MAO‐Free Activation of Metallocenes and other Single‐Site Catalysts for Ethylene Polymerization using Spherical Supports based on MgCl2

Summary: Supports of type MgCl₂/AlR_n(OEt)_3−n, obtained by reaction of AlR₃ with adducts of MgCl₂ and ethanol, have been shown to be effective for the immobilization and activation of [Cp₂TiCl₂] and other single‐site olefin polymerization catalysts without the use of methylaluminoxane or a borate activator. Polyethylene with a spherical particle morphology and narrow molecular weight distribution was obtained.

     

Synthesis and characterization of polyethylene/clay–silica nanocomposites: A montmorillonite/silica‐hybrid‐supported catalyst and in situ polymerization

A novel approach to the preparation of polyethylene (PE) nanocomposites, with montmorillonite/silica hybrid (MT‐Si) supported catalyst, was developed. MT‐Si was prepared by depositing silica nanoparticles between galleries of the MT. A common zirconocene catalyst [bis(cyclopentadienyl)zirconium dichloride/methylaluminoxane] was fixed on the MT‐Si surface by a simple method. After ethylene polymerization, two classes of nanofillers (clay layers and silica nanoparticles) were dispersed concurrently in the PE matrix and PE/clay–silica nanocomposites were obtained. Exfoliation of the clay layers and dispersion of the silica nanoparticles were examined with transmission electron microscopy. Physical properties of the nanocomposites were characterized by tensile tests, dynamic mechanical analysis, and DSC. The nanocomposites with a low nanofiller loading (<10 wt %) exhibited good mechanical properties. The nanocomposite powder produced with the supported catalyst had a granular morphology and a high bulk density, typical of a heterogeneous catalyst system. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 941–949, 2004     

Supported Metallocene Catalysts Prepared by Impregnation of Silica with Metallocene/Aluminoxane/1‐Hexene Solutions

A novel method for the preparation of supported metallocene/alkylaluminoxane catalysts has been developed. An incipient wetness impregnation of silica at ca. –40°C is performed in one step employing a solution of catalyst and cocatalyst in 1‐hexene. A prepolymerization of this system at ambient temperature yields a catalyst robust towards exposure to air, as demonstrated by a reasonable activity during ethene polymerization. A special feature of the catalyst is a uniform impregnation across the silica particles.     

Ethylene (Co)Polymerization with Metallocene Catalysts Encapsulated in Gel‐Type Poly(styrene‐co‐divinylbenzene) Beads

Gel‐type poly(styrene‐co‐divinylbenzene) beads (PS bead) were used as a carrier to encapsulate metallocene catalysts through a simple swelling‐shrinking procedure. The catalytic species were homogeneously distributed in the PS bead particle. The catalyst exhibited high and stable ethylene polymerization and ethylene/1‐hexene copolymerization activity affording uniform spherical polymer particles (1 mm). Polymerization rate profiles exhibited slow initiation and stable increase in polymerization activity with time.     

Synthesis and characterization of ethylene‐propylene‐1‐pentene terpolymers

Ethylene (E), propylene (P), and 1‐pentene (A) terpolymers differing in monomer composition ratio were produced, using the metallocenes rac‐ethylene bis(indenyl) zirconium dichloride/methylaluminoxane (rac‐Et(Ind)₂ZrCl₂/MAO), isopropyl bis(cyclopentadienyl)fluorenyl zirconium dichloride/methylaluminoxane (Me₂C(Cp)(Flu)ZrCl₂/MAO, and bis(cyclopentadienyl)zirconium dichloride, supported on silica impregnated with MAO (Cp₂ZrCl₂/MAO/SiO₂/MAO) as catalytic systems. The catalytic activities at 25 °C and normal pressure were compared. The best result was obtained with the first catalyst. A detailed study of ¹³C NMR chemical shifts, triad sequences distributions, monomer‐average sequence lengths, and reactivity ratios for the terpolymers is presented. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 947–957, 2008     

A Tandem Catalytic System for the Synthesis of Ethylene–Hex‐1‐ene Copolymers from Ethylene Stock

