The investigation of novel non‐metallocene catalysts with phenoxy‐imine ligands for ethylene (co‐)polymerization

Phthaldialdehyde and phthaldiketone were treated with substituted phenols of 2‐amino‐4‐methylphenol, 2‐amino‐5‐methylphenol and 2‐amino‐4‐t‐butylphenol, respectively, and then treated with transition metal halides of TiCl₄, ZrCl₄ and YCl₃. A series of novel non‐metallocene catalysts (1–12) with phenoxy‐imine ligands was obtained. The structures and properties of the catalysts were characterized by ¹H NMR and elemental analysis. The catalysts (1–12) were used to promote ethylene (co‐)polymerization after activation by methylaluminoxane. The effects of the structures and center atoms (Ti, Zr and Y) of these catalysts, polymerization temperature, Al/M (M = Ti, Zr and Y) molar ratio, concentration of the catalysts and solvents on the polymerization performance were investigated. The results showed that the catalysts were favorable for ethylene homopolymerization and copolymerization of ethylene with 1‐hexene. Catalyst 10 is most favorable for catalyzing ethylene homopolymerization and copolymerization of ethylene with 1‐hexene, with catalytic activity up to 2.93 × 10⁶ gPE (mol Y)^?1 h^?1 for polyethylene (PE) and 2.96 × 10⁶ gPE (mol Y)^?1 h^?1 for copolymerization of ethylene with 1‐hexene under the following conditions: polymerization temperature 50 °C, Al/Y molar ratio 300, concentration of catalyst 1.0 × 10^?4 L^?1 and toluene as solvent. The structures and properties of the polymers obtained were characterized by Fourier transform infrared spectroscopy, ¹³C NMR, wide‐angle X‐ray diffraction, gel permeation chromatography and DSC. The results indicated that the obtained PE catalyzed by 4 had the highest melting point of 134.8 °C and the highest weight‐average molecular weight of 7.48 × 10⁵ g mol^?1. The copolymer catalyzed by 4 had the highest incorporation of 1‐hexene, up to 5.26 mol%, into the copolymer chain. © 2012 Society of Chemical Industry     

Gas‐phase olefin polymerization over supported metallocene/MAO catalysts: influence of support on activity and polydispersity

Three catalysts obtained by supporting bis(n‐butylcyclopentadienyl)zirconium dichloride/methylaluminoxane on: (1) porous crosslinked poly(2‐hydroxyethylmethacrylate‐co‐styrene‐co‐divinylbenzene) particles (CAT1); (2) swellable crosslinked poly(styrene‐co‐divinylbenzene) particles (CAT2); and (3) by evaporating the catalyst precursors solution to dry powder, CAT3 were used in gas‐phase polymerization of ethylene, and ethylene/1‐hexene in a 2 L semi‐batch reactor at 80 °C and 1.4 MPa. The average polymerization activities of the three catalysts were 12.3–15.5, 4.2–10.1, and 14.3–62.9 ton PE (mol Zr h)^?1 respectively. CAT1 and CAT3 produced polyethylenes with a polydispersity range of 2.3–2.7, while that of CAT2 was 3.5–6.4. The supported catalysts produced polyolefin particles with bulk density of 0.36–0.43 g ml^?1, and essentially no fines. Ethylene/1‐hexene co‐polymerization (7 mol m^?3 initial 1‐hexene concentration in the reactor) increased polymerization activities and produced lower‐molar‐mass co‐polymers. At 21 mol m^?3 1‐hexene the polymerization activities decreased, but the relative amount of the low‐molar‐mass co‐polymer for CAT2 increased, leading to higher polydispersity. Copyright © 2006 Society of Chemical Industry     

Ethylene/α‐olefin copolymerization by nonbridged (cyclopentadienyl)(aryloxy)titanium(IV) dichloride/AliBu3/Ph3CB(C6F5)4 catalyst systems

