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     

Methylaluminoxane‐free ethylene polymerization with in situ activated zirconocene triisobutylaluminum catalysts and silica‐supported stabilized borate cocatalysts

Heterogenization of tris(pentafluorophenyl)borane [B(C₆F₅)₃] on a silica support stabilized with chlorotriphenylmethane (CICPh₃) and N,N‐dimethylaniline (HNMe₂Ph) creates the following supported borane cocatalysts: [HNMe₂Ph]⁺[B(C₆F₅)₃‐SiO₂]^? and [CPh₃]⁺[B(C₆F₅)₃‐SiO₂]^?. These supported catalysts were reacted with Cp₂ZrCl₂ TIBA in situ to generate active metallocene species in the reactor. Triisobutylaluminum (TIBA) was a good coactivator for dichloro‐zirconocene, acting as the prealkylating agent to generate cationic zirconocene (Cp₂ZrC₄H₉⁺). The catalytic performances were determined from the kinetics of ethylene‐consumption profiles that were independent of the time dedicated to the activation of the catalysts. The scanning electron microscopy‐energy dispersive X‐ray measurements showed that B(C₆F₅)₃ dispersed uniformly on the silica support. Under our reaction conditions, the [CPh₃]⁺[B(C₆F₅)₃‐SiO₂]^? system had higher productivity and weight‐average molecular weight than the [HNMe₂Ph]⁺[B(C₆F₅)₃‐SiO₂]^? system. For the [CPh₃]⁺[B(C₆F₅)₃‐SiO₂]^? system, the productivity increased with the amount catalyst; however, the polydispersity index of polyethylene synthesized did not change. The final shape of polymer particles was a larger‐diameter version of the original support particle. The polymer particles synthesized with supported [CPh₃]⁺[B(C₆F₅)₃‐SiO₂]^? catalysts had larger diameters. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 3240–3248, 2002     

Effect of TiO2 nanoparticles on structure and properties of high density polyethylene membranes prepared by thermally induced phase separation method

Polyethylene/TiO₂ membranes were fabricated via thermally induced phase separation (TIPS) method. A set of characterization tests including FE‐SEM, EDX, XRD, DSC, TGA, DMA, mechanical test and relative pure water flux for characterization of membranes were carried out to investigate the effect of TiO₂ nanoparticles on membrane properties. The results of EDX, XRD and TGA analyses confirmed the presence of TiO₂ nanoparticles in the polymer matrix. The results of DSC analysis revealed that the melting point as well as the crystallinity of the membranes increased slightly with increasing TiO₂ content. However, the glass transition temperature of the membranes was not affected by the presence of particles. Addition of nanoparticles also increased storage modulus, loss modulus and tensile strength at break of the membranes due to the stiffness improvement effect of inorganic TiO₂. Finally, it was observed that incorporation of the nanoparticles improved pure water flux of the membranes. Copyright © 2015 John Wiley & Sons, Ltd.     

Long‐lived layered silicates‐immobilized 2,6‐bis(imino)pyridyl iron (II) catalysts for hybrid polyethylene nanocomposites by in situ polymerization: Effect of aryl ligand and silicate modification

Heterogeneous‐layered silicate‐immobilized 2,6‐bis(imino)pyridyl iron (II) dichloride/MMAO catalysts, in which the active polymerization species are intercalated within sodium‐ and organomodified‐layered silicate galleries, were prepared for producing hybrid exfoliated polyethylene (PE) nanocomposites by means of in situ polymerization. The inorganic filler was first treated with modified‐methylaluminoxane (MMAO) to produce a supported cocatalyst: MMAO reacts with silicates replacing most of the organic surfactant, thus modifying the original crystallographic clay order. MMAO anchored to the nanoclay was able to activate polymerization iron complexes initiating the polymer growth directly from the filler lamellae interlayer. The polymerization mechanism taking place in between the montmorillonite lamellae separates the layers, thus promoting deagglomeration and effective clay dispersion. Transmission electron microscopy revealed that in situ polymerization by catalytically active iron complexes intercalated within the lower organomodified clay led to fine dispersion and high exfoliation extent. The intercalated clay catalysts displayed a longer polymerization life‐time and brought about ethylene polymerization more efficiently than analogous homogeneous systems. PEs having higher molecular masses were obtained. These benefits resulted to be dependent more on the filler nature than on the ligand environment around the iron metal center and the experimental synthetic route. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 548–564, 2009     

