Boussie, Thomas R. (Menlo Park, CA, US)
Diamond, Gary M. (San Jose, CA, US)
Goh, Christopher (San Francisco, CA, US)
Hall, Keith A. (San Jose, CA, US)
Lapointe, Anne M. (Sunnyvale, CA, US)
Leclerc, Margarete K. (Santa Clara, CA, US)
Lund, Cheryl (Milpitas, CA, US)
Murphy, Vince (Campbell, CA, US)

Plaque It!

10/720380

06/24/2004

11/25/2003

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SYMYX TECHNOLOGIES, INC. (Santa Clara, CA)

556/1

(IPC1-7): C07F001/00

VENABLE, BAETJER, HOWARD AND CIVILETTI, LLP (P.O. BOX 34385, WASHINGTON, DC, 20043-9998, US)

What is claimed is:

1. A composition comprising: (1) a ligand characterized by the following general formula: 101 wherein R¹ is characterized by the general formula: 102 wherein E is either carbon or nitrogen, Q¹ and Q⁵ are substituents on the R¹ ring at a position ortho to E, with Q¹ and Q⁵ are independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, aryl, substituted aryl and silyl, but provided that Q¹ and Q⁵ are not both methyl; Q″_q represents additional possible substituents on the ring, with q being 1, 2, 3, 4 or 5 and Q″ being selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof, T is a bridging group selected group consisting of —CR²R³— and —SiR²R³— with R² selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof; R³ selected from the group consisting of aryl, substituted aryl, heteroaryl, and substituted heteroaryl; and provided that R² is different from R³; J″ is selected from the group consisting of heteroaryl and substituted heteroaryl; (2) a metal precursor compound characterized by the general formula M(L)_n wherein M is either hafnium or zirconium and each L is independently selected from the group consisting of halide, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, hydroxy, boryl, silyl, amino, amine, hydrido, allyl, diene, seleno, phosphino, phosphine, carboxylates, thio, 1,3-dionates, oxalates, carbonates, nitrates, sulphates, ethers, thioethers and combinations thereof or optionally two or more L groups are joined into a ring structure; n is 1, 2, 3, 4, 5, or 6; and (3) optionally, at least one activator.

2. The composition of claim 1, wherein said ligand is characterized by the formula: 103 wherein each of R⁴, R⁵, R⁶ and R⁷ is independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof; and optionally, any combination of R¹, R², R³, R⁴, R⁵, R⁶ or R⁷ may be joined together in a ring structure.

3. The composition of claim 2, wherein said ligand is characterized by the general formula: 104 such that E is carbon and wherein Q², Q³ and Q⁴ are independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof; optionally two or more of Q², Q³ and Q⁴ are joined together in a ring structure.

4. The composition of claim 2, wherein said ligand is characterized by the general formula: 105 such that T is —CR²R³— and wherein R¹⁰, R¹¹, R¹² and R¹³ are each independently selected from the group consisting of hydrogen, halide, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof; optionally, two or more R¹⁰, R¹¹, R¹² and R¹³ groups may be joined to form a fused ring system having from 3-50 non-hydrogen atoms; and R¹⁴ is selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof.

5. The composition of claim 4, wherein said ligand is characterized by the formula: 106 such that E is carbon and wherein Q², Q³ and Q⁴ are independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof; optionally two or more of Q², Q³ and Q⁴ are joined together in a ring structure.

6. The composition of either of claims 1, 2, 3, 4 or 5 wherein M is hafnium.

7. A metal-ligand complex characterized by the following formula: 107 wherein R¹ is characterized by the general formula: 108 wherein E is either carbon or nitrogen, Q¹ and Q⁵ are substituents on the R¹ ring at a position ortho to E, with Q¹ and Q⁵ being independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, aryl, substituted aryl and silyl, but provided that Q¹ and Q⁵ are not both methyl; Q″_q represents additional possible substituents on the ring, with q being 1, 2, 3, 4 or 5 and Q″ being selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof; T is a bridging group selected group consisting of —CR²R³— and —SiR²R³— with R² selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof; R³ selected from the group consisting of aryl, substituted aryl, heteroaryl, and substituted heteroaryl; and provided that R² is different from R³; J″ is selected from the group consisting of heteroaryl and substituted heteroaryl; each L is independently selected from the group consisting of halide, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, hydroxy, boryl, silyl, amino, amine, hydrido, allyl, diene, seleno, phosphino, phosphine, carboxylates, thio, 1,3-dionates, oxalates, carbonates, nitrates, sulphates, ethers, thioethers and combinations thereof or optionally two or more L groups are joined into a ring structure; n is 1, 2, 3, 4, 5, or 6; and x is 1.

8. The metal complex of claim 7 having the formula: 109 wherein each of R⁴, R⁵, R⁶ and R⁷ is independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof; and optionally, any combination of R¹, R², R³, R⁴, R⁵, R⁶ or R⁷ may be joined together in a ring structure.

9. The metal complex of claim 8 having the formula: 110 such that E is carbon and wherein Q², Q³ and Q⁴ are independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof; optionally two or more of Q², Q³ and Q⁴ are joined together in a ring structure.

10. The metal complex of claim 8, wherein said complex is characterized by the formula: 111 such that T is —CR²R³— and wherein R¹⁰, R¹¹, R¹² and R¹³ are each independently selected from the group consisting of hydrogen, halide, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof; optionally, two or more R¹⁰, R¹¹, R¹² and R¹³ groups may be joined to form a fused ring system having from 3-50 non-hydrogen atoms; and R¹⁴ is selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof.

11. The metal complex of claim 10, wherein said complex is characterized by the general formula: 112 such that E is carbon and wherein Q², Q³ and Q⁴ are independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof; optionally two or more of Q², Q³ and Q⁴ are joined together in a ring structure.

12. A metal complex characterized by the formula: 113 where M is zirconium or hafnium; wherein R¹ is characterized by the general formula: 114 wherein E is either carbon or nitrogen, Q¹ and Q⁵ are substituents on the R¹ ring at a position ortho to E, with Q¹ and Q⁵ are independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, aryl, substituted aryl and silyl, but provided that Q¹ and Q⁵ are not both methyl; Q″_q represents additional possible substituents on the ring, with q being 1, 2, 3, 4 or 5 and Q″ being selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof; T is a bridging group selected group consisting of —CR²R³— and —SiR²R³— with R² selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof; R³ selected from the group consisting of aryl, substituted aryl, heteroaryl, and substituted heteroaryl; and provided that R² is different from R³; J′″ being selected from the group of substituted heteroaryls with 2 atoms bonded to the metal M, at least one of those 2 atoms being a heteroatom, and with one atom of J′″ is bonded to M via a dative bond, the other through a covalent bond; and L¹ and L² are independently selected from the group consisting of halide, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, hydroxy, boryl, silyl, amino, amine, hydrido, allyl, diene, seleno, phosphino, phosphine, carboxylates, thio, 1,3-dionates, oxalates, carbonates, nitrates, sulphates, ethers, thioethers and combinations thereof or optionally the two L groups are joined into a ring structure.