A series of nonbridged (cyclopentadienyl) (aryloxy)titanium(IV) complexes of the type, (η⁵‐Cp′)(OAr)TiCl₂ [OAr = O‐2,4,6‐^tBu₃C₆H₂ and Cp′ = Me₅C₅ ( 1 ), Me₄PhC₅ ( 2 ), and 1,2‐Ph₂‐4‐MeC₅H₂ ( 3 )], were prepared and used for the copolymerization of ethylene with α‐olefins (e.g., 1‐hexene, 1‐octene, and 1‐octadecene) in presence of AlⁱBu₃ and Ph₃CB(C₆F₅)₄ (TIBA/B). The effect of the catalyst structure, comonomer, and reaction conditions on the catalytic activity, comonomer incorporation, and molecular weight of the produced copolymers was examined. The substituents on the cyclopentadienyl group of the ligand in 1 – 3 play an important role in the catalytic activity and comonomer incorporation. The 1 /TIBA/B catalyst system exhibits the highest catalytic activity, while the 3 /TIBA/B catalyst system yields copolymers with the highest comonomer incorporation under the same conditions. The reactivity ratio product values are smaller than those by ordinary metallocene type, which indicates that the copolymerization of ethylene with 1‐hexene, 1‐octene, and 1‐octadecene by the 1–3/ TIBA/B catalyst systems does not proceed in a random manner. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Preparation of ethylene/1‐octene copolymers from ethylene stock with tandem catalytic system

Tandem catalysis offers a novel synthetic route to the production of linear low‐density polyethylene. This article reports the use of homogeneous tandem catalytic systems for the synthesis of ethylene/1‐octene copolymers from ethylene stock as the sole monomer. The reported catalytic systems involving a highly selective, bis(diphenylphosphino)cyclohexylamine/Cr(acac)₃/methylaluminoxane (MAO) catalytic systems for the synthesis of 1‐hexene and 1‐octene, and a copolymerization metallocene catalyst, rac‐Et(Ind)₂ZrCl₂/MAO for the synthesis of ethylene/1‐octene copolymer. Analysis by means of DSC, GPC, and ¹³C‐NMR suggests that copolymers of 1‐hexene and ethylene and copolymers of 1‐octene and ethylene are produced with significant selectivity towards 1‐hexene and 1‐octene as comonomers incorporated into the polymer backbone respectively. We have demonstrated that, by the simple manipulation of the catalyst molar ratio and polymerization conditions, a series of branched polyethylenes with melting temperatures of 101.1–134.1°C and density of 0.922–0.950 g cm^?3 can be efficiently produced. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

New fluorine‐containing bissalicylidenimine–titanium complexes for olefin polymerization

Three new titanium complexes bearing salicylidenimine ligands—bis[(salicylidene)‐2,3,5,6‐tetrafluoroanilinato]titanium(IV) dichloride ( 1 ), bis[(3,5‐di‐tert‐butylsalicylidene)‐2,3,5,6‐tetrafluoroanilinato]titanium(IV) dichloride ( 2 ), and bis[(3,5‐di‐tert‐butylsalicylidene)‐4‐trifluoromethyl‐2,3,5,6‐tetrafluoroanilinato]titanium(IV) dichloride ( 3 )—were synthesized. The catalytic activities of 1 – 3 for ethylene polymerization were studied with poly(methylaluminoxane) (MAO) as a cocatalyst. Complex 1 was inactive in ethylene polymerization. Complex 2 at a molar ratio of cocatalyst to pre catalyst of Al_MAO/Ti = 400–1600 showed very high activity in ethylene polymerization comparable to that of the most efficient metallocene complexes and titanium compounds with phenoxy imine and indolide imine chelating ligands. It gave linear high‐molecular‐weight polyethylene [weight‐average molecular weight (M_w) ≥ 1,700,000. weight‐average molecular weight/number‐average molecular weight (M_w/M_n) = 4–5] with a melting point of 142°C. The ability of the 2 /MAO system to copolymerize ethylene with hexene‐1 in toluene was analyzed. No measurable incorporation of the comonomer was observed at 1:1 and 2:1 hexene‐1/ethylene molar ratios. However, the addition of hexene‐1 had a considerable stabilizing effect on the ethylene consumption rate and lowered the melting point of the resultant polymer to 132°C. The 2 /MAO system exhibited low activity for propylene polymerization in a medium of the liquid monomer. The polymer that formed was high‐molecular‐weight atactic polypropylene (M_w ～ 870,000, M_w/M_n = 9–10) showing elastomeric behavior. The activity of 3 /MAO in ethylene polymerization was approximately 70 times lower than that of the 2 /MAO system. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 95: 1040–1049, 2005     

