Method for producing catalyst component for α-olefin polymerization, method for producing catalyst for α-olefin polymerization, and method for producing α-olefin polymer

Abstract

To provide a method for producing a catalyst component for α-olefin polymerization capable of obtaining an α-olefin polymer having a less amorphous component and high stereoregularity.SOLUTION: There is provided a method for producing a catalyst component for α-olefin polymerization which sequentially comprises the following steps 1 and 2. Step 1: a step of mixing the following components (a1), (a2), (a3) and (a4) to obtain a solid catalyst component (A1), a component (a1): a solid component containing magnesium, titanium, a halogen and an electron donor as essential components, a component (a2): a silane compound having an alkenyl group, a component (a3): an alkoxysilane compound [provided that it is different from a silane compound having an alkenyl group], a component (a4): an organoaluminum compound. Step 2: a step of mixing the solid catalyst component (A1), the following component (A2) and component (A3) in the presence of an α-olefin to obtain a catalyst component for α-olefin polymerization(A), a component (A2): at least one compound selected from the group consisting of (A2-1) an unsaturated cyclic ether compound and (A2-2) a cyclic compound having an amide bond, a component (A3): hydrogen.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a method for producing a catalyst component for α-olefin polymerization, a method for producing a catalyst for α-olefin polymerization, and a method for producing an α-olefin polymer. [Background technology]

[0002] Polypropylene is the most important plastic material for industrial use, and is widely used in a variety of applications, including as films and sheets for packaging materials and electrical materials, as molded articles for automotive components and home appliances, and as textile materials and building materials. Because polypropylene has such a wide range of uses and diversification, there has been a continuous demand for improvements and enhancements in various properties in order to meet these demands, and technological developments have been carried out mainly through improvements in polymerization catalysts.

[0003] Ziegler catalysts using transition metal compounds and organometallic compounds have significantly increased the polymerization activity of propylene, making industrial production possible. Since then, various improvements have been made to its performance, including improvements in the polymer's physical properties due to molecular weight distribution, reduction of amorphous components (polymers with low stereoregularity and low molecular weight) in propylene polymers, and improvement of stereoregularity. Specifically, catalysts using magnesium compounds as catalyst supports and solid catalyst components containing titanium and halogen as essential components have been developed. Furthermore, catalysts using electron donors to enhance catalytic activity and stereoregularity have been proposed (see, for example, Patent Documents 1 to 3). Subsequently, proposals have been made to further improve catalytic activity and stereoregularity by adding specific organosilicon compounds to the catalyst components (see, for example, Patent Document 4). Furthermore, proposals have been made to further improve catalytic activity and stereoregularity by using silicon compounds with special structures containing alkenyl groups, such as vinyl or allyl groups, in addition to specific organosilicon compounds, thereby improving performance, such as by improving the response to hydrogen used as a molecular weight regulator (see, for example, Patent Documents 5 to 8). Furthermore, proposals have been made to reduce amorphous components by using specific amide compounds or sulfites in combination with organosilicon compounds as external donors (see, for example, Patent Documents 9 and 10). It has also been proposed to use an alkoxysilane compound as a selectivity control agent and a monoether compound as an activity limiter during polymerization to avoid reactor contamination due to softening of the polymer at high polymerization temperatures (see Patent Document 11).Furthermore, many improved technologies have been disclosed, such as incorporating a specific furan compound into the catalyst component at a certain ratio with the electron donor to improve polymerization activity (see Patent Document 12). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 58-138706 [Patent Document 2] Japanese Patent Application Publication No. 57-59909 [Patent Document 3] Japanese Patent Application Publication No. 58-147409 [Patent Document 4] Japanese Patent Application Publication No. 187707 / 1983 [Patent Document 5] Japanese Patent Application Publication No. 03-234707 [Patent Document 6] Japanese Patent Application Publication No. 07-2923 [Patent Document 7] Japanese Patent Application Laid-Open No. 2006-169283 [Patent Document 8] Japanese Patent Application Laid-Open No. 2008-163151 [Patent Document 9] Japanese Patent Application Laid-Open No. 2004-124090 [Patent Document 10] Japanese Patent Application Laid-Open No. 2006-225449 [Patent Document 11] Japanese Patent Application Publication No. 2019-001992 [Patent Document 12] Japanese Patent Application Laid-Open No. 2007-119514 Summary of the Invention [Problem to be solved by the invention]

[0005] However, as far as the present researchers know, none of these catalyst systems has yet achieved sufficient improvements in the properties of the propylene polymers produced, such as reduction in amorphous components and enhancement of stereoregularity, and various improvements in properties are required in each field of application. For example, in the field of automotive parts materials, high rigidity is required for molded articles, and further improvements are particularly desired in terms of high crystallinity, i.e., stereoregularity, and reduction in amorphous components. In the field of packaging materials, further improvements in stickiness, etc. are also strongly desired.

[0006] An object of the present application is to provide a method for producing an α-olefin polymerization catalyst component that can further reduce amorphous components to further increase rigidity and thereby produce α-olefin polymers with improved stereoregularity in order to meet the demand for further improved performance in the field of polypropylene materials and propylene polymerization catalysts as described above. [Means for solving the problem]

[0007] As a result of intensive research conducted to achieve the above object, the present researchers have discovered a method for producing a catalyst component for α-olefin polymerization that allows for the production of α-olefin polymers with little amorphous content and high stereoregularity.

[0008] The method for producing a catalyst component for α-olefin polymerization of the present invention is characterized by sequentially undergoing the following steps 1 and 2. Step 1: A step of mixing the following components (a1), (a2), (a3), and (a4) to obtain a solid catalyst component (A1). Component (a1): A solid component containing magnesium, titanium, a halogen, and an electron donor as essential components. Component (a2): Silane compound having an alkenyl group Component (a3): Alkoxysilane compound (however, different from a silane compound having an alkenyl group). Component (a4): organoaluminum compound Step 2: A step of mixing the solid catalyst component (A1) and the following components (A2) and (A3) in the presence of an α-olefin to obtain a catalyst component (A) for α-olefin polymerization: Component (A2): (A2-1) at least one compound selected from the group consisting of unsaturated cyclic ether compounds and (A2-2) cyclic compounds having an amide bond Component (A3): Hydrogen

[0009] In the method for producing a catalyst component for α-olefin polymerization of the present invention, the component (A2-1) may be represented by the following general formula (1).

[0010] [ka]

[0011] (In general formula (1), R 1 and R 2 is a hydrogen atom or a hydrocarbon group, and R 1 and R 2 may be the same or different.)

[0012] In the method for producing a catalyst component for α-olefin polymerization of the present invention, the component (A2-2) may be represented by the following general formula (2).

[0013] [ka]

[0014] (In the general formula (2), X is a carbon atom, a nitrogen atom, or an oxygen atom, and R 3 and R 4 is a hydrogen atom or a hydrocarbon group, and R 3 and R 4 may be the same or different. However, when X is an oxygen atom, R 4 does not exist.)

[0015] In the method for producing a catalyst component for α-olefin polymerization of the present invention, the component (a2) may be a vinylsilane compound.

[0016] In the method for producing a catalyst component for α-olefin polymerization of the present invention, the component (a3) may be an alkoxysilane compound represented by the following general formula (3). R 5 R 6 m Si(OR 7 ) n ···(3) (In general formula (3), R 5 represents a hydrocarbon group or a heteroatom-containing hydrocarbon group. 6 represents a hydrogen atom, a halogen atom, a hydrocarbon group, or a heteroatom-containing hydrocarbon group. 7 is a hydrocarbon group. m and n are integers in the range of 0≦m≦2, 1≦n≦3, and m+n=3.

[0017] In the method for producing an α-olefin polymerization catalyst component of the present invention, the α-olefin in step 2 may be propylene, or propylene and ethylene, or propylene and an α-olefin having 4 to 22 carbon atoms.

[0018] In the method for producing an α-olefin polymerization catalyst component of the present invention, the amount of component (A2) used in step 2 may be, in terms of molar ratio relative to the titanium component contained in component (a1), component (A2) / titanium=2.0 to 30.

[0019] In the method for producing a catalyst component for α-olefin polymerization of the present invention, the mixing temperature in step 2 may be 70° C. or lower.

[0020] The method for producing an α-olefin polymerization catalyst of the present invention is characterized by mixing the α-olefin polymerization catalyst component (A) obtained by the above-mentioned method for producing a catalyst component for α-olefin polymerization with the following component (B): Component (B): Organoaluminum compound

[0021] The process for producing an α-olefin polymer of the present invention is characterized by homopolymerizing or copolymerizing an α-olefin in the presence of the above-mentioned α-olefin polymerization catalyst. [Effects of the Invention]

[0022] According to the present invention, there can be provided a method for producing a catalyst component for α-olefin polymerization, which allows for the production of α-olefin polymers with little amorphous components and high stereoregularity. DETAILED DESCRIPTION OF THE INVENTION

[0023] Hereinafter, the method for producing an α-olefin polymerization catalyst component, the method for producing an α-olefin polymerization catalyst, and the method for producing an α-olefin polymer of the present invention will be described in detail for each item. In this specification, the symbol "to" indicating a numerical range is used to mean that the numerical values before and after it are included as the lower limit and upper limit, respectively.