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     

Ethylene/1‐octene copolymerization studies with in situ supported metallocene catalysts: Effect of polymerization parameters on the catalyst activity and polymer microstructure

Ethylene and 1‐octene copolymerizations were carried out with an in situ supported rac‐[dimethylsilylbis(methylbenzoindenyl)] zirconium dichloride catalyst. In a previous study, it was found that some in situ supported metallocenes produced polyethylene/α‐olefin copolymers with broad and bimodal short chain branching distributions and narrow molecular weight distributions. The ability to produce polyolefins with multimodal microstructural distributions in a single metallocene and a single reactor is attractive for producing polymers with balanced properties with simpler reactor technology. In this study, a factorial experimental design was carried out to examine the effects of the polymerization temperature and ethylene pressure, the presence of hydrogen and an alkylaluminum activator, and the level of the comonomer in the feed on the catalyst activity, short chain branching distribution, and molecular weight distribution of the polymer. The temperature had the most remarkable effect on the polymer microstructure. At high 1‐octene levels, the short chain branching distribution of the copolymer broadened significantly with decreasing temperature. Several factor interactions, including the hydrogen and alkylaluminum concentrations, were also observed, demonstrating the sensitivity of the catalyst to the polymerization conditions. For this catalyst system, the responses to the polymerization conditions are not easily predicted from typical polymerization mechanisms, and several two‐factor interactions seem to play an important role. Given the multiple‐site nature of the catalyst, it has been shown that predicting the polymerization activity and the resulting microstructure of the polymer is a challenging task. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 4426–4451, 2002     

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.     

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.     

Novel Route to Immobilize Metallocenes within Silica‐Based Supports: Investigation of a Nonhydrolytic Sol–Gel Process

A novel approach to metallocene catalyst heterogenization is presented. Supported metallocenes are obtained by metallation of indenyl‐modified silica produced by a nonhydrolytic sol–gel process. The catalytic activities for ethylene polymerization are rather high for supported systems and may reach 190 grams of polyethylene per gram of catalyst per hour per bar. The influence of the preparation and composition of these supported metallocene systems on ethylene polymerization and polyethylene characteristics are reported.

Possible structure of the indenyl‐modified silicas.     

Copolymerization behavior of titanium imidazolin‐2‐iminato complexes

Monocyclopentadienyl titanium imidazolin‐2‐iminato complexes [Cp′Ti(L)X₂] 1a (Cp′ = cyclopentadienyl, L = 1,3‐di‐tert‐butylimidazolin‐2‐imide, X = Cl), 1b (X = CH₃); 2 (Cp′ = cyclopentadienyl, L = 1,3‐diisopropylimidazolin‐2‐imide, X = Cl); 3 (Cp′ = tert‐butylcyclopentadienyl, L = 1,3‐di‐tert‐butylimidazolin‐2‐imide, X = Cl), upon activation with methylaluminoxane (MAO) were active for the polymerization of ethylene and propylene and the copolymerization of ethylene and 1‐hexene. Catalysts derived from imidazolin‐2‐iminato tropidinyl titanium complex 4 = [(Trop)Ti(L)Cl₂] (Trop = tropidinyl, L = 1,3‐di‐tert‐butylimidazolin‐2‐imide) were much less active. Narrow polydispersities were observed for ethylene and propylene polymerization, but the copolymerization of ethylene/hexene led to bimodal molecular weight distributions. The productivity of catalysts derived from the dialkyl complex 1b activated with [Ph₃C][B(C₆F₅)₄] or B(C₆F₅)₃ were less active for ethylene/hexene copolymerization but yielded ethylene/hexene copolymers of narrower molecular weight distributions than those derived from 1a/MAO. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 6064–6070, 2008     

Nanocomposites based on polyethylene and nanosilver particles produced by metallocenic “in situ” polymerization: synthesis, characterization, and antimicrobial behavior

Polyethylene nanocomposites containing silver nanoparticles with antimicrobial properties were produced via in situ polymerization. The silver nanoparticles were added together with the catalytic system (metallocene catalyst and methylaluminoxane, MAO, as cocatalyst) directly to the reactor. The polymerization activity did not present significant changes with the incorporation of the silver nanoparticles in comparison to the homopolymerization without filler. The effect of various silver nanoparticle contents on silver ion release and antimicrobial efficacy against Escherichia Coli were studied. Nanocomposites containing higher nanosilver concentrations (5 wt.%) showed the highest silver ion release, and after 24 h reached 99.99% of efficacy against the bacteria compared with the neat PE. Transmission electron microscopy (TEM) images showed that the nanospheres were well dispersed throughout the polyethylene matrix.     

