Bis(pyrrolide-imine) Ti complexes with MAO: A new family of high performance catalysts for olefin polymerization

This contribution reports on the syntheses, structures and olefin polymerization behavior of Ti complexes having a pair of chelating pyrrolide-imine [N⁻,N] ligands. X-ray analyses as well as ¹H NMR studies demonstrate that bis(pyrrolide-imine) Ti complexes (named PI Catalysts) contain approximately octahedrally coordinated metal centers with mutually trans-pyrrolide-Ns, cis-imine-Ns and cis-Cls. DFT studies suggest that PI Catalysts, when activated, provide a metal alkyl in the cis position to a vacant coordination site for monomer binding. These theoretical studies also show that the active species derived from PI Catalysts normally possess higher electrophilicity and a sterically more open nature compared with those produced using bis(phenoxy-imine) Ti complexes (Ti-FI Catalysts) which are known as high performance olefin polymerization catalysts. These structural as well as electronic features suggest that PI Catalysts have high potential for the polymerization of olefinic monomers.Unlike high performance Ti-FI Catalysts, PI Catalysts do not require the presence of steric bulk in close proximity to the anionic donor. PI Catalysts combined with MAO display high ethylene polymerization activities (max. 33,200 kg-polymer/mol-cat/h, 25 °C, atmospheric pressure) comparable to those obtained with early group 4 metallocene catalysts (e.g., Cp₂TiCl₂ 16,700 kg-polymer/mol-cat/h) under identical conditions. As expected, PI Catalysts exhibit higher incorporation capability for propylene and 1-hexene relative to FI Catalysts though the incorporation levels are lower than those for Cp₂TiCl₂. To our surprise, PI Catalysts/MAO show remarkably high norbornene (NB) incorporation, superior to that seen with the [Me₂Si(Me₄Cp)N-tBu]TiCl₂ (CGC) catalyst system, and they readily form ethylene-NB copolymers with high NB contents. The highly electrophilic and sterically open nature is probably responsible for the high NB affinity. Additionally, PI Catalysts/MAO possess characteristics of living ethylene polymerization (though under limited conditions) and afford high molecular weight PEs with very narrow molecular weight distributions (M_n 225,000, M_w/M_n 1.15, 10-s polymerization, 25 °C). Moreover, these catalysts can copolymerize ethylene and NB in a highly controlled living manner to afford monodisperse alternating copolymers with very high molecular weights (M_n > 500,000, M_w/M_n < 1.2) at room temperature. This unique living nature allows the preparation of a number of ethylene- and NB-based block copolymers, including PE-b-poly(ethylene-co-NB) and poly(ethylene-co-NB)_a-b-poly(ethylene-co-NB)_b, in which each segment contains a different NB content. These are probably the first examples of the syntheses of block copolymers from ethylene and NB. Consequently, the discovery and application of PI Catalysts has exercised a significant influence on olefin polymerization catalysis and polymer synthesis.     

Fluorinated bis(phenoxy-imine) Ti complexes with MAO: Remarkable catalysts for living ethylene and syndioselective living propylene polymerization

Based on new results as well as the reported data, the ethylene and propylene polymerization behavior of bis(phenoxy-imine) Ti complexes (Ti-FI Catalysts) combined with MAO (particularly that of their fluorinated versions) is discussed, with an emphasis on the characteristics and mechanisms of living ethylene and syndioselective living propylene polymerization. Unlike common living olefin polymerization catalysts, fluorinated Ti-FI Catalysts with MAO display thermally robust living behavior and polymerize ethylene in a highly controlled manner at temperatures as high as 50 °C. Additionally, despite being C₂-symmetric catalysts, fluorinated Ti-FI Catalysts/MAO mediate highly syndioselective living propylene polymerization. Fluorinated Ti-FI Catalysts that we developed are the first examples of catalysts that induce the living polymerization of both ethylene and propylene. In addition, they are also the first examples of living and, at the same time, highly stereoselective propylene polymerization catalysts. The versatile and robust living nature of the fluorinated Ti-FI Catalysts allows the preparation of a wide variety of unique living polymers; some of which can even be produced catalytically. On the basis of theoretical calculations as well as experimental results, we conclude that these unusual polymerization features of fluorinated Ti-FI Catalysts originate from an attractive interaction between the ligand and a growing polymer chain and/or the fluxional character of the catalyst coupled with 2,1-regiochemistry. This is in stark contrast to group 4 metallocene catalysts, which control olefin polymerization mainly by repulsive interactions based on the rigidly organized ligand frameworks.     