[0024] 1. Method for producing catalyst component for α-olefin polymerization The method for producing a catalyst component for α-olefin polymerization of the present invention is characterized by sequentially undergoing the following steps 1 and 2. Step 1: A step of mixing the following components (a1), (a2), (a3), and (a4) to obtain a solid catalyst component (A1). Component (a1): A solid component containing magnesium, titanium, a halogen, and an electron donor as essential components. Component (a2): Silane compound having an alkenyl group Component (a3): Alkoxysilane compound (however, different from a silane compound having an alkenyl group). Component (a4): organoaluminum compound Step 2: A step of mixing the solid catalyst component (A1) and the following components (A2) and (A3) in the presence of an α-olefin to obtain a catalyst component (A) for α-olefin polymerization: Component (A2): (A2-1) at least one compound selected from the group consisting of unsaturated cyclic ether compounds and (A2-2) cyclic compounds having an amide bond Component (A3): Hydrogen

[0025] In the present invention, by simultaneously adding at least one of (A2-1) an unsaturated cyclic ether compound or (A2-2) a cyclic compound having an amide bond as component (A2) and hydrogen as component (A3), it is presumed that active sites that produce polymers (amorphous components) soluble at 40°C can be preferentially deactivated (poisoned). It is presumed that the bulkiness of active sites alkylated with organoaluminum compounds or active sites where polymer chains have grown makes it difficult for component (A2-1) an unsaturated cyclic ether compound or component (A2-2) a cyclic compound having an amide bond (hereinafter referred to as donor) to coordinate. However, by simultaneously adding hydrogen as component (A3), chain transfer occurs, and the alkyl group or polymer chain is removed from the active site, forming a smaller "Ti-H active site," which is presumed to be able to coordinate (poison) the donor.

[0026] 1-1.Process 1 Step 1 is a step of mixing the following components (a1), (a2), (a3), and (a4) to obtain a solid catalyst component (A1). Component (a1): A solid component containing magnesium, titanium, a halogen, and an electron donor as essential components. Component (a2): Silane compound having an alkenyl group Component (a3): Alkoxysilane compound (however, different from a silane compound having an alkenyl group). Component (a4): organoaluminum compound

[0027] 1-1-1. Component (a1) The component (a1) according to the present invention is a solid component containing magnesium (a1-1), titanium (a1-2), halogen (a1-3), and an electron donor (a1-4) as essential components.

[0028] 1-1-1-1. Magnesium (a1-1) As the magnesium compound serving as the magnesium source used in the solid component (a1) according to the present invention, any magnesium compound can be used. Typical examples thereof include the compounds disclosed in JP-A-3-234707. Generally, magnesium halide compounds typified by magnesium chloride, alkoxymagnesium compounds typified by diethoxymagnesium, metallic magnesium, oxymagnesium compounds typified by magnesium oxide, hydroxymagnesium compounds typified by magnesium hydroxide, Grignard compounds typified by butylmagnesium chloride, organic magnesium compounds typified by butyloctylmagnesium, magnesium salt compounds of inorganic acids and organic acids typified by magnesium carbonate and magnesium stearate, and mixtures thereof and compounds having an average composition formula that is a mixed formula thereof (for example, Mg(OEt) m Cl 2-m ; compounds such as 0 < m < 2), etc. can be used. Among these, magnesium chloride, diethoxymagnesium, metallic magnesium, and butylmagnesium chloride are particularly preferred.

[0029] In particular, when producing large particles, it is preferable to use dialkoxymagnesium, which is easy to control the catalyst particle size. Dialkoxymagnesium can be used not only as a pre-produced one but also as one obtained by reacting alcohol in the presence of metallic magnesium and halogen or a halogen-containing metal compound during the catalyst production process.

[0030] Furthermore, in the present invention, the dialkoxymagnesium suitable as component (a1-1) is in the form of granules or powder, and its shape may be irregular or spherical. For example, when a spherical dialkoxymagnesium is used, a polymer powder having a better particle shape and a narrow particle size distribution can be obtained, the handling of the produced polymer powder during the polymerization operation can be improved, and problems such as blockage caused by fine particles contained in the produced polymer powder can be resolved.

[0031] The spherical dialkoxymagnesium does not necessarily have to be perfectly spherical, and ellipsoidal or potato-shaped particles can also be used. Specifically, the particle shape has a ratio of the major axis diameter l to the minor axis diameter w (l / w) of 3 or less, preferably 1 to 2, and more preferably 1 to 1.5. The dialkoxymagnesium may have an average particle size of 1 μm to 200 μm, preferably 5 μm to 150 μm. In the case of spherical dialkoxymagnesium, the average particle size is 1 μm to 100 μm, preferably 5 μm to 50 μm, and more preferably 10 μm to 40 μm. It is also desirable to use a material with a narrow particle size distribution, with few fine or coarse particles. Specifically, the percentage of particles 5 μm or less is 20% or less, preferably 10% or less. On the other hand, the percentage of particles 100 μm or more is 10% or less, preferably 5% or less. Furthermore, when the particle size distribution is expressed as ln(D90 / D10) (where D90 is the particle size at 90% of the cumulative particle size, and D10 is the particle size at 10% of the cumulative particle size), it is 3 or less, and preferably 2 or less.

[0032] Methods for producing the above-mentioned spherical dialkoxymagnesium are exemplified in, for example, Japanese Patent Application Laid-Open Nos. 58-41832, 62-51633, 3-74341, 4-368391, and 8-73388.

[0033] 1-1-1-2. Titanium (a1-2) As the titanium compound serving as the titanium source used in the solid component (a1) according to the present invention, any compound can be used. Representative examples include the compounds disclosed in JP-A-3-234707. Regarding the valence of titanium, a titanium compound having an arbitrary valence of tetravalent, trivalent, divalent, or zero-valent can be used, but it is preferably a tetravalent and trivalent titanium compound, and more preferably a tetravalent titanium compound.

[0034] Specific examples of the tetravalent titanium compound include titanium halide compounds typified by titanium tetrachloride, alkoxytitanium compounds typified by tetrabutoxytitanium, condensed compounds of alkoxytitanium having a Ti-O-Ti bond typified by tetrabutoxytitanium dimer (BuO)3Ti-O-Ti(OBu)3, organometallic titanium compounds typified by dicyclopentadienyltitanium dichloride, and the like. Among these, titanium tetrachloride and tetrabutoxytitanium are particularly preferred. Specific examples of the trivalent titanium compound include titanium halide compounds typified by titanium trichloride. Titanium trichloride can be a compound produced by any known method such as a hydrogen reduction type, a metal aluminum reduction type, a metal titanium reduction type, an organoaluminum reduction type, and the like. The above titanium compounds can be used not only alone but also in combination of a plurality of compounds. Further, mixtures of the above titanium compounds, compounds having an average composition formula that is a mixed formula thereof (for example, compounds such as Ti(OBu) m Cl 4-m ; 0 < m < 4, etc.), and complexes with other compounds such as phthalic esters (for example, compounds such as Ph(CO2Bu)2·TiCl4) can be used.

[0035] 1-1-1-3. Halogen (a1-3) As the halogen used in the solid component (a1) according to the present invention, fluorine, chlorine, bromine, iodine, and mixtures thereof can be used. Among these, chlorine is particularly preferred. The halogen is generally supplied from the titanium compound and / or magnesium compound, but can also be supplied from other compounds. Representative examples include silicon halide compounds such as silicon tetrachloride, aluminum halide compounds such as aluminum chloride, organic halide compounds such as 1,2-dichloroethane and benzyl chloride, borane halide compounds such as trichloroborane, phosphorus halide compounds such as phosphorus pentachloride, tungsten halide compounds such as tungsten hexachloride, and molybdenum halide compounds such as molybdenum pentachloride. These compounds can be used alone or in combination. Among these, silicon tetrachloride is particularly preferred.

[0036] 1-1-1-4. Electron donor (a1-4) Representative examples of the electron donor (a1-4) used in the solid component (a1) according to the present invention include the compounds disclosed in JP 2004-124090 A. Generally, organic acids, inorganic acids, and their derivatives (esters, acid anhydrides, acid halides, amides), ether compounds, ketone compounds, aldehyde compounds, alcohol compounds, amine compounds, etc. can be used, and the donor may be one or a mixture of two or more selected from the group consisting of organic acids, inorganic acids, and their derivatives, ether compounds, and ketone compounds.

[0037] Examples of organic acid compounds that can be used as the electron donor (a1-4) include aromatic polycarboxylic acid compounds such as phthalic acid, aromatic carboxylic acid compounds such as benzoic acid, aliphatic polycarboxylic acid compounds such as malonic acid having one or two substituents at the 2-position, e.g., 2-n-butyl-malonic acid, and succinic acid having one or two substituents at the 2-position or one or more substituents at each of the 2- and 3-positions, e.g., 2-n-butyl-succinic acid, aliphatic carboxylic acid compounds such as propionic acid, and aromatic and aliphatic sulfonic acid compounds such as benzenesulfonic acid and methanesulfonic acid. These carboxylic acid compounds and sulfonic acid compounds may have any number of unsaturated bonds at any position in the molecule, like maleic acid, regardless of whether they are aromatic or aliphatic.

[0038] Examples of compounds derived from organic acids that can be used as the electron donor (a1-4) include esters (carboxylic acid ester compounds), acid anhydrides, acid halides, and amides of the above organic acids. The alcohol, which is a component of the ester, can be an aliphatic or aromatic alcohol. Among these alcohols, alcohols having an aliphatic free radical with 1 to 20 carbon atoms, such as an ethyl group, butyl group, isobutyl group, heptyl group, octyl group, or dodecyl group, are preferred. Alcohols having an aliphatic free radical with 2 to 12 carbon atoms are even more preferred. Alcohols having an alicyclic free radical, such as a cyclopentyl group, cyclohexyl group, or cycloheptyl group, can also be used.

[0039] The halogens that are components of the acid halide include fluorine, chlorine, bromine, iodine, etc. Among these, chlorine is most preferred. In the case of a polyhalide of a polyvalent organic acid, the multiple halogens may be the same or different. The amine, which is a component of the amide, may be an aliphatic or aromatic amine. Among these amines, preferred examples include ammonia, aliphatic amines such as ethylamine and dibutylamine, and amines having an aromatic free radical in the molecule such as aniline and benzylamine.

