; O represents oxygen; S represents sulfur;

and Y is selected from the group consisting of a neutral Lewis acid capable of abstracting Q.sup.- or W.sup.- to form a weakly coordinating anion, a cationic Lewis acid whose counterion is a weakly coordinating anion, or a Bronsted acid whose conjugate base is a weakly coordinating anion.

A further embodiment of the present invention is a process for the copolymerization of ethylene and a comonomer of the formula CH.sub.2 .dbd.CH(CH.sub.2).sub.n CO.sub.2 R.sup.1 which comprises contacting ethylene and a comonomer of the formula CH.sub.2 .dbd.CH(CH.sub.2).sub.n CO.sub.2 R.sup.1 with the complex formed by combining a first compound Y, which is selected from a neutral Lewis acid capable of abstracting Q.sup.- or W.sup.- to form a weakly coordinating anion, a cationic Lewis acid whose counterion is a weakly coordinating anion, or a Bronsted acid whose conjugate base is a weakly coordinating anion; with a second compound of the formula XXIV: ##STR22## wherein R.sup.1 is hydrogen, hydrocarbyl, substituted hydrocarbyl, fluoroalkyl or silyl;

n is an integer greater than 3, preferably greater than 5 and less than 25;

R.sup.2 and R.sup.3 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, or may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

Q is alkyl, chloride, iodide or bromide;

W is alkyl, chloride, iodide or bromide;

N is nitrogen;

Z is sulfur or oxygen; and

M is Ni(II).

It is further preferred that such compounds be attached to a solid support which has been pre-treated with a compound such as MAO or other aluminum sesquioxides. Thus, as a further embodiment, there is provided process for the copolymerization of ethylene and a comonomer of the formula CH.sub.2 .dbd.CH(CH.sub.2).sub.n CO.sub.2 R.sup.1 which comprises contacting ethylene and a comonomer of the formula CH.sub.2 .dbd.CH(CH.sub.2).sub.n CO.sub.2 R.sup.1 with a supported catalyst formed by combining silica with a compound selected from the group consisting of methylaluminoxane and other aluminum sesquioxides having the formulas R.sup.7.sub.3 Al, R.sup.7.sub.2 AlCl, and R.sup.7 AlCl.sub.2, wherein R.sup.7 is alkyl;

with a compound of the formula XXIV: ##STR23## wherein R.sup.1 is hydrogen, hydrocarbyl, substituted hydrocarbyl, fluoroalkyl or silyl;

n is an integer greater than 3;

R.sup.2 and R.sup.3 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, or may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

Q is alkyl, chloride, iodide or bromide;

W is alkyl, chloride, iodide or bromide;

N is nitrogen;

Z is sulfur or oxygen; and

M is Ni(II).

As a further aspect of the invention, there is provided a process for the polymerization of ethylene and a comonomer of the formula CH.sub.2 .dbd.CH(CH.sub.2).sub.n CO.sub.2 R.sup.1, which comprises contacting ethylene and a comonomer of the formula CH.sub.2 .dbd.CH(CH.sub.2).sub.n CO.sub.2 R.sup.1 with the complex formed by the reaction product of (a) a compound of formula XLII, (b) a suitable nickel(1) precursor, and (c) a Bronsted acid whose conjugate base is a weakly coordinating anion, ##STR24## wherein R.sup.1 is hydrogen, hydrocarbyl, substituted hydrocarbyl, fluoroalkyl or silyl;

n is an integer greater than 3, preferably greater than 5 and less than 25;

R.sup.2 and R.sup.3 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, or may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, --C(O)--, or a substituted silicon atom;

N is nitrogen; and

Z is sulfur or oxygen.

As a further embodiment of the invention, there is provided a process for the polymerization of olefins comprising contacting one or more monomers of the formula RCH.dbd.CHR.sup.8 with a binucleating or multinucleating ligand complexed to a Group 8-10 transition metal M and one or more Lewis acids, wherein the Lewis acid or acids are bound to one or more heteroatoms which are .pi.-conjugated to the donor atom or atoms bound to the transition metal M; and R and R.sup.8 each, independently, represent a hydrogen, a hydrocarbyl, or a fluoroalkyl, and may be linked to form a cyclic olefin.

The catalysts of the present invention comprise a Group 8-10 transition metal coordinated by the bidentate ligand X; these include, but are not limited to, the preferred compounds I, II, IV, V, VII, VIII, XI-XVI, XIX-XXVIII, and XXX-XLII, set forth in detail herein.