Self‐induced short chain branching in homopolymers and 1‐hexene copolymers of ethylene produced with amido functionalized ansa half‐sandwich complexes as catalysts

Amido ansa 3‐substituted indenyl complex precursors can be activated with methylaluminoxane and used for prepolymerization with ethylene to give a heterogeneous catalyst for olefin polymerization. Homo polymerization of ethylene with 1‐(3‐pent‐4‐enylindenylidene) dimethylsilyl'butylamidotitaniumdichloride (1), 1‐(3‐hex‐5‐enylindenylidene)dimethylsilyl'butylamidotitanium‐dichloride (2), and 1‐(3‐pent‐4‐enylindenylidene) (oct‐7‐enyl)methylsilyl'butylamidotitaniumdichloride (3) produces polyethylenes that contain ethyl branches. The ethyl branching in the polymers made with complexes 1 and 2 is barely above the ¹³C NMR detection limit, but the level observed in the polymer made with complex 3 is 17 times greater. Copolymerization of ethylene and 1‐hexene using prepolymerized 3 yields copolymers containing both ethyl and butyl branches. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 734–739, 2006     

Organic/inorganic support for immobilizing (n‐BuCp)2ZrCl2/TiCl3 hybrid catalyst for use in the preparation of polymer blends

Reactor blends of ultrahigh‐molecular‐weight polyethylene (UHMWPE) and low‐molecular‐weight polyethylene (LMWPE) were synthesized by two‐step polymerization using a hybrid catalyst. To prepare the hybrid catalyst, styrene acrylic copolymer (PSA) was first coated onto SiO₂/MgCl₂‐supported TiCl₃; then, (n‐BuCp)₂ZrCl₂ was immobilized onto the exterior PSA. UHMWPE was produced in the first polymerization stage with the presence of 1‐hexene and modified methylaluminoxane (MMAO), and the LMWPE was prepared with the presence of hydrogen and triethylaluminium in the second polymerization stage. The activity of the hybrid catalyst was considerable (6.5 × 10⁶ g PE (mol Zr)^?1 h^?1), and was maintained for longer than 8 h during the two‐step polymerization. The barrier property of PSA to the co‐catalyst was verified using ethylene polymerization experiments. The appearance of a lag phase in the kinetic curve during the first‐stage polymerization implied that the exterior catalyst ((n‐BuCp)₂ZrCl₂) could be activated prior to the interior catalyst (M‐1). Furthermore, the melting temperature, crystallinity, degree of branching, molecular weight and molecular‐weight distribution of polyethylene obtained at various polymerization times showed that the M‐1 catalyst began to be activated by MMAO after 40 min of the reaction. The activation of M‐1 catalyst led to a decrease in the molecular weight of UHMWPE. Finally, the thermal behaviors of polyethylene blends were investigated using differential scanning calorimetry. Copyright © 2011 Society of Chemical Industry     

Copolymerization of ethylene/α‐olefins over (2‐MeInd)2ZrCl2/MAO and (2‐BzInd)2ZrCl2/MAO systems

Ethylene homopolymerization and ethylene/α‐olefin copolymerization were carried out using unbridged and 2‐alkyl substituted bis(indenyl)zirconium dichloride complexes such as (2‐MeInd)₂ZrCl₂ and (2‐BzInd)₂ZrCl₂. Various concentrations of 1‐hexene, 1‐dodecene, and 1‐octadecene were used in order to find the effect of chain length of α‐olefins on the copolymerization behavior. In ethylene homopolymerization, catalytic activity increased at higher polymerization temperature, and (2‐MeInd)₂ZrCl₂ showed higher activity than (2‐BzInd)₂ZrCl₂. The increase of catalytic activity with addition of comonomer (the synergistic effect) was not observed except in the case of ethylene/1‐hexene copolymerization at 40°C. The monomer reactivity ratios of ethylene increased with the decrease of polymerization temperature, while those of α‐olefin showed the reverse trend. The two catalysts showed similar copolymerization reactivity ratios. (2‐MeInd)₂ZrCl₂ produced the copolymer with higher M_w than (2‐BzInd)₂ZrCl₂. The melting temperature and the crystallinity decreased drastically with the increase of the α‐olefin content but T_m as a function of weight fraction of the α‐olefins showed similar decreasing behavior. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 75: 928–937, 2000     