[0040] Examples of inorganic acid compounds that can be used as the electron donor (a1-4) include carbonic acid, phosphoric acid, silicic acid, sulfuric acid, and nitric acid. As the derivative compounds of these inorganic acids, it is desirable to use esters, and specific examples thereof include tetraethoxysilane (ethyl silicate), tetrabutoxysilane (butyl silicate), and tributyl phosphate.

[0041] Examples of ether compounds that can be used as the electron donor (a1-4) include aliphatic ether compounds typified by dibutyl ether, aromatic ether compounds typified by diphenyl ether, aliphatic polyvalent ether compounds typified by 1,3-dimethoxypropane having one or two substituents at the 2-position, such as 2-isopropyl-2-isobutyl-1,3-dimethoxypropane and 2-isopropyl-2-isopentyl-1,3-dimethoxypropane, and polyvalent ether compounds having an aromatic free radical in the molecule, such as 9,9-bis(methoxymethyl)fluorene.

[0042] Examples of ketone compounds that can be used as the electron donor (a1-4) include aliphatic ketone compounds such as methyl ethyl ketone, aromatic ketone compounds such as acetophenone, and polyhydric ketone compounds such as 2,2,4,6,6-pentamethyl-3,5-heptanedione. Examples of aldehyde compounds that can be used as the electron donor (a1-4) include aliphatic aldehyde compounds such as propionaldehyde, and aromatic aldehyde compounds such as benzaldehyde. Further, examples of alcohol compounds that can be used as the electron donor (a1-4) include aliphatic alcohol compounds such as butanol and 2-ethylhexanol, phenol derivative compounds such as phenol and cresol, and aliphatic or aromatic polyhydric alcohol compounds such as glycerin and 1,1'-bi-2-naphthol.

[0043] Examples of amine compounds that can be used as the electron donor (a1-4) include aliphatic amine compounds such as diethylamine, nitrogen-containing alicyclic compounds such as 2,2,6,6-tetramethyl-piperidine, aromatic amine compounds such as aniline, polyvalent amine compounds such as 1,3-bis(dimethylamino)-2,2-dimethylpropane, and nitrogen-containing aromatic compounds.

[0044] Furthermore, compounds containing the above-mentioned multiple functional groups in the same molecule can also be used as the electron donor (a1-4). Examples of such compounds include carboxylic acid ester compounds having an alkoxy group in the molecule, such as 2-ethoxyethyl acetate and ethyl 3-ethoxy-2-t-butylpropionate, ketoester compounds such as ethyl 2-benzoylbenzoate, ketoether compounds such as 1-t-butyl-2-methoxyethyl methyl ketone, aminoether compounds such as N,N-dimethyl-2,2-dimethyl-3-methoxypropylamine, and halogenoether compounds such as epoxychloropropane.

[0045] These electron donors (a1-4) can be used alone or in combination of two or more compounds. Among these, preferred are phthalate diester compounds typified by diethyl phthalate, dibutyl phthalate, diisobutyl phthalate, and diheptyl phthalate; phthalate dihalide compounds typified by phthaloyl dichloride; malonate compounds having one or two substituents at the 2-position such as 2-n-butyl-diethyl malonate; succinate compounds having one or two substituents at the 2-position or one or more substituents at each of the 2- and 3-positions such as 2-n-butyl-diethyl succinate; aliphatic polyvalent ether compounds typified by 1,3-dimethoxypropane having one or two substituents at the 2-position such as 2-isopropyl-2-isobutyl-1,3-dimethoxypropane and 2-isopropyl-2-isopentyl-1,3-dimethoxypropane; and polyvalent ether compounds having an aromatic free radical in the molecule such as 9,9-bis(methoxymethyl)fluorene. Among these, particularly preferred are organic acid ester compounds, acid halide compounds and ether compounds, and particularly preferred are those selected from the group consisting of phthalic acid diester compounds and phthalic acid dihalide compounds. The ratio of the amounts of the components constituting the solid component (a1) used in the present invention may be any ratio within a range that does not impair the effects of the present invention, but is generally preferably within the following ranges.

[0046] The amount of titanium compound (a1-2) used relative to the amount of magnesium compound (a1-1) used is preferably in the range of 0.0001 to 1,000, more preferably 0.001 to 100, and particularly preferably 0.01 to 50, in terms of molar ratio (number of moles of titanium compound / number of moles of magnesium compound).

[0047] When a compound serving as a halogen source (i.e., (a1-3)) other than the magnesium compound (a1-1) and the titanium compound (a1-2) is used, the amount of the compound (i.e., (a1-3)) used relative to the amount of the magnesium compound (a1-1) used is, regardless of whether the magnesium compound and the titanium compound each contain a halogen or not, preferably in a molar ratio (number of moles of compound serving as a halogen source / number of moles of magnesium compound) within a range of 0.01 to 1,000, particularly preferably 0.1 to 100.

[0048] The amount of the electron donor (a1-4) used is preferably in the range of 0.001 to 10, particularly preferably 0.01 to 5, in terms of molar ratio (number of moles of electron donor / number of moles of magnesium compound) relative to the amount of the magnesium compound (a1-1) used.

[0049] The solid component (a1) according to the present invention can be obtained by contacting the above-mentioned constituent components in the above-mentioned ratios. The contact conditions for the components must be such that oxygen is not present, but any conditions can be used as long as the effects of the present invention are not impaired. Generally, the following conditions are preferred: The contact temperature is about -50°C to 200°C, preferably 0°C to 150°C. Examples of the contacting method include a mechanical method using a rotary ball mill or a vibration mill, and a method of contacting by stirring in the presence of an inert diluent.

[0050] In preparing the solid component (a1), washing with an inert solvent may be carried out intermediately and / or finally. Preferred examples of the solvent include aliphatic hydrocarbon compounds such as heptane, aromatic hydrocarbon compounds such as toluene and xylene, and halogen-containing hydrocarbon compounds such as 1,2-dichloroethylene and chlorobenzene.

[0051] Any method can be used to prepare the solid component (a1) according to the present invention, and specific examples include the methods described below as (i) to (vii). However, the present invention is not limited to the following examples.

[0052] (i) Co-grinding method This method involves co-grinding a halogen-containing magnesium compound, typically magnesium chloride, with a titanium compound to support the titanium compound on the magnesium compound. An electron donor may be co-grinded at the same time or in a separate step. As a mechanical pulverization method, any pulverizer such as a rotary ball mill or a vibration mill can be used. Not only a dry pulverization method that does not use a solvent, but also a wet pulverization method in which pulverization is performed in the presence of an inert solvent can be used.

[0053] (ii) Heat treatment method This method involves stirring a halogen-containing magnesium compound, typically magnesium chloride, with a titanium compound in an inert solvent to carry out a contact treatment, thereby supporting the titanium compound on the magnesium compound. An electron donor may be contacted simultaneously or in a separate step. When a liquid compound such as titanium tetrachloride is used as the titanium compound, the contact treatment can be carried out without using an inert solvent. If necessary, an optional component such as a silicon halide compound may be contacted simultaneously or in a separate step. There is no particular limitation on the contact temperature, but it is often preferable to carry out the contact treatment at a relatively high temperature of about 90°C to 130°C.

[0054] (iii) Elution method The dissolution-precipitation method is a method in which a halogen-containing magnesium compound, such as magnesium chloride, is dissolved by contacting it with an electron donor, and the resulting solution is brought into contact with a precipitating agent to cause a precipitation reaction, thereby forming particles. Examples of electron donors used for dissolution include alcohol compounds, epoxy compounds, phosphate ester compounds, silicon compounds having an alkoxy group, titanium compounds having an alkoxy group, and ether compounds. Examples of precipitating agents include titanium halide compounds, silicon halide compounds, hydrogen chloride, halogen-containing hydrocarbon compounds, siloxane compounds having a Si-H bond (including polysiloxane compounds), and aluminum compounds. The method for contacting the solution with the precipitating agent may be to add the precipitating agent to the solution, or to add the solution to the precipitating agent. In either the dissolution or precipitation step, when no titanium compound is used, the particles formed by the precipitation reaction are further brought into contact with a titanium compound, thereby supporting the titanium compound on the magnesium compound. If necessary, the particles formed by the above method may be contacted with an optional component such as a titanium halide compound or a silicon halide compound, or may be contacted with an electron donor, which may be different from or the same as that used for dissolution. The order of contacting these optional components is not particularly limited, and they may be contacted in independent steps or together with the dissolution, precipitation and contact with titanium compounds. An inert solvent may be present in any of the steps of dissolution, precipitation, and contact with an optional component.

[0055] (iv) Granulation method The granulation method, like the dissolution-precipitation method, involves dissolving a halogen-containing magnesium compound, such as magnesium chloride, by contacting it with an electron donor, and granulating the resulting solution primarily by physical means. Examples of electron donors used for dissolution are the same as those used in the dissolution-precipitation method. Examples of granulation techniques include a method in which a high-temperature solution is dropped into a low-temperature inert solvent, a method in which the solution is sprayed from a nozzle toward a high-temperature gas phase to dry it, and a method in which the solution is sprayed from a nozzle toward a low-temperature gas phase to cool it. The particles formed by granulation are brought into contact with a titanium compound, thereby supporting the titanium compound on the magnesium compound. If necessary, the mixture may be contacted with optional components such as silicon halide compounds and electron donors. In this case, the electron donor may be the same as or different from that used in the dissolution. The order of contacting these optional components is not particularly limited, and they may be contacted as independent steps or together with the dissolution or contact with the titanium compound. An inert solvent may be present in any of the steps of dissolution, contact with titanium compounds, and contact with optional components.