13. The complex of claim 12, wherein said complex is characterized by the formula: 115 wherein each of R⁴, R⁵ and R⁶ is independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof; and optionally, any combination of R¹, R², R³, R⁴, R⁵, or R⁶ may be joined together in a ring structure; and E″ is either carbon or nitrogen and is part of a cyclic aryl, substituted aryl, heteroaryl, or substituted heteroaryl group.

14. The metal complex of claim 13, wherein said complex is characterized by the formula: 116 wherein R¹⁰, R¹¹, R¹² and R¹³ are each independently selected from the group consisting of hydrogen, halide, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof; optionally, two or more R¹⁰, R¹¹, R¹² and R¹³ groups may be joined to form a fused ring system having from 3-50 non-hydrogen atoms.

15. The metal complex of claim 14, wherein said complex is characterized by the formula: 117 wherein Q², Q³ and Q⁴ are independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof; or optionally, two of Q², Q³ and Q⁴ are joined together in a ring structure.

16. The composition or complex of either of claims 1, 2, 3, 4, 5, 7, 8, 9, 10, 11, 12, 13, 14 or 15 wherein R² is hydrogen.

17. The composition or complex of claim 16, wherein each of R⁴, R⁵ and R⁶ is hydrogen.

18. The composition or complex of claim 17, wherein R³ is selected from the group consisting of benzyl, phenyl, naphthyl, 2-biphenyl, 2-dimethylaminophenyl, 2-methoxyphenyl, anthracenyl, mesityl, 2-pyridyl, 3,5-dimethylphenyl, o-tolyl, and phenanthrenyl.

19. The composition or complex of claim 18, wherein Q¹ and Q⁵ are both isopropyl; or both ethyl; or both sec-butyl; or Q¹ is methyl and Q⁵ is isopropyl; or Q¹ is ethyl and Q⁵ is sec-butyl.

20. The composition or complex of claim 19, wherein R¹⁰, R¹¹, R¹², R¹³, are each hydrogen; or one or more of R¹⁰, R¹¹, R¹², R¹³ are methyl, fluoro, trifluoromethyl, methoxy, or dimethylamino; or R¹⁰ and R¹¹ are joined to form a benzene ring and R¹² and R¹³ are each hydrogen.

21. The composition or complex of either of claims 2, 3, 8, 9, 13 or 14, wherein each of R⁴ and R⁵ is hydrogen and R⁶ is either hydrogen or is joined to R¹ to form a fused ring system.

22. The composition or complex of either of claims 1, 2, 3, 4, 5, 7, 8, 9, 10, 11, 12, 13, 14 or 15, wherein R³is selected from the group consisting of benzyl, phenyl, naphthyl, 2-biphenyl, 2-dimethylaminophenyl, 2-methoxyphenyl, anthracenyl, mesityl, 2-pyridyl, 3,5-dimethylphenyl, o-tolyl, and phenanthrenyl.

23. The composition or complex of either of claims 1, 2, 3, 4, 5, 7, 8, 9, 10, 11, 12, 13, 14 or 15 wherein Q¹ and Q⁵ are, independently, selected from the group consisting of —CH₂R¹⁵, —CHR¹⁶R¹⁷ and methyl, provided that not both Q¹ and Q⁵ are methyl, wherein R¹⁵ is selected from the group consisting of alkyl, substituted alkyl, aryl and substituted aryl; R¹⁶ and R¹⁷ are independently selected from the group consisting of alkyl, substituted alkyl, aryl and substituted aryl; and optionally R¹⁶ and R¹⁷ are joined together in a ring structure having from 3-50 non-hydrogen atoms.

24. The composition or complex of claim 23, wherein Q², Q³, and Q⁴ are each hydrogen and Q¹ and Q⁵ are both isopropyl; or both ethyl; or both sec-butyl; or Q¹ is methyl and Q⁵ is isopropyl; or Q¹ is ethyl and Q⁵is sec-butyl.

25. The composition or complex of either of claims 1, 2, 3, 4, 5, 7, 8, 9, 10, 11, 12, 13, 14 or 15, wherein R¹ or the variables Q¹, Q², Q³, Q⁴ and Q⁵ are chosen so that the R¹ moiety is selected from the group consisting of 2,6-(Prⁱ)₂—C₆H₃—; 2-Prⁱ-6-Me-C₆H₃—; 2,6-Et₂-C₆H₃—; and 2-sec-butyl-6-Et-C₆H₃—.

26. The composition or complex of either of claims 2, 3, 8 or 9, wherein R⁷ is aryl, substituted aryl, heteroaryl or substituted heteroaryl.

27. The composition or complex of claim 26, wherein R⁷ is selected from the group consisting of phenyl, napthyl, mesityl, anthracenyl and phenanthrenyl.

28. The composition or complex of either of claims 4, 5, 10 or 11, wherein R¹⁰, R¹¹, R¹², R¹³, are each hydrogen; or one or more of R¹⁰, R¹¹, R ², R¹³ are methyl, fluoro, trifluoromethyl, methoxy, or dimethylamino; or R¹⁰ and R¹¹ are joined to form a benzene ring and R¹² and R¹³ are each hydrogen.

29. The composition or complex of either of claims 2, 3, 4, 5, 8, 9, 10, 11, 13, 14 or 15, wherein two or more of R⁴, R⁵, R⁶ and R⁷ is joined to form a fused ring system having from 3-50 non-hydrogen atoms in addition to the pyridine ring and/or R⁴, R⁵ and R⁶ are each independently selected from the group consisting of alkyl, aryl, halide, alkoxy, aryloxy, amino, and thio.

30. The composition or complex of either of claims 4, 5, 10, 11 or 15, wherein R⁶ and R¹⁰ are joined to form a ring system having from 5-50 non-hydrogen atoms.

31. A process for the stereospecific polymerization of an alpha-olefin, comprising polymerizing at least one alpha-olefin in the presence of a chiral complex characterized by either of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 or 15, optionally in the presence of one or more activators, under polymerization conditions.

32. The process of claim 31, wherein said alpha olefin is propylene.

33. The process of claim 31, further comprising providing a reactor with at least one polymerizable monomer and providing a composition or catalyst to said reactor.

34. Isotactic polypropylene produced by polymerization of propylene with the aid of a catalyst that comprises Hf or Zr in a solution polymerization process, wherein the tacticity index value of the polypropylene does not vary by more than 0.1 when the temperature of the solution process is varied from a temperature below 90° C. to a temperature above 100° C.

35. Isotactic polypropylene produced by polymerization of propylene with the with the aid of a catalyst that comprises Hf or Zr in a solution polymerization process, wherein the melting point of the polypropylene does not vary by more than 10° C. when the temperature of the solution process is varied from a temperature below 90° C. to a temperature above 100° C.