Branched polyethylene prepared by in situ copolymerization of ethylene with monotitanocene and modified methylaluminoxane catalyst

Branched polyethylene was synthesized in heptane used as a polymerization medium with monotitanocene catalyst composed of η⁵‐pentamethylcyclopentadienyl tribenzyloxy titanium and modified methylaluminoxane (mMAO) that contained different amounts of residual trimethylaluminum (TMA). The residual TMA more strongly reduced Ti(IV) complexes to Ti(III) and Ti(II) ones, and Ti(IV) active species were suggested to be more effective for ethylene polymerization. Influences of the polymerization temperature and Al/Ti molar ratio on the catalytic activity and the degree of branching, branch length, and molecular weight of polyethylene were investigated. The obtained polymers were confirmed by ¹³C NMR to be higher molecular weight polyethylene containing significant amounts of isolated ethyl branches, butyl branches, or both. Branched polyethylene was prepared by the in situ copolymerization of ethylene with 1‐butene and 1‐hexene, which were formed through a proposed mechanism including metallcycloheptane and metallcyclopentane intermediates of Ti(II) species that were produced by the reaction of Ti(IV) complexes with TMA coexisting in mMAO. There was a remarkable increase in the chance of 1‐butene being produced from metallcyclopentane of Ti(II) intermediates with an increase in the polymerization temperature. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 4258–4263, 2000     

Some mixed cyclopentadienyl–indenyl zirconium complexes with PhCH2 or PhCH2CH2 substituents in ethylene polymerization

(RCp)(R′Ind)ZrCl₂ complexes 1 – 6 (Cp = cyclopentadienyl; Ind = indenyl; 1 , R = PhCH₂ and R′ = H; 2 , R = PhCH₂ and R′ = PhCH₂; 3 , R = PhCH₂CH₂ and R′ = H; 4 , R = PhCH₂CH₂ and R′ = PhCH₂; 5 , R = o‐Me? PhCH₂CH₂ and R′ = H; 6 , R = o‐Me? PhCH₂ and R′ = H) were synthesized and characterized with ¹H NMR, elemental analysis, mass spectrometry, and infrared spectroscopy. Their catalytic behaviors were compared with those of (Et₃SiCp)(PhCH₂CH₂Cp)ZrCl₂, (PhCH₂Cp)₂ZrCl₂, (PhCH₂‐ CH₂Cp)₂ZrCl₂, (o‐Me? PhCH₂CH₂Cp)₂ZrCl₂, and (Ind)₂ZrCl₂ in ethylene polymerization in the presence of methylaluminoxane. Complex 5 showed high activity up to 2.43 × 10⁶ g of polyethylene (PE)/mol of Zr h, and complex 4 produced PE with bimodal molecular weight distributions. The methyl group at the 2‐position of phenyl in complex 5 increased the activity greatly. The relationships between the polymerization results and the structures were analyzed with NMR spectral data. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 1261–1269, 2005     

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     

Thermal and mechanical analysis of metallocene‐catalyzed ethene–α‐olefin copolymers: The influence of the length and number of the crystallizing side chains