新一代高活性后过渡金属烯烃聚合催化剂

介绍了近几年发展起来的新一代后期过渡金属(Fe,Co,Ni,Pd)烯烃聚合催化剂,对催化剂的结构、性能及催化烯烃聚合进行了阐述。     

New materials from new catalysts

The polyolefins, especially polypropylene and polyethylene, industry of today is very different from that of 10 years ago. The development of highly active and stereospecific catalysts, represented by Ti/Mg supported catalysts, have made the gas-phase polymerization process practical. The trend in catalyst development is shifting from an emphasis on improving the stereospecificity and activity toward improving the polymer physical properties, processability and morphology. Many hybrid thermoplastic olefins, such as high-impact copolymers, propylene–ethylene–butene terpolymers, and very low density polyethylene, have already been developed by utilizing the features of the gas-phase polymerization process. These hybrid thermoplastic olefins cover a very broad range of products. They cannot be clearly identified as polyethylenes, polypropylenes or elastomers. Incidentally, metallocene catalysts for polyolefins have been under development for the past 15 years, and are now in the early stage of commercialization. These catalysts differ significantly from the conventional heterogeneous catalysts. They can polymerize not only ethylene, propylene and other linear α-olefins, but also styrene, cycloolefins and functional monomers In addition, they can control the microstructure of polymer molecules by varying the transition metals and the cyclopentadienyl ligands. Because of these features, we have to be confident that the development of metallocene catalysts, or more widely homogeneous catalysts, may be a dominant force throughout the 1990s in the polyolefin industries.     

Polyethylene and elastomeric polypropylene using alumina-supported bis(arene) titanium,zirconium, and hafnium catalysts

Bis(arene) complexes of zerovalent titanium, zirconium, and hafnium supported on partially dehydroxylated, fumed alumina are effective catalysts for the polymerization of olefins. The zerovalent complexes react with surface hydroxyls with loss of one equivalent of arene to yield the active species. The polyethylenes derived from these catalysts are very high molecular weight. Polymerization of propylene yields elastomeric stereoblock polymers which are composed of isotactic and stereoirregular sequences. The polymers are stiffer than polypropylenes obtained with similar catalysts derived from tetra(neophyl)zirconium. The chain microstructures of the various components of the whole polymers have been characterized by ¹³C-NMR and solvent extraction studies. The ether soluble component of these polymers is of a relatively high molecular weight and the microstructure of the backbone is largely stereoirregular. It is the cocrystallization of this fraction of the polymer with the crystalline, isotactic fractions which is critical to the observed elastomeric properties.     

Chromocene catalysts for ethylene polymerization: Scope of the polymerization

Chromocene deposited on silica supports of high surface area forms a highly active catalyst for polymerization of ethylene. Polymerization is believed to occur by a coordinated anionic mechanism previously outlined. The catalyst formation step liberates cyclopentadiene and leads to a new divalent chromium species containing a cyclopentadienyl ligand. The catalyst has a very high chain-transfer response to hydrogen which permits facile preparation of a full range of molecular weights. Catalyst activity increases with an increase in silica dehydration temperature, chromium content on silica, and ethylene reaction pressure. The temperature-activity profile is characterized by a maximum near 60°C, presumably caused by a deactivation mechanism involving silica hydroxyl groups. A value of 72 was estimated for the ethylene–propylene reactivity ratio (r₁). Linear, highly saturated polymers are normally prepared below 100°C. By contrast with other commercial polyethylenes, the chromocene catalyst produces polyethylenes of relatively narrow molecular weight distribution. Above 100°C, unsaturated, branched polymers or oligomers are formed by a simultaneous polymerization–isomerization process.     

Homo-polymerization of alpha-olefins and co-polymerization of higher alpha-olefins with ethylene in the presence of CpTiCl2(OC6H4X-p)/MAO catalysts (X = CH3, Cl)