36. Isotactic polypropylene produced by polymerization of propylene with the with the aid of a catalyst that comprises Hf or Zr in a solution polymerization process, wherein the temperature of the solution process is at least 110° C. and the polypropylene has a weight average molecular weight of at least 100,000.

37. The isotactic polypropylene of either of claims 34 or 35, wherein said solution process is operated at a temperature at or above 110° C.

38. The isotactic polypropylene of either of claims 34, 35 or 36, wherein said catalyst is formed from the composition of claim 1.

39. The isotactic polypropylene of either of claims 34, 35 or 36, wherein said catalyst is formed from the composition of claim 2.

40. The isotactic polypropylene of either of claims 34, 35 or 36, wherein said catalyst is formed from the composition of claim 3.

41. The isotactic polypropylene of either of claims 34, 35 or 36, wherein said catalyst is formed from the composition of claim 4.

42. The isotactic polypropylene of either of claims 34, 35 or 36, wherein said catalyst is formed from the composition of claim 5.

43. The isotactic polypropylene of either of claims 34, 35 or 36, wherein said catalyst is formed from the complex of claim 6.

44. The isotactic polypropylene of either of claims 34, 35 or 36, wherein said catalyst is formed from the complex of claim 7.

45. The isotactic polypropylene of either of claims 34, 35 or 36, wherein said catalyst is formed from the complex of claim 8.

46. The isotactic polypropylene of either of claims 34, 35 or 36, wherein said catalyst is formed from the complex of claim 9.

47. The isotactic polypropylene of either of claims 34, 35 or 36, wherein said catalyst is formed from the complex of claim 10.

48. The isotactic polypropylene of either of claims 34, 35 or 36, wherein said catalyst is formed from the complex of claim 11.

49. The isotactic polypropylene of either of claims 34, 35 or 36, wherein said catalyst is formed from the complex of claim 12.

50. The isotactic polypropylene of either of claims 34, 35 or 36, wherein said catalyst is formed from the complex of claim 13.

51. The isotactic polypropylene of either of claims 34, 35 or 36, wherein said catalyst is formed from the complex of claim 14.

52. The isotactic polypropylene of either of claims 34, 35 or 36, wherein said catalyst is formed from the complex of claim 15.

53. A process for polymerizing propylene to crystalline polypropylene in a solution process, comprising contacting propylene monomer with a catalyst comprising a metal-ligand complex combined with an activator, combination of activators or activating technique, wherein at least one of said activators is a group 13 reagent and said metal-ligand complex is characterized by the formula: 118 where M is zirconium or hafnium; L¹, L² and L³ are independently selected from the group consisting of halide, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, hydroxy, boryl, silyl, amino, amine, hydrido, allyl, diene, seleno, phosphino, phosphine, carboxylates, thio, 1,3-dionates, oxalates, carbonates, nitrates, sulphates, ethers, thioethers and combinations thereof or optionally two or more L groups are joined into a ring structure; R¹ is selected from the group consisting of 2,6-(Prⁱ)₂—C₆H₃—; 2-Prⁱ-6-Me-C₆H₃—; 2,6-Et₂-C₆H₃—; or 2-sec-butyl-6-Et-C₆H₃—; T is a bridging group selected group consisting of —CR²R³— and —SiR²R³—; R³is selected from the group consisting of aryl and substituted aryl; R², R⁴, R⁵ and R⁶ are hydrogen; either R¹⁰, R¹¹, R¹², R¹³, are each hydrogen; or one or more of R¹⁰, R¹¹, R¹², R¹³ are methyl, fluoro, trifluoromethyl, methoxy, or dimethylamino; or R¹⁰ and R¹¹ are joined to form a benzene ring and R¹² and R¹³ are each hydrogen; and R¹⁴ is either hydrogen or methyl.

54. A process for polymerizing propylene to crystalline polypropylene in a solution process, comprising contacting propylene monomer with a catalyst comprising a metal-ligand complex combined with an activator, combination of activators or activating technique, wherein at least one of said activators is a group 13 reagent and said metal-ligand complex is characterized by the formula: 119 where M is zirconium or hafnium; L¹ and L² are independently selected from the group consisting of halide, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, hydroxy, boryl, silyl, amino, amine, hydrido, allyl, diene, seleno, phosphino, phosphine, carboxylates, thio, 1,3-dionates, oxalates, carbonates, nitrates, sulphates, ethers, thioethers and combinations thereof or optionally the two L groups are joined into a ring structure; R¹ is selected from the group consisting of 2,6-(Prⁱ)₂—C₆H₃—; 2-Prⁱ-6-Me-C₆H₃—; 2,6-Et₂-C₆H₃—; or 2-sec-butyl-6-Et-C₆H₃—; T is a bridging group selected group consisting of —CR²R³— and —SiR²R³—; R³ is selected from the group consisting of aryl and substituted aryl; R², R⁴, R⁵ and R⁶ are hydrogen; and either R¹⁰, R¹¹, R¹², R¹³, are each hydrogen; or one or more of R¹⁰, R¹¹, R¹², R¹³ are methyl, fluoro, trifluoromethyl, methoxy, or dimethylamino; or R¹⁰ and R¹¹ are joined to form a benzene ring and R¹² and R¹³ are each hydrogen.

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/246,781, filed Nov. 7, 2000 and the benefit of U.S. Provisional Patent Application No.60/301,666, filed Jun. 28, 2001, both of which are incorporated herein by reference for all purposes.

FIELD OF THE INVENTION

[0002] The present invention relates to ligands, complexes, compositions and/or catalysts that provide enhanced olefin polymerization capabilities based on a substituted pyridyl amine structure and hafnium. The invention also relates to methods of polymerization. The invention also relates to isotactic polypropylene and methods of preparing isotactic polypropylene.

BACKGROUND OF THE INVENTION

[0003] Ancillary (or spectator) ligand-metal coordination complexes (e.g., organometallic complexes) and compositions are useful as catalysts, additives, stoichiometric reagents, monomers, solid state precursors, therapeutic reagents and drugs. Ancillary ligand-metal coordination complexes of this type can be prepared by combining an ancillary ligand with a suitable metal compound or metal precursor in a suitable solvent at a suitable temperature. The ancillary ligand contains functional groups that bind to the metal center(s), remain associated with the metal center(s), and therefore provide an opportunity to modify the steric, electronic and chemical properties of the active metal center(s) of the complex.

[0004] Certain known ancillary ligand-metal complexes and compositions are catalysts for reactions such as oxidation, reduction hydrogenation, hydrosilylation, hydrocyanation, hydroformylation, polymerization, carbonylation, isomerization, metathesis, carbon-hydrogen activation, carbon-halogen activation, cross-coupling, Friedel-Crafts acylation and alkylation, hydration, dimerization, trimerization, oligomerization, Diels-Alder reactions and other transformations.

