Polypropylene reactor mixture obtained with homogeneous and supported catalysts

Propylene polymerizations were performed with homogeneous ?₂C(Flu)(Cp)ZrCl₂ and SiMe₂(Ind)₂ZrCl₂ catalyst mixtures and with mixtures supported on the zeolite acid mordenite. The polymerizations were performed in toluene and hexane/triisobutylaluminum at different temperatures and Al(MAO)/Zr concentration ratios. The effects of these variables on the catalyst activity were investigated with statistical experimental planning. The average molecular weights, molecular weight distributions, melting temperatures, and crystallinities of the obtained polymers were examined. The results showed lower activities for the homogeneous catalyst mixture than for the isolated systems. On the other hand, high activities were obtained for the syndiospecific heterogeneous system, but very low values were obtained for the supported isospecific metallocene, although both catalysts were prepared under the same conditions. The supported binary system showed intermediary catalyst activity in comparison with the syndiospecific and isospecific supported catalysts. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 263–272, 2005     

Influence of electronic effect on catalytic activity of salicylaldiminato nickel(II) complexes

A means of correlation between the activity and the net charge, the metal atom net charge correlation (MANCC), which was successful in the activity prediction of the early‐transition metal catalysts, has been used to study the catalytic activities of salicylaldiminato Ni(II) complexes, the late‐transition metal catalysts, in olefin polymerization or oligomerization. A comparison with the available quantum mechanics/molecular mechanics (QM/MM) calculation data suggests that even without a detailed mechanism, MANCC results mostly agree with QM/MM calculation data regarding insertion barrier data and enthalpy change. Eight experimental complexes were further built up by modeling; their catalytic activities predominantly increased in line with the net charges on the metal atoms. The same results were obtained for the other four complexes synthesized in the present work. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 4765–4774, 2004     

The discovery and progress of MgCl2‐supported TiCl4 catalysts

Polyolefins represented by polyethylene (PE) and polypropylene (PP) are indispensable materials in our daily lives. TiCl₃ catalysts, established by Ziegler and Natta in the 1950s, led to the births of the polyolefin industries. However, the activities and stereospecificities of the TiCl₃ catalysts were so low that steps for removing catalyst residues and low stereoregular PP were needed in the production of PE and PP. Our discovery of MgCl₂‐supported TiCl₄ catalysts led to more than 100 times higher activities and extremely high stereospecificities, which enabled us to dispense with the steps for the removals, meaning the process innovation. Furthermore, they narrowed the molecular weight and composition distributions of PE and PP, enabling us to control the polymer structures precisely and create such new products as very low density PE or heat‐sealable film at low temperature. The typical example of the product innovations by the combination of the high stereospecificity and the narrowed composition distribution is high‐performance impact copolymer used for an automobile bumper that used to be made of metal. These process and product innovations established these polyolefin industries. The latest MgCl₂‐supported TiCl₄ catalyst is very close to perfect control of isotactic PP structure and is expected to bring about further innovations. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 1–8, 2004     

Ethylene polymerization with porous polystyrene spheres supported Cp2ZrCl2 catalyst

A catalyst with porous polystyrene beads supported Cp₂ZrCl₂ was prepared and tested for ethylene polymerization with methylaluminoxane as a cocatalyst. By comparison, the porous supported catalyst maintained higher activity and produced polyethylene with better morphology than its corresponding solid supported catalyst. The differences between activities of the catalysts and morphologies of the products were reasonably explained by the fragmentation processes of support as frequently observed with the inorganic supported Ziegler–Natta catalysts. Investigation into the distribution of polystyrene in the polyethylene revealed the fact that the porous polystyrene supported catalyst had undergone fragmentation during polymerization. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 3313–3319, 2003     

Effect of the synthetic method and support porosity on the structure and performance of silica‐supported CuBr/pyridylmethanimine atom transfer radical polymerization catalysts. I. Catalyst preparation and characterization

