METALLOCENE COPOLYMER

Table 14 Comparison of Conventional Random Copolymner with Metallocene Copolymer and Homopolymer...

The absence of a second cyclopentadienyl ring coupled with the short bridge gives a very open environment at the metal site. This allows easier access for bulky monomers, including 1-alkenes and norbomene, compared to polymerization with metallocenes. CpA initiators yield ethylene copolymers not easily available with metallocenes. Copolymers containing significant amounts of comonomers such as styrene, norbomene, and a-olefins from 1-hexene to 1-octadecene are easily obtained with CpA, but not with metallocene or traditional Ziegler-Natta initiators. 

Conv. copolymer Metallocene copolymer Metallocene homopolymer... 

Accidental contamination of AlEt3 by water greatly increased Z-N catalytic activity and led to the development of diverse metallocene catalysts. By contrast, with earlier catalysts, the metallocene copolymers have well-defined structure, a single active polymerization center leading to high polymerization efficiency (1 kg polymer per 1 g catalyst), narrow MWD, and uniform properties. Metallocenes show better thermal stability, facile incorporation, high a-olefins even at high concentration (plastomers), and control of stereostructure. Most frequently, the active part of Z-N catalyst is a zirconocene cation... 

Table 6 Basic properties of metallocene copolymers and reference LDPE characterized with the melt elongational measurements...

The key feature of metallocene-based random copolymers is their homogeneity resulting in their low extrac-tibles content compared with conventional polymers. For polymers with a melting point of 120°C, the metallocene copolymer beats the conventional random... 

An interesting summary of property balanees and the position of metallocene copolymers of ethylene a-olefins in the balance of strength versus process-ability and moldability (Fig. 1) are shown. 

Tobita and Hamashima [56] used Monte Carlo simulations to show that this relationship is also valid for randomly branched polymers. Wood-Adams etal. [57] fotmd that Eq. 2.103 described the behavior of a series of long-chain branched metallocene copolymers. 

EinaHy, in 1976, Kaminsky and Sinn in Germany discovered a new family of catalysts for ethylene polymerization. These catalysts (ie, Kaminsky catalysts) contain two components a metallocene complex, usually a zkconocene, and an organoaluminum compound, methylaluminoxane (8,9). These catalysts and thek various later modifications enable the synthesis of ethylene copolymers with a high degree of branching uniformity. Formally classified as MDPE, LLDPE, or VLDPE, the resins thus produced have a number of properties that set them apart from common PE resins in terms of performance... 

Commercial production of PE resias with densities of 0.925 and 0.935 g/cm was started ia 1968 ia the United States by Phillips Petroleum Co. Over time, these resias, particularly LLDPE, became large volume commodity products. Their combiaed worldwide productioa ia 1994 reached 13 X 10 metric t/yr, accouatiag for some 30% market share of all PE resias ia the year 2000, LLDPE productioa is expected to iacrease by 50%. A aew type of LLDPE, compositioaaHy uniform ethylene—a-olefin copolymers produced with metallocene catalysts, was first introduced by Exxon Chemical Company in 1990. The initial production volume was 13,500 t/yr but its growth has been rapid indeed, in 1995 its combiaed production by several companies exceeded 800,000 tons. 

As a rule, LLDPE resins do not contain long-chain branches. However, some copolymers produced with metallocene catalysts in solution processes can contain about 0.002 long-chain branches per 100 ethylene units (1). These branches are formed in auto-copolymerisation reactions of ethylene with polymer molecules containing vinyl double bonds on their ends (2). 

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). 

Metallocene catalysis can also make possible the production of copolymers of propylenes with monomers such as long-chain olefins, cyclic olefins and styrene which is not possible with more conventional Ziegler-Natta catalysts. 

Ethylene-cyclo-olefin copolymers have been known since 1954 (DuPont USP2 721 189) but these materials only became of importance in the late 1990s with the development of copolymers of ethylene and 2-norbomene by Hoechst and Mitsui using metallocene technology developed by Hoechst. The product is marketed as Topas by Ticona. By adjustment of the monomer ratios polymers with a wide range of Tg values may be obtained including materials that are of potential interest as thermoplastic elastomers. This section considers only thermoplastic materials, cyclo-olefins of interest as elastomers are considered further in Section 11.10. 

Since the last edition several new materials have been aimounced. Many of these are based on metallocene catalyst technology. Besides the more obvious materials such as metallocene-catalysed polyethylene and polypropylene these also include syndiotactic polystyrenes, ethylene-styrene copolymers and cycloolefin polymers. Developments also continue with condensation polymers with several new polyester-type materials of interest for bottle-blowing and/or degradable plastics. New phenolic-type resins have also been announced. As with previous editions I have tried to explain the properties of these new materials in terms of their structure and morphology involving the principles laid down in the earlier chapters. 

Metallocene catalysts produce random copolymers [29-31] with different property profiles (Table 14). These data show that random copolymers have higher stiffness and higher transparency at certain melting point levels. A very low content of extractables in low-melting... 

Table 15 Low Melting Metallocene Versus Conventional Propylene-Ethylene Copolymer...

A long-standing goal in polyolefins is the synthesis of polymers bearing polar functional groups such as acrylate, esters, or vinyl ethers, etc [24,40]. These copolymers might endow polyolefins with useful properties such as adhesiveness, dyeability, paintability, and print-ibility. Advances have recently been made in polymerizing polar monomers with cationic metallocene catalysts... 

U. Moll and M. Lux, Manufacture of ethylene/alpha olefin copolymers with metallocene catalysts in slurry loop... 

A. Akimoto and A. Yano, Production of ethylene copolymers with metallocene catalysts at high pressure and its properties, MetCon 94 Proceedings, USA, May 1994. 

Polystyrene (PS) is the fourth big-volume thermoplastic. Styrene can be polymerized alone or copolymerized with other monomers. It can be polymerized by free radical initiators or using coordination catalysts. Recent work using group 4 metallocene combined with methylalumi-noxane produce stereoregular polymer. When homogeneous titanium catalyst is used, the polymer was predominantly syndiotactic. The heterogeneous titanium catalyst gave predominantly the isotactic. Copolymers with butadiene in a ratio of approximately 1 3 produces SBR, the most important synthetic rubber. 

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