Synthesis of poly(1‐hexene)s end‐functionalized with phenols

Electrophilic alkylations of phenol/2,6‐dimethylphenol were performed with vinylidene‐terminated poly(1‐hexene)s using BF₃·OEt₂ catalyst. Vinylidene‐terminated poly(1‐hexene)s with M_n varying from 400 to 10000 were prepared by bulk polymerization of 1‐hexene at 50 to ?20 °C using Cp₂ZrCl₂/MAO catalysts. The phenol/2,6‐dimethylphenol‐terminated poly(1‐hexene)s was characterized by NMR (¹H, ¹³C), UV, IR and vapor phase osmometer (VPO). The isomer distribution (ortho, para and ortho/para) was determined by ¹³P NMR using a phosphitylating reagent, namely 2‐chloro‐1,3,2‐dioxaphospholane. The number‐average degree of functionality (F_n) >0.9 with >95% para selectivity could be achieved using low‐molecular‐weight oligomers of poly(1‐hexene)s. Copyright © 2005 Society of Chemical Industry     

Silica‐supported (nBuCp)2ZrCl2: effect of catalyst active center distribution on ethylene–1‐hexene copolymerization

Metallocenes are a modern innovation in polyolefin catalysis research. Therefore, two supported metallocene catalysts—silica/MAO/(ⁿBuCp)₂ZrCl₂ (Catalyst 1) and silica/ⁿBuSnCl₃/MAO/(ⁿBuCp)₂ZrCl₂ (Catalyst 2), where MAO is methylaluminoxane—were synthesized, and subsequently used to prepare, without separate feeding of MAO, ethylene–1‐hexene Copolymer 1 and Copolymer 2, respectively. Fouling‐free copolymerization, catalyst kinetic stability and production of free‐flowing polymer particles (replicating the catalyst particle size distribution) confirmed the occurrence of heterogeneous catalysis. The catalyst active center distribution was modeled by deconvoluting the measured molecular weight distribution and copolymer composition distribution. Five different active center types were predicted for each catalyst, which was corroborated by successive self‐nucleation and annealing experiments, as well as by an extended X‐ray absorption fine structure spectroscopy report published in the literature. Hence, metallocenes impregnated particularly on an MAO‐pretreated support may be rightly envisioned to comprise an ensemble of isolated single sites that have varying coordination environments. This study shows how the active center distribution and the design of supported MAO anions affect copolymerization activity, polymerization mechanism and the resulting polymer microstructures. Catalyst 2 showed less copolymerization activity than Catalyst 1. Strong chain transfer and positive co‐monomer effect—both by 1‐hexene—were common. Each copolymer demonstrated vinyl, vinylidene and trans‐vinylene end groups, and compositional heterogeneity. All these findings were explained, as appropriate, considering the modeled active center distribution, MAO cage structure repeat units, proposed catalyst surface chemistry, segregation effects and the literature that concerns and supports this study. While doing so, new insights were obtained. Additionally, future research, along the direction of the present work, is recommended. © 2013 Society of Chemical Industry     

Comonomer effects in copolymerization of ethylene and 1‐hexene with MgCl2‐supported Ziegler‐Natta catalysts: New evidences from active center concentration and molecular weight distribution

In this article, comonomer effects in copolymerization of ethylene and 1‐hexene with four MgCl₂‐supported Ziegler‐Natta catalysts using either ethylene or 1‐hexene as the main monomer were investigated. It was found that no matter which monomer was used as the main monomer, the polymerization activity was significantly enhanced by introducing small amount of comonomer. In copolymerization with ethylene as the main monomer, the strength of comonomer effects was much stronger in active centers producing low‐molecular‐weight polymer than those producing high‐molecular‐weight polymer. In copolymerization with 1‐hexene as the main monomer, the number of active centers ([C*]/[Ti]) was determined, and the propagation rate constants (k_p) were calculated. Deconvolution of the polymer molecular weight distribution into Flory components were made to study the active center distribution. Introduction of small amount of ethylene caused marked increase in the number of active centers and decrease in average chain propagation rate constant. Introducing internal electron donor in the catalyst enhanced not only the number of active centers but also the chain propagation rate constant. In copolymerization of 1‐hexene with small amount of ethylene, the internal donor weakened the comonomer effects to some extent and changed the distribution of comonomer effects among different types of active centers. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41264.     