Silica‐supported CuBr/pyridylmethanimine (PMI) complexes that facilitate the atom transfer radical polymerization of methyl methacrylate have been prepared and characterized. Four different synthetic routes, including multistep‐grafting (M1), two‐step‐grafting (M2), one‐pot (M3), and preassembled‐complex (M4) methods, have been evaluated on three different silica supports (mesoporous SBA15 with 48‐ and 100‐Å pores and nonporous Cab‐O‐Sil EH5). The resulting solids have been characterized by a battery of techniques, including thermogravimetric analysis/differential scanning calorimetry, FT‐Raman spectroscopy, ¹³C and ²⁹Si magic‐angle‐spinning and cross‐polarity/magic‐angle‐spinning spectroscopy, low‐temperature nitrogen physisorption, and elemental analysis. The combination of elemental analysis and spectroscopic results has indicated that a variety of different surface species likely exist for most catalysts, including copper species that are both monocoordinated and biscoordinated by PMI ligands, and PMI‐free copper bromide species interacting with the silica surface. M4 appears to give a material that has the smallest amount of the uncomplexed ligand (by FT‐Raman spectroscopy) and is, therefore, the most homogeneous. After M4, the metallation efficiency decreases in the order M2 ≥ M3 > M1, with M1 giving a material with a highly heterogeneous surface composition. The ligand loading on all the catalysts has been determined to be approximately 1 mmol/g of SiO₂, with Cab‐O‐Sil‐supported materials giving much higher ligand densities because of its lower surface area. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 1367–1383, 2004     

Syntheses of poly(siloxane)-supported zirconocene catalysts and application to olefin polymerizations

Poly(siloxane)s with bisindenyl, bisfluorenyl, bis(1,2,3,4-tetramethylcyclopentadienyl), bis(2,4,7-trimethylindenyl) and monoindenylmethyl side groups were synthesized by condensation of the corresponding dichlorosilanes and water. For reference, diphenylsilanediol or hydroquinone was also employed in place of water. A series of poly(siloxane)-supported zirconocene catalysts were then prepared from these precursors and applied to ethene and propene polymerizations as well as to the copolymerization of ethene with 1-octene in the presence of methylalumoxane. The polymerization activity of the new supported metallocenes depends drastically upon the substituents in the siloxane backbone. The zirconocene catalysts supported on poly(bisindenylsiloxane) and poly(bisfluorenylsiloxane) give the highest activities for ethene and propene polymerizations, respectively. The weight-average molecular weights of the polymers are also markedly dependent upon the substituents. On the other hand, the molecular mass distributions (MMD) are generally not so sharp, suggesting that the active species formed in these supported catalysts are not uniform. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36 : 421–428, 1998     

Implementing the reversible addition–fragmentation chain transfer process in PREDICI

There is currently a highly controversial debate about the nature of the reversible addition–fragmentation chain transfer (RAFT) mechanism. In this debate, kinetic computer modeling is frequently used as a powerful tool to correlate experimental data with theoretical models to deduce the rate coefficients that govern the process. Frequently, the PREDICI program package has been used as a simulation tool. Recently, the implementation and mathematical basis of the RAFT process, with respect to PREDICI, have been criticized. This communication discusses the mathematical and mechanistic implementation of the RAFT process in the PREDICI program package and elucidates the well‐founded mathematical basis of the approach. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 1441–1448, 2004     

Hydrogen effects in propylene polymerization reactions with titanium‐based Ziegler–Natta catalysts. II. Mechanism of the chain‐transfer reaction

Hydrogen is a very effective chain‐transfer agent in propylene polymerization reactions with Ti‐based Ziegler–Natta catalysts. However, measurements of the hydrogen concentration effect on the molecular weight of polypropylene prepared with a supported TiCl₄/dibutyl phthalate/MgCl₂ catalyst show a peculiar effect: hydrogen efficiency in the chain transfer significantly decreases with concentration, and at very high concentrations, hydrogen no longer affects the molecular weight of polypropylene. A detailed analysis of kinetic features of chain‐transfer reactions for different types of active centers in the catalyst suggests that chain transfer with hydrogen is not merely the hydrogenolysis reaction of the Ti? C bond in an active center but proceeds with the participation of a coordinated propylene molecule. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 1899–1911, 2002     

Isothermal and nonisothermal crystallization kinetics of poly(propylene terephthalate)

