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     

Crystallization behavior of ultrahigh‐molecular‐weight polyethylene/polyhedral oligomeric silsesquioxane nanocomposites prepared by ethylene in situ polymerization

A [3‐t‐Bu‐2‐O? C₆H₃CH?N(C₆F₅)]₂TiCl₂ catalyst (bis(phenoxyimine)titanium dichloride complex – FI catalyst) was immobilized on disilanolisobutyl polyhedral oligomeric silsesquioxane (OH‐POSS) to prepare ultrahigh molecular‐weight polyethylene (UHMWPE)/polyhedral oligomeric silsesquioxane (POSS) nanocomposites during ethylene in situ polymerization. The dispersion state of POSS in the UHMWPE matrix was characterized by X‐ray diffraction measurements and transmission electron microscopy. It was shown that the OH‐POSS achieved uniformed dispersion in the UHMWPE matrix, although its polarity was unmatched. The isothermal and nonisothermal crystallization behavior of the nanocomposites was investigated by means of differential scanning calorimetry. The crystallization rate of the nanocomposites was enhanced because of the incorporation of POSS during the isothermal crystallization. POSS acted as a nucleus for the initial nucleation and the subsequent growth of the crystallites. For nonisothermal studies, POSS showed an increase in the crystallinity. The crystallization rate of the nanocomposites decreased because the presence of POSS hindered the crystal growth. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40847.     

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.     

Preparation of ultra high molecular weight polyethylene with MgCl<Subscript>2</Subscript>/TiCl<Subscript>4</Subscript> catalyst: effect of internal and external donor on molecular weight and molecular weight distribution

Ultra high molecular weight polyethylene (UHMWPE) was prepared by using MgCl₂-supported TiCl₄ catalyst in conjunction with triethylaluminium (TEA) cocatalyst. The effects of internal and external donor on polydispersity index (PDI) of UHMWPE were investigated. The catalyst activity with various kinds of internal donor decreased in the following order: none > succinate > phthalate > diether, while the catalyst activity was less influenced by the structure of external donor. The PDI of UHMWPE was examined by using gel permeation chromatography (GPC) analysis and/or rheometry measurements. The PDI obtained by rheometer was matched with the results obtained by GPC within an error of max. 20%. The highest molecular weight and PDI of UHMWPE were obtained by the catalyst of succinate as internal donor. It was also observed that the molecular weight and PDI of UHMWPE were less affected by the introduction of external donor.     

Control of both molecular weight and comonomer response of ethylene polymerization via utilization of alkyl branches at the para-xylene bridge of new dinuclear constrained geometry catalysts

We synthesized a series of four dinuclear constrained geometry catalysts (DCGCs) containing alkyl-substituted para-xylene bridges [TiCl₂{N(^tBu)Si(Me)₂}C₉H₅]₂[(CH₂){(R)₂C₆H₂}(CH₂)]: 13 (R = hydrogen), 14 (R = isopropyl), 15 (R = n-hexyl), and 16 (R = n-octyl). The structures and compositions of the synthesized complexes were conveniently identified by ¹H NMR, ¹³C NMR and elemental analysis (EA). In order to determine the effect of steric and electronic properties of various alkyl branches on the xylene group, ethylene homo and copolymerization experiments by use of these metallocenes have been conducted. Dow CGC ([Me₂Si (μ⁵-Me₄Cp)N^tBu]TiCl₂) has been used as the control catalyst for comparison. It was found that the activity of Catalyst 13 was highest and the activities of the new DCGCs were much higher than that of Dow CGC. Polyethylene having more than 1,000,000 g/mol of molecular weight that may be classified as ultra high molecular weight polyethylene (UHMWPE) has been able to be successfully produced from the new DCGCs. Most importantly it was demonstrated that the control of polymerization properties of DCGCs was determined by the nature of the alkyl substituent at para-xylene bridge. Catalyst 14 having isopropyl substituent at the bridge produced the longest polymer with the lowest catalytic activity. On the other hand, DCGCs 15 and 16 exhibited the greatest comonomer reactivity to make ethylene/styrene copolymers with the highest styrene contents.     