[0005] One example of the use of these types of ancillary ligand-metal complexes and compositions is in the field of polymerization catalysis. In connection with single site catalysis, the ancillary ligand typically offers opportunities to modify the electronic and/or steric environment surrounding an active metal center. This allows the ancillary ligand to assist in the creation of possibly different polymers. Group 4 metallocene based single site catalysts are generally known for polymerization reactions. See, generally, “Chemistry of Cationic Dicyclopentadienyl Group 4 Metal-Alkyl Complexes”, Jordan, Adv. Organometallic Chem., 1991, Vol. 32, pp. 325-153 and “Stereospecific Olefin Polymerization with Chiral Metallocene Catalysts”, Brintzinger, et al., Angew. Chem. Int. Ed. Engl., 1995, Vol. 34, pp. 1143-1170, and the references therein, all of which is incorporated herein by reference.

[0006] However, those of skill in the art of single site catalysis appreciate that there may be substantial differences in performance between different metal centers. For example, U.S. Pat. No. 5,064,802 discloses a broad category of mono-cyclopentadienyl ligand catalysts with a broad disclosure of useful metals, and U.S. Pat. No. 5,631,391 more specifically discloses that titanium metal centers offer performance advantages with respect to the same or similar ligands. Additionally, Coates, et al., Angew. Chem. Int. Ed., 2000, vol. 39, pp. 3626-3629 describes the unpredictable nature of olefin polymerization catalyst structure-activity relationships. Thus, references that describe, for example, groups 3-13 and the lanthanides, for example in U.S. Pat. No. 6,103,657, are not of adequate performance indicators of all that is within the scope of what is allegedly described. Moreover, as those of skill in the art appreciate, differences in ligand substituents typically polymerize different monomers at different performances under different polymerization conditions, and discovering those specifics remains a challenge.

[0007] One application for metallocene catalysts is producing isotactic polypropylene. An extensive body of scientific literature examines catalyst structures, mechanism and polymers prepared by metallocene catalysts. See, e.g., Resconi et al., “Selectivity in Propene Polymerization with Metallocene Catalysts,” Chem. Rev. 2000, 100, 1253-1345 and G. W. Coates, “Precise Control of Polyolefin Stereochemistry Using Single-Site Metal Catalysts,” Chem. Rev. 2000, 100, 1223-1252 and the references sited in these review articles. See also, U.S. Pat. No. 5,026,798 that reports a mono-cyclopentadienyl metallocene for the production of isotactic polypropylene. Isotactic polypropylene has historically been produced with heterogeneous catalysts that may be described as a catalyst on a solid support (e.g., titanium tetrachloride and aluminum alkyls on magnesium dichloride). This process typically uses hydrogen to control the molecular weight and electron-donor compounds to control the isotacticity. See also EP 0622380, U.S. Pat. No. 4,297,465, U.S. Pat. No. 5,385,993 and U.S. Pat. No. 6,239,236.

[0008] Given the extensive research activities with respect to metallocene catalysts, there is continued interested in the next generation of non-cyclopentadienyl ligands for olefin polymerization catalysts providing attractive alternatives. See, e.g., “The Search for New-Generation Olefin Polymerization Catalysts: Life beyond Metallocenes”, Gibson, et al., Angew. Chem. Int. Ed., 1999, vol. 38, pp. 428-447; Organometallics 1999, 18, pp. 3649-3670. Recently, such systems have been discovered, see, e.g., U.S. Pat. No. 6,103,657 and U.S. Pat. No. 5,637,660. For isotactic polypropylene, bis-amide catalysts have been disclosed in U.S. Pat. No. 5,318,935 and amidinate catalysts have been disclosed in WO 99/05186. See also U.S. Pat. No. 6,214,939.

[0009] There remains a need for the discovery and optimization of non-cyclopentadienyl based catalysts for olefin polymerization, and in particular for certain polymers, such as isotactic polypropylene and ethylene-□-olefin copolymers. For a solution polymerization methodology, this need may be acute in view of the lack of versatile catalysts for the preparation of isotactic polypropylene at commercially acceptable temperatures. Indeed, new polymer properties are disclosed herein for isotactic polypropylene, ethylene-styrene copolymers and ethylene-isobutylene copolymers.

SUMMARY OF THE INVENTION

[0010] This invention discloses surprising enhanced catalytic performances for olefin polymerization when certain combinations of ligands and hafnium metal precursors are employed. This invention also discloses surprising enhanced catalytic performances for olefin polymerization when certain metal complexes are employed in a catalyst, including 2,1 metal complexes and 3,2 metal complexes. In addition, some of the ligands employed herein are themselves novel.

[0011] In some embodiments, this invention discloses both the preferred use of a hafnium metal center and certain pyridyl-amine ligands. Such combinations lead to new ligand-metal complexes, catalyst compositions and processes for the polymerization of olefins, diolefins, or other polymerizable monomers. In particular, copolymers of ethylene and another monomer may be prepared with controlled incorporation of the other monomer (e.g., 1-octene, isobutylene, or styrene) into the polymer backbone. In some embodiments, this control is adjusted so that the olefin incorporation is considered to be high with respect to polymers currently known or commercially available. Also in particular, propylene may be polymerized into very high molecular weight isotactic polypropylene. Thus, polymers having novel, improved or desired properties may be prepared using the catalysts and processes of this invention.

[0012] More specifically, in some embodiments, the use of a hafnium metal has been found to be preferred as compared to a zirconium metal for pyridyl-amine ligand catalysts. A broad range of ancillary ligand substituents may accommodate the enhanced catalytic performance. The catalysts in some embodiments are compositions comprising the ligand and metal precursor, and optionally may additionally include an activator, combination of activators or activator package.

[0013] The invention disclosed herein additionally includes catalysts comprising ancillary ligand-hafnium complexes, ancillary ligand-zirconium complexes and optionally activators, which catalyze polymerization and copolymerization reactions, particularly with monomers that are olefins, diolefins or other unsaturated compounds. Zirconium complexes, hafnium complexes, compositions or compounds using the disclosed ligands are within the scope of this invention. The metal-ligand complexes may be in a neutral or charged state. The ligand to metal ratio may also vary, the exact ratio being dependent on the nature of the ligand and metal-ligand complex. The metal-ligand complex or complexes may take different forms, for example, they may be monomeric, dimeric or higher orders thereof.

[0014] For example, suitable ligands useful in this invention may be characterized by the following general formula: 1

[0015] wherein R ¹ is a ring having from 4-8 atoms in the ring generally selected from the group consisting of substituted cycloalkyl, substituted heterocycloalkyl, substituted aryl and substituted heteroaryl, such that R ¹ may be characterized by the general formula: 2

[0016] where Q ¹ and Q ⁵ are substituents on the ring ortho to atom E, with E being selected from the group consisting of carbon and nitrogen and with at least one of Q ¹ or Q ⁵ being bulky (defined as having at least 2 atoms). Q″ _q represents additional possible substituents on the ring, with q being 1, 2, 3, 4 or 5 and Q″ being selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof. T is a bridging group selected group consisting of —CR ² R ³ — and —SiR ² R ³ — with R ² and R ³ being independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof. J″ is generally selected from the group consisting of heteroaryl and substituted heteroaryl, with particular embodiments for particular reactions being described herein.