A more preferred embodiment of the catalyst of the present invention is a compound of the formula I: ##STR25## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

R.sup.2, R.sup.3, R.sup.4 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl; in addition, any two of R.sup.2, R.sup.3, R.sup.4, and R.sup.5 may collectively form a bridging group;

T represents a hydrogen or hydrocarbyl;

L represents a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;

M represents a Group 8-10 transition metal, preferably Ni(II), Pd(II), Co(II), or Fe(II), more preferably Ni(II) or Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

Also disclosed is a catalyst comprising a compound of formula II: ##STR26## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

R.sup.2, R.sup.3, R.sup.4 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl; in addition, any two of R.sup.2, R.sup.3, R.sup.4, and R.sup.5 may collectively form a bridging group;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

N represents nitrogen; and

M represents a Group 8-10 transition metal, preferably Ni(II) Pd(II), Co(II), or Fe(II), more preferably Ni(II) or Pd(II).

Also described is a catalyst comprising a compound of formula IV: ##STR27## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

T represents a hydrogen or hydrocarbyl;

L represents a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;

M represents Ni(II), Pd(II), Co(II), or Fe(II), more preferably Ni(II) or Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

Additionally disclosed is a catalyst comprising a compound of formula V: ##STR28## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl or silyl, preferably phenyl, or 4-methoxyphenyl or sterically hindered aryl;

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

N represents nitrogen; and

M represents a Group 8-10 transition metal, preferably Ni(II), Pd(II), Co(II), or Fe(II) more preferably Ni(II) or Pd(II);

In addition this invention teaches the use of a catalyst comprising a compound of formula VI: ##STR29## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl; and

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom.

Described herein is a catalyst comprising a compound of the formula VII: ##STR30## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

T represents a hydrogen or hydrocarbyl;

L represents a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;

M represents Ni(II), Pd(II), Co(II), or Fe(II), more preferably Ni(II) or Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

Also described herein is a catalyst comprising a compound of formula VIII: ##STR31## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

N represents nitrogen; and

M represents a Group 8-10 transition metal, preferably Ni(II), Pd(II), Co(II), or Fe(II), more preferably Ni(II) or Pd(II).

Also described herein is a catalyst comprising a compound of formula IX: ##STR32## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl; and

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition any two of R.sup.2, R.sup.3 and R.sup.4 may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom.

Also described herein is a catalyst comprising a compound of the formula XIII: ##STR33## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

R.sup.2, R.sup.3, and R.sup.4 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition any two of R.sup.2, R.sup.3 and R.sup.4 may collectively form a bridging group;

T represents a hydrogen or hydrocarbyl;

L represents a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;

M represents Ni(II), Pd(II), Co(II), or Fe(II), more preferably Ni(II) or Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

Also provided herein is a catalyst comprising a compound of the formula XIV: ##STR34## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

R.sup.2 and R.sup.5 each, independently, represent a hydrogen hydrocarbyl, substituted hydrocarbyl, or silyl;

T represents a hydrogen or hydrocarbyl;

L represents a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;

M represents a Group 8-10 transition metal, preferably Ni(II), Pd(II), Co(II), or Fe(II) more preferably Ni(II) or Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

Also provided herein is a catalyst comprising a compound of formula XV: ##STR35## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

R.sup.2, R.sup.3, and R.sup.4 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition any two of R.sup.2, R.sup.3 and R.sup.4 may collectively form a bridging group;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

N represents nitrogen; and

M represents a Group 8-10 transition metal, preferably Ni(II), Pd(II), Co(II), or Fe(II), preferably Ni(II) or Pd(II).

Also described herein is a catalyst comprising a compound of formula XVII ##STR36## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl; and

R.sup.2, R.sup.3, and R.sup.4 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl; in addition, any two of R.sup.2, R.sup.3, or R.sup.4 may collectively form a bridging group.

Also provided herein is a catalyst comprising a compound of formula XVI: ##STR37## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

R.sup.2 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, preferably sterically hindered aryl;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

N represents nitrogen; and

M represents a Group 8-10 transition metal, preferably Ni(II), Pd(II), Co(II), or Fe(II), more preferably Ni(II) or Pd(II);

Also provided herein is a catalyst comprising a compound of formula XVIII: ##STR38## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

R.sup.2 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl.