Blending ultrahigh‐molecular‐weight polyethylene and poly(ethylene/10‐undecen‐1‐ol) in one nascent particle

Ultrahigh‐molecular‐weight polyethylene (UHMWPE)/polar polyethylene (PE) composites were blended in one nascent particle by in situ polymerization with a hybrid catalyst. Polystyrene‐coated SiO₂ particles were used to support the hybrid catalyst. Fe(acac)₃/2,6‐bis[1‐(2‐isopropylanilinoethyl)] was supported on SiO₂ for the synthesis of UHMWPE, whereas [PhN?C(CH₃)CH?C(Ph)O]VCl₂ was immobilized on a polystyrene layer to prepare a copolymer of ethylene and 10‐undecen‐1‐ol (polar PE). Importantly, the core part of the supports (the polystyrene layer) exhibited pronounced transfer resistance to 10‐undecen‐1‐ol; this provided an opportunity to keep the inside iron active sites away from the poisoning of 10‐undecen‐1‐ol. Therefore, UHMWPE was simultaneously synthesized with polar PE by in situ polymerization. Interestingly, the morphological results show that UHMWPE and the polar PE were successfully blended in one nascent polymer. This improved the miscibility of the composites, where most of the chains were difficult to crystallize because of the strong interactions between the PE chains and polar chains. The blends showed an extremely low crystallinity, that is, 9.9%. Finally, the hydrophilic properties of the polymer composites were examined. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 46652.     

Immobilized Me2Si(C5Me4)(N‐tBu)TiCl2/(nBuCp)2ZrCl2 hybrid metallocene catalyst system for the production of poly(ethylene‐co‐hexene) with pseudo‐bimodal molecular weight and inverse comonomer distribution

Me₂Si(C₅Me₄)(N‐tBu)TiCl₂, (nBuCp)₂ZrCl₂, and Me₂Si(C₅Me₄)(N‐tBu)TiCl₂/(nBuCp)₂ZrCl₂ catalyst systems were successfully immobilized on silica and applied to ethylene/hexene copolymerization. In the presence of 20 mL of hexene and 25 mg of butyloctyl magnesium in 400 mL of isobutane at 40 bar of ethylene, Me₂Si(C₅Me₄)(N‐tBu)TiCl₂ immobilized catalyst afforded poly(ethylene‐co‐hexene) with high molecular weight ([η] = 12.41) and high comonomer content (%C₆ = 2.8%), while (nBuCp)₂ZrCl₂‐immobilized catalyst afforded polymers with relatively low molecular weight ([η] = 2.58) with low comonomer content (%C₆ = 0.9%). Immobilized Me₂Si(C₅Me₄)(N‐tBu)TiCl₂/(nBuCp)₂ZrCl₂ hybrid catalyst exhibited high and stable polymerization activity with time, affording polymers with pseudo‐bimodal molecular weight distribution and clear inverse comonomer distribution (low comonomer content for low molecular weight polymer fraction and vice versa). The polymerization characteristics and rate profiles suggest that individual catalysts in the hybrid catalyst system are independent of each other. POLYM. ENG. SCI., 47:131–139, 2007. © 2007 Society of Plastics Engineers     

Copolymerization of styrene and ethylene with mononuclear and dinuclear half-titanocenes

With mononuclear half-titanocenes such as CpTiCl₃, IndTiCl₃, and Me₅CpTiCl₃, as well as the constrained geometry catalyst (CGC) and a new dinuclear hexamethyltrisiloxanediylbis(cyclopentadienyltitanium trichloride) (TSDT), the copolymerization of styrene and ethylene was examined. The thermal properties and structure of copolymerization products were investigated with differential scanning calorimetry and ¹³C-nuclear magnetic resonance. In addition, the raw polymer was separated into homopolymer and copolymer with an extraction method and cross fractionation chromatography. With the above analysis, it was concluded that the raw polymer obtained with CpTiCl₃ and IndTiCl₃ was a mixture of syndiotactic polystyrene and polyethylene homopolymers with 10–30 wt % copolymer, whereas that produced by Me₅CpTiCl₃ and TSDT was a homopolymer mixture with a negligible amount of copolymer. Only CGC produced the copolymer of styrene and ethylene perfectly. © 1998 John Wiley & Sons, Inc. J Appl Polym Sci 67:2187–2198, 1998     

