Recent Advances in Transition Metal-Based Catalysts for Ethylene Copolymerization with Polar Comonomer

The synthesis of polar functionalized polyolefin (PFP) offers improvement in mixing properties, polymer surface, and rheological properties with the potential of upgraded polyolefins for modern and ingenious applications. The synthesis of PFP from metal-based catalyzed olefin (non-polar in nature) copolymerization with polar comonomers embodies energy-efficient, atom-efficient, and apparently an upfront methodology. Despite their outstanding success during conventional polymerization of olefin, 3^rd and 4^th group (early transition metal)-based catalysts, owing to their electrophilic nature, face challenges mainly due to Lewis basic sites of the polar monomers. On the contrary, late transition metal-based catalysts have also made progress, in recent years, for PFP synthesis. The recent past has also witnessed several advancements in the development of dominating palladium-based catalysts while their lower resistance towards ligand functional groups has limited the practical application of abundant and cheaper nickel-based catalysts. However, the relentless efforts of the scientific community, during the past half-decade, have indicated rigorous progress in the development of nickel-based catalysts for PFP synthesis. In this review, we have abridged the recent research trends in both early as well as late transition metal-based catalyst development. Furthermore, we have highlighted the role of transition metal-based catalysts in influencing the polymer properties.

Access to Disentangled Ultrahigh Molecular Weight Polyethylene via a Binuclear Synergic Effect

Disentangled ultrahigh molecular weight polyethylene (dis-UHMWPE) has excellent processability but can be achieved under extreme conditions. Herein, we report ethylene polymerization with the binuclear half-sandwich scandium complexes C1-Sc₂ and C2-Sc₂ to afford UHMWPE. C1-Sc₂ bearing a short linker shows higher activity and gives higher molecular weight PEs than C2-Sc₂ containing a flexible spacer and the mononuclear Sc₁ . Strikingly, all UHMWPEs isolated from C1-Sc₂ under broad temperature range (25-120 °C) and wide ethylene pressures (2-13 bar) feature very low degree of entanglement as proved by rheological test, DSC annealing study and SEM. These dis-UHMWPEs are facilely mediated solid-state-process at 130 °C and their tensile strength and modulus reach up to 149.2 MPa and 1.5 GPa, respectively. DFT simulations reveal that the formation of dis-UHMWPE is attributed to the binuclear synergic effect and the agostic interaction between the active center and the growing chain.

Highly Active and Thermally Robust Nickel Enolate Catalysts for the Synthesis of Ethylene-Acrylate Copolymers

The insertion copolymerization of polar olefins and ethylene remains a significant challenge in part due to catalysts' low activity and poor thermal stability. Herein we demonstrate a strategy toward addressing these obstacles through ligand design. Neutral nickel phosphine enolate catalysts with large phosphine substituents reaching the axial positions of Ni achieve activity of up to 7.7×10³  kg mol^-1  h^-1 (efficiency >35×10³  g copolymer/g Ni) at 110 °C, notable for ethylene/acrylate copolymerization. NMR analysis of resulting copolymers reveals highly linear microstructures with main-chain ester functionality. Structure-performance studies indicate a strong correlation between axial steric hindrance and catalyst performance.

Effect of para-Substituents in Ethylene Copolymerizations with 1-Decene, 1-Dodecene, and with 2-Methyl-1-Pentene Using Phenoxide Modified Half-Titanocenes-MAO Catalyst Systems

Effect of para-substituents in the ethylene (E) copolymerization with 1-decene (DC), 1-dodecene (DD), and with 2-methyl-1-pentene (2M1P) using a series of Cp*TiCl2 (O-2,6-i Pr2 -4-R-C6 H2 ) [R=H (1), t Bu (2), Ph (3), CHPh2 (4), CPh3 (5), SiMe3 (6), SiEt3 (7), and newly prepared 4-t BuC6 H4 (8) and 3,5-Me2 C6 H3 (9)]-MAO catalyst systems has been studied. The activities in these copolymerization reactions were affected by the para-substituent, and the SiMe3 (6), SiEt3 (7) and 3,5-Me2 C6 H3 (9) analogues showed the higher activities at 50 °C in the E copolymerization reactions with DC (1.06-1.44×106  kg-polymer/mol-Ti⋅h), DD (1.04-1.88×106  kg-polymer/mol-Ti⋅h) than the others, whereas no significant differences were observed in the comonomer incorporations. Complexes 6 and 7 also showed the higher activities at 50 °C in the E/2M1P copolymerization, and the 2M1P incorporation was affected by the para-substituent and the polymerization temperature; complex 9 showed better 2M1P incorporation at 25 °C.