Also provided herein is a catalyst comprising a compound of the formula XIX: ##STR39## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl. 4-methoxyphenyl, or sterically hindered aryl;

R.sup.2, R.sup.3, R.sup.4 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl; in addition, any two of R.sup.2, R.sup.3, R.sup.4, and R.sup.5 may collectively form a bridging group;

G is a .pi.-allyl or .pi.-benzyl group;

M represents Ni(II) or Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

Also provided herein is a catalyst comprising a compound of formula XX: ##STR40## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

G is a .pi.-allyl or .pi.-benzyl;

M represents Ni(II) or Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

Also provided herein is a catalyst comprising a compound of the formula XXI: ##STR41## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

R.sup.2 and R.sup.3 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl, and, in addition, may collectively form a bridging hydrocarbyl, bridging substituted hydrocarbyl, or a substituted silicon atom;

G is a .pi.-allyl or .pi.-benzyl;

M represents Ni(II) or Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

Also provided herein is a catalyst comprising a compound of the formula XXII: ##STR42## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

R.sup.2, R.sup.3, and R.sup.4 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl; in addition, any two of R.sup.2, R.sup.3, and R.sup.4 may collectively form a bridging group;

G is a .pi.-allyl or .pi.-benzyl;

M represents Ni(II) or Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

Also provided herein is a catalyst comprising a compound of the formula XXIII: ##STR43## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

R.sup.2 and R.sup.5 each, independently, represent a hydrogen, hydrocarbyl, substituted hydrocarbyl, or silyl;

G is a .pi.-allyl or .pi.-benzyl;

M represents Ni(II) or Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

Also provided is a compound of formula XXIV, ##STR44## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

A and B are each, independently, a heteroatom connected mono-radical wherein the connected heteroatom is selected from Group 15 or 16; in addition, A and B may be linked by a bridging group;

T represents a hydrogen or a hydrocarbyl;

L represents a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;

M represents Ni(II) or Pd(II);

N represents nitrogen; and

X.sup.- is a weakly coordinating anion.

Also provided herein is a catalyst for the polymerization of olefins, comprising a compound of formula XXV, ##STR45## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; and X.sup.- is a weakly coordinating anion.

Also provided herein is a catalyst for the polymerization of olefins, comprising a compound of formula XXVI, ##STR46## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl; and X.sup.- is a weakly coordinating anion.

Also provided herein is a catalyst for the polymerization of olefins, comprising a compound of formula XXVII, ##STR47## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl.

Also provided herein is a catalyst for the polymerization of olefins, comprising a compound of formula XXVIII, ##STR48## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl.

Also provided herein is a catalyst comprising a compound of formula XXIX, ##STR49## wherein R.sup.1 and R.sup.6 each, independently, represent hydrocarbyl, substituted hydrocarbyl, or silyl, preferably phenyl, 4-methoxyphenyl, or sterically hindered aryl;

A and B are each, independently, a heteroatom connected mono-radical wherein the connected heteroatom is selected from Group 15 or 16; in addition, A and B may be linked by a bridging group;

Q represents a hydrocarbyl, chloride, iodide or bromide;

W represents a hydrocarbyl, chloride, iodide or bromide;

M represents Ni(II) or Pd(II); and

N represents nitrogen.

Also provided herein is a catalyst for the polymerization of olefins comprising a compound of formula XXX, ##STR50## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; and X.sup.- is a weakly coordinating anion.

Also provided herein is a catalyst for the polymerization of olefins, comprising a compound of formula XXXI, ##STR51## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl; and X.sup.- is a weakly coordinating anion.

Also provided herein is a catalyst for the polymerization of olefins, comprising a compound of formula XXXII, ##STR52## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl.

Also provided herein is a catalyst for the polymerization of olefins, comprising a compound of formula XXXIII, ##STR53## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl.

Also provided herein is a catalyst for the polymerization of olefins, comprising a compound of formula XXXIV, ##STR54## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl; and X.sup.- is a weakly coordinating anion.

Also provided herein is a catalyst for the polymerization of olefins, comprising a compound of formula XXXV, ##STR55## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl; and X is a weakly coordinating anion.

Also provided herein is a catalyst for the polymerization of olefins, comprising a compound of formula XXXVI, ##STR56## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl; and X.sup.- is a weakly coordinating anion.

Also provided herein is a catalyst for the polymerization of olefins, comprising a compound of formula XXXVII, ##STR57## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl; and X.sup.- is a weakly coordinating anion.

