Abstract: Metallocene catalysts and their preparation and use in the polymerization of olefins. Specifically, the catalysts and processes relate to polymerization of olefins in which an aluminum ionizing agent containing a triphenylcarbenium ion is utilized in preparing the catalyst. The preparation of an olefin polymerization catalyst comprising a metallocene-type catalyst and triphenylcarbenium tetrakis(pentafluorophenyl)aluminate is disclosed.

Abstract: Metallocene catalysts and their preparation and use in the polymerization of olefins. Specifically, the catalysts and processes relate to polymerization of olefins in which an aluminum ionizing agent containing a triphenylcarbenium ion is utilized in preparing the catalyst. The preparation of an olefin polymerization catalyst comprising a metallocene-type catalyst and triphenylcarbenium tetrakis(pentafluorophenyl)aluminate is disclosed.

Abstract: This invention is for a method for varying the melting points and molecular weights of syndiotactic polyolefins by using metallocene catalysts with substituents on the aryl rings of a fluorene ligand in certain positions. Electron donating substituents, for example, dialkylamino, halogen, and alkoxy groups, when present on fluorene at C1, C2, C3 or C2 and C7 render the catalyst less active and decrease the polymer molecular weight. Electron donating substituents, such as alkyl, dialkylamino, halogen or alkoxy, at C4 not only increased the catalyst efficiency but also dramatically increased the polymer molecular weight. Bulky hydrocarbyl substituents, such as alkyl, cyaloalkyl and aryl groups, at C2 and C7 increase the melting point. Bulky substituents such as hydrocarbyl groups like alkyl, cycloalkyl, aryl, alkoxy and dialkylamino groups etc., at C4/C5 decrease the melting point. When multiple substituents are present on fluorene, their effects are additive.

Abstract: This invention is for a method for varying the melting points and molecular weights of syndiotactic polyolefins by using metallocene catalysts with substituents on the aryl rings of a fluorene ligand in certain positions. Electron donating substituents, for example, dialkylamino, halogen, and alkoxy groups, when present on fluorene at C1, C2, C3 or C2 and C7 render the catalyst less active and decrease the polymer molecular weight. Electron donating substituents, such as alkyl, dialkylamino, halogen or alkoxy, at C4 not only increased the catalyst efficiency but also dramatically increased the polymer molecular weight. Bulky hydrocarbyl substituents, such as alkyl, cycloalkyl and aryl groups, at C2 and C7 increase the melting point. Bulky substituents such as hydrocarbyl groups like alkyl, cycloalkyl, aryl, alkoxy and dialkylamino groups etc., at C4/C5 decrease the melting point. When multiple substituents are present on fluorene, their effects are additive.

Abstract: This invention uses a new method of producing ionic metallocene compounds. These compounds are useful as catalysts for polymerization of olefins, primarily propylene. This method uses an ionizing agent which ionizes the neutral metallocene compound. The ionizing ionic compound does not contain an active proton and contains a carbonium, oxonium or sulfonium cation. The anion of the ionizing ionic compound is not coordinated or is only loosely coordinated to the metallocene cation and is chemically unreactive with the metallocene cation. Examples of such compounds are triphenylcarbenium tetrakis(pentafluorophenyl)boronate, triphenylcarbenium tris(pentafluorophenyl)phenyl boronate and triphenylcarbenium tris(pentafluorophenyl)4-trimethylsilyl-2,3,5,6-tetrafluorophenylboronate.The process of making catalysts with this invention produces catalysts having high activity and does not produce by-products which can inhibit catalyst activity. This new synthesis is a clean reaction which does not produce a Lewis base.

Abstract: This invention is for a catalyst system for polymerization of olefins using an ionic metallocene catalyst with aluminum alkyl. The metallocene catalyst is an ion pair formed from a neutral metallocene compound and an ionizing compound. The invention can be used in any method of producing ionic metallocene catalysts. Use of aluminum alkyl with an ionic metallocene catalyst eliminates the need for using methylaluminoxane (MAO). Catalysts produced by the method of this invention have high activity. The invention reduces catalyst poisons which cause low activity, no activity or uncontrolled polymerizations. Polymerization using this catalyst system are reproducible and controllable.

Abstract: This invention is for a catalyst system comprising a neutral metallocene compound, an aluminum alkyl and a Lewis acid. The Lewis acid must be of sufficient acidity to ionize a neutral metallocene compound to form a cationic metallocene catalyst. The ligands of the Lewis acid should not be reactive with the metallocene cation. Any metallocene catalyst compound having two cyclopentadienyl rings, substituted or unsubstituted, attached to a transition metal which can be ionized by a Lewis acid would be useful in this invention. The invention is also for the process of making the catalyst system and the process for using the catalyst system in polymerization of olefins. The metallocene is contacted with the Lewis acid. The aluminum alkyl is contacted with the olefin. The two mixtures are contacted with each other under polymerization conditions.