Fluorinated α-Diimine Nickel Mediated Ethylene (Co)Polymerization

Fluorine substituents in transition metal catalysts are of great importance in olefin polymerization catalysis; however, the comprehensive effect of fluorine substituents is elusive in seminal late transition metal α-diimine catalytic system. In this contribution, fluorine substituents at various positions (ortho-, meta-, and para-F) and with different numbers (F_n ; n=0, 1, 2, 3, 5) were installed into the well-defined N-terphenyl amine and thus were studied for the first time in the nickel α-diimine promoted ethylene polymerization and copolymerization with polar monomers. The position of the fluorine substituent was particularly crucial in these polymerization reactions in terms of catalytic activity, polymer molecular weight, branching density, and incorporation of polar monomer, and thus a picture on the fluorine effect was given. As a notable result, the ortho-F substituted α-diimine nickel catalyst produced highly linear polyethylenes with an extremely high molecular weight (M_w =8703 kDa) and a significantly low degree of branching of 1.4/1000 C; however, the meta-F and/or para-F substituted α-diimine nickel catalysts generated highly branched (up to 80.2/1000 C) polyethylenes with significantly low molecular weights (M_w =20-50 kDa).

Photoresponsive Palladium and Nickel Catalysts for Ethylene Polymerization and Copolymerization

In this contribution, we install an azobenzene functionality in olefin polymerization catalysts and use light to modulate their properties via photoinduced trans-cis isomerization of the azobenzene moiety. The initially targeted azobenzene-functionalized α-diimine palladium and nickel catalysts are not photoresponsive. To address this issue, an imine-amine system bearing interrupted conjugation with the metal center, and a sandwich-type α-diimine system bearing an azobenzene unit at a position covalently far from the metal center were prepared and studied. We demonstrate that light can be used to tune their properties in ethylene polymerization and copolymerization with polar comonomers, enabling light-induced control of the polymerization processes, polymer microstructures and polymer properties. More interestingly, the light-mediated property changes were attributed to ligand electronic effects in one system and ligand steric effects in the other.

Hydrogen-Bonding-Induced Heterogenization of Nickel and Palladium Catalysts for Copolymerization of Ethylene with Polar Monomers

The practical synthesis of polar-functionalized polyolefins using transition-metal-catalyzed copolymerization of olefins with polar monomers is a challenge; the use of heterogeneous catalysts is little explored. Herein, we report the synthesis of heterogeneous naphthoquinone-based nickel (Ni/SiO₂ ) and palladium (Pd/SiO₂ ) catalysts through hydrogen bonding interactions of the ligands with the silica surface. Ni/SiO₂ exhibits high activities (up to 2.65×10⁶  g mol^-1  h^-1 ) during the copolymerization of ethylene with 5-hexene-1-yl-acetate, affording high-molecular-weight (M_n up to 630 000) polar-functionalized semicrystalline polyethylene (comonomer incorporation up to 2.8 mol %), along with great morphology control. The resulting copolymers possess improved surface properties and great mechanical properties. Pd/SiO₂ can mediate ethylene copolymerization with polar monomers with moderate activity to produce high-molecular-weight copolymers with tunable comonomer incorporation.

Efficient Suppression of Chain Transfer and Branching via Cs -Type Shielding in a Neutral Nickel(II) Catalyst

An effective shielding of both apical positions of a neutral NiII active site is achieved by dibenzosuberyl groups, both attached via the same donors' N-aryl group in a Cs -type arrangement. The key aniline building block is accessible in a single step from commercially available dibenzosuberol. This shielding approach suppresses chain transfer and branch formation to such an extent that ultrahigh molecular weight polyethylenes (5×106  g mol-1 ) are accessible, with a strictly linear microstructure (<0.1 branches/1000C). Key features of this highly active (4.3×105  turnovers h-1 ) catalyst are an exceptionally facile preparation, thermal robustness (up to 90 °C polymerization temperature), ability for living polymerization and compatibility with THF as a polar reaction medium.