[0056] (v) Halogenation of magnesium (Mg) compounds The halogenation method for magnesium (Mg) compounds is a method in which a halogen-free magnesium compound is contacted with a halogenating agent to halogenate it, and an electron donor may be contacted simultaneously or in a separate step. Examples of halogen-free magnesium compounds include dialkoxy magnesium compounds, magnesium oxide, magnesium carbonate, and magnesium salts of fatty acids. When a dialkoxymagnesium compound is used, it is also possible to use one prepared in situ by reacting metallic magnesium with an alcohol. When this preparation method is used, particles are generally formed by granulation or the like at the stage of the starting material, a halogen-free magnesium compound. Examples of the halogenating agent include titanium halide compounds, silicon halide compounds, and phosphorus halide compounds. When a titanium halide compound is not used as the halogenating agent, the halogen-containing magnesium compound formed by halogenation is further contacted with a titanium compound to support the titanium compound on the magnesium compound. If necessary, the grains formed by the above method may be contacted with an optional component such as a titanium halide compound or a silicon halide compound, or may be contacted with an electron donor. The order of contacting these optional components is not particularly limited, and they may be contacted as independent steps, or they may be contacted together with the halogenation of a halogen-free magnesium compound or the contact with a titanium compound. An inert solvent may be present in either the step of contacting with the titanium halide compounds or the step of contacting with the optional components.

[0057] (vi) Precipitation from organomagnesium compounds This method involves contacting a precipitating agent with a solution of an organomagnesium compound such as a Grignard reagent, typically butylmagnesium chloride, or a dialkylmagnesium compound. An electron donor may be contacted simultaneously or in a separate step. Examples of the precipitating agent include titanium compounds, silicon compounds, and hydrogen chloride. When a titanium compound is not used as the precipitating agent, the particles formed by the precipitation reaction are further brought into contact with a titanium compound, thereby supporting the titanium compound on the magnesium compound. If necessary, the grains formed by the above method may be contacted with an optional component such as a titanium halide compound or a silicon halide compound, or may be contacted with an electron donor. There is no particular restriction on the order of contacting these optional components, and they may be contacted as independent steps or together with the precipitation or contact with titanium compounds. An inert solvent may be present in any of the steps of precipitation, contact with titanium compounds, and contact with optional components.

[0058] (vii) Impregnation method This method involves impregnating an inorganic compound support or an organic compound support with a solution of an organomagnesium compound or a solution in which a magnesium compound is dissolved with an electron donor. Examples of organomagnesium compounds are the same as those in the example of the precipitation method from organomagnesium compounds. The magnesium compound used to dissolve the magnesium compound may or may not contain a halogen, and examples of electron donors are the same as those in the example of the dissolution-precipitation method. Examples of inorganic carriers include silica, alumina, magnesia, and the like. Examples of organic carriers include polyethylene, polypropylene, and polystyrene. After the impregnation treatment, the carrier particles are subjected to a chemical reaction with a precipitating agent or physical treatment such as drying to precipitate and immobilize the magnesium compound. Examples of the precipitating agent are the same as those in the dissolution-precipitation method. When a titanium compound is not used as a precipitating agent, the particles thus formed are further contacted with a titanium compound to support the titanium compound on the magnesium compound. If necessary, the particles thus formed may be further contacted with an optional component such as a titanium halide compound or a silicon halide compound, or may be contacted with an electron donor. The order of contacting these optional components is not particularly limited, and they may be contacted as independent steps, or they may be contacted together during impregnation, precipitation, drying, and contact with titanium compounds. In addition, an inert solvent may be present in any of the steps of impregnation, precipitation, contact with titanium compounds, and contact with optional components.

[0059] (viii) Combined method The methods (i) to (vii) above can also be used in combination. Examples of such combinations include "a method in which magnesium chloride is co-ground with an electron donor, followed by heat treatment with titanium halide compounds," "a method in which a magnesium chloride compound is co-ground with an electron donor, then dissolved using another electron donor, and then precipitated using a precipitating agent," "a method in which a dialkoxymagnesium compound is dissolved using an electron donor, and then contacted with titanium halide compounds to precipitate and simultaneously halogenate the magnesium compound," and "a method in which a dialkoxymagnesium compound is contacted with carbon dioxide to produce and simultaneously dissolve magnesium carbonate compounds, the resulting solution is impregnated into silica, and then contacted with hydrogen chloride to simultaneously halogenate and precipitate and fix the magnesium compound, and then further contacted with titanium halide compounds to support the titanium compound."

[0060] 1-1-2. Silane compounds having alkenyl groups (a2) As the silane compound (a2) having an alkenyl group used in the present invention, compounds disclosed in JP-A-2-34707, JP-A-2003-292522, JP-A-2006-169283, and JP-A-2011-74360 can be used. In general, it is desirable to use a compound represented by the following general formula (a). SiR 8 n R 9 4-n··· (a) (where R 8 is an alkenyl group, and R 9 is a hydrogen atom, a halogen atom, an alkyl group, or an alkoxy group, and n is 1≦n≦4. When 1≦n≦2, R 9 They may be linked to each other to form a ring structure.)

[0061] In general formula (a), R 8represents an alkenyl group, preferably a vinyl group, an allyl group, or a 3-butenyl group, and more preferably a vinyl group or an allyl group. When the value of n is 2 or more, a plurality of R 8 may be the same or different.

[0062] In addition, in the general formula (a), R 9 represents a hydrogen atom, a halogen atom, an alkyl group, or an alkoxy group. R 9 Examples of halogens that can be used as the halogen atom include fluorine, chlorine, bromine, and iodine. Also, R 9 When R is an alkyl group, it is generally an alkyl group having 1 to 20 carbon atoms, preferably 1 to 12 carbon atoms. 7 Specific examples of alkyl groups that can be used as the alkyl group include a methyl group, an ethyl group, a propyl group, an i-propyl group, an i-butyl group, an s-butyl group, a t-butyl group, a thexyl group, a cyclopentyl group, and a cyclohexyl group. R 9 When R is an alkoxy group, it is generally an alkoxy group having 1 to 20 carbon atoms, preferably 1 to 12 carbon atoms. 9 Specific examples of alkoxy groups that can be used as R include methoxy, ethoxy, propoxy, i-propoxy, i-butoxy, s-butoxy, and t-butoxy. When the value of n is 2 or less, multiple R 9 may be the same or different. When 1≦n≦2, R 9 They may be linked together to form a ring structure.

[0063] Specific examples of the silane compound (a2) having an alkenyl group include vinylsilane, methylvinylsilane, dimethylvinylsilane, trimethylvinylsilane, trichlorovinylsilane, dichloromethylvinylsilane, chlorodimethylvinylsilane, chloromethylvinylsilane, triethylvinylsilane, chlorodiethylvinylsilane, dichloroethylvinylsilane, dimethylethylvinylsilane, diethylmethylvinylsilane, tripentylvinylsilane, triphenylvinylsilane, and diphenylmethylvinylsilane. Nylsilane, dimethylphenylvinylsilane, CH2=CH-Si(CH3)2(C6H4CH3), (CH2=CH)(CH3)2Si-O-Si(CH3)2(CH=CH2), divinylsilane, dichlorodivinylsilane, dimethyldivinylsilane, diphenyldivinylsilane, allyltrimethylsilane, allyltriethylsilane, allyltrivinylsilane, allylmethyldivinylsilane, allyldimethylvinylsilane, allylmethyldichlorosilane, allyltrichlorosilane, allyltribromo Silane, diallyldimethylsilane, diallyldiethylsilane, diallyldivinylsilane, diallylmethylvinylsilane, diallylmethylchlorosilane, diallyldichlorosilane, diallyldibromosilane, triallylmethylsilane, triallylethylsilane, triallylvinylsilane, triallylchlorosilane, triallylbromosilane, tetraallylsilane, di-3-butenyldimethylsilane, di-3-butenylsilane, diethylsilane, di-3-butenylsilane, divinylsilane, di-3-butenyl Silane methyl vinyl silane, di-3-butenyl silane methyl chloro silane, di-3-butenyl silane dichloro silane, tri-3-butenyl silane ethyl silane, tri-3-butenyl silane vinyl silane, tri-3-butenyl silane chloro silane, tri-3-butenyl silane bromo silane, tetra-3-butenyl silane, 1-methyl-1-vinyl silacyclobutane, 1-methyl-1-vinyl silacyclopentane, 1-methyl-1-vinyl silacyclohexane, 1,1-divinyl silacyclopentane, 1,Examples include 1-divinylsilacyclohexane, 1-chloro-1-vinylsilacyclopentane, 1-chloro-1-vinylsilacyclohexane, 1-allyl-1-methylsilacyclopentane, and 1-allyl-1-methylsilacyclohexane. Among these, vinylsilane compounds are preferred, with trimethylvinylsilane, trichlorovinylsilane, dimethyldivinylsilane, and 1-methyl-1-vinylsilacyclopentane being particularly preferred.

[0064] The amount of the silane compound (a2) having an alkenyl group used may be any amount within a range that does not impair the effects of the present invention, but is generally preferably within the following range. The amount of the silane compound (a2) having an alkenyl group used is preferably in the range of 0.001 to 1,000, particularly preferably 0.01 to 100, in terms of the molar ratio to the titanium component constituting the solid component (a1) (number of moles of the silane compound (a2) having an alkenyl group / number of moles of titanium atoms in the solid component (a1)).

[0065] The silane compound (a2) having an alkenyl group used in the present invention usually has a greater steric hindrance than an α-olefin monomer, and cannot be polymerized with a Ziegler-Natta catalyst. However, due to the presence of an organic silyl group with very strong electron-donating properties, the charge density at the carbon-carbon double bond is very high, and coordination to the titanium atom, which is the active center, is thought to be very rapid. Therefore, by coordinating and complexing with the Lewis acid sites on the magnesium compound carrier, silane compounds with alkenyl groups can suppress the extraction of titanium compounds into the solvent, and are expected to prevent over-reduction of titanium atoms by organoaluminum compounds and deactivation of active sites by impurities.

