Metallocenes polymerisation catalysts

This brief review attempts to summarise some recent advances in the mechanistic understanding of metallocene polymerisation catalysts and the role of NMR spectroscopy in these endeavors. For further information the reader is referred to a series of excellent recent reviews covering various aspects of the chemistry of metallocene polymerisation catalysts, for example Refs. [20-28]. 

Mohring, P. C., CoviUe, N. J. Group 4 metallocene polymerisation catalysts Quantification of ring substituent steric effects. Coord. Chem. Rev., 250, 18-35... 

With the exception of LDPE, polyolefins like other polyethylenes and polypropylene, which represent the largest amount of vinyl-type polymers produced in the world, are neither synthesized by radical nor by classical ionic polymerisation processes. Different types of polymerisation catalysts are in use for these purposes. The Cr-based Phillips catalyst, Ziegler-Natta type catalysts, metallocene or other more recently discovered catalysts, including late transition metal catalysts, are all characterized by their propagation step where the olefin monomer inserts into a carbon-transition metal link. ... 

For more general overviews of post-metallocene a-olefin polymerisation catalysts, the reader is referred to a series of reviews [8, 9, 10, 11, 12], while recent reviews pertaining to the importance of 2,6-bis(imino)pyridines and to iron and cobalt systems per se have also been documented [13, 14],... 

Group 4 metallocene complexes were reported by Wilkinson in early 1953 [4], a few months before Ziegler s seminal discovery that mixtures of TiCl4 and AlEt3 catalysed the polymerisation of ethene. It was not long before the new compounds were tested as potential ethene polymerisation catalysts, not least because these... 

Whether or not such electrophilic organometallic species can be identified, or indeed isolated, depends primarily on the stability of the counteranion. The per-fluorophenyl boron compounds B(C,sF5)3 and [B(C6F5)4] , first prepared by Stone and co-workers in 1963 [33], proved particularly useful in this respect. Their use in metallocene polymerisation catalysis [34, 35] led to significantly more active catalysts and well-defined catalyst systems that proved mechanistically informative. These results have then enabled similar species to be detected in the more complex MAO-activated catalyst systems (vide infra). 

Most of the spectroscopic investigations discussed above were carried out on well-defined metallocene systems, either isolated species or those generated from a well-defined metallocene alkyl precursor activated with one equivalent of a borane or borate activator. Most practical polymerisation catalysts, on the other hand, include a scavenger, usually an aluminum alkyl, and may contain ill-defined activators such as methylaluminoxane (MAO), usually at high MAO/Zr ratios. Such systems are less amenable to quantitative studies nevertheless, the identifications of species such as those depicted in Schemes 8.5-8.8 has enabled similar compounds to be identified in more complex mixtures. An idea of the possible mode of action... 

The breakthrough in metallocene catalyst development occurred in the early 1980s when a metallocene catalyst, instead of an aluminium alkyl, was combined with methylaluminoxane (MAO) [8, 9, 10]. This catalyst system boosted the activity of metallocene-based catalyst and produced uniform polyethene with the narrow molar mass distribution typical for single-site catalysts. Efforts to polymerise propene failed, however the product was found to be fully atactic, indicating complete lack of stereospecificity of the catalyst [10]. 

The symmetry of the metallocene and also the kind of procatalyst metal atom, the nature of the catalyst activator and the polymerisation temperature determine the polypropylene tacticity. The general stereoregulation behaviour of metallocene catalysts may be explained in terms of the local chirality, or chirotopicity, of the catalytic sites bonded to the same metal atom. For this analysis, the structure of metallocenes as catalysts should be considered. 

Extensive efforts have also been made to develop olefin polymerisation catalysts based on metallocenes with only one ligand of the cyclopentadienyl type. Ethylene-,dimethylsilylene- or tetramethyldisilylene-bridged mono(l-tetra -methylcyclopentadienyl), mono(l-indenyl) or mono(9-fluorenyl)-amidotita-nium complexes, such as dimethylsilylene(l-tetramethylcyclopentadienyl)(t-butyl)amidotitanium dichloride [Me2Si(Me4Cp)N(/-Bu)TiCl2] (Figure 3.10), have recently attracted both industrial and scientific interest as precursors for methylaluminoxane-activated catalysts, which polymerise ethylene and copolymerise ethylene with 1-butene, 1-hexene and 1-octene [30,105,148-152]. 

Homogeneous alkylaluminium (alkylaluminoxane)-free olefin polymerisation catalysts are commonly referred to as catalysts containing group 4 metallocene cationic species. These catalysts resemble the structure and properties of the respective metallocene-based Ziegler-Natta catalysts but, by definition, are not included among the latter catalysts. The development of alkylaluminium-free metallocene-based olefin polymerisation catalysts is connected with discoveries... 

Homogeneous alkylaluminium-free olefin polymerisation catalysts also comprise non-metallocene cationic group 4 metal complexes such as those with benzyl ligands [162]. A distinct group of alkylaluminium-free homogeneous olefin polymerisation catalysts consists of nickel complexes [181-183],... 

At the end of considerations of metallocene supported catalysts, it should be noted that the catalyst derived from chromocene, biscyclopentadienylchro-mium (Cp2Cr), deposited on silica supports, also exhibits very high activity for the polymerisation of ethylene [214]. The formation of the catalyst has been formulated as follows [215] ... 

In the case of olefin polymerisation in the presence of homogeneous metallocene-based catalysts, the individual polymerisation stages have not been very thoroughly investigated. However, kinetic studies have helped, among others, to define the nature of the active centres and to establish the occurrence of some polymerisation elementary steps in a quantitative way. 

The mechanism that is commonly considered to operate in the polymerisation of ethylene and a-olefins in the presence of group 4 metallocene-based catalysts is that devised by Cossee [268, 276, 277] for propylene polymerisation with heterogeneous Ziegler-Natta catalysts, though modifications invoking effects such as a-agostic hydrogen interactions with the metal centre have been proposed [343,344]. 

Possible pathways for monomer insertion in olefin polymerisation systems with homogeneous single-site metallocene-based catalysts and heterogeneous Zieg-ler-Natta catalysts are shown in Figure 3.17 [122],... 

Similarly to the case of heterogeneous Ziegler Natta olefin polymerisation catalysts, the coordination of the olefin molecule at the cationic metallocene species, due to n bond formation (Figure 2.1), leads to lowering of the energy of the resultant n complex, e.g. the [Cp 2Mt(R)-olefin]1 [Alx(R)x OxX2] complex, which results in activation of the catalyst Mt-C bond and olefin C=C bond for the insertion reaction [136]. 

However, another factor that determines the properties of metallocene-based catalysts for catalysing olefin polymerisation has to be taken into consideration - the already mentioned agostic interaction of one of the 7-hydrogen atoms of the metal-bound alkyl chain with the metal centre of the metallocene-based catalyst [343,344],... 

Figure 3.19 Chain migratory insertion mechanism for olefin polymerisation with metallocene-based catalysts...

At the end of considerations of the role of alkylaluminoxanes as activators for metallocenes as Ziegler-Natta olefin polymerisation catalysts, it should be noted that the analogy between methylaluminoxane and simple acidic moieties does not appear to hold. For example, highly Lewis acidic perfluorinated boranes, such as Bf CgFs, show enhanced activity as activators when compared with [Al(Me)0]x, but the stability of the resulting zirconocene-based catalyst is drastically lower than that of the catalyst formed with [Al(Me)0]x [98]. 

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