Summary: A tandem catalytic system, composed of (η⁵‐C₅H₄CMe₂C₆H₅)TiCl₃ ( 1 )/MMAO (modified methyl aluminoxane) and [(η⁵‐C₅Me₄)SiMe₂(tBuN)]TiCl₂ ( 2 )/MMAO, was applied for the synthesis of ethylene–hex‐1‐ene copolymers with ethylene as the only monomer stock. During the reaction, 1 /MMAO trimerized ethylene to hex‐1‐ene, while 2 /MMAO copolymerized ethylene with the in situ produced hex‐1‐ene to poly(ethylene–hex‐1‐ene). By changing the catalyst ratio and reaction conditions, a series of copolymer grades with different hex‐1‐ene fractions at high purity were effectively produced.

The overall strategy of the tandem 1 / 2 /MMAO catalytic system.     

Carbon Nanotubes as a Ligand in Cp2ZrCl2‐Based Ethylene Polymerization

Summary: We report a simple method for tuning catalytic property of a metallocene‐based catalyst, Cp₂ZrCl₂, for ethylene polymerization by the direct adsorption of Cp₂ZrCl₂ onto multi‐walled carbon nanotubes (MWCNTs). The direct interactions between MWCNTs and the Cp rings of Cp₂ZrCl₂ controlled the polymerization behaviors, and we could generate polyethylene with an extremely high molecular weight ( = 1 000 000) at 30 °C and under 1 atm of ethylene gas.

Preparation of Cp₂ZrCl₂‐MWCNT.     

Ethylene Polymerization Studies with an MAO Synthesized by a Non‐Hydrolytic Synthetic Route

A facile nonaqueous synthetic route to methylaluminoxane (MAO) by heating a mixture of benzophenone and trimethylaluminium (TMA) is described. The MAO prepared such reveals to be an efficient activator of metallocenes and late transition metal complexes for ethylene polymerization. The [TMA]/[benzophenone] ratio used for the preparation of MAO is shown to have a dramatic effect on the catalytic activity as well as the molecular weight distribution of the resulting polyethylenes.     

Polyethylene Made with Combinations of Single‐Site‐Type Catalysts: Monte Carlo Simulation of Long‐Chain Branch Formation

The formation of long‐chain branches (LCBs) during ethylene polymerization with a combination of catalysts was studied by Monte Carlo simulation. The model describes polymerization with a non‐branching catalyst that produces linear macromonomers, and a branching catalyst that produces linear and branched macromonomers. The LCBs are formed when the branching catalyst incorporates a macromonomer. The discussion is based on the three types of chain topology obtained during the synthesis: linear, comb‐branched, or hyperbranched. Simulation results show how the chain length distribution and the number of LCBs change according to the ratio between the two catalysts present in the reactor. The ratio hyperbranched/comb‐branched is defined to evaluate the system composition and the contribution of each catalyst.     

Block copolymer micelles as nanoreactors for single‐site polymerization catalysts

New micelle‐like organic supports for single site catalysts based on the self‐assembly of polystyrene‐b‐poly(4‐vinylbenzoic acid) block copolymers have been designed. These block copolymers were synthesized by sequential atom transfer radical polymerization (ATRP) of styrene and methyl 4‐vinylbenzoate, followed by hydrolysis. As evidenced by dynamic light scattering, self‐assembly in toluene that is a selective solvent of polystyrene, induced the formation of micelle‐like nanoparticles composed of a poly(4‐vinylbenzoic acid) core and a polystyrene corona. Further addition of trimethylaluminium (TMA) afforded in situ MAO‐like species by diffusion of TMA into the core of the micelles and its subsequent reaction with the benzoic acid groups. Such reactive micelles then served as nanoreactors, MAO‐like species being efficient activators of 2,6‐bis[1‐{(2,6‐diisopropylphenyl)imino}ethyl]pyridinyl iron toward ethylene polymerization. These new micelle‐like organic supports enabled the production of polyethylene beads with a spherical morphology and a high bulk density through homogeneous‐like catalysis. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 197–209, 2009     

Generation of Ultra‐High‐Molecular‐Weight Polyethylene from Metallocenes Immobilized onto N‐Doped Graphene Nanoplatelets