[0066] 1-1-3. Alkoxysilane compound (a3) The alkoxysilane compound (a3) used in the production method of the present invention is different from the silane compound (a2) having an alkenyl group. In the production method of the present invention, the component (a3) may be an alkoxysilane compound represented by the following general formula (3). R 5 R 6 m Si(OR 7 ) n ···(3) (In general formula (3), R 5 represents a hydrocarbon group or a heteroatom-containing hydrocarbon group. 6 represents a hydrogen atom, a halogen atom, a hydrocarbon group, or a heteroatom-containing hydrocarbon group. 7 is a hydrocarbon group. m and n are integers in the range of 0≦m≦2, 1≦n≦3, and m+n=3.

[0067] In general formula (3), R 3 represents a hydrocarbon group or a heteroatom-containing hydrocarbon group. R 5 When is a hydrocarbon group, it is a hydrocarbon group excluding an alkenyl group. R 5 The hydrocarbon group that can be used as R generally has 1 to 20 carbon atoms, preferably 3 to 10 carbon atoms. 5 Specific examples of hydrocarbon groups that can be used as R include linear aliphatic hydrocarbon groups such as n-propyl groups, branched aliphatic hydrocarbon groups such as i-propyl groups and t-butyl groups, alicyclic hydrocarbon groups such as cyclopentyl groups and cyclohexyl groups, and aromatic hydrocarbon groups such as phenyl groups. 5 It is desirable to use a branched aliphatic hydrocarbon group or an alicyclic hydrocarbon group as the alkyl group, and it is particularly desirable to use an i-propyl group, an i-butyl group, a t-butyl group, a thexyl group, a cyclopentyl group, a cyclohexyl group, or the like. Also, R 5 When is a heteroatom-containing hydrocarbon group, the heteroatom is preferably selected from a nitrogen atom, an oxygen atom, a sulfur atom, a phosphorus atom, or a silicon atom, and is particularly preferably a nitrogen atom or an oxygen atom. R 5 The skeleton structure of the heteroatom-containing hydrocarbon group is5 is a hydrocarbon group. In particular, an N,N-diethylamino group, a quinolino group, an isoquinolino group, etc. are preferred.

[0068] Also, in the formula, R 6 represents a hydrogen atom, a halogen atom, a hydrocarbon group, or a heteroatom-containing hydrocarbon group. R 6 Examples of halogen atoms that can be used as the halogen atom include a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom. Also, R 6 When is a hydrocarbon group, it is a hydrocarbon group excluding an alkenyl group. R 6 The hydrocarbon group that can be used as R generally has 1 to 20 carbon atoms, preferably 1 to 10 carbon atoms. 6 Specific examples of hydrocarbon groups that can be used as include linear aliphatic hydrocarbon groups such as methyl and ethyl groups, branched aliphatic hydrocarbon groups such as i-propyl and t-butyl groups, alicyclic hydrocarbon groups such as cyclopentyl and cyclohexyl groups, and aromatic hydrocarbon groups such as phenyl groups. Of these, it is desirable to use methyl, ethyl, propyl, i-propyl, i-butyl, s-butyl, t-butyl, thexyl, cyclopentyl, cyclohexyl, and the like. Also, R 6 is a heteroatom-containing hydrocarbon group, R 5 is a heteroatom-containing hydrocarbon group. In particular, an N,N-diethylamino group, a quinolino group, an isoquinolino group, etc. are preferred. Moreover, regardless of the value of m, R 6 is R 5 may be the same as or different from.

[0069] Also, in the formula, R 7 represents a hydrocarbon group. 7The hydrocarbon group that can be used as the alkyl group generally has 1 to 20 carbon atoms, preferably 1 to 10 carbon atoms, and more preferably 1 to 5 carbon atoms. R 7 Specific examples of hydrocarbon groups that can be used as R include linear aliphatic hydrocarbon groups such as methyl and ethyl groups, and branched aliphatic hydrocarbon groups such as i-propyl and t-butyl groups. Among these, methyl and ethyl groups are most preferred. When the value of n is 2 or greater, multiple R 7 may be the same or different.

[0070] Preferred examples of the alkoxysilane compound (a3) that can be used in the present invention include t-butylmethyldimethoxysilane, t-butylmethyldiethoxysilane, t-butylethyldimethoxysilane, t-butyl-n-propyldimethoxysilane, cyclohexylmethyldimethoxysilane, cyclohexylethyldimethoxysilane, dicyclopentyldimethoxysilane, diisopropyldimethoxysilane, diisobutyldimethoxysilane, isobutylisopropyldimethoxysilane, n-propylmethyldimethoxysilane, t-butyltriethoxysilane, bis(diethylamino)dimethoxysilane, diethylaminotriethoxysilanemethoxysilane, and bisperhydroisoquinolinodimethoxysilane. These alkoxysilane compounds can be used alone or in combination of two or more compounds.

[0071] The amount of the alkoxysilane compound (a3) used may be any amount within a range that does not impair the effects of the present invention, but is generally preferably within the following range. The amount of the alkoxysilane compound (a3) used is preferably in the range of 0.01 to 1,000, particularly preferably 0.1 to 100, in terms of the molar ratio to the titanium component constituting the solid component (a1) (number of moles of alkoxysilane compound (a3) / number of moles of titanium atoms in the solid component (a1)).

[0072] The alkoxysilane compound (a3) used in the present invention is thought to be coordinated in the vicinity of a titanium atom that can serve as an active site, and to control catalytic performance such as the catalytic activity of the active site and the regularity of the polymer.

[0073] 1-1-4.Organoaluminum compounds (a4) The organoaluminum compound (a4) used in the present invention may be a compound disclosed in JP-A-2004-124090, etc. In general, it is desirable to use a compound represented by the following general formula (b): R 10 a AlX b (OR 11 ) c (b) (In general formula (b), R 10 represents a hydrocarbon group. X represents a halogen atom or a hydrogen atom. R 11 represents a hydrocarbon group or an Al-based crosslinking group. a≧1, 0≦b≦2, 0≦c≦2, and a+b+c=3. In general formula (b), R 10 R is a hydrocarbon group, preferably having 1 to 10 carbon atoms, more preferably having 1 to 8 carbon atoms, and particularly preferably having 1 to 6 carbon atoms. 10 Specific examples of the alkyl group include a methyl group, an ethyl group, a propyl group, a butyl group, an isobutyl group, a hexyl group, an octyl group, etc. Among these, a methyl group, an ethyl group, and an isobutyl group are most preferred. In the general formula (b), X is a halogen atom or a hydrogen atom. Examples of halogen atoms that can be used as X include fluorine, chlorine, bromine, and iodine. Among these, chlorine is particularly preferred. In general formula (b), R 11 is a hydrocarbon group or a crosslinking group based on Al. 11 When R is a hydrocarbon group, 10 Examples of hydrocarbon groups are shown in the same group as R 11 It is also possible to use an alumoxane compound, such as methylalumoxane, as the organoaluminum compound (A4). In this case, R11 represents a crosslinking group due to Al.

[0074] Examples of compounds that can be used as the organoaluminum compound (a4) include trimethylaluminum, triethylaluminum, triisobutylaluminum, trioctylaluminum, diethylaluminum chloride, ethylaluminum chloride, diethylaluminum ethoxide, and methylalumoxane. Of these, triethylaluminum and triisobutylaluminum are preferred. The organoaluminum compound (a4) may be used not only as a single compound, but also as a combination of two or more compounds.

[0075] The amount ratio of the organoaluminum compound (a4) used may be any amount within a range that does not impair the effects of the present invention, but is generally preferably within the following range. The amount of the organoaluminum compound (a4) used is preferably in the range of 0.1 to 100, particularly preferably 1 to 50, in terms of the molar ratio (number of moles of aluminum atoms / number of moles of titanium atoms in solid component (a1)) to the titanium component constituting solid component (a1).

[0076] The organoaluminum compound (a4) used in the present invention is used mainly for the purpose of efficiently supporting the alkoxysilane compound (a3) on the solid catalyst component (A1). Therefore, the main purpose of the organoaluminum compound is different from that of the organoaluminum compound used as a co-catalyst in the polymerization reaction during the prepolymerization or main polymerization, and the organoaluminum compound is therefore distinguished.

[0077] 1-1-5. Preparation method of solid catalyst component (A1) In the production method of the present invention, the solid catalyst component (A1) may be prepared by contacting the solid component (a1) with an alkenyl group-containing silane compound (a2), an alkoxysilane compound (a3), and an organoaluminum compound (a4) at a predetermined temperature. In the production method of the present invention, the contact treatment may be carried out multiple times during the preparation of the solid catalyst component (A1). When the contact treatment is carried out multiple times, the compounds used in the multiple contact treatments, including the silane compound (a2) having an alkenyl group, the alkoxysilane compound (a3), and the organoaluminum compound (a4), may be the same or different from one another. The solid catalyst component (A1) used in the present invention can be obtained by contacting the above-mentioned constituent components in the above-mentioned ratios. Furthermore, although the range of the amount of each component used was indicated above, this is the amount used per contact, and from the second time onwards, contact can be carried out any number of times as long as the amount used per contact is within the range of the amount used above.

[0078] The contact conditions for the components of the solid catalyst component (A1) must be such that oxygen is not present, but any conditions can be used as long as the effects of the present invention are not impaired. Generally, the following conditions are preferred:

[0079] Examples of the contacting method include a mechanical method using a rotary ball mill or a vibration mill, and a method of contacting by stirring in the presence of an inert diluent. Preferably, it is desirable to use the method of contacting by stirring in the presence of an inert diluent. The contact temperature is about -50 to 200°C, preferably -10 to 100°C, more preferably 0 to 90°C, and particularly preferably 20°C or higher and lower than 80°C.