Ethylene/1‐hexene copolymerization with supported Ziegler–Natta catalysts prepared by immobilizing TiCl3(OAr) onto MgCl2

Five titanium complexes TiCl₃(OAr) (Ar = C₆H₅? , 2,6‐Me₂C₆H₃? , 2,6‐i‐Pr₂C₆H₃? , 2,6‐t‐Bu₂C₆H₃? , 4‐Me‐2,6‐t‐Bu₂C₆H₃? ) were immobilized, respectively, on MgCl₂ in semibatch reaction to form supported catalysts for olefin polymerization. Comparing with the catalysts prepared by immobilizing TiCl₃(OAr) onto MgCl₂ in batch reaction, the catalysts prepared by semibatch reaction have lower titanium content and higher ArO/Ti ratio. The aryloxy‐containing catalysts studied in this work showed higher ethylene/1‐hexene copolymerization activity and higher 1‐hexene incorporation rate than the blank catalyst when activated by triisobutylaluminum. Similar effects of the aryloxy ligand were observed when the copolymerization is conducted in the presence of hydrogen. Introducing aryloxy ligand in the catalysts either by semibatch or batch reaction caused similar effects of enhancing copolymerization activity and α‐olefin incorporation rate. Mechanism of the effects of aryloxy ligand has been discussed. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41329.     

Isobutylaluminum aryloxides as metallocene activators in Homo‐ and copolymerization of olefins

The article describes that sterically hindered isobutylaluminum aryloxides with bulky ^tBu substituents at 2,6‐ positions of aryl fragment, i.e. (2,6‐di‐^tBu,4‐R‐C₆H₂O)AlⁱBu₂ (R = H ( 1‐DTBP ), Me ( 1‐BHT ), ^tBu ( 1‐TTBP )) and (2,6‐di‐^tBu,4‐R‐C₆H₂O)₂AlⁱBu (R=H( 2‐DTBP ), Me( 2‐BHT )) can serve as cocatalysts for metallocene complexes. Isobutylaluminum aryloxides have been applied for activation of rac‐Et(2‐MeInd)₂ZrMe₂ in homopolymerization of ethylene, propylene, copolymerization of ethylene and propylene, and terpolymerization of ethylene, propylene, and 5‐ethylidene‐2‐norbornene at Al/Zr = 300 mol/mol. The type of R substituent at 4‐position has a significant effect on catalyst activity. The catalytic system with 1‐TTBP showed the highest activity in all homo‐ and copolymerization processes. Diisobutylaluminum aryloxides provide much higher activity to the systems in all polymerization processes and stronger ability for propylene incorporation in copolymer than diaryloxides. The activities of the systems with isobutylaluminum aryloxides are similar or exceed that of the system with MAO as activator as have shown for propylene polymerization. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43276.     

Polymerization of acrylonitrile catalyzed by single yttrium tris(2,6‐di‐tert‐butyl‐4‐methyl phenolate)

Polymerization of acrylonitrile was carried out using yttrium tris(2,6‐di‐tert‐butyl 4‐methyl‐phenolate) (Y(OAr)₃) as single component catalyst for the first time. The effects of concentrations of the monomer and catalyst, kinds of rare earth element and solvent, as well as temperature and polymerization time were investigated. The overall activation energy of polymerization in n‐hexane and THF mixture is 18.3 kJ mol^?1. Polyacrylonitriles (PANs) obtained by using Y(OAr)₃ in n‐hexane and THF mixture at 50 °C are predominantly atactic, while yellow PANs obtained in DMF under the same conditions have a syndiotactic‐rich configuration (>50%), and their highly branched and/or cyclized structures have also been found. © 2002 Society of Chemical Industry     

Effects of aluminum alkyls on ethylene/1‐hexene polymerization with supported metallocene/MAO catalysts in the gas phase