Cyclopentadienyl-titanium complexes containing -OC6H4X ligands (X = Cl,CH3) activated with methylaluminoxane (MAO) were used in the homo-polymerization of ethylene, propylene, 1-butene, 1-pentene, 1-butene, and 1-hexene, and also in co-polymerization of ethylene with the alpha-olefins mentioned. The -X substituents exhibit different electron donor-acceptor properties, which is described by Hammett's factor (sigma).The chlorine atom is electron acceptor, while the methyl group is electron donor. These catalysts allow the preparation of polyethylene in a good yield. Propylene in the presence of the catalysts mentioned dimerizes and oligomerizes to trimers and tetramers at 25 degrees C under normal pressure. If the propylene pressure was increased to 7 atmospheres,CpTiCl2(OC6H4CH3)/MAO catalyst at 25 degrees gave mixtures with different contents of propylene dimers, trimers and tetramers. At 70 degrees C we obtained only propylene trimer.Using the catalysts with a -OC(6)H(4)Cl ligand we obtained atactic polymers with M(w) 182,000 g/mol (at 25 degrees C) and 100,000 g/mol (at 70 degrees C). The superior activity of the CpTiCl2(OC6H4Cl)/MAO catalyst used in polymerization of propylene prompted us to check its activity in polymerization of higher alpha-olefins (1-butene, 1-pentene, 1-hexene)and in co-polymerization of these olefins with ethylene. However, when homo-polymerization was carried out in the presence of this catalyst no polymers were obtained. Gas chromatography analysis revealed the presence of dimers. The activity of the CpTiCl2(OC6H4Cl)/MAO catalyst in the co-polymerization of ethylene with higher alpha-olefins is limited by the length of the co-monomer carbon chain. Hence, the highest catalyst activities were observed in co-polymerization of ethylene with propylene (here a lower pressure of the reagents and shorter reaction time were applied to obtain catalytic activity similar to that for other co-monomers). For other co-monomers the activity of the catalyst decreases as follows: propylene >1-butene > 1-pentene > 1-hexene. In the case of co-polymerization of ethylene with propylene, besides an increase in catalytic activity, an increase in the average molecular weight M(w) of the polymer was observed. Other co- monomers used in this study caused a decrease of molecular weight. A significant increase in molecular weight distribution (M(w)/M(n)) evidences a great variety of polymer chains formed during the reaction.     

Olefin copolymerization with metallocene catalysts. I. Comparison of catalysts

A number of metallocene/methylaluminoxane (MAO) catalysts have been compared for ethylene/propylene copolymerizations to find relationship between the polymerization activities, copolymer structures, and copolymerization reactivity ratio with the catalyst structures. Stereorigid racemic ethylene bis (indenyl) zirconium dichloride and the tetrahydro derivative exhibit very high activity of 10 ⁷ g (mol Zr h bar)^?1, giving copolymers having comonomer compositions about the same as the feed compositions, molecular weights increasing with the increase of ethylene in the feed, random incorporation of comonomers, and narrow molecular weight distribution indicative of a single catalytic species. Nonbridged bis (indenyl) zirconium behaved differently, favoring the incorporation of ethylene over propylene, producing copolymers whose molecular weight decreases with the increase of ethylene in the feed, broad molecular weight distribution, and a methanol soluble fraction. This catalyst system contains two or more active species. Simple methallocene catalysts have much lower polymerization activities. C_pTiCl₂/MAO produced copolymers with tendency toward alternation, whereas Cp₂HfCl₂/MAO gave copolymer containing short blocks of monomers.     

Ethylene and propylene polymerization with bis(indenyl)zirconium/Mao catalytic systems modified by sterically demanding alcohols

Ethylene and propylene polymerization using Ind₂ZrCl₂ and Ind₂Zr(CH₃)₂/MAO catalytic systems modified by the sterically demanding bridged alicyclic alcohols, adamantan‐1‐ol, adamantan‐2‐ol, 2‐methyladamantan‐2‐ol, and fenchyl alcohol, was investigated. Lower alcohols like isopropanol completely deactivate the system, whereas in the case of catalysts modified by these voluminous alcohols only a slight decrease in the catalytic activity proportional to alcohol/metallocene molar ratio was observed. The addition of the modifiers gives rise to polymers with higher molecular weights than the nonmodified systems, but no structural changes in the polyethylenes were observed. The addition of the sterically demanding alcohols to the reaction medium changes the regioregularity of polypropylenes, but does not significantly influence their stereoregularity, at 30 °C. Propylene–ethylene copolymers containing up to 8.6% of ethylene units derived from 1,3‐insertion and significant amount of rr‐centered pentads were obtained by single‐monomer polymerization of propylene with Ind₂ZrCl₂/MMAO/adamantan‐1‐ol, at 70 °C. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 4248–4259, 2005     

Novel polyolefin materials via catalysis and reactive processing

Recent advances in transition metal catalyzed olefin polymerization and melt processing stimulate the production of new polymers derived from old monomers. Modern polyolefin processes do not require polymer purification and give excellent control of molecular and supermolecular polyolefin architectures. Progress in catalyst design and preparation of tailor-made homo-and copolymers is highlighted for isotactic, syndiotactic, atactic and stereo-block polypropylene (PP), novel 1-olefin copolymers, and ethylene copolymers with polar monomers, e.g., CO and acrylics. Today polyethylene short-and long-chain-branching is controlled either by uniform ethylene copolymerization with 1-olefins using single-site” metallocene catalysts, or by migratory polyinsertion of ethylene, respectively. Stiff cycloaliphatic polymers expand the frontiers of polyolefins into engineering applications. New families of polyethylenes and EPM with pendent polypropylene chains are obtained via copolymerization of PP macromonomers or polymer-analoguous coupling of functionalized PP during melt processing.     