[0080] In the contact treatment, any procedure can be used for contacting the solid component (a1), the silane compound (a2) having an alkenyl group, the alkoxysilane compound (a3), and the organoaluminum compound (a4). Specific examples include the following procedures (i) to (iv), among which procedures (i) and (ii) are preferred. Step (i): A method in which a solid component (a1) is contacted with a silane compound (a2) having an alkenyl group, then with an alkoxysilane compound (a3), and then with an organoaluminum compound (a4). Step (ii): A method in which the solid component (a1) is contacted with an alkenyl group-containing silane compound (a2) and an alkoxysilane compound (a3), and then with an organoaluminum compound (a4). Step (iii): A method in which the solid component (a1) is contacted with an alkoxysilane compound (a3), then with a silane compound (a2) having an alkenyl group, and then with an organoaluminum compound (a4). Procedure (iv): A method in which all compounds are contacted simultaneously.

[0081] In the preparation of the solid catalyst component (A1), washing with an inert solvent may be carried out intermediately and / or finally. Preferred examples of the solvent used for washing include aliphatic hydrocarbon compounds such as heptane, aromatic hydrocarbon compounds such as toluene and xylene, and halogen-containing hydrocarbon compounds such as 1,2-dichloroethylene and chlorobenzene.

[0082] 1-2. Process 2 Step 2 is a step of mixing the solid catalyst component (A1) and the following components (A2) and (A3) in the presence of an α-olefin to obtain a catalyst component (A) for α-olefin polymerization. Component (A2): (A2-1) at least one compound selected from the group consisting of unsaturated cyclic ether compounds and (A2-2) cyclic compounds having an amide bond Component (A3): Hydrogen

[0083] 1-2-1. Unsaturated cyclic ether compounds (A2-1) It is presumed that the unsaturated cyclic ether compound (A2-1) used in the present invention, due to its structural size and the electronic state of its oxygen atom, preferentially reacts with titanium atoms, which serve as active sites for generating amorphous components, thereby poisoning and deactivating them. In particular, the dipole moment of unsaturated cyclic ethers is due to the difference in electronegativity of the carbon-oxygen σ bond, as well as the imbalance of π electrons due to the resonance of the lone electron pair. These two forces act in opposite directions and cancel each other out, so the dipole moment tends to be small. Therefore, compared with acyclic ethers and saturated cyclic ethers, the electron density of the oxygen atom of unsaturated cyclic ethers is lower, which is presumed to result in preferential reaction with the active sites for generating amorphous components. The unsaturated cyclic ether compound (A2-1) used in the present invention includes an unsaturated cyclic ether compound containing at least one oxygen atom.Specific examples of the unsaturated cyclic ether compound include furans, dioxenes, pyrans, and oxepins. As the unsaturated cyclic ether compound (A2-1) used in the present invention, furans are particularly preferred, and can be selected from compounds represented by the following general formula (1).

[0084] [ka]

[0085] (In general formula (1), R 1 and R 2 is a hydrogen atom or a hydrocarbon group, and R 1 and R 2 may be the same or different.) In general formula (1), R 1 and R 2 is a hydrogen atom or a hydrocarbon group. 1 and R 2When is a hydrocarbon group, it is preferably a substituent with a small structural bulk, such as an alkyl group or a cycloalkyl group, having 1 to 10 carbon atoms, more preferably 1 to 5. Specific examples include a hydrogen atom, a methyl group, an ethyl group, a vinyl group, an allyl group, an n-propyl group, an i-propyl group, an n-butyl group, an i-butyl group, a t-butyl group, an n-hexyl group, an i-hexyl group, a cyclopropyl group, a cyclobutyl group, a cyclopentyl group, a cyclohexyl group, and a cyclooctyl group, with a hydrogen atom, a methyl group, and an ethyl group being particularly preferred. Specific examples of the compound include furan compounds such as furan, 2-methylfuran, 2-ethylfuran, 2-i-propylfuran, 2,5-dimethylfuran, 2,5-diethylfuran, 2,5-diisopropylfuran, etc. Among these furan compounds, furan, 2-methylfuran, 2-ethylfuran, 2,5-dimethylfuran, and 2,5-diethylfuran are preferred, and furan, 2-methylfuran, 2,5-dimethylfuran, and 2,5-diethylfuran are particularly preferred. Two or more of these furan compounds can also be used.

[0086] The amount of the unsaturated cyclic ether compound (A2-1) used may be any amount within the range that does not impair the effects of the present invention, but is generally preferably within the following range. The amount of the unsaturated cyclic ether compound (A2-1) used relative to the titanium component contained in the component (a1) may be such that the molar ratio of component (A2-1) / titanium is 2.0 to 30, or 5.3 to 26.8.

[0087] 1-2-2. Cyclic compounds containing amide bonds (A2-2) It is presumed that the cyclic compound (A2-2) having an amide bond used in the present invention reacts preferentially with titanium atoms, which serve as active sites for generating amorphous components, and poisons and deactivates them, due to its structural size and the electronic state of the oxygen atoms of the amide group.

[0088] Specific examples of the cyclic compound (A2-2) having an amide bond used in the present invention include pyrrolidones, piperidones, imidazolidinones, pyrimidinones, and oxazolidones. The cyclic compound (A2-2) having an amide bond used in the present invention is preferably a five-membered ring pyrrolidone, imidazolidinone, or oxazolidon, and can be selected from compounds represented by the following general formula (2).

[0089] [ka]

[0090] In the general formula (2), X is a carbon atom, a nitrogen atom, or an oxygen atom. 3 and R 4 is a hydrogen atom or a hydrocarbon group, and R 3 and R 4 may be the same or different. However, when X is an oxygen atom, R 4 does not exist. R 3 and R 4 When is a hydrocarbon group, it is preferably a substituent with a small structural bulk, such as an alkyl group or a cycloalkyl group, having 1 to 10 carbon atoms, more preferably 1 to 5. Specific examples include a hydrogen atom, a methyl group, an ethyl group, a vinyl group, an allyl group, an n-propyl group, an i-propyl group, an n-butyl group, an i-butyl group, a t-butyl group, an n-hexyl group, an i-hexyl group, a cyclopropyl group, a cyclobutyl group, a cyclopentyl group, a cyclohexyl group, and a cyclooctyl group, with a hydrogen atom, a methyl group, and an ethyl group being particularly preferred.

[0091] Specific examples of the compound include pyrrolidones such as 2-pyrrolidone, 1-methyl-2-pyrrolidone, 1-ethyl-2-pyrrolidone, 1-vinyl-2-pyrrolidone, 1-propyl-2-pyrrolidone, 1-butyl-2-pyrrolidone, 1-hexyl-2-pyrrolidone, 1-pentyl-2-pyrrolidone, and 1-cyclohexyl-2-pyrrolidone; imidazolidinones such as 2-imidazolidone, 1-methyl-2-imidazolidinone, 1,3-dimethyl-2-imidazolidinone, 1-ethyl-2-imidazolidinone, and 1,3-diethyl-2-imidazolidone; and oxazolidones such as 2-oxazolidone, 3-methyl-2-oxazolidone, and 3-ethyl-2-oxazolidone. Among these, 1-ethyl-2-pyrrolidone, 3-methyl-2-oxazolidone, and 1,3-dimethyl-2-imidazolidinone are particularly preferred. Two or more of these cyclic compounds having an amide bond can also be used. The unsaturated cyclic ether compound (A2-1) and the cyclic compound (A2-2) having an amide bond may be used in combination.

[0092] The amount of the cyclic compound (A2-2) having an amide bond used may be any amount within a range that does not impair the effects of the present invention, but is generally preferably within the following range. The amount of the cyclic compound (A2-2) having an amide bond used may be, in terms of molar ratio relative to the titanium component contained in the component (a1), component (A2-2) / titanium=2.0 to 30, or may be 5.3 to 26.8. The amount of the unsaturated cyclic ether compound (A2-1) and the cyclic compound (A2-2) having an amide bond used in combination may be any amount within a range that does not impair the effects of the present invention, but is generally preferably within the following range. When the unsaturated cyclic ether compound (A2-1) and the cyclic compound (A2-2) having an amide bond are used in combination, the total amount used relative to the titanium component contained in component (a1) may be such that the molar ratio {component (A2-1) + component (A2-2)} / titanium=2.0 to 30 or 5.3 to 26.8.

[0093] 1-2-3. Hydrogen (A3) The amount of hydrogen (A3) used may be any amount within a range that does not impair the effects of the present invention, but is generally preferably within the following range: The amount of hydrogen (A3) used may be 10 to 10,000 ml per 1 g of the solid catalyst component (A1).

[0094] 1-2-4. Other compounds As long as the effects of the present invention are not impaired, components other than the above-mentioned component (A2) and hydrogen (A3) can be used during mixing. For example, an organoaluminum compound that acts as a scavenger to remove water and other impurities from the system can be used. The material and amount of the organoaluminum compound can be the same as those described for the organoaluminum compound (a4), which is a component used in preparing the solid catalyst component (A1).

[0095] 1-2-5.α-Olefins In the present invention, examples of the α-olefin include ethylene, propylene, α-olefins having 4 to 22 carbon atoms represented by the following general formula (c), dienes, and styrenes. R 12 -CH=CH2 (c) (In general formula (c), R 12 is a hydrocarbon group having 2 to 20 carbon atoms, which may have a branched group. Specific examples of the α-olefin having 4 to 22 carbon atoms include butene-1, pentene-1, hexene-1, and 4-methylpentene-1. The α-olefin used in the polymerization in the present invention may be one type of α-olefin, propylene alone, a combination of two types of propylene and ethylene, a combination of propylene and an α-olefin having 4 to 22 carbon atoms represented by the above general formula (c), or a combination of any two or more types of α-olefins.