[0017] Also for example, in some embodiments, the ligands of the invention may be combined with a metal precursor compound that may be characterized by the general formula Hf(L) _n where L is independently selected from the group consisting of halide (F, Cl, Br, I), alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, hydroxy, boryl, silyl, amino, amine, hydrido, allyl, diene, seleno, phosphino, phosphine, carboxylates, thio, 1,3-dionates, dionates, oxalates, carbonates, nitrates, sulphates, ethers, thioethers and combinations thereof, and optionally two L groups may be linked together in a ring structure. n is 1, 2, 3, 4, 5, or 6.

[0018] In another aspect of the invention, a polymerization process is disclosed for monomers. The polymerization process involves subjecting one or more monomers to the catalyst compositions or complexes of this invention under polymerization conditions. The polymerization process can be continuous, batch or semi-batch and can be homogeneous, supported homogeneous or heterogeneous. Another aspect of this invention relates to arrays of ligands, metal precursors and/or metal-ligand-complexes. These arrays are useful for the high speed or combinatorial materials science discovery or optimization of the catalyst compositions or complexes disclosed herein.

[0019] These catalysts comprising ancillary ligand-metal complexes or compositions comprising metal precursors and ligands and, optionally, activators are particularly effective at polymerizing α-olefins (such as propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, and styrene), copolymerizing ethylene with α-olefins (such as propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, and styrene), and copolymerizing ethylene with 1,1-disubstituted olefins (such as isobutylene). These compositions might also polymerize monomers that have polar functionalities in homopolymerizations or copolymerizations. Also, diolefins in combination with ethylene and/or α-olefins or 1,1-disubstituted olefins may be copolymerized. The new catalyst compositions can be prepared by combining a hafnium precursor with a suitable ligand and, optionally, an activator or combination of activators. This invention discloses a novel class of catalysts and improved method for preparing isotactic polypropylene. The catalyst is useful for polymerizing a wide variety of polymerizable monomers.

[0020] In particular, a method of producing isotactic polypropylene is in a solution process is disclosed and is surprisingly tunable. In one aspect, the temperature of the solution polymerization process can be increased, which generally decreases the molecular weight, but surprisingly, while maintaining a relatively high isotacticity of the polypropylene and while maintaining a relatively high melting point for the polypropylene. In another aspect, the temperature of the solution process can be increased without the molecular weight of the polypropylene dropping so low to levels that are unacceptable for certain commercial applications.

[0021] In certain aspects, it has been discovered that certain ligands complex to the metal resulting in novel complexes. In one aspect, the 3,2 metal-ligand complexes of this invention may be generally characterized by the following formula: 3

[0022] where M is zirconium or hafnium;

[0023] R ¹ and T are defined above;

[0024] J′″ being selected from the group of substituted heteroaryls with 2 atoms bonded to the metal M, at least one of those atoms being a heteroatom, and with one atom of J′″ is bonded to M via a dative bond, the other through a covalent bond; and L ¹ and L ² are independently selected from the group consisting of halide, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, hydroxy, boryl, silyl, amino, amine, hydrido, allyl, diene, seleno, phosphino, phosphine, carboxylates, thio, 1,3-dionates, oxalates, carbonates, nitrates, sulphates, ethers, thioethers and combinations thereof; and optionally the L groups may be linked together in a ring structure.

[0025] In another aspect, a solution process to prepare isotactic polypropylene is provided comprising adding a catalyst and propylene monomer to a reactor and subjecting the contents to polymerization conditions, where the temperature of the solution process is at least 110° C. and polypropylene is produced that has a weight average molecular weight of at least 100,000, without a drop off in tacticity value (i.e., crystallinity index).

[0026] Thus, it is a feature of this invention to use hafnium-ligand complexes as polymerization catalysts with enhanced performance.

[0027] It is an object of this invention to polymerize olefins and unsaturated monomers with hafnium-ligand complexes. It is also an object of this invention to polymerize olefins and unsaturated monomers with compositions including substituted pyridyl amine ligands and hafnium metal precursors.

[0028] It is still a further object of this invention to polymerize olefins and unsaturated monomers with the hafnium-ligand complexes that additionally comprise an activator or combination of activators.

[0029] It is also an object of this invention to use non-metallocene group 4 complexes as polymerization catalysts for the production of isotactic polypropylene.

[0030] It is a further object of this invention to polymerize olefins and unsaturated monomers with a catalyst comprised of metal complexes comprising 3,2 ligands.

[0031] Further objects and aspects of this invention will be evident to those of skill in the art upon review of this specification.

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] FIG. 1 depicts Table 1, which lists compounds that may be useful for synthesizing the ligands in this invention.

[0033] FIG. 2 depicts Table 2, which lists other compounds that may be useful for synthesizing the ligands in this invention.

[0034] FIG. 3 depicts Table 3, which shows the ligands and results from examples, below, using the Hf metal precursor.

[0035] FIG. 4 depicts Table 4, which shows the ligands and results from comparative examples, below, using the Zr metal precursor.

DETAILED DESCRIPTION OF THE INVENTION

[0036] The inventions disclosed herein include metal complexes and compositions, which are useful as catalysts for polymerization reactions.

[0037] As used herein, the phrase “characterized by the formula” is not intended to be limiting and is used in the same way that “comprising” is commonly used. The term “independently selected” is used herein to indicate that the R groups, e.g., R ¹ , R ² , R ³ , R ⁴ , and R ⁵ can be identical or different (e.g. R ¹ , R ² , R ³ , R ⁴ , and R ⁵ may all be substituted alkyls or R ¹ and R ² may be a substituted alkyl and R ³ may be an aryl, etc.). Use of the singular includes use of the plural and vice versa (e.g., a hexane solvent, includes hexanes). A named R group will generally have the structure that is recognized in the art as corresponding to R groups having that name. The terms “compound” and “complex” are generally used interchangeably in this specification, but those of skill in the art may recognize certain compounds as complexes and vice versa For the purposes of illustration, representative certain groups are defined herein. These definitions are intended to supplement and illustrate, not preclude, the definitions known to those of skill in the art.

[0038] “Hydrocarbyl” refers to univalent hydrocarbyl radicals containing 1 to about 30 carbon atoms, preferably 1 to about 24 carbon atoms, most preferably 1 to about 12 carbon atoms, including branched or unbranched, saturated or unsaturated species, such as alkyl groups, alkenyl groups, aryl groups, and the like. “Substituted hydrocarbyl” refers to hydrocarbyl substituted with one or more substituent groups, and the terms “heteroatom-containing hydrocarbyl” and “heterohydrocarbyl” refer to hydrocarbyl in which at least one carbon atom is replaced with a heteroatom.

