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

Recent Advancements in the Synthesis of Ultra-High Molecular Weight Polyethylene via Late Transition Metal Catalysts

Ultra-high molecular weight polyethylenes (UHMWPEs) are significant engineering plastics for their unique properties, such as high impact resistance, abrasion resistance, weatherability, lubricity, and chemical resistance. Consequently, developing a suitable catalyst is vital in facilitating the preparation of UHMWPE. The late transition metal catalysts have emerged as effective catalysts in producing UHMWPE due to their availability, enhanced tolerance to heteroatom groups, active polymerization characteristics, and good copolymerization ability with polar monomers. In this review, we mainly focus on the late transition metal catalysts, summarizing advancements in their application over the past decade. Four key metals (Ni, Pd, Fe, Co) for generating linear or branched UHMWPE will be primarily explored in this manuscript.

Ethylene Polymerizations Catalyzed by Fluorinated "Sandwich" Diimine-Nickel and Palladium Complexes

Nickel and palladium complexes bearing "sandwich" diimine ligands with perfluorinated aryl caps have been synthesized, characterized, and explored in ethylene polymerization reactions. The X-ray crystallographic analysis of the precatalysts 16 and 6b shows differences from their nonfluorinated analogues 17 and 19, with the perfluorinated aryl caps centered precisely over the nickel and palladium centers, which results in higher buried volumes of the metal centers relative to the nonfluorinated analogues. The sandwich diimine-palladium complexes 5a and 5b containing perfluorinated aryl caps polymerize ethylene in a controlled fashion with activities that are substantially increased compared with their nonfluorinated analogues. Migratory insertion rates in relevant methyl ethylene complexes agree with the activities exhibited in bulk polymerization experiments. DFT studies suggest that facility of ethylene rotation from its preferred orientation perpendicular to the Pd-alkyl bond into a parallel in-plane conformation contributes to the higher polymerization activity for 5b relative to 18a. For these palladium systems, polymer molecular weights can be controlled via hydrogen addition (hydrogenolysis), which is unusual for late-transition-metal-catalyzed olefin polymerizations with no catalyst deactivation occurring. Sandwich diimine-nickel complexes 6a and 6b with perfluorinated aryl caps show ethylene polymerization activities that are about half of those of classical tetraisopropyl-substituted catalyst 2 but again are more active than the analogous nonfluorinated sandwich complexes. Ethylene polymerizations exhibit living behavior, and branched ultrahigh-molecular-weight polyethylenes (UHMWPEs) with very low-molecular-weight distributions (less than 1.1) are obtained. The activated nickel catalysts are stable in the absence of monomer and show good long-term stability at 25 °C.

Ambient Catalytic Spinning of Polyethylene Nanofibers

A novel single-atom Ni(II) catalyst (Ni-OH) is covalently immobilized onto the nano-channels of mesoporous Santa Barbara Amorphous (SBA)-15 particles and isotropic Anodized Aluminum Oxide (AAO) membrane for confined-space ethylene extrusion polymerization. The presence of surface-tethered Ni complexes (Ni@SBA-15 and Ni@AAO) is confirmed by the inductively coupled plasma-optical emission spectrometry (ICP-OES) and X-ray photoelectron spectroscopy (XPS). In the catalytic spinning process, the produced PE materials exhibit very homogeneous fibrous morphology at nanoscale (diameter: ~50 nm). The synthesized PE nanofibers extrude in a highly oriented manner from the nano-reactors at ambient temperature. Remarkably high Mw (1.62×106  g mol-1 ), melting point (124 °C), and crystallinity (41.8 %) are observed among PE samples thanks to the confined-space polymerization. The chain-walking behavior of surface tethered Ni catalysts is greatly limited by the confinement inside the nano-channels, leading to the formation of very low-branched PE materials (13.6/1000 C). Due to fixed supported catalytic topology and room temperature, the filaments are expected to be free of entanglement. This work signifies an important step towards the realization of a continuous mild catalytic-spinning (CATSPIN) process, where the polymer is directly synthesized into fiber shape at negligible chain branching and elegantly avoiding common limitations like thermal degradation or molecular entanglement.

Effects of surface acidity on the structure of organometallics supported on oxide surfaces

Well-defined organometallics supported on high surface area oxides are promising heterogeneous catalysts. An important design factor in these materials is how the metal interacts with the functionalities on an oxide support, commonly anionic X-type ligands derived from the reaction of an organometallic M-R with an -OH site on the oxide. The metal can either form a covalent M-O bond or form an electrostatic M⁺⋯^-O ion-pair, which impacts how well-defined organometallics will interact with substrates in catalytic reactions. A less common reaction pathway involves the reaction of a Lewis site on the oxide with the organometallic, resulting in abstraction to form an ion-pair, which is relevant to industrial olefin polymerization catalysts. This Feature Article views the spectrum of reactivity between an organometallic and an oxide through the prism of Brønsted and/or Lewis acidity of surface sites and draws analogies to the molecular frame where Lewis and Brønsted acids are known to form reactive ion-pairs. Applications of the well-defined sites developed in this article are also discussed.

