Highly Robust Palladium(II) α-Diimine Catalysts for Slow-Chain-Walking Polymerization of Ethylene and Copolymerization with Methyl Acrylate

Recent Advances in Controlled Production of Long-Chain Branched Polyolefins

Polyolefins, composed of carbon and hydrogen atoms, dominate global polymer production. This stems from the wide range of physical and mechanical properties that various polyolefins can cover. Their versatile properties are largely tuned by chain microstructure, including molar mass distribution, comonomer content, and long-chain branching (LCB). Specifically, LCB imparts unique characteristics, notably enhances processability crucial for downstream applications. Tailoring LCB structural features has encouraged academic and industrial efforts, chronicle in this review from a chemistry standpoint. While encompassing post-reaction modification based traditional methods like peroxide grafting, ionizing beam irradiation, and coupling reactions, the main focus is given to catalyst-centric strategies and innovative polymerization schemes. The advent of single-site catalysts-metallocenes and late transition metals catalysts-amplifies interest in tailored chemical methods, but the progress in LCB formation flourishes via tandem catalytic systems and bimetallic catalysts under controlled reaction conditions. Specifically, the breakthrough in coordinative chain transfer polymerization unveils a novel avenue for controlled LCB synthesis by sequential chain propagation, transfer, liberation, and enchainment. This short review highlights recent approaches for the production of LCB polyolefins that can provide a roadmap crucial for researchers in academia and industry, steering their efforts toward further advancements in the production of tailored polyolefin.

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.

Suppression of Chain Transfer at High Temperature in Catalytic Olefin Polymerization

Living polymerization by suppressing chain transfer is a very useful method for achieving precise molecular weight and structure control. However, the suppression of chain transfer at high temperatures is extremely challenging in any catalytic polymerization. This has been a severe limitation for catalytic olefin polymerization, which is one of the most important chemical reactions. Here, we report the unprecedented living polymerization of ethylene at 130 °C, with a narrow molecular weight distribution range of 1.04 to 1.08. This is a significant increase in the reaction temperature. Tailor-made α-diimine nickel catalysts that exhibit both the steric shielding and fluorine effects play an essential role in this breakthrough. These nickel catalysts are even active at 200 °C, and enable the formation of semi-crystalline, ultrahigh-molecular-weight polyethylene at 150 °C. Mechanistic insights into the key chain transfer reaction are elucidated by density functional theory calculations.

Synthesis of High-Molecular-Weight Branched Polyethylene Using a Hybrid "Sandwich" Pyridine-Imine Ni(II) Catalyst

Most pyridine-imine Ni(II) and Pd(II) catalysts tend to yield low-molecular-weight polyethylene and ethylene-based copolymers in olefin insertion polymerization, as the unilateral axial steric structure of such complexes often cannot provide effective shielding of the metal center. In this study, we synthesized a series of hybrid "semi-sandwich" and "sandwich" type pyridine-imine Ni(II) complexes by incorporating diarylmethyl or dibenzosuberyl groups onto 8-aryl-naphthyl motif. The as-prepared Ni(II) complexes afforded highly branched polyethylene with high molecular weights (level of 105 g/mol), and moderate activities (level of 105 g/(molh)) in ethylene polymerization. Most interestingly, compared to "semi-sandwich" Ni(II) complexes bearing (2-diarylmethyl-8-aryl)naphthyl units, the "full-sandwich" counterpart containing (2-dibenzosuberyl-8-aryl)naphthyl motif was able to produce higher-molecular-weight polyethylene with higher branching density. In addition, the effect of remote non-conjugated electronic substituents in diarylmethyl groups of the Ni(II) system was also observed in ethylene polymerization.

Distorted Sandwich a-Diimine Pd(II) Catalyst: Linear Polyethylene and Synthesis of Ethylene/Acrylate Elastomers

The introduction of m-xylyl substituents to α-diimine Pd(II) catalyst promotes living ethylene polymerization at room temperature and low pressure to yield high molecular weight polyethylene (PE) with low branching (<17/1000C). m-Xylyl groups provide a highly effective blockage to the axial sites of the catalytic center and form a distorted sandwich geometry. The shielding prevents chain-transfer and easy accessibility of polar monomers, leading to a living polymerization. Conducting a light irradiation as part of the one-step metal-organic insertion light initiated radical (MILRad) process leads to diblock copolymers of ethylene and acrylates. Incorporation of different acrylate block sequences can significantly modify the mechanical and chemical properties of block copolymers which can be modulated to be a hard plastic, elastomer, or semi-amorphous polymer.

Flexible "Sandwich" (8-Alkylnaphthyl α-Diimine) Catalysts in Insertion Polymerization

8-Arylnaphthyl substituents are privileged motifs frequently integrated into late-transition-metal catalysts, endowing them with an ability to retard chain transfer in ethylene polymerization. In this contribution, we disclose a sort of novel α-diiminenickel and -palladium complexes containing flexible 8-alkylnaphthyl in lieu of rigid 8-arylnaphthyl and their catalytic performance in ethylene polymerization. An interesting feature of these 8-alkylnaphthyl-substituted α-(diimine)PdMeCl complexes is that they present as a mixture of syn and anti isomers (syn:anti = ca. 1:1 ratio, determined by ¹H and ¹³C NMR spectroscopy). In ethylene polymerization, these nickel complexes displayed high activity (up to 3.37 × 10⁶ g mol^-1 h^-1) and generated branched polyethylenes with broad or bimodal molecular weight distributions (4.6-29.3), while the corresponding palladium complexes exhibited moderate activity, producing highly branched polyethylenes with unimodal and narrow molecular weight distributions (<1.8). In ethylene (E)/methyl acrylate (MA) copolymerization, highly branched E-MA copolymers with considerable MA incorporations were achieved by these palladium complexes. Most interestingly, compared to rigid 8-arylnaphthyl-substituted α-diiminenickel and -palladium complexes, the flexible 8-alkylnaphthyl ones showed significantly improved activity and generated lower or comparable molecular weight polyethylenes or E-MA copolymers.

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.

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.

Direct Synthesis of Functionalized High-Molecular-Weight Polyethylene by Copolymerization of Ethylene with Polar Monomers

The introduction of even a small amount of polar functional groups into polyolefins could excise great control over important material properties. As the most direct and economic strategy, the transition-metal-catalyzed copolymerization of olefins with polar, functionalized monomers represents one of the biggest challenges in this field. The presence of polar monomers usually dramatically reduces the catalytic activity and copolymer molecular weight (to the level of thousands or even hundreds Da), rendering the copolymerization process and the copolymer materials far from ideal for industrial applications. In this contribution, we demonstrate that these obstacles can be addressed through rational catalyst design. Copolymers with highly linear microstructures, high melting temperatures, and very high molecular weights (close to or above 1 000 000 Da) were generated. The direct synthesis of polar functionalized high-molecular-weight polyethylene was thus achieved.