Influence of supported vanadium catalyst on ethylene polymerization reactions

BACKGROUND: In the research area of homogeneous Ziegler–Natta olefin polymerization, classic vanadium catalyst systems have shown a number of favourable performances. These catalysts are useful for (i) the preparation of high molecular weight polymers with narrow molecular weight distributions, (ii) the preparation of ethylene/R‐olefin copolymers with high R‐olefin incorporation and (iii) the preparation of syndiotactic polypropylenes. In view of the above merits of vanadium‐based catalysts for polymerization reactions, the development of well‐defined single‐site vanadium catalysts for polymerization reactions is presently an extremely important industrial goal. The main aim of this work was the synthesis and characterization of a heterogeneous low‐coordinate non‐metallocene (phenyl)imido vanadium catalyst, V(NAr)Cl₃, and its utility for ethylene polymerization. RESULTS: Imido vanadium complex V(NAr)Cl₃ was synthesized and immobilized onto a series of inorganic supports: SiO₂, methylaluminoxane (MAO)‐modified SiO₂ (4.5 and 23 wt% Al/SiO₂), SiO₂? Al₂O₃, MgCl₂, MCM‐41 and MgO. Metal contents on the supported catalysts determined by X‐ray fluorescence spectroscopy remained between 0.050 and 0.100 mmol V g^?1 support. Thermal stability of the catalysts was determined by differential scanning calorimetry (DSC). Characterization of polyethylene was done by gel permeation chromatography and DSC. All catalyst systems were found to be active in ethylene polymerization in the presence of MAO or triisobutylaluminium/MAO mixture (Al/V = 1000). Catalyst activity was found to depend on the support nature, being between 7.5 and 80.0 kg PE (mol V)^?1 h^?1. Finally, all catalyst systems were found to be reusable for up to three cycles. CONCLUSION: Best results were observed in the case of silica as support. Acid or basic supports afforded less active systems. In situ immobilization led to higher catalyst activity. The resulting polyethylenes in all experiments had ultrahigh molecular weight. Finally, this work explains the synthesis and characterization of reusable supported novel vanadium catalysts, which are useful in the synthesis of very high molecular weight ethylene polymers. Copyright © 2007 Society of Chemical Industry     

A supported titanium postmetallocene catalyst: Effect of selected conditions on ethylene polymerization

Ethylene polymerization with a titanium complex [N,N‐ethylenebis(3‐methoxysalicylideneiminato)titanium dichloride] immobilized on the magnesium support with the formula MgCl₂(THF)_0.32(Et₂AlCl)_0.36 was studied. In particular, the effects of polymerization temperature, monomer pressure, and polymerization time on the activity of the catalyst and on the polyethylene properties (molecular weight and its distribution, melting point, crystallinity, and bulk density) were evaluated. The findings of investigations prove that the studied supported titanium catalyst is highly active in ethylene polymerization, and its activity increases with increasing temperature and monomer pressure. Moreover, stability of the catalytic systems is dependent on the activator type used. Me₃Al, when employed as an activator, makes the catalytic system undergo no deactivation in practice. The catalyst coupled with MAO turned out less stable. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Investigation of ethylene and styrene copolymerization initiated with dinuclear constrained geometry catalysts holding polymethylene as a bridging ligand and indenyl as a cyclopentadienyl derivative

A series of polymethylene‐bridged dinuclear constrained geometry catalysts (CGC) [Me₂Si(Ind)(N^tBu) TiCl₂]₂[(CH₂)_n] ( 1 , n = 6; 2 , n = 9; 3 , n = 12) were synthesized to study the copolymerization of ethylene and styrene. The experiments display that the polymerization activity of the dinuclear catalysts increased in the order of 1 < 2 < 3 , which indicated that the dinuclear CGC with the longest methylene units as a bridge showed the greatest activity. According to the activity correlation with the monomer ratio, all the catalysts exhibited maximum polymerization activity at the monomer ratio of ([styrene]/[ethylene]) of 2. The dinuclear CGC 2 and 3 represented excellent characteristics of styrene reactivity while catalyst 1 represented considerably low styrene reactivity. The relation between the molecular weights of the polymers and the catalysts used in the polymerization is not straightforward. The steric interference in catalyst 1 , containing just six methylene bridges, can be applied to explain not only the strikingly decreased activity but also the very low styrene content in the copolymer. In contrast, the electronic effect seems to be more pronounced in manipulating the polymerization properties of catalysts 2 and 3 having nine and 12 methylene bridges, respectively. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 2469–2474, 2003     