The Effect of SiMe3 and SiEt3 Para Substituents for High Activity and Introduction of a Hydroxy Group in Ethylene Copolymerization Catalyzed by Phenoxide-Modified Half-Titanocenes

Remarkable effects of SiMe₃ and SiEt₃ para-substituents in the phenoxide-modified half-titanocenes, Cp*TiCl₂ (O-2,6-ⁱ Pr₂ -4-R-C₆ H₂ ) [R=SiMe₃ (6), SiEt₃ (7)], toward the catalytic activities in ethylene copolymerizations with 2-methyl-1-pentene, 1-decene, 1-dodecene and with 9-decen-1-ol (DC-OH) have been demonstrated. The activities by 6, 7 at 50 °C showed higher than those conducted at 25 °C in all cases in the presence of MAO cocatalyst. Efficient synthesis of high-molecular-weight (HMW) ethylene copolymers incorporating DC-OH (or 5-hexen-1-ol, HX-OH) has been attained in the copolymerization by 7, which showed better DC-OH (HX-OH) incorporation at 50 °C to afford the HMW copolymers, poly(ethylene-co-DC-OH)s, with high activities (activity 1.21-3.81×10⁵  kg-polymer mol^-1 -Ti h, M_n =6.55-10.0×10⁴ , DC-OH 2.3-3.6 mol %).

Ultrahigh Branching of Main-Chain-Functionalized Polyethylenes by Inverted Insertion Selectivity

Branched polyolefin microstructures resulting from so-called "chain walking" are a fascinating feature of late transition metal catalysts; however, to date it has not been demonstrated how desirable branched polyolefin microstructures can be generated thereby. We demonstrate how highly branched polyethylenes with methyl branches (220 Me/1000 C) exclusively and very high molecular weights (ca. 106  g mol-1 ), reaching the branch density and microstructure of commercial ethylene-propylene elastomers, can be generated from ethylene alone. At the same time, polar groups on the main chain can be generated by in-chain incorporation of methyl acrylate. Key to this strategy is a novel rigid environment in an α-diimine PdII catalyst with a steric constraint that allows for excessive chain walking and branching, but restricts branch formation to methyl branches, hinders chain transfer to afford a living polymerization, and inverts the regioselectivity of acrylate insertion to a 1,2-mode.

A Self-Supporting Strategy for Gas-Phase and Slurry-Phase Ethylene Polymerization using Late-Transition-Metal Catalysts

The polyolefin industry is dominated by gas-phase and slurry-phase polymerization using heterogeneous catalysts. In contrast, academic research is focused on homogeneous systems, especially for late-transition-metal catalysts. The heterogenization of homogeneous catalysts is a general strategy to provide catalyst solutions for existing industrial polyolefin synthesis. Herein, we report an alternative, potentially general strategy for using homogeneous late-transition-metal catalysts in gas-phase and slurry-phase polymerization. In this self-supporting strategy, catalysts with moderate chain-walking capabilities produced porous polymer supports during gas-phase ethylene polymerization. Chain walking, in which the metal center can move up and down the polymer chain during polymerization, ensures that the metal center can travel along the polymer chain to find suitable sites for ethylene enchainment. This strategy enables simple heterogenization of catalysts on solid supports for slurry-phase polymerization. Most importantly, various branched ultra-high-molecular-weight polyethylenes can be prepared under various polymerization conditions with proper catalyst selection.

Coordinative Chain Transfer Polymerization of Butadiene with Functionalized Aluminum Reagents

Functionalized aluminum alkyls enable effective coordinative chain transfer polymerization with selective chain initiation by the functionalized alkyl. (ω-Aminoalkyl)diisobutylaluminum reagents (12 examples studied) obtained by hydroalumination of α-amino-ω-enes with diisobutylaluminum hydride promote the stereoselective catalytic chain growth of butadiene on aluminum in the presence of Nd(versatate)3 , Cp*2 Nd(allyl), or Cp*2 Gd(allyl) precatalysts and [PhNMe2 H+ ]/[B(C6 F5 )4 - ]. Carbazolyl- and indolylaluminum reagents result in efficient molecular weight control and chain initiation by the aminoalkyl rather than the isobutyl substituent bound to aluminum. As confirmed for (3-(9H-carbazol-9-yl)propyl)-initiated polybutadiene (PBD), for example, by deuterium quenching studies, polymer chain transfer by β-hydride transfer is negligible in comparison to back-transfer to aluminum.