[0096] 1-2-6. Method for preparing catalyst component (A) for α-olefin polymerization In the method for producing the catalyst component (A) for α-olefin polymerization of the present invention, the catalyst component (A) for α-olefin polymerization is prepared by mixing the solid catalyst component (A1), the component (A2), the component (A3), and hydrogen in the presence of an α-olefin. This mixing treatment may be carried out multiple times. The above mixing can be carried out in any order. For example, the α-olefin can be introduced after the solid catalyst component (A1) is brought into contact with the components (A2) and (A3). Furthermore, the solid catalyst component (A1) may be placed in an α-olefin atmosphere, and then the components (A2) and (A3) may be introduced. Any conditions can be used as the treatment conditions in step 2 as long as they do not impair the effects of the present invention. Generally, the following ranges are preferred. The reaction amount (polymerization amount) of α-olefin per gram of solid catalyst component (A1) is in the range of 0.001 g to 100 g, preferably 0.1 g to 50 g, and more preferably 0.5 g to 10 g. The mixing temperature is -150°C to 150°C, preferably -10°C to 100°C, and more preferably 0°C to 70°C. The mixing is generally preferably carried out under stirring, and an inert solvent such as hexane or heptane may be present at this time. The mixing treatment may be carried out multiple times, and the α-olefins used in these treatments may be the same or different. After the mixing treatment, the mixture may be washed with an inert solvent such as hexane or heptane.

[0097] 2. Method for producing α-olefin polymerization catalyst The method for producing an α-olefin polymerization catalyst of the present invention is characterized by mixing the α-olefin polymerization catalyst component (A) obtained by the above-mentioned method for producing a catalyst component for α-olefin polymerization with the following component (B): Component (B): Organoaluminum compound

[0098] 2-2.Organoaluminum compounds (B) The organoaluminum compound (B) acts mainly as a co-catalyst in the polymerization treatment, and also as a scavenger for removing water and other impurities from the system. As the organoaluminum compound (B) that can be used in the present invention, the compounds disclosed in JP-A No. 2004-124090 and the like can be used. Preferably, it can be selected from the same group as the examples of the organoaluminum compound (a4) which is a component in preparing the solid catalyst component (A1). The organoaluminum compound (B) may be the same as or different from the organoaluminum compound (a4) that can be used in preparing the solid catalyst component (A1). The organoaluminum compound (B) may be used not only as a single compound, but also as a combination of two or more compounds. The amount of the organoaluminum compound (B) used may be any amount within the range that does not impair the effects of the present invention, but is generally preferably within the following range. The amount of the organoaluminum compound (B) used is preferably in the range of 1 to 5,000, particularly preferably 10 to 500, in terms of the molar ratio to the titanium component contained in the solid component (a1) (number of moles of organoaluminum compound (B) / number of moles of titanium atoms in the solid component (a1)).

[0099] 2-3. Preparation of α-olefin polymerization catalyst The α-olefin polymerization catalyst component (A) and component (B) can be mixed under any conditions as long as the effects of the present invention are not impaired, and may be mixed under conditions in the absence of oxygen. Examples of the mixing temperature include the temperatures exemplified as the polymerization temperature of α-olefins described below. The device used for mixing may be a conventionally known device having stirring and temperature control functions.

[0100] 3. Method for producing α-olefin polymer The process for producing an α-olefin polymer of the present invention is characterized by homopolymerizing or copolymerizing an α-olefin in the presence of the above-mentioned α-olefin polymerization catalyst.

[0101] 3-1. α-olefin polymerization treatment The polymerization of α-olefins may be carried out by slurry polymerization using a hydrocarbon solvent, liquid phase solventless polymerization using substantially no solvent, or gas phase polymerization. In the case of slurry polymerization, a hydrocarbon solvent such as pentane, hexane, heptane, or cyclohexane is used as the polymerization solvent. The polymerization method to be employed may be any method such as continuous polymerization, batch polymerization or multi-stage polymerization. The polymerization temperature is usually about 30° C. to 200° C., preferably 50° C. to 150° C., and hydrogen may be used as a molecular weight regulator. The polymerization of α-olefins can be carried out not only by homopolymerization of one type of α-olefin, but also by random copolymerization with propylene and a monomer copolymerizable with propylene, such as ethylene, an α-olefin having 4 to 22 carbon atoms represented by the above general formula (c), dienes, and styrenes. It is also possible to carry out block copolymerization in which propylene is homopolymerized in the first stage and then randomly copolymerized in the second stage. The copolymerizable monomer can be used in an amount of up to 15% by weight in random copolymerization and up to 50% by weight in block copolymerization. Among these, propylene homopolymerization and block copolymerization are preferred, and propylene homopolymerization and block copolymerization in which the first stage is propylene homopolymerization are most preferred.

[0102] 4. α-olefin polymer The index of the α-olefin polymer polymerized according to the present invention is not particularly limited and can be appropriately adjusted depending on various applications.

[0103] 4-1.MFR(g / 10min) The MFR of the α-olefin polymer is preferably within a range of 0.01 g / 10 min to 10,000 g / 10 min, and particularly preferably within a range of 0.1 g / 10 min to 1,000 g / 10 min.

[0104] 4-2.Melting point (℃) The α-olefin polymer obtained by the production method of the present invention preferably has high stereoregularity. The degree of stereoregularity of an α-olefin polymer can be evaluated by measuring the melting point. The α-olefin polymer obtained by the production method of the present invention preferably has a melting point of 162.6°C or higher and 166.0°C or lower. If the melting point is within the above range, the α-olefin polymer has the desired rigidity.

[0105] 4-3.40℃ soluble content (mass%) The α-olefin polymers produced by the present invention are characterized by an extremely small amount of amorphous components, high stereoregularity, and good odor and color. The preferred range of the 40°C soluble content as an amorphous component of an α-olefin polymer generally varies depending on the application. For example, in applications where hard molded articles are preferred, such as general injection molding, the upper limit of the 40°C soluble content in the case of polypropylene is preferably 1.4 mass% or less.

[0106] The α-olefin polymer produced by the present invention has an extremely small amount of amorphous components and high stereoregularity, and therefore has high density, rigidity, and heat resistance, among other excellent properties. Furthermore, this α-olefin polymer can be produced with high yield and is particularly suitable for use as an industrial material, such as an automobile part or a home appliance part, which requires high rigidity and high heat resistance, or as a packaging material, since it is less sticky. [Example]

[0107] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to these examples. The methods for measuring the various physical properties in the present invention are shown below.

[0108] (1) Titanium content: The sample was accurately weighed, hydrolyzed, and measured by colorimetry. For the sample after prepolymerization, the content was calculated using the mass excluding the prepolymerized polymer.

[0109] (2) Phthalate ester content: The sample was accurately weighed, decomposed with sulfuric acid, and the phthalate esters were extracted into heptane. The phthalate ester concentration in the resulting heptane solution was determined by comparison with a standard sample using gas chromatography. The phthalate ester content in the sample was calculated from the phthalate ester concentration in heptane and the sample mass. For samples after prepolymerization, the content was calculated using the mass excluding the prepolymerized polymer.

[0110] (3) Alkoxysilane compound content: The sample was accurately weighed and decomposed in methanol. The concentration of the silicon compound in the resulting methanol solution was determined by comparison with a standard sample using gas chromatography. The content of the silicon compound in the sample was calculated from the concentration of the silicon compound in methanol and the mass of the sample. For samples after prepolymerization, the content was calculated using the mass excluding the prepolymerized polymer.

[0111] (4)MFR: Using a melt indexer manufactured by Takara Corporation, evaluation was carried out under conditions of 230°C and 21.18N based on JIS-K6921.

[0112] (5) 40℃ soluble content (TREF): The amount of soluble matter at 40°C measured by TREF is as follows. The sample was dissolved in orthodichlorobenzene (containing 0.5 mg / mL of BHT (3,5-dibutyl-4-hydroxytoluene)) at 140°C to prepare a solution. This was then introduced into a temperature-rising elution fractionation chromatography (TREF) column at 140°C, cooled to 100°C at a rate of 8°C / min, then cooled to 40°C at a rate of 4°C / min, and held at 40°C for 10 minutes. Then, the solvent, orthodichlorobenzene (containing 0.5 mg / ml of BHT), was passed through the column at a flow rate of 1 mL / min, and the components dissolved in orthodichlorobenzene at 40°C in the TREF column were eluted for 10 minutes to determine the 40°C soluble components. The TREF device configuration used is as follows: Column size: 4.3mmφ x 150mm stainless steel column Column packing material: 100 μm surface-deactivated glass beads Solvent: orthodichlorobenzene Sample concentration: 5mg / mL Sample injection volume: 0.1 mL Solvent flow rate: 1 mL / min Detector: Fixed wavelength infrared detector, FOXBORO, MIRAN, 1A ·Measurement wavelength: 3.42μm

[0113] (6) Melting point: A Seiko Instruments DSC6200 differential scanning calorimeter was used. 5 mg of a sheet-shaped sample piece was placed in an aluminum pan, heated from room temperature to 200°C at a heating rate of 100°C / min, held at 200°C for 5 minutes, cooled to 20°C at a rate of 10°C / min to allow crystallization, and then heated back to 200°C at a rate of 10°C / min to obtain a melting curve. The peak-top temperature of the main endothermic peak during the heating stage of the melting curve was taken as the melting point.

[0114] Example 1 [Preparation of solid component (a1)] A 10 L autoclave equipped with a stirrer was thoroughly purged with nitrogen, and 2 L of purified toluene was introduced. To this, 200 g of diethoxymagnesium (Mg(OEt)2) as a magnesium source and 1 L of titanium tetrachloride (TiCl4) as a titanium source were added at room temperature. The temperature was raised to 90° C. and 50 ml of di-n-butyl phthalate was introduced as an electron donor. Then, the temperature was raised to 110°C and the reaction was carried out for 3 hours. The reaction product was then thoroughly washed with purified toluene. Next, purified toluene was introduced into the autoclave to adjust the total liquid volume to 2 L. Thereafter, 1 L of TiCl4 was added at room temperature, and the temperature was raised to 110°C to carry out the reaction for 2 hours. The reaction product was then thoroughly washed with purified toluene. Next, purified toluene was again introduced into the autoclave to adjust the total liquid volume to 2 L. 1 L of TiCl4 was added at room temperature, and the temperature was raised to 110°C to carry out the reaction for 2 hours. The reaction product was thoroughly washed with purified toluene. Furthermore, purified n-heptane was used to replace the toluene with n-heptane. The resulting slurry was removed from the autoclave and vacuum dried to obtain solid component (a1). Analysis of this solid component (a1) revealed that it contained 0.50 mmol / g of Ti and 0.56 mmol / g of di-n-butyl phthalate.