[0039] The term “alkyl” is used herein to refer to a branched or unbranched, saturated or unsaturated acyclic hydrocarbon radical. Suitable alkyl radicals include, for example, methyl, ethyl, n-propyl, i-propyl, 2-propenyl (or allyl), vinyl, n-butyl, t-butyl, i-butyl (or 2-methylpropyl), etc. In particular embodiments, alkyls have between 1 and 200 carbon atoms, between 1 and 50 carbon atoms or between 1 and 20 carbon atoms.

[0040] “Substituted alkyl” refers to an alkyl as just described in which one or more hydrogen atom bound to any carbon of the alkyl is replaced by another group such as a halogen, aryl, substituted aryl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, halogen, alkylhalos (e.g., CF ₃ ), hydroxy, amino, phosphido, alkoxy, amino, thio, nitro, and combinations thereof. Suitable substituted alkyls include, for example, benzyl, trifluoromethyl and the like.

[0041] The term “heteroalkyl” refers to an alkyl as described above in which one or more hydrogen atoms to any carbon of the alkyl is replaced by a heteroatom selected from the group consisting of N, O, P, B, S, Si, Sb, Al, Sn, As, Se and Ge. This same list of heteroatoms is useful throughout this specification. The bond between the carbon atom and the heteroatom may be saturated or unsaturated. Thus, an alkyl substituted with a heterocycloalkyl, substituted heterocycloalkyl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, boryl, phosphino, amino, silyl, thio, or seleno is within the scope of the term heteroalkyl. Suitable heteroalkyls include cyano, benzoyl, 2-pyridyl, 2-furyl and the like.

[0042] The term “cycloalkyl” is used herein to refer to a saturated or unsaturated cyclic non-aromatic hydrocarbon radical having a single ring or multiple condensed rings. Suitable cycloalkyl radicals include, for example, cyclopentyl, cyclohexyl, cyclooctenyl, bicyclooctyl, etc. In particular embodiments, cycloalkyls have between 3 and 200 carbon atoms, between 3 and 50 carbon atoms or between 3 and 20 carbon atoms.

[0043] “Substituted cycloalkyl” refers to cycloalkyl as just described including in which one or more hydrogen atom to any carbon of the cycloalkyl is replaced by another group such as a halogen, alkyl, substituted alkyl, aryl, substituted aryl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, boryl, phosphino, amino, silyl, thio, seleno and combinations thereof. Suitable substituted cycloalkyl radicals include, for example, 4-dimethylaminocyclohexyl, 4,5-dibromocyclohept-4-enyl, and the like.

[0044] The term “heterocycloalkyl” is used herein to refer to a cycloalkyl radical as described, but in which one or more or all carbon atoms of the saturated or unsaturated cyclic radical are replaced by a heteroatom such as nitrogen, phosphorous, oxygen, sulfur, silicon, germanium, selenium, or boron. Suitable heterocycloalkyls include, for example, piperazinyl, morpholinyl, tetrahydropyranyl, tetrahydrofuranyl, piperidinyl, pyrrolidinyl, oxazolinyl and the like.

[0045] “Substituted heterocycloalkyl” refers to heterocycloalkyl as just described including in which one or more hydrogen atom to any atom of the heterocycloalkyl is replaced by another group such as a halogen, alkyl, substituted alkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, boryl, phosphino, amino, silyl, thio, seleno and combinations thereof. Suitable substituted heterocycloalkyl radicals include, for example, N-methylpiperazinyl, 3-dimethylaminomorpholinyl and the like.

[0046] The term “aryl” is used herein to refer to an aromatic substituent, which may be a single aromatic ring or multiple aromatic rings that are fused together, linked covalently, or linked to a common group such as a methylene or ethylene moiety. The aromatic ring(s) may include phenyl, naphthyl, anthracenyl, and biphenyl, among others. In particular embodiments, aryls have between 1 and 200 carbon atoms, between 1 and 50 carbon atoms or between 1 and 20 carbon atoms. In some embodiments herein, multi-ring moieties are substituents and in such an embodiment the multi-ring moiety can be attached at an appropriate atom. For example, “naphthal” can be 1-naphthyl or 2-naphthyl; “anthracenyl” can be 1-anthracenyl, 2-anthracenyl or 9-anthracenyl; and “phenanthrenyl” can be 1-phenanthrenyl, 2-phenanthrenyl, 3-phenanthrenyl, 4-phenanthrenyl or 9-phenanthrenyl.

[0047] “Substituted aryl” refers to aryl as just described in which one or more hydrogen atom bound to any carbon is replaced by one or more functional groups such as alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, halogen, alkylhalos (e.g., CF ₃ ), hydroxy, amino, phosphido, alkoxy, amino, thio, nitro, and both saturated and unsaturated cyclic hydrocarbons which are fused to the aromatic ring(s), linked covalently or linked to a common group such as a methylene or ethylene moiety. The common linking group may also be a carbonyl as in benzophenone or oxygen as in diphenylether or nitrogen in diphenylamine.

[0048] The term “heteroaryl” as used herein refers to aromatic or unsaturated rings in which one or more carbon atoms of the aromatic ring(s) are replaced by a heteroatom(s) such as nitrogen, oxygen, boron, selenium, phosphorus, silicon or sulfur. Heteroaryl refers to structures that may be a single aromatic ring, multiple aromatic ring(s), or one or more aromatic rings coupled to one or more non-aromatic ring(s). In structures having multiple rings, the rings can be fused together, linked covalently, or linked to a common group such as a methylene or ethylene moiety. The common linking group may also be a carbonyl as in phenyl pyridyl ketone. As used herein, rings such as thiophene, pyridine, isoxazole, pyrazole, pyrrole, furan, etc. or benzo-fused analogues of these rings are defined by the term “heteroaryl.”

[0049] “Substituted heteroaryl” refers to heteroaryl as just described including in which one or more hydrogen atoms bound to any atom of the heteroaryl moiety is replaced by another group such as a halogen, alkyl, substituted alkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, boryl, phosphino, amino, silyl, thio, seleno and combinations thereof. Suitable substituted heteroaryl radicals include, for example, 4-N,N-dimethylaminopyridine.

[0050] The term “alkoxy” is used herein to refer to the —OZ ¹ radical, where Z ¹ is selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocylcoalkyl, substituted beterocycloalkyl, silyl groups and combinations thereof as described herein. Suitable alkoxy radicals include, for example, methoxy, ethoxy, benzyloxy, t-butoxy, etc. A related term is “aryloxy” where Z ¹ is selected from the group consisting of aryl, substituted aryl, heteroaryl, substituted heteroaryl, and combinations thereof. Examples of suitable aryloxy radicals include phenoxy, substituted phenoxy, 2-pyridinoxy, 8-quinalinoxy and the like.