Catalytic natures of organometallic catalysts are modulated by coordinating organic ligands with proper steric and electronic properties to metal centers. Carbon‐based nanomaterials such as graphene nanoplatelets are used with and without N‐doping and multiwalled carbon nanotube as a ligand for ethylene polymerizations. Zirconocenes or titanocenes are immobilized on such nanomaterials. Polyethylenes (PEs) produced by such hybrids show a great increase in molecular weight relative to those produced by free catalysts. Specially, ultra‐high‐molecular‐weight PEs are produced from the polymerizations at low temperature using the hybrid with N‐doped graphene nanoplatelets. This result shows that such nanomaterials act a crucial role to tune the catalytic natures of metallocenes.     

Ethylene/1‐hexene copolymers synthesized with a single‐site catalyst: Crystallization analysis fractionation,modeling, and reactivity ratio estimation

A series of poly(ethylene‐co‐1‐hexene) samples made with rac‐ethylene bis(indenyl)zirconium dichloride/methylaluminoxane were analyzed by crystallization analysis fractionation (CRYSTAF). The nine samples had comonomer contents of 0–4.2 mol % 1‐hexene with a narrow range of molecular weights (34,000–39,000 g/mol). Because all the copolymer samples had narrow, unimodal chemical composition distributions, they were ideal as calibration standards for CRYSTAF. A linear calibration curve was constructed relating the peak crystallization temperature from CRYSTAF operated at a cooling rate of 0.1 °C/min and the comonomer content as determined by ¹³C NMR. Reactivity ratios for ethylene and 1‐hexene were estimated by the fitting of reactant liquid‐phase compositional data to the Mayo–Lewis equation. It was found that a value of the 1‐hexene reactivity ratio could not be unequivocally determined from the set of samples analyzed because the range of comonomer incorporation was too narrow. Stockmayer's bivariate distribution was used to model the fractionation process in CRYSTAF, and although a good fit to experimental CRYSTAF profiles was attained, the model did not fully describe the underlying crystallization phenomena. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 40: 2595–2611, 2002     

Synthesis and morphology of polyethylene‐block‐poly(methyl methacrylate) through the combination of metallocene catalysis with living radical polymerization

Polyethylene‐block‐poly(methyl methacrylate) (PE‐b‐PMMA) was successfully synthesized through the combination of metallocene catalysis with living radical polymerization. Terminally hydroxylated polyethylene, prepared by ethylene/allyl alcohol copolymerization with a specific zirconium metallocene/methylaluminoxane/triethylaluminum catalyst system, was treated with 2‐bromoisobutyryl bromide to produce terminally esterified polyethylene (PE‐Br). With the resulting PE‐Br as an initiator for transition‐metal‐mediated living radical polymerization, methyl methacrylate polymerization was subsequently performed with CuBr or RuCl₂(PPh₃)₃ as a catalyst. Then, PE‐b‐PMMA block copolymers of different poly(methyl methacrylate) (PMMA) contents were prepared. Transmission electron microscopy of the obtained block copolymers revealed unique morphological features that depended on the content of the PMMA segment. The block copolymer possessing 75 wt % PMMA contained 50–100‐nm spherical polyethylene lamellae uniformly dispersed in the PMMA matrix. Moreover, the PE‐b‐PMMA block copolymers effectively compatibilized homopolyethylene and homo‐PMMA at a nanometer level. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 3965–3973, 2003     

New tethered ansa‐bridged zirconium catalysts: Insights into the “self‐immobilization” mechanism

New ω‐alkenyl‐substituted ansa‐bridged bisindenyl zirconium complexes are prepared and tested as self‐immobilized catalysts for ethene polymerization. But, even at very high concentration of the tethered complexes and low pressure of ethene, there is no evidence of their insertion into the polyethene chain. A “cross polymerization” test, performed by copolymerizing the tethered complexes with ethene using rac‐Me₂Si(2‐MeBenzInd)₂ZrCl₂ ( MBI ), does not lead to their incorporation into the polyethene chain. However, the corresponding ligand proves to be a suitable comonomer for ethene, and, through copolymerization promoted by MBI, innovative poly(ethene‐co‐2,2′‐bis[(1H‐inden‐3′‐yl)‐hex‐5‐ene) copolymers are prepared and characterized by ¹³C NMR. © 2012 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2013     