Ethylene polymerization using heterogeneous multinuclear nickel catalysts supported by a crosslinked alpha diimine ligand network

A crosslinked alpha diimine ligand supporting a nickel metal center polymerizes ethylene to produce polyethylene with controlled microstructures, high activities, and can be removed from the product.

Recent Advances in the Copolymerization of Ethylene with Polar Comonomers by Nickel Catalysts

The less-expensive and earth-abundant nickel catalyst is highly promising in the copolymerization of ethylene with polar monomers and has thus attracted increasing attention in both industry and academia. Herein, we have summarized the recent advancements made in the state-of-the-art nickel catalysts with different types of ligands for ethylene copolymerization and how these modifications influence the catalyst performance, as well as new polymerization modulation strategies. With regard to α-diimine, salicylaldimine/ketoiminato, phosphino-phenolate, phosphine-sulfonate, bisphospnine monoxide, N-heterocyclic carbene and other unclassified chelates, the properties of each catalyst and fine modulation of key copolymerization parameters (activity, molecular weight, comonomer incorporation rate, etc.) are revealed in detail. Despite significant achievements, many opportunities and possibilities are yet to be fully addressed, and a brief outlook on the future development and long-standing challenges is provided.

Efficient suppression of the chain transfer reaction in ethylene coordination polymerization with dibenzosuberyl substituents

Catalysts with dibenzosuberyl substituents possess a superior ability to suppress chain transfer in ethylene (co)polymerization, producing high molecular weight polyethylenes and functionalized polyethylenes (ethylene-MA copolymers).

Influences of Ligand Backbone Substituents on Phosphinecarbonylpalladium and -nickel Catalysts for Ethylene Polymerization and Copolymerization with Polar Monomers

A series of phosphinecarbonylpalladium and -nickel catalysts bearing various substituents on the ligand backbone were prepared, characterized, and used in ethylene polymerization and copolymerization with polar monomers. The Pd and Ni catalysts can achieve high activities as well as high polymer molecular weights in both ethylene polymerization and copolymerization with polar monomers. The electron-donating group from the carbonyl side can effectively increase the polymer molecular weights. Utilization of a cyclic backbone structure can increase the catalytic activities at the expense of the polymer molecular weights. Moreover, installation of a pyridyl moiety in the ligand backbone can enable Lewis acid responsiveness and can enhance the polymerization activities. These results suggest the importance of the ligand backbone for the properties of catalysts in ethylene polymerization and copolymerization reactions.

Ethylene Polymerization Activity of (R3P)Ni(codH)+ (cod = 1,5-cylcooctadiene) Sites Supported on Sulfated Zirconium Oxide

PAr₃ containing o-OMe, o-Me, or o-Et substituents reacts with Brønsted sites on sulfated zirconium oxide (SZO) to form [HPAr₃][SZO]. The phosphonium sites on this material react with bis(cyclooctadiene)nickel [Ni(cod)₂] to form [Ni(PAr₃)(codH)][SZO] that are active in ethylene polymerization reactions. Selective poisoning studies with pyridine show that ∼90% of the Ni(PAr₃)(codH)⁺ sites in this material are active in polymerization reactions.

Preparation of High-Purity Ammonium Tetrakis(pentafluorophenyl)borate for the Activation of Olefin Polymerization Catalysts

Homogeneous olefin polymerization catalysts are activated in situ with a co-catalyst ([PhN(Me)₂-H]⁺[B(C₆F₅)₄]⁻ or [Ph₃C]⁺[B(C₆F₅)₄]⁻) in bulk polymerization media. These co-catalysts are insoluble in hydrocarbon solvents, requiring excess co-catalyst (>3 eq.). Feeding the activated species as a solution in an aliphatic hydrocarbon solvent may be advantageous over the in situ activation method. In this study, highly pure and soluble ammonium tetrakis(pentafluorophenyl)borates ([Me(C₁₈H₃₇)₂N-H]⁺[B(C₆F₅)₄]⁻ and [(C₁₈H₃₇)₂NH₂]⁺[B(C₆F₅)₄]⁻) containing neither water nor Cl⁻ salt impurities were prepared easily via the acid–base reaction of [PhN(Me)₂-H]⁺[B(C₆F₅)₄]⁻ and the corresponding amine. Using the prepared ammonium salts, the activation reactions of commercial-process-relevant metallocene (rac-[ethylenebis(tetrahydroindenyl)]Zr(Me)₂ (1-ZrMe₂), [Ph₂C(Cp)(3,6-^tBu₂Flu)]Hf(Me)₂ (3-HfMe₂), [Ph₂C(Cp)(2,7-^tBu₂Flu)]Hf(Me)₂ (4-HfMe₂)) and half-metallocene complexes ([(η⁵-Me₄C₅)Si(Me)₂(κ-N^tBu)]Ti(Me)₂ (5-TiMe₂), [(η⁵-Me₄C₅)(C₉H₉(κ-N))]Ti(Me)₂ (6-TiMe₂), and [(η⁵-Me₃C₇H₁S)(C₁₀H₁₁(κ-N))]Ti(Me)₂ (7-TiMe₂)) were monitored in C₆D₁₂ with ¹H NMR spectroscopy. Stable [L-M(Me)(NMe(C₁₈H₃₇)₂)]⁺[B(C₆F₅)₄]⁻ species were cleanly generated from 1-ZrMe₂, 3-HfMe₂, and 4-HfMe₂, while the species types generated from 5-TiMe₂, 6-TiMe₂, and 7-TiMe₂ were unstable for subsequent transformation to other species (presumably, [L-Ti(CH₂N(C₁₈H₃₇)₂)]⁺[B(C₆F₅)₄]⁻-type species). [L-TiCl(N(H)(C₁₈H₃₇)₂)]⁺[B(C₆F₅)₄]⁻-type species were also prepared from 5-TiCl(Me) and 6-TiCl(Me), which were newly prepared in this study. The prepared [L-M(Me)(NMe(C₁₈H₃₇)₂)]⁺[B(C₆F₅)₄]⁻-, [L-Ti(CH₂N(C₁₈H₃₇)₂)]⁺[B(C₆F₅)₄]⁻-, and [L-TiCl(N(H)(C₁₈H₃₇)₂)]⁺[B(C₆F₅)₄]⁻-type species, which are soluble and stable in aliphatic hydrocarbon solvents, were highly active in ethylene/1-octene copolymerization performed in aliphatic hydrocarbon solvents.