[0051] As used herein the term “silyl” refers to the —SiZ ¹ Z ² Z ³ radical, where each of Z ¹ , Z ² , and Z ³ is independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, heterocycloalkyl, heterocyclic, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, amino, silyl and combinations thereof.

[0052] As used herein the term “boryl” refers to the —BZ ¹ Z ² group, where each of Z ¹ and Z ² is independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, heterocycloalkyl, heterocyclic, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, amino, silyl and combinations thereof.

[0053] As used herein, the term “phosphino” refers to the group —PZ ¹ Z ² , where each of Z ¹ and Z ² is independently selected from the group consisting of hydrogen, substituted or unsubstituted alkyl, cycloalkyl, heterocycloalkyl, heterocyclic, aryl, substituted aryl, heteroaryl, silyl, alkoxy, aryloxy, amino and combinations thereof.

[0054] As used herein, the term “phosphine” refers to the group :PZ ¹ Z ² Z ³ , where each of Z ¹ , Z ³ and Z ² is independently selected from the group consisting of hydrogen, substituted or unsubstituted alkyl, cycloalkyl, heterocycloalkyl, heterocyclic, aryl, substituted aryl, heteroaryl, silyl, alkoxy, aryloxy, amino and combinations thereof.

[0055] The term “amino” is used herein to refer to the group —NZ ¹ Z ² , where each of Z ¹ and Z ² is independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl and combinations thereof.

[0056] The term “amine” is used herein to refer to the group :NZ ¹ Z ² Z ³ , where each of Z ¹ , Z ² and Z ² is independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl (including pyridines), substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl and combinations thereof.

[0057] The term “thio” is used herein to refer to the group —SZ ¹ , where Z ¹ is selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl and combinations thereof.

[0058] The term “seleno” is used herein to refer to the group —SeZ ¹ , where Z ¹ is selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl and combinations thereof.

[0059] The term “saturated” refers to lack of double and triple bonds between atoms of a radical group such as ethyl, cyclohexyl, pyrrolidinyl, and the like.

[0060] The term “unsaturated” refers to the presence one or more double and triple bonds between atoms of a radical group such as vinyl, acetylide, oxazolinyl, cyclohexenyl, acetyl and the like.

[0061] Other abbreviations used herein include: “Pr ⁱ ” to refer to isopropyl; “Bu ^t ” to refer to tertbutyl; “Me” to refer to methyl; and “Et” to refer to ethyl.

[0062] Ligands

[0063] Suitable ligands useful in this invention can be characterized broadly as monoanionic ligands having an amine and a heteroaryl or substituted heteroaryl group. The ligand substituents for particular monomers are detailed near the end of this section. The ligands of the invention may be characterized by the following general formula: 4

[0064] wherein R ¹ is generally selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl and combinations thereof In many embodiments, R ¹ is a ring having from 4-8 atoms in the ring generally selected from the group consisting of substituted cycloalkyl, substituted heterocycloalkyl, substituted aryl and substituted heteroaryl, with R ¹ being characterized by the general formula: 5

[0065] where Q ¹ and Q ⁵ are substituents on the ring ortho to atom E, with E being selected from the group consisting of carbon and nitrogen and with at least one of Q ¹ or Q ⁵ being bulky (defined as having at least 2 non-hydrogen atoms). Q ¹ and Q ⁵ are independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, aryl, substituted aryl and silyl, but provided that Q ¹ and Q ⁵ are not both methyl. Q″ _q represents additional possible substituents on the ring, with q being 1, 2, 3, 4 or 5 and Q″ being selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof. T is a bridging group selected group consisting of —CR ² R ³ — and —SiR ² R ³ — with R ² and R ³ being independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof. J″ is generally selected from the group consisting of heteroaryl and substituted heteroaryl, with particular embodiments for particular reactions being described herein.

[0066] In a more specific embodiment, suitable ligands useful in this invention may be characterized by the following general formula: 6

[0067] wherein R ¹ and T are as defined above and each of R ⁴ , R ⁵ , R ⁶ and R ⁷ is independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof. Optionally, any combination of R ¹ , R ² , R ³ and R ⁴ may be joined together in a ring structure.

[0068] In certain more specific embodiments, the ligands in this invention may be characterized by the following general formula: 7

[0069] wherein Q ¹ , Q ⁵ , R ² , R ³ , R ⁴ , R ⁵ , R ⁶ and R ⁷ are as defined above. Q ² , Q ³ and Q ⁴ are independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof.

[0070] In other more specific embodiments, the ligands of this invention and suitable herein may be characterized by the following general formula: 8

[0071] wherein R ¹ , R ² , R ³ , R ⁴ , R ⁵ , and R ⁶ are as defined above. In this embodiment the R ⁷ substituent has been replaced with an aryl or substituted aryl group, with R ¹⁰ , R ¹¹ , R ¹² and R ¹³ being independently selected from the group consisting of hydrogen, halide, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof; optionally, two or more R ¹⁰ , R ¹¹ , R ¹² and R ¹³ groups may be joined to form a fused ring system having from 3-50 non-hydrogen atoms. R ¹⁴ is selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof.

[0072] In still more specific embodiments, the ligands in this invention may be characterized by the general formula: 9

[0073] wherein R ² —R ⁶ , R ¹⁰ —R ¹⁴ and Q ¹ -Q ⁵ are all as define above.

[0074] In certain embodiments, R ² is preferably hydrogen. Also preferably, each of R ⁴ and R ⁵ is hydrogen and R ⁶ is either hydrogen or is joined to R ⁷ to form a fused ring system. Also preferred is where R ³ is selected from the group consisting of benzyl, phenyl, naphthyl, 2-biphenyl, t-butyl, 2-dimethylaminophenyl (2-(NMe ₂ )-C ₆ H ₄ —),2-methoxyphenyl (2-MeO—C ₆ H ₄ —), anthracenyl, mesityl, 2-pyridyl, 3,5-dimethylphenyl, o-tolyl and phenanthrenyl. Also preferred is where R ¹ is selected from the group consisting of mesityl, 4-isopropylphenyl (4-Pr ⁱ —C ₆ H ₄ —), napthyl, 3,5-(CF ₃ ) ₂ —C ₆ H ₃ —, 2-Me-napthyl, 2,6-(Pr ⁱ ) ₂ —C ₆ H ₃ —, 2-biphenyl, 2-Me-4-MeO-C ₆ H ₃ —, 2-Bu ^t -C ₆ H ₄ —, 2,5-(Bu ^t ) ₂ -C ₆ H ₃ —, 2-Pr ⁱ -6-Me-C ₆ H ₃ —, 2-Bu ^t -6-Me-C ₆ H ₃ —, 2,6-Et ₂ -C ₆ H ₃ — or 2-sec-butyl-6-Et-C ₆ H ₄ —, preferred is where R ⁷ is selected from the group consisting of hydrogen, phenyl, napthyl, methyl, anthracenyl, phenanthrenyl, mesityl, 3,5-(CF ₃ ) ₂ —C ₆ H ₃ —, 2-CF ₃ —C ₆ H ₄ , 4-CF ₃ —C ₆ H ₄ —, 3,5-F ₂ —C ₆ H ₃ —, 4-F—C ₆ H ₄ —, 2,4-F ₂ -C ₆ H ₃ —, 4-(NMe ₂ )-C ₆ H ₄ —, 3-MeO—C ₆ H ₄ —, 4-MeO—C ₆ H ₄ —, 3,5-Me ₂ -C ₆ H ₃ —, o-tolyl, 2,6-F ₂ —C ₆ H ₃ — or where R ⁷ is joined together with R ⁶ to form a fused ring system, e.g., quinoline. In some preferred embodiment, R ⁴ , R ⁵ and R ⁶ are each independently selected from the group consisting of alkyl, aryl, halide, alkoxy, aryloxy, amino, and thio.

