Post-metallocene catalysts for the synthesis of ultrahigh molecular weight polyethylene: Recent advances

Single-Site Catalyst for the Synthesis of Disentangled Ultra-High-Molecular-Weight Polyethylene

Disentangled ultra-high-molecular-weight polyethylene (d-UHMWPE) solves the problem of the difficult processing of traditional UHMWPE caused by entanglements between molecular chains. In this review, we look into the innovative realm of nascent disentangled UHMWPE, concentrating on the recent advances achieved through the in situ polymerization of ethylene by single-site catalysts. The effect of single-site catalysts and polymerization conditions on the molecular characteristics is discussed in detail from the perspective of mechanism and DFT calculations. The key factors to low entanglement are revealed, which have instructive implications for the development of new single-site catalytic systems that can generate d-UHMWPE more efficiently and become closer to industrial production. The progress in the preparation for nascent d-UHMWPE with homogeneous and heterogeneous single-site catalysts is systematically reviewed. Rheology and DSC can be used to characterize the degree of entanglement. High-modulus and high-strength biaxial films, tapes, and fibers are obtained by the solid-state processing of these nascent d-UHMWPE.

Accessing Functionalized Ultra-High Molecular Weight Poly(α-olefin)s via Hafnium-Mediated Highly Isospecific Copolymerization

Inspired by the favorable impact of heteroatom-containing groups in phenoxy-imine titanium and late transition metal catalysts, a series of novel pyridylamido hafnium catalysts bearing ─OMe (Cat-OMe), ─CF3 (Cat-CF3), and ─C6F5 (Cat-C6F5) substituents are designed and synthesized. Together with the established hafnium catalysts Cat-H and Cat-iPr by Dow/Symyx, these catalysts are applied in the polymerization of α-olefins, including 1-hexene, 1-octene, and 4M1P, as well as in the copolymerization of these α-olefins with a specifically designed polar monomer. The enhancement of polymer molecular weight derived from catalyst modification and the incorporation of polar monomers is discussed in detail. Notably, the new catalysts are all highly active for α-olefins polymerization, with catalyst Cat-CF3 producing isotactic polymers with the highest molecular weight (Mw = 1649 kg mol-1); in copolymerization with polar monomers, catalyst Cat-OMe yields isotactic copolymer with the highest molecular weight (Mw = 2990 kg mol-1). Interestingly, catalyst Cat-C6F5 bearing a ─C6F5 group in the N-aryl moiety gives rise to poly(α-olefin) with reduced stereoselectivity. The findings of this study underscore the potential of heteroatom-containing groups in the development of early transition metal catalysts and the synthesis of polymer with novel structures.

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.

Trends in Structure and Ethylene Polymerization Reactivity of Transition-Metal Permethylindenyl-phenoxy (PHENI*) Complexes

A family of ansa-permethylindenyl-phenoxy (PHENI*) transition-metal chloride complexes has been synthesized and characterized (1-7; {(η5-C9Me6)Me(R″)Si(2-R-4-R'-C6H2O)}MCl2; R,R' = Me, tBu, Cumyl (CMe2Ph); R″ = Me, nPr, Ph; M = Ti, Zr, Hf). The ancillary chloride ligands could readily be exchanged with halides, alkyls, alkoxides, aryloxides, or amides to form PHENI* complexes [L]TiX2 (8-17; X = Br, I, Me, CH2SiMe3, CH2Ph, NMe2, OEt, ODipp). The solid-state crystal structures of these PHENI* complexes indicate that one of two conformations may be preferred, parametrized by a characteristic torsion angle (TA'), in which the η5 system is either disposed away from the metal center or toward it. Compared to indenyl PHENICS complexes, the permethylindenyl (I*) ligand appears to favor a conformation in which the metal center is more accessible. When heterogenized on solid polymethylaluminoxane (sMAO), titanium PHENI* complexes exhibit exceptional catalytic activity toward the polymerization of ethylene. Substantially greater activities are reported than for comparable PHENICS catalysts, along with the formation of ultrahigh-molecular-weight polyethylenes (UHMWPE). Catalyst-cocatalyst ion pairing effects are observed in cationization experiments and found to be significant in homogeneous catalytic regimes; these effects are also related to the influence of the ancillary ligand leaving groups in slurry-phase polymerizations. Catalytic efficiency and polyethylene molecular weight are found to increase with pressure, and PHENI* catalysts can be categorized as being among the most active for the controlled synthesis of UHMWPE.

New Ni(II)-Ni(II) Dinuclear Complex, a Resting State of the (α-diimine)NiBr2/AlMe3 Catalyst System for Ethylene Polymerization

A novel room-temperature stable diamagnetic nickel complex 2 was detected upon activation of Brookhart-type ethylene polymerization pre-catalyst LNiBr2 (1, L = 1,4-bis-2,4,6-trimethylphenyl-2,3-dimethyl-1,4-diazabuta-1,3-diene) with AlMe3. Using in situ 1H, 2H, and 13C NMR spectroscopy, as well as DFT calculations, this species has been identified as an antiferromagnetically coupled homodinuclear complex [LNiII(μ-Me)(μ-CH2)NiIIL]+Br−. Its behavior in the reaction solution is characteristic of the resting state of nickel catalyzed ethylene polymerization.