The kinetics of crystallization of poly(propylene terephthalate) (PPT) samples of different molecular weights were studied under both isothermal and nonisothermal conditions. The Avrami and Lauritzen–Hoffmann treatments were applied to evaluate kinetic parameters of PPT isothermal crystallization. It was found that crystallization is faster for low‐molecular‐weight samples. The modified Avrami equation, and the combined Avrami–Ozawa method were found to successfully describe the nonisothermal crystallization process. Also, the analysis of Lauritzen–Hoffmmann was tested and it resulted in values close to those obtained with isothermal crystallization data. The nonisothermal kinetic data were corrected for the effect of the temperature lag and shifted alone with the isothermal kinetic data to obtain a single master curve, according to the method of Chan and Isayev, testifying to the consistency between the isothermal and corrected nonisothermal data. A new method for ranking of polymers, referring to the crystallization rates, was also introduced. This involved a new index that combines the maximum crystallization rate observed during cooling with the average crystallization rates over the temperature range of the crystallization peak. Furthermore, the effective energy barrier of the dynamic process was evaluated with the isoconversional methods of Flynn and Friedmann. It was found that the energy barrier is lower for the low‐molecular‐weight PPT. The effect of the catalyst remnants on the crystallization kinetics was also investigated and it was found that this is significant only for low‐molecular‐weight samples. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 3775–3796, 2004     

AlR2Cl/MgR2 combinations as universal cocatalysts for Ziegler–Natta,metallocene, and post‐metallocene catalysts

Combinations of dialkylaluminum chlorides and dialkylmagnesium compounds, when used at molar [AlR₂Cl]:[MgR₂] ratios ≥ 2, act as universal cocatalysts for all three presently known types of alkene polymerization catalysts—Ziegler–Natta, metallocene, and post‐metallocene. When these cocatalysts are used with supported Ti‐based Ziegler–Natta catalysts, they produce catalyst systems which are 1.5–2 times more active than the systems utilizing AlR₃ compounds as cocatalysts. Combinations of AlR₂Cl/MgR₂ cocatalysts and various metallocene complexes produce single‐center catalyst systems similar to those formed in the presence of MAO. The same cocatalysts activate numerous post‐metallocene Ti complexes containing bidentate ligands of a different nature and produce multicenter systems of very high activity. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 3271–3285, 2009     

Kinetic features of ethylene polymerization over supported catalysts [2,6‐bis(imino)pyridyl iron dichloride/magnesium dichloride] with AlR3 as an activator

The effects of polymerization temperature, polymerization time, ethylene and hydrogen concentration, and effect of comonomers (hexene‐1, propylene) on the activity of supported catalyst of composition LFeCl₂/MgCl₂‐Al(i‐Bu)₃ (L = 2,6‐bis[1‐(2,6‐dimethylphenylimino)ethyl] pyridyl) and polymer characteristics (molecular weight (MW), molecular‐weight distribution (MWD), molecular structure) have been studied. Effective activation energy of ethylene polymerization over LFeCl₂/MgCl₂‐Al(i‐Bu)₃ has a value typical of supported Ziegler–Natta catalysts (11.9 kcal/mol). The polymerization reaction is of the first order with respect to monomer at the ethylene concentration >0.2 mol/L. Addition of small amounts of hydrogen (9–17%) significantly increases the activity; however, further increase in hydrogen concentration decreases the activity. The IRS and DSC analysis of PE indicates that catalyst LFeCl₂/MgCl₂‐Al(i‐Bu)₃ has a very low copolymerizing ability toward propylene and hexene‐1. MW and MWD of PE produced over these catalysts depend on the polymerization time, ethylene and hexene‐1 concentration. The activation effect of hydrogen and other kinetic features of ethylene polymerization over supported catalysts based on the Fe (II) complexes are discussed. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 5057–5066, 2007     

Alumina as support for metallocene catalyst in ethylene polymerization

Aluminas thermally and/or chemically treated were used as support for Cp₂ZrCl₂ and evaluated in ethylene polymerization at constant reaction conditions. Two different calcination temperatures were employed, and the metallocene was fixed either directly or after support pretreatment with MAO, TMA, or NaOH solutions. The obtained alumina‐supported catalysts showed activities comparable to the homogeneous precursor. It was noticed that the textural properties of the supports strongly influenced the catalyst performance. The direct fixation of the metallocene on alumina produced catalysts presenting lower activities in comparison to the ones obtained from the chemically treated supports. The chemical pretreatment of hydrated alumina with TMA originated catalysts whose activities were superior to those obtained by pretreatment with MAO. The pretreatment with NaOH produced the more active catalyst and generated branched polymer. The molecular weight of the PE produced by the supported catalysts was higher than the ones obtained with the homogeneous system. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 9–21, 2004     