Also provided herein is a catalyst for the polymerization of olefins, comprising a compound of formula XXXVIII, ##STR58## wherein R.sup.1 and R.sup.6 are 2,6-dimethylphenyl.

Also provided herein is a catalyst for the polymerization of olefins, comprising a compound of formula XXXIX, ##STR59## wherein R.sup.1 and R.sup.6 are 2,6-diisopropylphenyl.

Also provided herein is a catalyst for the polymerization of olefins, comprising a compound of formula XL, ##STR60## wherein R.sup.1, R.sup.2, R.sup.5 and R.sup.6 are 2,6-dimethyl-4-methoxyphenyl;

and X.sup.- is a weakly coordinating anion.

Also provided herein is a catalyst for the polymerization of olefins, comprising a compound of formula XLI, ##STR61## wherein R.sup.1, R.sup.2, R.sup.5 and R.sup.6 are 2,6-dimethyl-4-methoxyphenyl;

and X.sup.- is a weakly coordinating anion.

The invention also provides certain novel polymer compositions. Thus, as a further aspect of the invention, there is provided a polymer composition comprised of monomer units derived from ethylene and from 0.1 to 50 wt % of a comonomer of the formula CH.sub.2 .dbd.CH(CH.sub.2).sub.n CO.sub.2 R.sup.1, wherein R.sup.1 is hydrogen, hydrocarbyl, substituted hydrocarbyl, fluoroalkyl or silyl, and n is an integer between 3 and 18; in addition to the branches attributable to the incorporation of said comonomer, alkyl branches are present in said polymer composition, wherein between 5 and 50 alkyl branches per 1000 carbon atoms are present and the majority of alkyl branches are methyl branches.

In a preferred embodiment, there is provided a composition comprising an ester containing semicrystalline copolyethylene with 5 to 30 alkyl branches/1000 carbon atoms, wherein the majority of alkyl branches are methyl branches, and an average of from about 1 to 50 ester terminated branches per chain resulting from ester comonomer incorporation.

In a further preferred embodiment, there is provided a composition comprising an olefin containing semicrystalline copolyethylene with 5 to 30 alkyl branches/1000 carbon atoms, wherein the majority of alkyl branches are methyl branches, and an average of from about 1 to 50 olefin terminated branches per chain resulting from linear diene comonomer incorporation.

As a further aspect of the invention, there is also provided a polymer composition comprising an ethylene homopolymer with greater than 125 alkyl branches per 1000 carbon atoms, useful as an adhesive or tackifying agent.

As noted above, it is preferred that certain of the compounds of the present invention be attached to a solid support which has been pre-treated with a compound Y, for example, MAO, or mixed with Y in any order. We have discovered that when such supported catalysts are used in slurry and gas phase ethylene polymerizations, novel polymer compositions are provided insofar as such compositions are blends of different polyolefin polymers. It is believed that when such catalysts are attached to a solid support, such as silica, polyolefin polymerizations using such supported catalysts provide a polymer composition which possesses a broad compositional distribution. This is believed to be due at least in part to both the creation of unique reaction sites, and the sensitivity of these catalysts to ethylene concentration. These unique reaction sites are believed to result from the unique microenvironments created by the location of the catalyst on the support. The resulting polymer composition, which can be prepared solely from ethylene as an olefin feedstock, is one which is actually a blend or plurality of polymers having a variety of alkyl branched distributions with some catalyst sites giving less branched high density polymer and other sites giving more branched lower density polymer. Thus, as a further aspect of the invention, there is provided a polyethylene composition comprising a blend of polyethylene polymers, wherein said blend has an average degree of branching of from 5 to 120 alkyl branches per 1000 carbon atoms, wherein any individual component of said blend has a degree of branching of from 0 to 150 alkyl branches per 1000 carbon atoms, wherein said polymers are prepared in one reaction vessel solely from ethylene, and wherein said polymers are prepared utilizing a Group 8-10 transition metal catalyst supported on a solid support which has been pre-treated with a compound Y selected from the group consisting of methylaluminoxane and other aluminum sesquioxides having the formulas R.sup.7.sub.3 Al, R.sup.7.sub.2 AlCl, and R.sup.7 AlCl.sub.2, wherein R.sup.7 is alkyl.