Abstract: This invention is for a catalyst system for polymerization of olefins using an ionic metallocene catalyst with aluminum alkyl. The metallocene catalyst is an ion pair formed from a neutral metallocene compound and an ionizing compound. The invention can be used in any method of producing ionic metallocene catalyst. Use of aluminum alkyl with an ionic metallocene catalyst eliminates the need for using methylaluminoxane (MAO). Catalysts produced by the method of this invention have high activity. The invention reduces catalyst poisons which cause low activity, no activity or uncontrolled polymerizations. Polymerizations using this catalyst system are reproducible and controllable.

Abstract: This invention is for a metallocene catalyst component useful in preparing isotactic polyolefins, a catalyst system using this component and a process for polymerizing olefins using the catalyst component. The catalyst component consists of a bridged metallocene in which one of the cyclopentadienyl rings is substituted in a different manner from the other ring. One of the cyclopentadienyl ligands contains a bulky group in one and only one distal position and the other cyclopentadienyl ligand has bilateral or pseudobilateral symmetry. There is a steric difference between the two Cp rings.The catalyst component is a stereorigid metallocene described by the formula:R" (CpR.sub.n)(CpR'.sub.m)MeQ.sub.kwherein each Cp is a cyclopentadienyl or substituted cyclopentadienyl ring; each R.sub.n and R'.sub.

Abstract: This invention concerns a making a catalyst system comprising at least one homogeneous catalyst and at least one heterogeneous catalyst, specifically, a metallocene catalyst and a conventional Ziegler-Natta catalyst, respectively. This invention is useful for making a catalyst for the polymerization of any polymer in which separate polymerizations with a homogeneous catalyst and with a heterogeneous catalyst are possible, but preferably, polymerization of olefins, more preferably, .alpha.-olefins, and, most preferably, propylene. This invention provides a catalyst system which facilitates use of a homogeneous catalyst but eliminates the disadvantages of such a system. This invention produces a polymer with molecular weight distribution (MWD) as broad or broader than the MWD of the heterogeneous catalyst alone. Hydrogen can be used to control molecular weight distribution of a polymer produced with this invention.

Abstract: This invention uses a new method of producing ionic metallocene compounds. These compounds are useful as catalysts for polymerization of olefins, primarily propylene. This method uses an ionizing agent which ionizes the neutral metallocene compound. The ionizing ionic compound does not contain an active proton and contains a carbonium, oxonium or sulfonium cation. The anion of the ionizing ionic compound is not coordinated or is only loosely coordinated to the metallocene cation and is chemically unreactive with the metallocene cation. Examples of such compounds are triphenylcarbenium tetrakis(pentafluorophenyl)boronate, triphenylcarbenium tris(pentafluorophenyl)phenyl boronate and triphenylcarbeniumtris(pentafluorophenyl)4-trimethylsilyl-2,3,5,6-tetraflu orophenylboronate.The process of making catalysts with this invention produces catalysts having high activity and does not produce by-products which can inhibit catalyst activity. This new synthesis is a clean reaction which does not produce a Lewis base.

Abstract: This invention concerns a catalyst system comprising at least one homogeneous catalyst and at least one heterogeneous catalyst, specifically, a metallocene catalyst and a conventional Ziegler-Natta catalyst, respectively. This invention is useful in the polymerization of any polymer in which separate polymerizations with a homogeneous catalyst and with a heterogeneous catalyst are possible, but preferably, polymerization of olefins, more preferably, .alpha.-olefins, and, most preferably, propylene. This invention provides a catalyst system which facilitates use of a homogeneous catalyst but eliminates the disadvantages of such a system. This invention produces a polymer with molecular weight distribution (MWD) as broad or broader than the MWD of the heterogeneous catalyst alone. Hydrogen can be used to control molecular weight distribution of a polymer produced with this invention.

Abstract: Syndiospecific catalysts and processes for the syndiotactic propagation of a polymer chain derived from an ethylenically unsaturated monomer which contains 3 or more carbon atoms or is a substituted vinyl compound. The catalysts comprise an unbalanced metallocene cation, characterized by a cationic metallocene ligand having sterically dissimilar ring structures joined to a positively charged coordinating transition metal atom, and a stable noncoordinating counter anion for the metallocene cation. One of said ring structures is a substituted or unsubstituted cyclopentadienyl ring and the other of the ring structures is a substituted cyclopentadienyl group which is sterically different from the first cyclopentadienyl group. A structural bridge between cyclopentadienyl groups imparts stereorigidity to the catalyst. The catalyst is contacted with a C.sub.

Abstract: Syndiospecific catalysts and processes for the syndiotactic propagation of a polymer chain derived from an ethylenically unsaturated monomer which contains 3 or more carbon atoms or is a substituted vinyl compound. The catalysts comprise an unbalanced metallocene cation, characterized by a cationic metallocene ligand having sterically dissimilar ring structures joined to a positively charged coordinating transition metal atom, and a stable noncoordinating counter anion for the metallocene cation. One of said ring structures is a substituted or unsubstituted cyclopentadienyl ring and the other of the ring structures is a substituted cyclopentadienyl group which is sterically different from the first cyclopentadienyl group. A structural bridge between cyclopentadienyl groups imparts stereorigidity to the catalyst. The catalyst is contacted with a C.sub.