Polymerization Catalyst Homogeneity and Activity via Component Ratios
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Solution Overview
Problem
Current polymerization catalysts used in α-olefin polymerization exhibit limited activity and stability, requiring improved methods for preparation and storage to maintain effectiveness in polymerization reactions.
Innovation Solution
A polymerization catalyst is produced by bringing transition metal compounds, solid boron compounds capable of forming ion pairs, organoaluminum compounds, and unsaturated hydrocarbons into contact in specific proportions and temperature conditions, followed by storage at controlled temperatures to maintain catalyst activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a boron compound which is difficult to dissolve in a hydrocarbon solvent is employed as a promoter, then the catalyst can be prepared in a homogeneous state by bringing the boron compound into contact with a transition metal compound in a hydrocarbon solvent, but the polymerization activity of the catalyst is insufficient
Solution Approach 1:
The patent changes the temperature parameter from conventional low temperatures to specifically 30 to 60°C, and adjusts the molar ratios of components (B)/(A) to 1.2 to 4.0 and (C)/(A) to 5.0 to 50.0, thereby achieving both homogeneous catalyst preparation and high polymerization activity
Solution Approach 2:
The patent creates a composite catalyst system comprising four components: transition metal compound (A), solid boron compound (B), organoaluminum compound (C), and unsaturated hydrocarbon compound (D). This composite approach synergistically improves both homogeneity and polymerization activity
2Productivity
If a catalyst is prepared by bringing a transition metal compound, a boron compound, and an α-olefin into contact with one another in a hydrocarbon solvent, then the catalyst exhibits improved activity, but further improvement in polymerization activity is still required
Solution Approach 1:
The patent merges the catalyst preparation and activation steps into a single contact process where components (A), (B), (C), and (D) are brought into contact simultaneously or sequentially under controlled conditions, simplifying the overall process while achieving high activity
Solution Approach 2:
The patent optimizes temperature (30 to 60°C) and molar ratios ((B)/(A) = 1.2 to 4.0, (C)/(A) = 5.0 to 50.0) to maximize polymerization activity without increasing process complexity
3Ease of operation
If the catalyst is stored at ambient temperature, then the catalyst is readily available for use, but the activity of the catalyst reduces over time
Solution Approach 1:
The patent identifies and controls the storage temperature parameter, specifying 0 to 35°C as the optimal range to maintain catalyst activity over time, balancing ease of operation with activity stability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting catalyst exhibits high activity and stability, facilitating efficient polymerization reactions and long-term storage without significant activity reduction.
Implementation Method 1
the component (B) is a solid boron compound capable of forming an ion pair with the component (A)
Implementation Method 2
a polymerization catalyst produced by bringing components (A) to (D) into contact with one another in a hydrocarbon solvent at 30 to 60° C.
Implementation Method 3
polymerization of an α-olefin in the presence of a metallocene catalyst
Data Source
AI summary
The invention provides a polymerization catalyst produced by bringing components (A) to (D) into contact with one another in a hydrocarbon solvent at 30 to 60° C., wherein the component (A) is a transition metal compound, the component (B) is a solid boron compound capable of forming an ion pair with component (A), the component (C) is an organoaluminum compound, and the component (D) is one or more unsaturated hydrocarbon compounds selected from among an α-olefin, an internal olefin, and a polyene; and the amounts of component (B) and component (C) are 1.2 to 4.0 mol and 5.0 to 50.0 mol, respectively, on the basis of 1 mol of component (A), which catalyst exhibits high activity and can be readily supplied to a polymerization reaction system. The invention also provides a method of storing the polymerization catalyst at 0 to 35° C.