Preparation and characterization of SBA‐15 supported iron(II)‐bisimine pyridine catalyst for ethylene polymerization

2,6‐Diacetylpyridinebis (2,6‐diisopropylani) iron dichloride, a late‐transition metal catalyst for olefin polymerization, was supported on SBA‐15 successfully and the property of the supported catalyst was carefully studied. Ethylene polymerization was systematically investigated in the presence of MAO under various conditions employing this type of catalyst system. In general, after support, a decrease in the catalytic activity was observed and higher molecular weight and fibrous morphology of polyethylene were obtained. The “extrusion polymerization” phenomenon was observed in ethylene polymerization by using the supported catalyst system. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 4830–4837, 2004     

Copolymerization of propylene and disubstituted diallylsilanes involving intramolecular cyclization with stereoselective zirconocene catalysts

The copolymerization of propylene and disubstituted diallylsilanes [(CH₂ ?CH? CH₂? )₂R₂Si (R = CH₃ or C₆H₅)] was investigated with isoselective and syndioselective zirconocene catalysts with methylaluminoxane as a cocatalyst. The syndioselective catalyst showed a higher reactivity for disubstituted diallylsilanes than the isoselective catalysts. Diallyldimethylsilane was incorporated into the polymer chain via cyclization insertion preferentially and formed 3,5‐disubstituted dimethylsilacyclohexane units in the polypropylene main chain. In the copolymerization with diallyldiphenylsilane, diallyldiphenylsilane was copolymerized via both cyclization insertion and 1,2‐insertion, which formed a pendant allyl group. The structures of isolated silacyclohexane units, determined by ¹³C NMR and distortionless enhancement by polarization transfer spectroscopy, proved that the 1,2‐insertion of diallylsilanes proceeded with enantiomorphic site control; however, the diastereoselectivity of the cyclization reaction was independent of the stereoselectivity of the catalysts used, and cis‐silacyclohexane units were mainly formed. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 6083–6093, 2006     

Effect of the synthetic method and support porosity on the structure and performance of silica‐supported CuBr/pyridylmethanimine atom transfer radical polymerization catalysts. II. Polymerization of methyl methacrylate

A systematic study of the effect of the synthesis method and catalyst structure on the atom transfer radical polymerization (ATRP) performance of copper(I) bromide/pyridylmethanimine complexes supported on silica is described. Four different synthetic routes, including multistep‐grafting (M1), two‐step‐grafting (M2), one‐pot (M3), and preassembled‐complex (M4) methods, have been evaluated on three different silica supports (mesoporous SBA15 with 48‐ and 100‐Å pores and nonporous Cab‐O‐Sil EH5). The resulting solids have been used for ATRP of methyl methacrylate. The catalysts allow for moderate to poor control of the polymerization, with polydispersity indices (PDIs) ranging from 1.46 to greater than 2. The materials made with the preassembled‐complex (M4) and one‐pot (M3) approaches are generally more effective than those prepared with a grafting method (M1 and M2) on porous silica, whereas all the methods provide similarly performing catalysts on the nonporous support. Nonporous Cab‐O‐Sil EH5 is the most effective support because of its small particle size, lack of porosity, and relative compatibility in the reaction media. All the catalysts leach copper into solutions in small amounts. In addition, the catalysts can be effectively recycled, with improved controlled character in recycle runs (PDI ～ 1.2). Control experiments have shown that this improved performance of the used catalysts is likely due to the presence of a soluble Cu(II) complex in the materials that effectively deactivates the growing polymer chain, leading to narrow PDIs and controlled molecular weights. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 1384–1399, 2004     

Synthesis of polyethylene and polypropylene containing fluorene units in the side chain

Copolymerizations of ethylene or propylene and allyl monomers containing 9‐fluorenyl group, diallyl‐di‐9‐fluorenylsilane (DAFS), 9,9‐diallylfluorene (DAF), and 9‐allylfluorene (AF), were investigated with various zirconocene catalysts using methylaluminoxane as a cocatalyst. The bridged zirconocene catalysts, especially a syndioselective catalyst, showed a higher reactivity for all the comonomers than the nonbridged catalysts. DAFS was mainly incorporated into the polymer chain via cyclization insertion, whereas DAF was copolymerized via both 1,2‐ and cyclization insertions. Cyclization selectivity, ratio of cyclized insertion unit, of DAF in the copolymerization with propylene was higher than that in the copolymerization with ethylene. Copolymerization with AF yielded low‐molecular weight copolymer because of frequent chain transfer reaction. Optical properties of the propylene based‐copolymers were investigated by UV‐vis and photoluminescence spectroscopy, and absorption‐ and emission‐derived from fluorenyl groups were detected in the copolymers. © 2010 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 48: 3542–3552, 2010     