A study of the effect of styrene concentration on the molecular weight of polypropylene produced using metallocene catalysts

It has been observed in the production of polypropylene nanocomposites containing silicate materials that the molecular weight of the polymer used can have a significant effect on the final quality of the composites. The availability of polypropylene over a range of molecular weights with similar material properties (e.g. melting temperature and tacticity) is limited. Therefore, the ability to use a single catalyst system to generate polypropylene with a range of molecular weights is an attractive goal. In this contribution the use of styrene as a chain‐terminating agent is explored, in order to produce materials with a range of molecular weights from a single catalyst system. It is found that the molecular weight of the polypropylene produced can be varied in the range from 120 000 to 9000 g mol^?1 using the Me₂Si(Ind)₂ZrCl₂/methylaluminoxane catalyst system. Copyright © 2011 Society of Chemical Industry     

Ethylene polymerization using fluorinated FI Zr-based catalyst

A fluorinated FI Zr-based catalyst of bis[N-(3,5-dicumylsalicylidene)-2′,6′-flouroanilinato]zirconium(IV) dichloride was prepared and used for polymerization of ethylene. It was revealed that ortho-F-substituted phenyl ring on the N electronically plays a key role in the suppression of chain transfer reactions especially β-hydride transfer which resulted in an increase in the molecular weight of the obtained polymer and moderation of the catalyst activity as well. Methylaluminoxane (MAO) and triisobuthylaluminum (TIBA) were used as a cocatalyst and a scavenger, respectively. The catalyst showed the maximum activity at about [Al]:[Zr] = 32000:1 M ratio and further addition of MAO did not affect the activity of the catalyst. Ortho-F not only impressed the activity, but also reduced the [Al]:[Zr] molar ratio needed to reach the highest activity in comparison with the similar non-fluorinated FI catalysts. The highest activity of the prepared catalyst was obtained at 35 °C. At the monomer pressure of 3 bars polyethylene was obtained with the viscosity average molecular weight (M _v) of 1.3 × 10⁶ indicating the dramatic effect of ortho-F substitution on the polymerization mechanism. The polymerization was carried out using different amounts of hydrogen. Neither the activity of the catalyst nor the viscosity average molecular weight (M _v) of the obtained polymer was sensitive to the hydrogen concentration. However, higher amount of hydrogen could slightly increase the activity of the catalyst.     

SiO2-covered graphene oxide nanohybrids for in situ preparation of UHMWPE/GO(SiO2) nanocomposites with superior mechanical and tribological properties

The modified Hummer technique was used in the preparation of graphene oxide (GO) nanosheets, and then SiO₂ decorated GO [GO(SiO₂)] nanosheets were synthesized via the sol–gel method. Then, ultrahigh-molecular-weight polyethylene (UHMWPE) nanocomposites loaded with 0.5, 1, 1.5, and 2 wt % of GO(SiO₂) were prepared using magnesium ethoxide/GO(SiO₂)-supported Ziegler–Natta catalysts via the in situ polymerization. Morphological study of the prepared polymer powders was assessed using field-emission scanning electron microscopy, which showed that GO(SiO₂) nanohybrids have been uniformly dispersed and distributed into the UHMWPE matrix. Also, the neat UHMWPE and its nanocomposites were evaluated with different analyses, including viscosity-average molecular weight measurement, differential scanning calorimetry, thermogravimetric analysis, tensile test, scratch hardness, and pin-on-disk test. The characterization of the UHMWPE nanocomposites indicated that many characterizations, including the mechanical, thermal, and tribological properties of UHMWPE, were significantly improved by incorporation of these new nanosheets in spite of the molecular weight reduction of the polymeric matrix and the improved flowability and processability of the produced nanocomposite. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 136, 47796.     

Preparation and characteristics of nano-B4C/PVA particles and ultra high molecular weight polyethylene composites

In-situ mechanical process for preparation of the polyvinyl alcohol (PVA) coated nano-B₄C powder was investigated by using a high-energy ball mill. The produced PVA coat on the surface of nano-B₄C particles was observed by x-ray diffraction (XRD) and confirmed by TEM images. The average particle size of the produced nano-B₄C/PVA particles was in the range of several tens to hundreds of nanometers depending on the milling conditions. The polymer composites were fabricated by hot pressing ultra high molecular weight polyethylene (UHMWPE) powder mixed with nano-B₄C/PAV and micro-B₄C powders, respectively. Nano-B₄C/PVA dispersed UHMWPE shows slightly lower crystallinity and stiffness than micro-B₄C dispersed UHMWPE based on differential scanning calorimetry (DSC) and dynamic mechanical analysis (DMA) evaluations.     