Advances in the catalyses of polymerizations

Abstract

Nearly all technical processes for the production of polymers are carried out in the presence of catalysts. In the case of addition polymerization reactions, two mechanisms are possible: Start of the reaction via an initiator (e.g., peroxides) or start via a true catalyst (e.g., Ziegler/ Natta systems). In both areas remarkable progress has been made: Cationic “living” polymerizations of oxacycloalkanes, group transfer polymerization, metal-catalyzed alternating copolymerization of ethylene with carbon monoxide, and metallocene-catalyzed polymerizations of alpha-olefins. The polymerization of alpha-olefins with metallocene catalysts not only leads to the improvement of well-known polymers like polyethylene and polypropylene, but also enables the production of new polymers like syndiotactic polypropylene, syndiotactic polystyrene, and cycloolefin copolymers on an industrial scale.     

High-performance olefin polymerization catalysts discovered on the basis of a new catalyst design concept

This critical review highlights the "ligand oriented catalyst design concept", a new catalyst design concept for olefin polymerization that has led to the development of high-activity catalysts. The concept has created a series of highly active ethylene polymerization catalysts, many of which show high activities comparable to those of group 4 metallocene catalysts. Moreover, these catalysts display unique polymerization catalysis to produce a wide variety of polymers that possess unprecedented molecular architectures that are either difficult or impossible to achieve using conventional catalysts (98 references).     

Unprecedented living olefin polymerization derived from an attractive interaction between a ligand and a growing polymer chain

Ti complexes incorporating fluorine-containing phenoxy-imine chelate ligands (fluorinated Ti-FI catalysts) have been demonstrated to induce an unprecedented living polymerization effect with both ethylene and propylene, through an attractive interaction between the fluorine atom in the ligand and a beta-hydrogen atom on the growing polymer chain. With the aid of this attractive interaction, highly controlled living ethylene polymerization, highly-syndiospecific living propylene polymerization, the synthesis of unique block copolymers from ethylene and propylene, and the catalytic production of monodisperse polyethylene and Zn-terminated polyethylene have been realized. The attractive interaction provides a conceptually new strategy for the achievement of controlled living olefin polymerization.     

New phenoxyketimine titanium complexes: combining isotacticity and living behavior in propylene polymerization

A series of titanium bis(phenoxyketimine) olefin polymerization catalysts were synthesized and screened for propylene polymerization. The phenoxyketimine ligands contain pentafluorophenyl N-aryl groups and ortho-phenol substituents of varying size. Catalysts with ortho-phenol substituents of intermediate size produce living, substantially isotactic polypropylene. The living nature of these catalyst systems is demonstrated through the synthesis of block copolymers with narrow molecular weight distributions.     

Ethylene and propylene polymerization behavior of a series of bis(phenoxy–imine)titanium complexes

This contribution reports ethylene and propylene polymerization behavior of a series of Ti complexes bearing a pair of phenoxy–imine chelate ligands. The bis(phenoxy–imine)Ti complexes in conjunction with methylalumoxane (MAO) can be active catalysts for the polymerization of ethylene. Unexpectedly, this C₂ symmetric catalyst produces syndiotactic polypropylene. ¹³C NMR spectroscopy has revealed that the syndiotacticity arises from a chain-end control mechanism. Substitutions on the phenoxy–imine ligands have substantial effects on both ethylene and propylene polymerization behavior of the complexes. In particular, the steric bulk of the substituent ortho to the phenoxy–oxygen is fundamental to obtaining high activity and high molecular weight for ethylene polymerization and high syndioselectivity for the chain-end controlled propylene polymerization. The highest ethylene polymerization activity, 3240 kg/mol-cat h, exhibited by a complex having a t-butyl group ortho to the phenoxy–oxygen, represents one of the highest reported to date for Ti-based non-metallocene catalysts. Additionally, the polypropylene produced exhibits a T_m, 140 °C, and syndioselectivity, rrrr 83.7% (achieved by a complex bearing a trimethylsilyl group ortho to the phenoxy–oxygen) that are among the highest for polypropylenes produced via a chain-end control mechanism. Hence, the bis(phenoxy–imine)Ti complexes are rare examples of non-metallocene catalysts that are useful for the polymerization of not only ethylene but also propylene.     

