Metallocene–methylaluminoxane catalysts for olefin polymerization. I. Trimethylaluminum as coactivator

Ethylene was polymerized by Cp₂ZrCl₂–methylaluminoxane (MAO) catalysts where a portion of the MAO was replaced with trimethyl aluminum (TMA). At a total Al to Zr ratio of 1070, there is neither appreciable loss of productivity nor change in polymerization profile for TMA/MAO ≤ 10. The productivity is reduced only by two- to three-fold for TMA/MAO ≤ 100 accompanied by a 10 min induction period. Aging of this catalyst did not affect the induction period, but improves its productivity. The kinetic isotope effect for radiolabeling with tritiated methanol is 2.0. About 40% of the Zr is active for the catalyst with {99 [TMA] + 1[MAO]} to Zr ratio of 100. The rate constants for propagation and chain transfer were obtained. The mechanisms for the mixed TMA and MAO cocatalyst system are discussed. The results of this work have important practical significance. MAO is a hazardous material to synthesize and only in low yields. The replacement of > 90% of MAO with TMA represents a substantial saving since as much as 0.1M of the former is commonly used for a polymerization.