Copolymerization of Ethylene and Propylene Using Silicon Tetrachloride‐Modified Silica/MAO with Et[Ind]2ZrCl2 Metallocene Catalyst

For the copolymerization of ethylene with propylene or a higher α‐olefin, using Et[Ind]₂ZrCl₂ metallocene catalyst, modification of silica with silicon tetrachloride prior to MAO adsorption can increase the activity, which is more pronounced for ethylene/1‐hexene copolymerization at higher pressure and temperature. The molecular weight of the copolymer produced was lower and the polydispersity tends to be decreased. No significant effect of SiCl₄ addition on the microstructure and the chemical composition distribution of the copolymer produced was observed.     

Ethylene Polymerization with Combinations of Early- and Late-Transition Metal Catalysts Immobilized on MgCl2 Supports

Immobilization of combinations of early- and late-transition metal catalysts on MgCl₂ supports has led to significant increases in catalyst activity when a nickel diimine is incorporated into a Fe-, Cr- or Ti-based catalyst system, and to the formation of intimately mixed, bimodal blends of high- and low-molecular weight polyethylene via coimmobilization of Cr and Fe catalysts.     

Novel antimicrobial polyethylene composites prepared by metallocenic in situ polymerization with TiO2‐based nanoparticles

Polyethylene (PE) composites with titanium oxide (TiO₂) nanoparticles were produced via in situ polymerization representing a novel route to obtain antimicrobial polymeric materials. The TiO₂ nanoparticles synthesized by the sol–gel method were used either as‐synthesized or modified organically with hexadecyltrimethoxysilane (Mod‐TiO₂). These particles were added, together with the catalytic system (formed by a metallocenic catalyst and methylaluminoxane as cocatalyst), directly to the reactor, yielding in situ PE composites with 2 and 8 wt % content of nanofiller. The catalytic polymerization activity presented a slight decrease with the incorporation of the TiO₂ and Mod‐TiO₂ nanoparticles compared to polymerization without filler. Regarding the properties of the composites, crystallinity increased slightly when the different nanofillers were added, and the elastic modulus increased around 15% compared to neat PE. PE/TiO₂ nanocomposites containing 8 wt % of TiO₂ exposed to UVA irradiations presented antimicrobial activity against Escherichia coli. The PE/Mod‐TiO₂ nanocomposite with 8 wt % filler killed 99.99% of E. coli, regardless of light and time irradiation. © 2012 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2012     

Styrene‐ethylene co‐oligomerization with bis‐(diphenylphosphino)‐amine/chromium catalysts and the use of the co‐oligomerization products in copolymerization reactions with metallocenes

Ethylene‐styrene (or 4‐methylstyrene) co‐oligomerization using various bis(diphenylphoshino)amine ligands in combination with chromium is discussed. GC analysis of the reaction mixture shows that various phenyl‐hexene and phenyl‐octene isomers are formed either through cotrimerization or cotetramerization. It seems that the more bulky ligands display lower selectivity to co‐oligomerization and favor ethylene homo‐oligomerization. Subsequent copolymerization of the oligomerization reaction mixture using a metallocene polymerization catalyst results in a copolymer with a branched structure as indicated by Crystaf and ¹³C NMR analysis. Assignments of the ¹³C NMR spectrum are proposed from an APT NMR experiment combined with calculated NMR chemical shift data using additivity rules. An indication of the ability of the different co‐oligomerization products to copolymerize into the polyethylene chain could be established from these assignments. Unreacted styrene and the more bulky isomers, 3‐phenyl‐1‐hexene and 3‐phenyl‐1‐octene, are not readily incorporated while branches resulting from the other isomers present in the co‐oligomerization reaction mixture are detected in the NMR spectrum. © 2008 Wiley Periodicals, Inc. JPolym Sci Part A: Polym Chem 46: 1488–1501, 2008