Further, the catalysts of this invention when supported in this fashion and utilized in a gas or slurry phase process provide polymers having a broad composition distribution while having an intermediate molecular weight distribution, thus providing certain processing advantages. When fractionated based on solubility using supercritical propane by isothermal increasing profiling and critical, isobaric, temperature rising elution fractionation, into ten fractions, an analysis of such fractions provides data on the distribution of the relative branching of the components of said composition. Thus, in a further embodiment, the present invention provides a polyolefin which when fractionated based on solubility using supercritical propane by isothermal increasing profiling and critical, isobaric, temperature rising elution fractionation, into ten fractions between about 40 and about 140.degree. C., wherein a first fraction taken at about 40.degree. C. has between about 40 and about 100 branches per 1000 carbon atoms, wherein between about 50 to about 90% are methyl branches, about 5 to about 15% are ethyl branches, about 1 to about 10% are propyl branches, about 0 to about 15% are butyl branches, and between about 5 and about 15% are pentyl or longer branches, a second fraction taken between about 40-60.degree. C. has between about 30 and about 90 branches per 1000 carbon atoms, wherein between about 50 to about 90% are methyl branches, about 5 to about 15% are ethyl branches, about 1 to about 10% are propyl branches, about 0 to about 15% are butyl branches, and between about 5 and about 15% are pentyl or longer branches; a third fraction taken between about 60-65.degree. C. has between about 30 and about 80 branches per 1000 carbon atoms, wherein between about 50 to about 90% are methyl branches, about 5 to about 15% are ethyl branches, about 1 to about 10% are propyl branches, about 0 to about 15% are butyl branches, and between about 5 to about 15% are pentyl or longer branches; a fourth fraction taken between about 65-70.degree. C. has between about 20 and about 60 branches per 1000 carbon atoms, wherein between about 50 to about 90% are methyl branches, about 5 to about 15% are ethyl branches, about 1 to about 10% are propyl branches, about 0 to about 15% are butyl branches, and between about 5 to about 15% are pentyl or longer branches; a fifth fraction taken between about 75-85.degree. C. has between about 10 and about 50 branches per 1000 carbon atoms, wherein between about 50 to about 90% are methyl branches, about 5 to about 15% are ethyl branches, about 0 to about 10% are propyl branches, about 0 to about 15% are butyl branches, and between about 5 to about 15% are pentyl or longer branches; a sixth fraction taken between about 85-95.degree. C. has between about 10 and about 40 branches per 1000 carbon atoms, wherein between about 50 to about 90% are methyl branches, about 5 to about 15% are ethyl branches, about 0 to about 10% are propyl branches, about 0 to about 15% are butyl branches, and between about 5 and about 15% are pentyl or longer branches; a seventh fraction taken between about 95-100.degree. C. has between about 5 and about 35 branches per 1000 carbon atoms, wherein between about 50 to about 90% are methyl branches, about 5 to about 15% are ethyl branches, about 0 to about 10% are propyl branches, about 0 to about 15% are butyl branches, and between about 0 and about 15% are pentyl or longer branches; an eighth fraction taken between about 100-110.degree. C. has between about 0 and about 25 branches per 1000 carbon atoms, wherein between about 50 to about 90% are methyl branches, about 5 to about 15% are ethyl branches, about 0 to about 10% are propyl branches, about 0 to about 15% are butyl branches, and between about 0 and about 15% are pentyl or longer branches; a ninth fraction taken between about 110-140.degree. C. has between about 0 and about 30 branches per 1000 carbon atoms, wherein between about 50 to about 90% are methyl branches, about 5 to about 15% are ethyl branches, about 0 to about 10% are propyl branches, about 0 to about 15% are butyl branches, and between about 0 to about 15% are pentyl or longer branches; a tenth fraction taken between about 140-150.degree. C. has between about 0 and about 20 branches per 1000 carbon atoms, wherein between about 50 to about 90% are methyl branches, about 5 to about 15% are ethyl branches, about 0 to about 10% are propyl branches, about 0 to about 15% are butyl branches, and between about 0 to about 15% are pentyl or longer branches; and a tenth fraction has between about 0 and about 20 branches per 1000 carbon atoms. (See also the Examples below).

Further, in contrast to a polymer prepared by solution polymerization, where the melting temperature as defined by the endothermic maximum is inversely correllated with the average degree of branching of said polymer, the polymers prepared from such supported catalysts exhibit a relatively constant melting temperature (endothermic maximum) over a relatively wide range of average branching. In certain cases, this also provides a free flowing powder which is again, a significant processing advantage in the gas phase.