[0115] [Step 1: Preparation of solid catalyst component (A1)] A 1 L round-bottom flask equipped with a stirrer was thoroughly purged with nitrogen, and 10 g of the above solid component (a1) was introduced into the round-bottom flask. Purified n-heptane was introduced into a round-bottom flask, and the concentration of the solid component (a1) was adjusted to 25 g / L. To this mixture were added 2.5 ml of dimethyldivinylsilane as component (a2), 2.0 ml of t-butylmethyldimethoxysilane (t-Bu(Me)Si(OMe)2) as component (a3), and 4.2 g of a solution of triethylaluminum (Et3Al) diluted in n-heptane as component (a4), and the reaction was carried out for 2 hours at 70°C. After completion of the reaction, the reaction product was thoroughly washed with purified n-heptane, and the liquid level was then adjusted to 400 ml with n-heptane to obtain a slurry of solid catalyst component (A1).

[0116] [Step 2: Preparation of α-olefin polymerization catalyst component (A)] A 1 L autoclave equipped with a stirrer was thoroughly purged with nitrogen, and the slurry of the solid catalyst component (A1) obtained in step 1 was introduced thereinto. After cooling the inside of the autoclave to 20°C, 2,5-dimethylfuran was introduced as component (A2) into the autoclave in an amount of 13.39 mmol / g (component (A2-1) / titanium: 26.8) relative to the component (a1), 1.5 g of a solution of EtAl diluted in n-heptane was added as EtAl as a scavenger, and then 510 ml of hydrogen, which was component (A3), was introduced. Then, 20 g of propylene was fed at a rate of 6 g / hr. After the propylene feed was completed, the reaction was continued for another 30 minutes. Next, the gas phase was thoroughly replaced with nitrogen gas, and the reaction product was thoroughly washed with purified n-heptane. The resulting slurry was removed from the autoclave and vacuum dried to obtain catalyst component (A) for α-olefin polymerization. This catalyst component (A) for α-olefin polymerization contained 1.7 g of polypropylene per 1 g of catalyst component (A). Analysis revealed that the portion of catalyst component (A) for α-olefin polymerization excluding polypropylene contained 0.28 mmol / g of Ti, 0.01 mmol / g of di-n-butyl phthalate, and 0.22 mmol / g of t-butylmethyldimethoxysilane.

[0117] [Propylene polymerization] A 3.0 L stainless steel autoclave equipped with a stirrer and a temperature controller was heated and dried under vacuum, cooled to room temperature, and then propylene was substituted. Thereafter, 550 mg (0.00482 mol) of Et3Al as component (B) and 8000 ml of hydrogen were introduced, and then 1000 g of liquid propylene was introduced as a polymerization monomer, and the internal temperature was adjusted to 70°C. Thereafter, 7 mg of the above catalyst component (A) for α-olefin polymerization was injected to polymerize propylene. After 1 hour, 10 ml of ethanol was injected to terminate the polymerization. The resulting polypropylene was dried and weighed, and the results are shown in Table 1.

[0118] Example 2 Propylene polymerization was carried out in the same manner as in Example 1, except that the amount of 2,5-dimethylfuran used as component (A2) was 5.50 mmol / g (component (A2-1) / titanium: 11.0). The results are shown in Table 1.

[0119] Example 3 Propylene polymerization was carried out in the same manner as in Example 1, except that the amount of 2,5-dimethylfuran used as component (A2) was 2.63 mmol / g (component (A2-1) / titanium: 5.3). The results are shown in Table 1.

[0120] Example 4 Propylene polymerization was carried out in the same manner as in Example 3, except that the mixing temperature in step 2 was set to 50° C. The results are shown in Table 1.

[0121] (Comparative Example 1) Propylene polymerization was carried out in the same manner as in Example 1, except that component (A3) was not used in Example 2. The results are shown in Table 1.

[0122] (Comparative Example 2) Propylene polymerization was carried out in the same manner as in Example 1, except that the components (A2) and (A3) were not used. The results are shown in Table 1.

[0123] Example 5 Propylene polymerization was carried out in the same manner as in Example 1, except that 2,5-dimethylfuran used as component (A2) was replaced with 2.63 mmol / g of 1-ethyl-2-pyrrolidone (component (A2-2) / titanium: 5.3). The results are shown in Table 2.

[0124] Example 6 Propylene polymerization was carried out in the same manner as in Example 1, except that 2.63 mmol / g (component (A2-2) / titanium: 5.3) of 3-methyl-2-oxazolidone was used instead of 2,5-dimethylfuran used as component (A2). The results are shown in Table 2.

[0125] Example 7 Propylene polymerization was carried out in the same manner as in Example 1, except that 2,5-dimethylfuran used as component (A2) was replaced by 2.63 mmol / g of 1,3-dimethyl-2-imidazolidinone (component (A2-2) / titanium: 5.3). The results are shown in Table 2.

[0126] (Comparative Example 3) In Example 5, propylene polymerization was carried out in the same manner as in Example 1, except that component (A3) was not used. The results are shown in Table 2.

[0127] [Table 1]

[0128] [Table 2]

[0129] As is clear from Tables 1 and 2, when the Examples and Comparative Examples are compared, the α-olefin polymerization catalyst containing the α-olefin polymerization catalyst component (A) of the present invention can produce polypropylene with a low content of solubles at 40°C (amorphous components) and a high melting point (stereoregularity). Specifically, when Examples 1 to 7 are compared with Comparative Examples 1 to 3, it is found that by using hydrogen as component (A2) and component (A3), the soluble content of the polymer obtained by polymerization can be significantly reduced and the melting point is also improved. Therefore, it can be said that the Examples were able to obtain polymers with extremely low soluble content and high melting points, and that superior results were obtained compared to the Comparative Examples. [Industrial Applicability]

[0130] According to the present invention, an α-olefin polymer having a small amount of amorphous components and high stereoregularity can be produced, and the present invention has high industrial applicability.

Claims

1. A method for producing a catalyst component for α-olefin polymerization, which comprises sequentially carrying out the following steps 1 and 2: Step 1: A step of mixing the following components (a1), (a2), (a3), and (a4) to obtain a solid catalyst component (A1). Component (a1): A solid component containing magnesium, titanium, a halogen, and an electron donor as essential components. Component (a2): Silane compound having an alkenyl group Component (a3): Alkoxysilane compound (however, different from a silane compound having an alkenyl group). Component (a4): organoaluminum compound Step 2: A step of mixing the solid catalyst component (A1) and the following components (A2) and (A3) in the presence of an α-olefin to obtain a catalyst component (A) for α-olefin polymerization: Component (A2): (A2-1) at least one compound selected from the group consisting of unsaturated cyclic ether compounds and (A2-2) cyclic compounds having an amide bond Component (A3): Hydrogen

2. 2. The method for producing a catalyst component for α-olefin polymerization according to claim 1, wherein the component (A2-1) is represented by the following general formula (1): 【Chemical 1】 (In general formula (1), R １ and R ２ is a hydrogen atom or a hydrocarbon group, and R １ and R ２ may be the same or different.)

3. 2. The method for producing a catalyst component for α-olefin polymerization according to claim 1, wherein the component (A2-2) is represented by the following general formula (2): 【Chemistry 2】 (In the general formula (2), X is a carbon atom, a nitrogen atom, or an oxygen atom, and R ３ and R ４ is a hydrogen atom or a hydrocarbon group, and R ３ and R ４ may be the same or different, provided that when X is an oxygen atom, R ４ does not exist.)

4. The method for producing a catalyst component for α-olefin polymerization according to any one of claims 1 to 3, wherein the component (a2) is a vinylsilane compound.

5. The method for producing a catalyst component for α-olefin polymerization according to any one of claims 1 to 4, wherein the component (a3) is an alkoxysilane compound represented by the following general formula (3): R ５ R ６ ｍ Si(OR ７ ) ｎ ・・・(3) (In general formula (3), R ５ represents a hydrocarbon group or a heteroatom-containing hydrocarbon group. ６ represents a hydrogen atom, a halogen atom, a hydrocarbon group, or a heteroatom-containing hydrocarbon group. ７ is a hydrocarbon group. m and n are integers such that 0≦m≦2, 1≦n≦3, and m+n=3.

6. The method for producing a catalyst component for α-olefin polymerization according to any one of claims 1 to 5, wherein the α-olefin in step 2 is propylene, or propylene and ethylene, or propylene and an α-olefin having 4 to 22 carbon atoms.

7. The method for producing a catalyst component for α-olefin polymerization according to any one of claims 1 to 6, wherein the amount of component (A2) used in step 2 relative to the titanium component contained in component (a1) is such that the molar ratio of component (A2) / titanium is 2.0 to 30.

8. The method for producing a catalyst component for α-olefin polymerization according to any one of claims 1 to 7, wherein the mixing temperature in step 2 is 70°C or lower.

9. A method for producing an α-olefin polymerization catalyst, comprising mixing the α-olefin polymerization catalyst component (A) obtained by the method for producing an α-olefin polymerization catalyst component according to any one of claims 1 to 8 with the following component (B): Component (B): Organoaluminum compound

10. A method for producing an α-olefin polymer, which comprises homopolymerizing or copolymerizing an α-olefin in the presence of the α-olefin polymerization catalyst according to claim 9.

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