Supported Bis(Hydroxylarylaryloxy) Catalysts For Manufacture Of Polymers

1 . A supported, heterogeneous catalyst composition for use in polymerization of addition polymerizable monomers to form high molecular weight polymers, comprising:

1) a substrate comprising a solid, particulated, high surface area, surface modified, inorganic oxide compound,

2) a Group 4 metal complex of a bis(hydroxyarylaryloxy) ligand; and optionally,

3) an activating cocatalyst for the metal complex.

2 . The composition according to claim 1 wherein the metal complex corresponds to the formula:

wherein:

T 2 is a divalent bridging group of from 2 to 20 atoms not counting hydrogen; and

Ar 2 independently each occurrence is an arylene or an alkyl- or aryl-substituted arylene group of from 6 to 20 atoms not counting hydrogen;

M is a Group 4 metal;

X independently each occurrence is an anionic, neutral or dianionic ligand group;

x is a number from 1 to 5 indicating the number of such X groups; and

bonds and electron donative interactions are represented by lines and dotted lines respectively.

3 . The composition according to claim 2 wherein the metal complex is selected from the group consisting of compounds of the formula:

where Ar 4 is C 6-20 aryl or inertly substituted derivatives thereof, and

T 3 independently each occurrence is C 3-6 alkylene or an inertly substituted derivative thereof;

R 14 independently each occurrence is hydrogen, halo, hydrocarbyl, trihydrocarbylsilyl, or trihydrocarbylsilylhydrocarbyl of up to 50 atoms not counting hydrogen; and

X, independently each occurrence is halo or a hydrocarbyl or trihydrocarbylsilyl group of up to 20 atoms not counting hydrogen, or 2 X groups together are a divalent derivative of the foregoing hydrocarbyl or trihydrocarbylsilyl groups.

4 . The composition according to claim 3 wherein the metal complex is selected from compounds corresponding to the formula:

wherein Ar 4 is 3,5-di(isopropyl)phenyl, 3,5-di(isobutyl)phenyl, dibenzo-1H-pyrrole-1-yl, or anthracen-5-yl,

R 14 is hydrogen, halo, or C 1-4 alkyl,

T 3 is propan-1,3-diyl or butan-1,4-diyl, and

X is chloro, methyl or benzyl.

5 . The composition according to claim 4 wherein the metal complex is propane-1,3-bis[oxyphenyl-2-((N-2,3,4,5-dibenzopyrole)-5-methyl-2-oxy)phenyl]hafnium dimethyl.

6 . A composition according to claim 1 additionally comprising a polymerization modifier.

7 . A composition according to claim 6 wherein the polymerization modifier is hydroxyaluminum di(stearate), zinc di(2-propionate), zinc di(salicylate), zinc bis-3,5-di(i-propyl)salicylate, or zinc bis-3,5-di(t-butyl)salicylate.

8 . A composition according to claim 1 prepared by spray drying a solution or slurry of the components.

9 . A process for preparing a prepolymerized catalyst or a high molecular weight polymer comprising contacting one or more addition polymerizable monomers under addition polymerization conditions with a catalyst composition according to any one of claims 1 - 8 .

10 . A process according to claim 9 wherein a mixture comprising ethylene and one or more C 3-8 α-olefins is polymerized.

11 . A process according to claim 10 wherein a mixture comprising ethylene and propylene is polymerized to form a polymer comprising at least 90 weight percent polymerized propylene.

12 . A process according to claim 9 wherein propylene is homopolymerized.

13 . A propylene/ethylene copolymer in particle form, said copolymer having Mw/Mn of 3.0 or less, a propylene content of at least 90 percent by weight, a Tm of at least 155° C., having been prepared by the process of claim 11.