Thus, the present invention provides a polymer derived from essentially ethylene alone that has greater than 30 branches per 1000 carbon atoms and a melt transition (endothermic maximum) in the DSC(differential scanning calorimetry) of greater than about 110.degree. C.

In a further preferred embodiment, there is provided a polymer derived from ethylene alone that has a broad composition distribution and a molecular weight distribution of less than 6 and greater than 2.5, wherein said polymer has an average degree of branching of from 5 to 120 alkyl branches per 1000 carbon atoms, and wherein any individual component of said polymer has a degree of branching of from 0 to 150 alkyl branches per 1000 carbon atoms. In a further preferred embodiment, an individual component of the polymer has between about 40 and 100 branches per 1000 carbon atoms, another component has between about 30 and 90 branches per 1000 carbon atoms, another component has between about 30 and 80 branches per 1000 carbon atoms, another component has between about 20 and 60 branches per 1000 carbon atoms, another component has between about 10 and 50 branches per 1000 carbon atoms, another component has between about 10 and 40 branches per 1000 carbon atoms, another component has between about 5 and 35 branches per 1000 carbon atoms, another component has between about 0 and 25 branches per 1000 carbon atoms, another component has between about 0 and 30 branches per 1000 carbon atoms, another component has between about 0 and 20 branches per 1000 carbon atoms.

Preferred olefins useful in the practice of the processes of the present invention include ethylene and .alpha.-olefins such as propylene, 1-butene, 1-hexene, 1-octene, ethyl undecenoate and cyclic olefins such as cyclopentene.

When the polymerizations are conducted in the liquid phase, said liquid phase may include solvent or neat monomer. The molar ratio of neutral Lewis acid to transition metal complex can be from 1 to 10000, preferably 10 to 1000. The pressure at which the ethylene polymerizations and copolymerizations take place can be from 1 atmosphere to 1000 atmospheres, preferably 1 to 100 atmospheres.

While not wishing to be bound by theory, the present inventors believe that the Lewis acid may be acting to further activate the catalysts provided herein via coordination to one or more of those heteroatoms which are not directly bound to the transition metal M, but which are .pi.-conjugated to the nitrogens which are bound to the transition metal M. Substituents which contain additional Lewis basic groups, including, but not limited to, methoxy groups, positioned so as to further promote the binding of the Lewis acid at such .pi.-conjugated heteroatoms, are also included in this invention. A nonlimiting example of secondary Lewis acid binding would include the following: ##STR62## wherein R.sup.1, R.sup.2, R.sup.5, and R.sup.6 are 2,6-dimethylphenyl; and X.sup.- is a weakly coordinating anion.

The polymerizations may be conducted as solution polymerizations, as non-solvent slurry type polymerizations, as slurry polymerizations using one or more of the olefins or other solvent as the polymerization medium, or in the gas phase. One of ordinary skill in the art, with the present disclosure, would understand that the catalyst could be supported using a suitable catalyst support and methods known in the art. Substantially inert solvents, such as toluene, hydrocarbons, methylene chloride and the like, may be used. Propylene and 1-butene are excellent monomers for use in slurry-type copolymerizations and unused monomer can be flashed off and reused.

Temperature and olefin pressure have significant effects on polymer structure, composition, and molecular weight. Suitable polymerization temperatures are preferably from about -100.degree. C. to about 200.degree. C., more preferably in the 20.degree. C. to 150.degree. C. range.

After the reaction has proceeded for a time sufficient to produce the desired polymers, the polymer can be recovered from the reaction mixture by routine methods of isolation and/or purification.

In general, the polymers of the present invention are useful as components of thermoset materials, as elastomers, as packaging materials, films, compatibilizing agents for polyesters and polyolefins, as a component of tackifying compositions, and as a component of adhesive materials.

High molecular weight resins are readily processed using conventional extrusion, injection molding, compression molding, and vacuum forming techniques well known in the art. Useful articles made from them include films, fibers, bottles and other containers, sheeting molded objects and the like.

Low molecular weight resins are useful, for example, as synthetic waxes and they may be used in various wax coatings or in emulsion form. They are also particularly useful in blends with ethylene/vinyl acetate or ethylene/methyl acrylate-type copolymers in paper coating or in adhesive applications.

Although not required, typical additives used in olefin or vinyl polymers may be used in the new homopolymers and copolymers of this invention. Typical additives include pigments, colorants, titanium dioxide, carbon black, antioxidants, stabilizers, slip agents, flame retarding agents, and the like. These additives and their use in polymer systems are known per se in the art.

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