Boosting the Thermal Stability of α-Diimine Palladium Complexes in Norbornene Polymerization from Construction of Intraligand Hydrogen Bonding and Simultaneous Increasing Axial/Equatorial Bulkiness

Increasing the thermostability of α-diimine late-transition-metal complexes and therefore rendering them more active at higher temperatures is of great importance, yet challenging for the olefin polymerization field. In the present research, a new family of α-diimine palladium complexes that can promote norbornene polymerization at high temperatures (up to 140 °C) is disclosed. Because of the conformational restriction caused by increasing the axial and equatorial bulkiness as well as the presence of intraligand H···F hydrogen bonds, N-aryl rotations can be efficiently restricted, therefore circumventing the deactivation of the active species at high temperatures. At 80-140 °C, these complexes can efficiently catalyze norbornene homopolymerizations, giving high catalytic activities up to 5.65 × 10⁷ g of PNB per mole Ni per hour and polymers with high molecular weights up to 37.2 × 10⁴ g/mol, which are highly superior to catalytic systems mediated by CF₃-free complexes. Moreover, these complexes could also afford medium catalytic activities in the presence of polar 5-norbornene-2-carboxylic acid methyl ester (NB-COOCH₃).

Suppression of chain transfer via a restricted rotation effect of dibenzosuberyl substituents in polymerization catalysis

Catalysts with dibenzosuberyl substituents possess superior thermostability and outstanding ability to suppress chain transfer in ethylene (co)polymerization, producing high molecular weight polyethylene and functionalized polyethylene.

The synergistic effect of rigid and flexible substituents on insertion polymerization with α-diimine nickel and palladium catalysts

The introduction of flexible cycloalkyl groups greatly enhanced the chain growth in the Ni(ii) catalytic system and facilitated the insertion of polar monomers in the Pd(ii) catalytic system.

Combining hydrogen bonding interactions with steric and electronic modifications for thermally robust α-diimine palladium catalysts toward ethylene (co)polymerization

Thermally robust α-diimine palladium catalysts are highly active for ethylene (co)polymerization at high temperatures by steric and electronic modifications in combination with hydrogen bonding interactions.

Ortho-Functionalized Dibenzhydryl Substituents in α-Diimine Pd Catalyzed Ethylene Polymerization and Copolymerization

Sterically bulky diarylmethyl-based ligands have received increasing attention in the field of late-transition-metal catalyzed olefin polymerization. Ortho-substituents may have a significant impact on the performance of diarylmethyl-based α-diimine Pd catalysts. In this contribution, a series of α-diimine Pd catalysts bearing ortho-methoxyl/hydroxyl functionalized dibenzhydryl units were prepared, characterized, and investigated in ethylene polymerization and copolymerization with methyl acrylate (MA). The catalytic performances were improved by introducing more ortho-substituents. The catalysts exhibited good thermal stabilities at high temperatures, producing branched polyethylenes. The catalysts bearing hydroxyl groups possessing intramolecular H-bonding, resulted in slightly higher incorporation ratios of MA unit when compared with the catalysts bearing methoxyl groups.

Living Chain-Walking (Co)Polymerization of Propylene and 1-Decene by Nickel α-Diimine Catalysts

Homo- and copolymers of propylene and 1-decene were synthesized by controlled chain-walking (co)polymerization using phenyl substituted α-diimine nickel complexes activated with modified methylaluminoxane (MMAO). This catalytic system was found to polymerize propylene in a living fashion to furnish high molecular weight ethylene-propylene (EP) copolymers. The copolymerizations proceeded to give high molecular weight P/1-decene copolymers with narrow molecular weight distribution (Mw/Mn ≈ 1.2), which indicated a living nature of copolymerization at room temperature. The random copolymerization results indicated the possibility of precise branched structure control, depending on the polymerization temperature and time.