Effect of Activator and Outgoing Ligand Nature on the Catalytic Behavior of Bis(phenoxy-imine) Ti(IV) Complexes in the Polymerization of Ethylene and Its Copolymerization with Higher Olefins

A series of bis(phenoxy-imine) (FI) titanium(IV) and zirconium(IV) complexes have been synthesized. The effect of the nature of the activator (MAO, combinations EtnAlCl3-n + Bu2Mg and iBu3Al + [Ph3C]+[B(C6F5)4]-) on the catalytic activity and properties of the resulting polymers was studied. It was found that Ti-Fi complexes, despite the nature of the outgoing ligands (Cl or iPrO) in the presence of Al/Mg activators, effectively catalyze the polymerization of ethylene (with the formation of UHMWPE); copolymerization of ethylene with 1-octene (with the formation of ultra-high molecular weight copolymers); and the ternary copolymerization of ethylene, propylene and 5-vinyl-2-norbornene (with the formation of polyolefin elastomers). It has been shown that Zr-FI complexes are not activated by these Al/Mg compositions. The resulting UHMWPE can be processed by a solventless method into high-strength and high-modulus oriented films; however, their mechanical characteristics do not exceed those obtained using MAO.

Syntheses of Silylene-Bridged Thiophene-Fused Cyclopentadienyl ansa-Metallocene Complexes for Preparing High-Performance Supported Catalyst

We synthesized a series of Me2Si-bridged ansa-zirconocene complexes coordinated by thiophene-fused cyclopentadienyl and fluorenyl ligands (Me2Si(2-R1-3-R2-4,5-Me2C7S)(2,7-R32C13H6))ZrMe2 (R1 = Me or H, R2 = H or Me, R3 = H, tBu, or Cl) for the subsequent preparation of supported catalysts. We determined that the fluorenyl ligand adopts an η3-binding mode in 9 (R1 = Me, R2 = H, R3 = H) by X-ray crystallography. Further, we synthesized a derivative 15 by substituting the fluorenyl ligand in 9 with a 2-methyl-4-(4-tert-butylphenyl)indenyl ligand, derivatives 20 and 23 by substituting the Me2Si bridge in 12 (R1 = Me, R2 = H, R3 = tBu) and 15 with a tBuO(CH2)6(Me)Si bridge, and the dinuclear congener 26 by connecting two complexes with a –(Me)Si(CH2)6Si(Me)– spacer. The silica-supported catalysts prepared using 12, 20, and 26 demonstrated up to two times higher productivity in ethylene/1-hexene copolymerization than that prepared with conventional (THI)ZrCl2 (21–26 vs. 12 kg-PE/g-(supported catalyst)), producing polymers with comparable molecular weight (Mw, 330–370 vs. 300 kDa), at a higher 1-hexene content (1.3 vs. 1.0 mol%) but a lower bulk density of polymer particles (0.35 vs. 0.42 g/mL).

α-Diimine Ni-Catalyzed Ethylene Polymerizations: On the Role of Nickel(I) Intermediates

Nickel(II) complexes with bidentate N,N-α-diimine ligands constitute a broad class of promising catalysts for the synthesis of branched polyethylenes via ethylene homopolymerization. Despite extensive studies devoted to the rational design of new Ni(II) α-diimines with desired catalytic properties, the polymerization mechanism has not been fully rationalized. In contrast to the well-characterized cationic Ni(II) active sites of ethylene polymerization and their precursors, the structure and role of Ni(I) species in the polymerization process continues to be a “black box”. This perspective discusses recent advances in the understanding of the nature and role of monovalent nickel complexes formed in Ni(II) α-diimine-based ethylene polymerization catalyst systems.

Synthesis of Ethylene/1-Octene Copolymers with Ultrahigh Molecular Weights by Zr and Hf Complexes Bearing Bidentate NN Ligands with the Camphyl Linker

Ultrahigh molecular weight polyethylene (UHMWPE) is a class of high-performance engineering plastics, exhibiting a unique set of properties and applications. Although many advances have been achieved in recent years, the synthesis of UHMWPE is still a great challenge. In this contribution, a series of zirconium and hafnium complexes, [2,6-(R1)2-4-R2-C6H2-N-C(camphyl)=C(camphyl)-N-2,6-(R1)2-4-R2-C6H2]MMe2(THF) (1-Zr: R1 = Me, R2 = H, M = Zr; 2-Zr: R1 = Me, R2 = Me, M = Zr; 1-Hf: R1 = Me, R2 = H, M = Hf; 2-Hf: R1 = Me, R2 = Me, M = Hf), bearing bidentate NN ligands with the bulky camphyl backbone were synthesized by the stoichiometric reactions of α-diimine ligands with MMe4 (M = Hf or Zr). All Zr and Hf metal complexes were analyzed using 1H and 13C NMR spectroscopy, and the molecular structures of complexes 1-Zr and 1-Hf were determined by single-crystal X-ray diffraction, revealing that the original α-diimine ligand was selectively reduced into the ene-diamido form and generated an 1,3-diaza-2-metallocyclopentene ring in the metal complexes. Zr complexes 1-Zr and 2-Zr showed moderate activity (up to 388 kg(PE)·mol−1(M)·h−1), poor copolymerization ability, but unprecedented molecular weight capability toward ethylene/1-octene copolymerization. Therefore, copolymers with ultrahigh molecular weights (>600 or 337 × 104 g∙mol−1) were successfully synthesized by 1-Zr or 2-Zr, respectively, with the borate cocatalyst [Ph3C][B(C6F5)4]. Surprisingly, Hf complexes 1-Hf and 2-Hf showed negligible activity under otherwise identical conditions, revealing the great influence of metal centers on catalytic performances.

Homo- and copolymerization of norbornene using tridentate IzQO palladium catalysts with dimethylaminoethyl as a side arm

Rigid IzQO–Pd catalysts were synthesized by Rh(iii)-catalyzed C–H/alkyne annulation and applied for the homo- and copolymerizations of norbornene with polar vinyl monomers.