Homogeneous ethylene copolymers

The second type of solution polymerization concept uses mixtures of supercritical ethylene and molten PE as the medium for ethylene polymerization. Some reactors previously used for free-radical ethylene polymerization in supercritical ethylene at high pressure (see Olefin POLYMERS,LOW DENSITY polyethylene) were converted for the catalytic synthesis of LLDPE. Both stirred and tubular autoclaves operating at 30—200 MPa (4,500—30,000 psig) and 170—350°C can also be used for this purpose. Residence times in these reactors are short, from 1 to 5 minutes. Three types of catalysts are used in these processes. The first type includes pseudo-homogeneous Ziegler catalysts. In this case, all catalyst components are introduced into a reactor as hquids or solutions but form soHd catalysts when combined in the reactor. Examples of such catalysts include titanium tetrachloride as well as its mixtures with vanadium oxytrichloride and a trialkyl aluminum compound (53,54). The second type of catalysts are soHd Ziegler catalysts (55). Both of these catalysts produce compositionaHy nonuniform LLDPE resins. Exxon Chemical Company uses a third type of catalysts, metallocene catalysts, in a similar solution process to produce uniformly branched ethylene copolymers with 1-butene and 1-hexene called Exact resins (56). 

Cyclopentadienyl ligands have become extremely important in catalysis for metal such as Ti, Zr, and Hf (Chapter 10) and in academic studies of related elements such as Ta. Ethylene polymerisation with the use of CpiTiCE (alkylated with aluminium alkyl compounds) has been known for many decades, but the intensive interest in derivatives of these compounds started in the early 1980 s following the discovery of MAO (methaluminoxane - see chapter 10) which boosted metallocene catalyst activities by several orders of magnitude. Commercial interest focussed on ethylene copolymers (LLDPE where more homogeneous comonomer incorporation resulted in greatly improved copolymer properties) and in enantiospecific polymerisations for propene, styrene, etc. 

The first section of this chapter describes the most important high pressure process run under homogeneous conditions to manufacture Low Density PolyEthylene (LDPE). The radical polymerization of ethylene to LDPE is carried out in tubular reactors or in stirred autoclaves. Tubular reactors exhibit higher capacities than stirred autoclaves. The latter are preferred to produce ethylene copolymers having a higher comonomer content. 

MAJOR APPLICATIONS POE is a new family of ethylene a-olefin copolymers produced using metallocene catalyst. The uncross-linked polymers referred to in this chapter are known to have only moderate elastomeric recovery properties (up to 96%). These copolymers are characterized by a narrow molecular weight distribution (MWD) (M /Mn = 2-2.5) and homogeneous comonomer distribution.The control of chain microstructure by the use of metallocene catalyst makes it possible to produce poly(a-olefin) copolymers with considerably lower density, which has not been possible before using the conventional Ziegler-Natta catalyst. Some of the highly branched ethylene copolymers presented in the entry on Polyethylene, metallocene linear low-density, in this handbook may be closely related. 

ACRONYMS, ALTERNATIVE NAMES mLLDPE, metallocene PE, single site catalyzed LLDPE (SSC), polyolefin plastomers (POP), homogeneous ethylene copolymers... 

The overall nucleation and crystalhzation rates of PLA tmder heterogeneous conditions are relatively higher than in homogenous conditions. The nucleation and crystallization rates of propylene-ethylene copolymer are increased tmder isothermal conditions. Addition of nucleating agent accelerates crystallization. Avrami equation is in popular use in the analysis of isothermal crystallization kinetics of polymers ... 

PVC polyvinyl chloride with low-molecular organic admixtures as softeners, ECB ethylene copolymer bitumen, a mixture of about 50 % ethylene and 50 % bitumen, CPE chlorinated polyethylene and/or homogeneous mixture from chlorinated polyethylenes and PVC, EPDM terpolymer from polyethylene, polypropylene and a small amount of diene monomer. A flexible mbber is obtained by vulcanisation. 