Copolymers of ethene and 1‐octene, 1‐dodecene, 1‐octadecene, and 1‐hexacosene were carried out with [Ph₂C(2,7‐di‐^tertBuFlu)(Cp)]ZrCl₂/methylalumoxane as a catalyst to obtain short‐chain branched polyethylenes with branch lengths of 6–26 carbon atoms. This catalyst provided high activity and a very good comonomer and hydrogen response. In this study, the influence of the length and number of the side chains on the mechanical properties of the materials was investigated. The crystalline methylene sequence lengths of the copolymers and lamellar thicknesses were calculated after the application of a differential scanning calorimetry/successive self‐annealing separation technique. By dynamic mechanical analysis, the storage modulus as an indicator of the stiffness and the loss modulus as a measure of the effect of branching on the α and β relaxations were studied. The results were related to the measurements of the polymer density and tensile strength to determine the effect of longer side chains on the material properties. The hexacosene copolymers had side chains of 24 carbons and remarkable material properties very different from those of conventional linear low‐density polyethylenes. The side chains of these copolymers crystallized with one another and not only parallel to the backbone lamellar layer, depending on the hexacosene concentration in the copolymer. The side chains crystallized even at low hexacosene concentrations in the copolymer. A transfer of these results to 16 carbons side chains in ethene–octadecene copolymers was also possible. © 2006 The Authors. Journal of Polymer Science Part A: Polymer Chemistry Published by Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 1600–1612, 2006     

Morphology and physical properties of polyethylene/silicate nanocomposite prepared by melt intercalation

Maleated polyethylene (PEMA)/silicate nanocomposites with a different aspect ratio of silicate and maleated PEMA/SiO₂ composite were prepared by melt intercalation. The nanocomposites with a high aspect ratio silicate (montmorillonite) showed a faster decrease in the terminal slope of the storage modulus and a steeper increase in complex viscosity than those with a low aspect ratio silicate (laponite) and SiO₂. The addition of montmorillonite increases the crystallization and the melting temperature of PEMA but decreases above 3 vol % of the silicate content because of the increased viscosity. The nanocomposite with montmorillonite showed the highest yield strength and secant modulus among the composites because of the highest aspect ratio of the filler. It also revealed strong interfacial adhesion with the matrix and orientation during tensile deformation. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 40: 1454–1463, 2002     

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.

     

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     

Salicylaldiminato nickel(II) catalysts with 5‐halo‐3‐methoxy groups for ethylene polymerization

Two neutral salicylaldiminato methyl pyridine nickel(II) complexes were synthesized and evaluated for ethylene polymerization. Each catalyst bears a methoxy group in the 3‐position and a halogen atom in the 5‐position of the salicyl ligand, chlorine in case of catalyst 3a and bromine in 3b . Molecular structures of the catalysts were obtained by X‐ray crystallography. The resulting polymerization activities, for example, indicated by a maximum turnover frequency of 4,870 mol ethylene/(mol Ni × h) for 1‐h runs obtained with 3a , were higher than those of similar catalysts at comparable conditions reported in the literature. Catalyst 3a was slightly more active than catalyst 3b . The polymers are branched as measured by ¹H NMR and ¹³C NMR. This was also reflected in the melting temperatures between 76 and 113 °C obtained by differential scanning calorimetry. By using gel permeation chromatography measurements, it was determined that the M_w of the polymers ranges between about 5,400 and 21,600 g/mol. In particular, the effect of the polymerization temperature on the catalyst activity, degree of branching, and molecular weight properties has been described. © 2011 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2012     

Dielectric,thermal, and mechanical properties of CeO2‐filled HDPE composites for microwave substrate applications

Cerium oxide‐filled high density polyethylene (HDPE) composites for microwave substrate applications were prepared by sigma‐blend technique. The HDPE was used as the matrix and the dispersion of CeO₂ in the composite was varied up to 0.5 by volume fraction, and the dielectric properties were studied at 1 MHz and microwave frequencies. The variations of thermal conductivity (k_eff), coefficient of thermal expansion (α_c) and Vicker's microhardness with the volume fraction of the filler were also measured. The relative permittivity (ε_eff) and dielectric loss (tan δ) were found to increase with increase in CeO₂ content. For 0.4 volume fraction loading of the ceramic, the composite had ε_eff = 5.7, tan δ = 0.0068 (at 7 GHz), k_eff = 2.6 W/m °C, α_c = 98.5 ppm/°C, Vicker's microhardness of 18 kg/mm² and tensile strength of 14.6 MPa. Different theoretical approaches have been used to predict the effective permittivity, thermal conductivity, and coefficient of thermal expansion of composite systems and the results were compared with the experimental data. © 2010 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 48: 998–1008, 2010