The effects of aluminum alkyls on the gas‐phase ethylene homopolymerization and ethylene/1‐hexene copolymerization over polymer‐supported metallocene/methylaluminoxane [(n‐BuCp)₂ZrCl₂/MAO] catalysts were investigated. Results with triisobutyl aluminum (TIBA), triethyl aluminum (TEA), and tri‐n‐octyl aluminum (TNOA) showed that both the type and the amount of aluminum alkyl influenced the polymerization activity profiles and to a lesser extent the polymer molar masses. The response to aluminum alkyls depended on the morphology and the Al : Zr ratio of the catalyst. Addition of TIBA and TEA to supported catalysts with Al : Zr >200 reduced the initial activity but at times resulted in higher average activities due to broadening of the kinetic profiles, i.e., alkyls can be used to control the shape of the activity profiles. A catalyst with Al : Zr = 110 exhibited relatively low activity when the amount of TIBA added was <0.4 mmol, but the activity increased fivefold by increasing the TIBA amount to 0.6 mmol. The effectiveness of the aluminum alkyls in inhibiting the initial polymerization activity is in the following order: TEA > TIBA >> TNOA. A 2‐L semibatch reactor, typically run at 80°C and 1.4 MPa ethylene pressure for 1 to 5 h was used for the gas‐phase polymerization. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 92: 3549–3560, 2004     

Study of the influence of the reaction parameters on the composition of the metallocene‐catalyzed ethylene copolymers using temperature rising elution fractionation and 13C nuclear magnetic resonance

Polyethylene copolymers prepared using the metallocene catalyst rac‐Et[Ind]₂ZrCl₂ were fractionated by preparative Temperature Rising Elution Fractionation (p‐TREF) and characterized by ¹³C nuclear magnetic resonance (NMR), differential scanning calorimetry (DSC), and gel permeation chromatography (GPC) to study the heterogeneity caused by experimental conditions. Two ethylene–1‐hexene copolymers with different 1‐hexene content and an ethylene–1‐octene copolymer all obtained using low (1.6 bar) ethylene pressure were compared with two ethylene–1‐hexene copolymers with different 1‐hexene content obtained at high ethylene pressure (7.0 bar). Samples obtained at low ethylene pressure and with low 1‐hexene concentration in the reactor presented narrow distributions in composition. Samples prepared with high comonomer concentration in the reactor or with high ethylene pressure showed an heterogeneous composition. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 155–163, 2002; DOI 10.1002/app.10284     

Ring‐opening metathesis polymerization of norbornene catalyzed by tantalum and niobium complexes with chelating O‐donor ligands

BACKGROUND: In comparison with group 6 transition metals, such as tungsten and molybdenum, and group 8 metal ruthenium, group 5 metal‐based catalysts for ring‐opening metathesis polymerization (ROMP) have remained much less studied. The few reported ROMP catalysts of group 5 metals require multiple reaction steps to be synthesized, and are highly sensitive to air and moisture. RESULTS: A series of pentavalent tantalum and niobium complexes having catecholato, tropolonato, hinokitiolato, biphenolato and binaphtholato ligands were prepared and their catalytic activities for the ROMP of norbornene (NBE) were studied in the presence of trialkylaluminium as a co‐catalyst. Among these complexes, the tantalum complexes showed high activity upon activation with Buⁱ₃Al. In sharp contrast, the niobium complexes were effectively activated with Me₃Al. The polymers obtained with these complexes had high molecular weights (M_n > 10⁵ g mol⁻¹) and relatively narrow molecular weight distributions (M_w/M_n ≈ 2). CONCLUSION: We found that easily accessible and relatively stable tantalum and niobium complexes with such chelating O‐donor ligands showed high catalytic activity for ROMP of NBE depending on the kind of co‐catalyst. These findings could contribute to future development of ROMP catalysts. Copyright © 2008 Society of Chemical Industry     

Copolymerization and characterization of ethene–1‐hexene copolymers prepared by using the (Me5Cp)2ZrCl2–MAO catalyst system