Vanden Eynde, S., Mathot, V., Koch, M.H.J., Reynaers, H., Thermal behaviour and morphology of homogeneous ethylene-propylene and ethylene-1-butene copolymers with high comonomer contents. Polymer 2000,41 3437-3453. Al-Hussein, M., Strobl, G., Strain-controlled tensile deformation behavior of isotactic poly(l-butene) and its ethylene copolymers. Macromolecules 2002, 35 8515-8520. 

Mathot, V.B.F.. Reynaers, H., Crystallization, Melting and Morphology of Homogeneous Ethylene Copolymers Handbook of Thermal Analysis And Calorimetry, Vol. 3, Elsevier, Amsterdam, 2002, pp. 197-244. 

DuPont s Sclair process was extremely important technology which was introduced in the 1960s, as it offered commercial ethylene copolymers at densities as low as 0.916 g/cc with improved physical properties over comparable polyethylene resins produced with the high-pressure process. In addition, DuPont scientists also developed improved catalysts for the Sclair process based on vanadium compounds that produced homogeneous branching distribution of the short-chain branches introduced along the polymer backbone by incorporation of a comonomer such as 1-butene into the polymer structure. 

Seguela R, Gaucher-Miri V and Elkoun S (1998) Plastic deformation of polyethylene and ethylene copolymers. Part I homogeneous crystal slip and molecular mobility, J Mater Sci, 33 1273-1279. 

The method has severe limitations for systems where gradients on near-atomic scale are important (as in the protein folding process or in bilayer membranes that contain only two molecules in a separated phase), but is extremely powerful for (co)polymer mixtures and solutions [147, 148, 149]. As an example Fig. 6 gives a snapshot in the process of self-organisation of a polypropylene oxide-ethylene oxide copolymer PL64 in aqueous solution on its way from a completely homogeneous initial distribution to a hexagonal structure. 

Although the reaction rate of ethylene and various copolymers differs substantially, the reaction constants can be estabUshed by using an arbitrary value of 1 for ethylene (5). Thus, a value of 0.1 would indicate that the comonomer reacts at 10 times the rate of ethylene. However, the wide range of reaction rates can present problems not only in determining the comonomer content of the final product but also in producing a homogeneous product (4,6). 

Poly(ethyl methacrylate) (PEMA) yields truly compatible blends with poly(vinyl acetate) up to 20% PEMA concentration (133). Synergistic improvement in material properties was observed. Poly(ethylene oxide) forms compatible homogeneous blends with poly(vinyl acetate) (134). The T of the blends and the crystaUizabiUty of the PEO depend on the composition. The miscibility window of poly(vinyl acetate) and its copolymers with alkyl acrylates can be broadened through the incorporation of acryUc acid as a third component (135). A description of compatible and incompatible blends of poly(vinyl acetate) and other copolymers has been compiled (136). Blends of poly(vinyl acetate) copolymers with urethanes can provide improved heat resistance to the product providing reduced creep rates in adhesives used for vinyl laminating (137). 

Reactive compatibilization is also carried out by adding a monomer which in the presence of a catalyst can react with one or both phases providing a graft copolymer in situ that acts as a compatibilizer. Beaty and coworkers added methyl methacrylate and peroxide to waste plastics (containing polyethylene [PE], polypropylene [PP], PS, and poly(ethylene terephthalate) [PET]). The graft copolymer formed in situ homogenized the blend very effectively [19]. 

Figure 19 (a) Peak melting temperature as a function of the branch content in ethylene-octene copolymers (labelled -O, and symbol —B (symbol, ) and -P (symbol, A) are for ethylene-butene and ethylene-propylene copolymers, respectively) and obtained from homogeneous metallocene catalysts show a linear profile, (b) Ziegler-Natta ethylene-octene copolymers do not show a linear relationship between peak melting point and branch content [125]. Reproduced from Kim and Phillips [125]. Reprinted with permission of John Wiley Sons, Inc. 

In some very recent work by Karssenberg et al. [130], attempts have been made to improve the analytical ability of a technique like NMR spectroscopy to effectively predict the distribution of sequence lengths in polyethylene-alkene copolymers. They analyzed the entire [ C-NMR spectrum for homogeneous ethylene-propene copolymers. They used quantitative methods based on Markov statistics to obtain sequence length distributions as shown in Figure 22 [130]. The... 

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