[0075] In some embodiments, Q ¹ and Q ⁵ are, independently, selected from the group consisting of —CH ₂ R ¹⁵ , —CHR ¹⁶ R ¹⁷ and methyl, provided that not both Q ¹ and Q ⁵ are methyl. In these embodiments, R ¹⁵ is selected from the group consisting of alkyl, substituted alkyl, aryl and substituted aryl. R ¹⁶ and R ¹⁷ are independently selected from the group consisting of alkyl, substituted alkyl, aryl and substituted aryl; and optionally R ¹⁶ and R ¹⁷ are joined together in a ring structure having from 3-50 non-hydrogen atoms.

[0076] Also optionally, two or more R ⁴ , R ⁵ , R ⁶ , R ⁷ groups may be joined to form a fused ring system having from 3-50 non-hydrogen atoms in addition to the pyridine ring, e.g. generating a quinoline group. In these embodiments, R ³ is selected from the group consisting of aryl, substituted aryl, heteroaryl, substituted heteroaryl, primary and secondary alkyl groups, and —PY ₂ where Y is selected from the group consisting of aryl, substituted aryl, heteroaryl, and substituted heteroaryl.

[0077] Optionally within above formulas IV and V, R ⁶ and R ¹⁰ may be joined to form a ring system having from 5-50 non-hydrogen atoms. For example, if R ⁶ and R ¹⁰ together form a methylene, the ring will have 5 atoms in the backbone of the ring, which may or may not be substituted with other atoms. Also for example, if R ⁶ and R ¹⁰ together form an ethylene, the ring will have 6 atoms in the backbone of the ring, which may or may not be substituted with other atoms. Substituents from the ring can be selected from the group consisting of halide, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof.

[0078] Specific examples of ligands within the scope of these formulas include: 10 11 12

[0079] In certain embodiments, the ligands are novel compounds and those of skill in the art will be able to identify such compounds from the above. One example of the novel ligand compounds, includes those compounds generally characterized by formula (III), above where R ² is selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, aryl, and substituted aryl; and R ³ is a phosphino characterized by the formula —PZ ¹ Z ² , where each of Z ¹ and Z ² is independently selected from the group consisting of hydrogen, substituted or unsubstituted alkyl, cycloalkyl, heterocycloalkyl, heterocyclic; aryl, substituted aryl, heteroaryl, silyl, alkoxy, aryloxy, amino and combinations thereof. Particularly preferred embodiments of these compounds include those where Z ¹ and Z ² are each independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, heterocycloalkyl, aryl, and substituted aryl; and more specifically phenyl; where Q ¹ , Q ³ , and Q ⁵ are each selected from the group consisting of alkyl and substituted alkyl and each of Q ² and Q ⁴ is hydrogen; and where R ⁴ , R ⁵ , R ⁶ and R ⁷ are each hydrogen.

[0080] Certain embodiments of these ligands are preferred for the polymerization of certain monomers. In any of the above formulas I, II, III, IV or V, for the production of isotactic polypropylene it is an aspect of this invention that R ² cannot be the same group as R ³ , leading to a chiral center on the carbon atom from which R ² and R ³ stem. Thus, generally, R ³ may be selected from the group consisting of hydrogen, halide, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof, but it has also been learned that for isotactic polypropylene production R ³ is aryl, substituted aryl, heteroaryl or substituted heteroaryl. In more specific embodiments for isotactic polypropylene production R ³ is selected from the group consisting of benzyl, phenyl, naphthyl, 2-biphenyl, 2-dimethylaminophenyl, 2-methoxyphenyl, anthracenyl, mesityl, 2-pyridyl, 3,5-dimethylphenyl, o-tolyl, or phenanthrenyl. Also here, R ¹ is selected from the group consisting of 2,6-(Pr ⁱ ) ₂ -C ₆ H ₃ —, 2-Pr ⁱ -6-Me-C ₆ H ₃ —, 2,6-Et ₂ -C ₆ H ₃ — or 2-sec-butyl-6-Et-C ₆ H ₃ —.

[0081] Also for isotactic polypropylene production it is preferred that within formula A, above, it is currently preferred that Q ¹ and Q ⁵ are alkyl, substituted alkyl, heteroalkyl, substituted heteroalkyl, silyl, cycloalkyl, or substituted cycloalkyl, provided that Q ¹ and Q ⁵ are not both methyl. Here also, Q ¹ and Q ⁵ can be, independently, selected from the group consisting of —CH ₂ R ¹⁵ , —CHR ¹⁶ R ¹⁷ and methyl, provided that not both Q ¹ and Q ⁵ are methyl. In a more specific embodiment for isotactic polypropylene production, it is currently preferred that Q ¹ and Q ⁵ are both isopropyl; or both ethyl; or both sec-butyl; or Q ¹ is methyl and Q ⁵ is isopropyl; or Q ¹ is ethyl and Q ⁵ is sec-butyl. Even more specifically, with these Q ¹ and Q ⁵ preferences, R ¹ is either or 13 14

[0082] with the above definitions of the variables applying.

[0083] For isotactic polypropylene production it is preferred R ⁷ is aryl, substituted aryl, heteroaryl or substituted heteroaryl, and more specifically R ⁷ is phenyl, napthyl, mesityl, anthracenyl or phenanthrenyl. Thus, most preferably, formulas IV and V above apply to isotactic polypropylene production, with it currently being preferred that R ¹⁰ , R ¹¹ , R ¹² , R ¹³ , are each hydrogen; or one or more of R ¹⁰ , R ¹¹ , R ¹² , R ¹³ are methyl, fluoro, trifluoromethyl, methoxy, or dimethylamino; or where R ¹⁰ and R ¹¹ are joined to form a benzene ring and R ¹² and R ¹³ are each hydrogen (thus forming a napthyl group with the existing phenyl ring).

[0084] Specific ligands that are preferred for the production of crystalline polypropylene are: 15