Very rapid copper‐mediated atom transfer radical polymerization of benzyl methacrylate at ambient temperature

The ability to do very rapid bulk atom transfer radical polymerization (ATRP) of benzyl methacrylate using a CuX/PMDETA complex at room temperature was demonstrated in this study. The experimental conditions required to synthesize low‐ and high‐molecular‐weight poly(benzyl methacrylate) with low polydispersity are reported here. The controlled/living nature of the polymerization was demonstrated through kinetic studies, and chain‐extension studies. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 1053–1057, 2004     

Copolymerization of 3‐buten‐1‐ol and propylene with an isospecific zirconocene/methylaluminoxane catalyst

The copolymerization of propylene and 3‐buten‐1‐ol protected with alkylaluminum [trimethylaluminum (TMA) or triisobutylaluminum] was conducted with an isospecific zirconocene catalyst [rac‐dimethylsilylbis(1‐indenyl)zirconium dichloride], combined with methylaluminoxane as a cocatalyst, in the presence of additional TMA or H₂ as the chain‐transfer reagent if necessary. The results indicated that end‐hydroxylated polypropylene was obtained in the presence of the chain‐transfer reagents because of the formation of dormant species after the insertion of the 3‐buten‐1‐ol‐based monomer followed by chain‐transfer reactions. The selectivity of the chain‐transfer reactions was influenced by the alkylaluminum protecting the comonomer and the catalyst structure. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 5600–5607, 2004     

Synthesis and properties of fluorine‐containing polyethers with pendant hydroxyl groups by the polyaddition of bis(epoxide)s with diols

Fluorine‐containing polyethers with pendant hydroxyl groups were synthesized by the polyaddition of fluorine‐containing bis(epoxide)s with certain fluorine‐containing diols with quaternary onium salts as catalysts. When the polyaddition was performed with 2,2′,6,6′‐tetrafluoro‐4,4′‐biphenol diglycidiyl ether and 2,2′,6,6′‐tetrafluoro‐4,4′‐biphenol, the corresponding polyether with pendant hydroxyl groups was successfully obtained in good yield. The polyaddition of certain fluorine‐containing bis(epoxide)s with diols also proceeded in bulk to provide the corresponding fluorine‐containing polyethers with high molecular weights. These polyethers were highly transparent at 157 nm for 0.1 μm thickness, with their transmittance of 14–75% at 157 nm. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 2543–2550, 2004     

In situ polymerization of ethylene with bis(imino)pyridine iron(II) catalysts supported on clay: The synthesis and characterization of polyethylene–clay nanocomposites

Polyethylene–clay nanocomposites were synthesized by in situ polymerization with 2,6‐bis[1‐(2,6‐diisopropylphenylimino)ethyl] pyridine iron(II) dichloride supported on a modified montmorillonite clay pretreated with methylaluminoxane (MAO). The catalysts and the obtained nanocomposites were examined with wide‐angle X‐ray scattering. The exfoliation of the clay was further established by transmission electron microscopy. Upon the treatment of the clay with MAO, there was an increase in the d‐spacing of the clay galleries. No further increase in the d‐spacing of the galleries was observed with the iron catalyst supported on the MAO‐treated clay. The catalyst activity for ethylene polymerization was independent of the Al/Fe ratio. The exfoliation of the clay inside the polymer matrix depended on various parameters, such as the clay content, catalyst content, and Al/Fe ratio. The crystallinity percentage and crystallite size of the nanocomposites were affected by the degree of exfoliation of the clay. Moreover, when ethylene was polymerized with a mixture of the homogeneous iron(II) catalyst and clay, the degree of exfoliation was significantly lower than when the polymerization was performed with a preformed clay‐supported catalyst. This observation suggested that in the supported catalyst, at least some of the active centers resided within the galleries of the clay. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 304–318, 2005