Emerging Palladium and Nickel Catalysts for Copolymerization of Olefins with Polar Monomers

Transition-metal-catalyzed copolymerization of olefins with polar monomers represents a challenge because of the large variety of substrate-induced side reactions. However, this approach also holds the potential for the direct synthesis of polar functionalized polyolefins with unique properties. After decades of research, only a few catalyst systems have been found to be suitable for this reaction. Some major advances in catalyst development have been made in the past five years. This Minireview summarizes some of the recent progress in the extensively studied Brookhart and Drent catalyst systems, as well as emerging alternative palladium and nickel catalysts.

Two Discrete RuCp* (Cp*=Pentamethylcyclopentadienyl) Binding Modes of N-Confused Porphyrins: Peripheral π Complex and Sitting Atop Ruthenocenophane Complex by Skeletal Transformation

Complexation of a RuCp* cation with N-confused tetraarylporphyrins (NCPs) forms directly bound ruthenium(II) pentamethylcyclopentadienyl (Cp*) π-complex on a specific meso-aryl group (e.g., phenyl) neighboring peripheral imino nitrogen of NCPs in high yields. In contrast, in the case of NCPs bearing bulky meso-substituents (e.g., 3,5-di-tert-butylphenyl), new ruthenocenophane-like complex embedded on an N-confused calix[4]phyrin was formed through multiple C-H bond activation of methyl groups of Cp* ligand. The mechanistic insight into the formation of the ruthenocenophane was derived from DFT calculations.

Controlled Radical Polymerization of Ethylene Using Organotellurium Compounds

The first successfully controlled radical polymerization (CRP) of ethylene is reported using several organotellurium chain-transfer agents (CTAs) under mild conditions (70 °C, 200 bar of ethylene) within the concept of organotellurium-mediated radical polymerization (TERP). In contrast to preceding works on CRPs of ethylene applying reversible addition-fragmentation chain-transfer (RAFT), the TERP system provided a high livingness and chain-end functionalization of polyethylene chains. Molar-mass distributions with dispersities between 1.3 and 2.1 were obtained up to average molar masses of 5000 g mol^-1 . As in the RAFT system, the high reactivity of the growing polyethylenyl radical led to an inherent side reaction. For the presented TERP systems, however, this side reaction did not result in dead chains, while it could even be effectively suppressed by a good choice of the CTA.

Insight into Oxide-Bridged Heterobimetallic Al/Zr Olefin Polymerization Catalysts

Reaction of (TBBP)AlMe⋅THF with [Cp*₂ Zr(Me)OH] gave [(TBBP)Al(THF)-O-Zr(Me)Cp*₂ ] (TBBP=3,3',5,5'-tetra-tBu-2,2'-biphenolato). Reaction of [DIPPnacnacAl(Me)-O-Zr(Me)Cp₂ ] with [PhMe₂ NH]⁺ [B(C₆ F₅ )₄ ]^- gave a cationic Al/Zr complex that could be structurally characterized as its THF adduct [(DIPPnacnac)Al(Me)-O-Zr(THF)Cp₂ ]⁺ [B(C₆ F₅ )₄ ]^- (DIPPnacnac=HC[(Me)C=N(2,6-iPr₂ -C₆ H₃ )]₂ ). The first complex polymerizes ethene in the presence of an alkylaluminum scavenger but in the absence of methylalumoxane (MAO). The adduct cation is inactive under these conditions. Theoretical calculations show very high energy barriers (ΔG=40-47 kcal mol^-1 ) for ethene insertion with a bridged AlOZr catalyst. This is due to an unfavorable six-membered-ring transition state, in which the methyl group bridges the metal and ethene with an obtuse metal-Me-C angle that prevents synchronized bond-breaking and making. A more-likely pathway is dissociation of the Al-O-Zr complex into an aluminate and the active polymerization catalyst [Cp*₂ ZrMe]⁺ .