It is demonstrated that the catalyst system bis(pentamethylcyclopentadienyl)‐zirconium dichloride (Me₅Cp)₂ZrCl₂–methylaluminoxane (MAO) is able to produce random copolymers of ethene and 1‐hexene. The 1‐hexene incorporation in the copolymers is extremely small. Even in the case of a molar ratio of [ethene] to [1‐hexene] of 1/20 in the monomer feed, only 1.4 mol % 1‐hexene are incorporated according to ¹³C nuclear magnetic resonance (NMR) spectra. Nevertheless, the physical properties of the random copolymers change significantly in this small range of 1‐hexene incorporation, from a high‐density polyethene to a linear low‐density polyethene. Thus, the melting temperature, the degree of crystallinity, the density and lamella thickness, and the long period of the alternating crystalline and amorphous regions decrease with increasing 1‐hexene content in the random copolymers. Blends of high‐density polyethene prepared with the system (Me₅Cp)₂ZrCl₂–MAO and an elastomeric random copolymer of ethene and 1‐hexene are phase‐separated and show good compatibility, as demonstrated by transmission electron microscopy. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 74: 439–447, 1999     

Behavior of poly(ethylene‐co‐olefin) polymers as elastomeric materials

The properties of two new ethylene‐α‐olefin copolymers, namely, ethylene–1‐hexene copolymer (EHC) and ethylene–1‐octadecene copolymers (EOC), synthesized via metallocene catalysts were evaluated. The copolymerization was carried out in an autoclave reactor with Et(Indenyl)₂ZrCl₂/methylaluminoxane as a catalyst system. These single‐site catalysts (metallocene type) allow one to obtain very homogeneous copolymers with excellent control of the molecular weight distribution and proportion of comonomer incorporation. So, copolymers with 18 mol % comonomer in the case of EHC and 12 mol % for EOC were shaped, and activities around 100,000 kg of polymer mol^?1 of Zr bar^?1 h^?1 were reached. The properties of these copolymers were compared with other commercial elastomers, such as ethylene–propylene copolymers synthesized by Ziegler–Natta catalysts and an ethylene–octene copolymer obtained via metallocene catalysts. The results show that these new copolymers, in particular, EOC, had excellent elastomeric properties. Furthermore, they had a relatively low viscosity, which implied a good response during processing. Moreover, the effectiveness of these copolymers as impact modifiers for polyolefins was also studied. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 92: 3008–3015, 2004     

FI Catalysts: A New Family of High Performance Catalysts for Olefin Polymerization

This paper reviews a new family of olefin polymerization catalysts. The catalysts, named FI catalysts, are based on non‐symmetrical phenoxyimine chelate ligands combined with group 4 transition metals and were developed using “ligand‐oriented catalyst design”. FI catalysts display very high ethylene polymerization activities under mild conditions. The highest activity exhibited by a zirconium FI catalyst reached an astonishing catalyst turnover frequency (TOF) of 64,900 s ^–1 atm ^–1, which is two orders of magnitude greater than that seen with Cp₂ZrCl₂ under the same conditions. In addition, titanium FI catalysts with fluorinated ligands promote exceptionally high‐speed, living ethylene polymerization and can produce monodisperse high molecular weight polyethylenes (M_w/M_n<1.2, max. M_n>400,000) at 50 °C. The maximum TOF, 24,500 min ^–1 atm ^–1, is three orders of magnitude greater than those for known living ethylene polymerization catalysts. Moreover, the fluorinated FI catalysts promote stereospecific room‐temperature living polymerization of propylene to provide highly syndiotactic monodisperse polypropylene (max. [rr] 98%). The versatility of the FI catalysts allows for the creation of new polymers which are difficult or impossible to prepare using group 4 metallocene catalysts. For example, it is possible to prepare low molecular weight (M_v∼10³) polyethylene or poly(ethylene‐co‐propylene) with olefinic end groups, ultra‐high molecular weight polyethylene or poly(ethylene‐co‐propylene), high molecular weight poly(1‐hexene) with atactic structures including frequent regioerrors, monodisperse poly(ethylene‐co‐propylene) with various propylene contents, and a number of polyolefin block copolymers [e.g., polyethylene‐b‐poly(ethylene‐co‐propylene), syndiotactic polypropylene‐b‐poly(ethylene‐co‐propylene), polyethylene‐b‐poly(ethylene‐co‐propylene)‐b‐syndiotactic polypropylene]. These unique polymers are anticipated to possess novel material properties and uses.