Polypropylene fractions produced by binary metallocene catalysts

Because of the great economic interest in propylene‐based polymers and the possibility of designing materials with desired properties with metallocene catalyst mixtures, we investigated the characteristics of polypropylenes produced by mixtures of SiMe₂Ind₂ZrCl₂: dimethylsilane‐bis(indenyl) zirconocene ( 1 ) and Et(Flu)(Cp)ZrCl₂: ethylidene (fluorenyl cyclopentadienyl) zirconocene ( 2 ) in different proportions. The polymers were fractionated with solvents, and the fractions were characterized. We observed that the polymers produced by the different mixed systems showed lower weight‐average molecular weights and only slightly broader molecular weight distributions than polypropylenes synthesized by the individual catalysts. We concluded that catalyst 1 acted independently of catalyst 2 , producing polymers with the same isotacticity. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 1478–1485, 2003     

Targeted synthesis of homo-and copolymers of propylene in liquid propylene initiated by highly efficient homogenous metallocene catalysts

Studies devoted to the homo-and copolymerization of propylene with ethylene and higher olefins (1-butene, 1-hexene, 4-methyl-1-pentene, 1-octene) in liquid propylene under the action of homogeneous metallocene catalysts of various types are surveyed in brief. The main kinetic features of the processes and the properties of the polymers are discussed. The optimal conditions for the highly efficient syntheses of isotactic, syndiotactic, hemiisotactic, and stereoblock PPs are described. It is shown that the combined cocatalyst—polymethylaluminoxane coupled with (i-Bu)₃Al—shows promise for the processes under consideration. Depending on the type of catalyst used, the copolymerization of propylene with ethylene yields copolymers with a block, random, or close to alternating distribution of comonomer units in a polymer chain. The copolymerization of propylene with higher olefins in the monomer bulk initiated by highly active sterically hindered isospecific catalytic systems shows an ideal character, and the reactivity ratios are r ₁ ≈ r ₂ ≈ 1; that is, the composition of the copolymer is equal to the composition of the monomer mixture at all comonomer ratios. It is demonstrated that the synthesis of homo-and copolymers of propylene in the monomer bulk in the presence of modern homogeneous catalysts is promising for highly efficient production of both traditional and new polymer materials with a unique combination of mechanical and thermal properties.     

Synthesis of polyethylene thermoplastic elastomer by using robust α-diimine Ni(II) catalysts with abundant tBu substituents

The synthesis of polyethylene thermoplastic elastomers via α-diimine-nickel-catalyzed ethylene polymerization using polymerization conditions of elevated temperatures and alkane solvents is highly desirable in industrial production. In this contribution, we constructed a series of highly sterically demanding α-diimine Ni(II) catalysts with abundant ^tBu substituents for this purpose. These nickel catalysts were examined for ethylene polymerization in hexanes at elevated temperatures (up to 90°C) and proved to be thermally robust at temperatures as high as 90°C. Generally, these nickel catalysts can generate highly branched (ca. 70–80/1000°C) polyethylenes with very high molecular weight (M_n up to 55.79 × 10⁴ g/mol) and the resultant polyethylenes displayed characteristics of thermoplastic elastomers with excellent elastic recovery (SR up to 84%). Compared with some similar α-diimine Ni(II) catalysts, it is shown that the presence of axial remote ^tBu substituents not only facilitates the dissolution of the catalyst in alkanes, but also improves the elastic recovery value of the obtained polyethylene.     

后过渡金属催化烯烃可控/活性聚合的研究进展

烯烃活性聚合由于可以制备出预定分子量的窄分布聚合物,以及各种嵌段共聚物、末端功能化聚合物等而受到广泛关注.过渡金属催化的烯烃配位聚合反应活性高,催化剂性能可通过配体结构的修饰进行调节,聚合物微观结构易于调控,其活性聚合进一步拓展了对烯烃聚合物分子设计的手段,具有重要的意义.除了以钛、锆、钒等为金属中心的前过渡系催化剂之...     

Synthesis of zirconocenes bearing benz[f]indenyl ligand and their use as a catalyst in ethylene polymerization

Benz[f]indenyl zirconium complexes have been successfully synthesized and characterized. Their catalytic activities were evaluated for the polymerization of ethylene. The complexes combined with MAO can be highly active single site catalysts, which display activities comparable with that of the Cp₂ZrCl₂/MAO system and provide very high molecular weight polyethylenes. The melting point of the polymers indicates the formation of linear polyethylene.