J Integral measurements of ultra high molecular weight polyethylene

Fracture of ultra high molecular weight polyethylene (UHMWPE) contributes to damage modes occurring on the articulating surfaces of total joint replacement components. To minimize damage through the optimization of component design requires an understanding of the fracture behavior of UHMWPE. A fracture/mechanics approach was taken in which J integral tests were performed on three-point bend specimens of two thicknesses. J_IC was determined to be 99.5 kJ/m² and was independent of specimen thickness. The fracture surfaces for both specimen thicknesses showed extensive orientation and failure through multiple layers of material, suggesting that UHMWPE experiences plane stress conditions at the crack tip, regardless of thickness.     

Viscosity and molecular weight distribution of ultrahigh molecular weight polyethylene using a high temperature low shear rate rotational viscometer

To obtain accurate measurements of the limiting viscosity number (LVN) or the intrinsic viscosity [η] of solutions of ultrahigh molecular weight polyethylene (UHMWPE), a low shear floating-rotor viscometer of the Zimm-Crothers type was constructed to measure viscosities at elevated temperatures (135°C) and near zero shear rate. The zero shear rate measurements for UHMWPE whole polymer and UHMWPE fractionated by hydrodynamic crystallization were compared with viscosity measurements at moderate and high shear rates (up to 2000 _s^?1) carried out in a capillary viscometer. The limiting viscosity number of UHMWPE decreases, as expected, with shear rate. The higher shear rate data could not be extrapolated to yield the correct zero-shear rate viscosities. Fractionation of UHMWPE gave 10 fractions ranging in LVN from 9 to 50 dL/g. A tentative integral molecular weight distribution for the whole polymer was calculated on the basis of the Mark-Houwink equation, but because it had been previously established only for lower molecular weight polyethylenes, it may not be accurate. A correlation was found between the LVNs for the fractions in the two types of viscometers.     

Structure of ultrahigh molecular weight polyethylene–air counterflow flame

The combustion of ultrahigh molecular weight polyethylene (UHMWPE) in airflow perpendicular to the polyethylene surface (counterflow flame) was studied in detail. The burning rate of pressed samples of UHMWPE was measured. The structure of the UHMWPE–air counterflow flame was first determined by mass spectrometric sampling taking into account heavy products. The composition of the main pyrolysis products was investigated by mass spectrometry, and the composition of heavy hydrocarbons (C₇—C₂₅) in products sampled from the flame at a distance of 0.8 mm from the UHMWPE surface was analyzed by gas-liquid chromatography mass-spectrometry. The temperature and concentration profiles of eight species (N₂, O₂, CO₂, CO, H₂O, C₃H₆, C₄H₆, and C₆H₆) and a hypothetical species with an average molecular weight of 258.7 g/mol, which simulates more than 50 C₇—C₂₅ hydrocarbons were measured. The structure of the diffusion flame of the model mixture of decomposition products of UHMWPE in air counterflow was simulated using the OPPDIF code from the CHEMKIN II software package. The simulation results are in good agreement with experimental data on combustion of UHMWPE.     

In Situ Synthesis of Ultrahigh Molecular Weight Polyethylene/Graphene Oxide Nanocomposite Using the Immobilized Single-site Catalyst

We address the immobilization of single-site catalyst on the graphite oxide (GO) surface using methylaluminoxane. Ethylene polymerization was performed using the immobilized catalyst and the nanocomposite of ultrahigh molecular weight polyethylene (UHMWPE)/GO with less entanglement density was obtained. It was observed that the drawability, mechanical and thermal properties of the produced polymer significantly are affected by the anchoring of polymer chains to the GO nanosheets. The orientation and location of crystalline lamellae and nanosheets were verified by microscopic techniques. Besides, X-ray analysis demonstrated the dispersion of GO within the UHMWPE phase and crystallinity of UHMWPE/GO nanocomposites enhanced during drawing process.