Syndiotactic polystyrene catalysts

Schellenberg, J. Tomotsu, N. Syndiotactic polystyrene catalysts and polymerization. Prog. Polym. Sci. 2002, 27, 1925-1982. 

For comprehensive reviews, see (a) Schellenberg, J., Tomotsu, N. Syndiotactic polystyrene catalysts and polymerization. Prog. Polym. Sci., 27,1925-1982 (2002). (b) Schellenberg, J. Recent transition metal catalysts for syndiotactic polystyrene. Progress Polym. Sci.,34, 688-718 (2009). 

The first production of syndiotactic polystyrene has been credited to research workers at Idemitsu Kosan in 1985 who used cyc/opentadienyl titanium compounds with methyl aluminoxane as catalyst. 

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. 

A radical initiator based on the oxidation adduct of an alkyl-9-BBN (47) has been utilized to produce poly(methylmethacrylate) (48) (Fig. 31) from methylmethacrylate monomer by a living anionic polymerization route that does not require the mediation of a metal catalyst. The relatively broad molecular weight distribution (PDI = (MJM ) 2.5) compared with those in living anionic polymerization cases was attributed to the slow initiation of the polymerization.69 A similar radical polymerization route aided by 47 was utilized in the synthesis of functionalized syndiotactic polystyrene (PS) polymers by the copolymerization of styrene.70 The borane groups in the functionalized syndiotactic polystyrenes were transformed into free-radical initiators for the in situ free-radical graft polymerization to prepare s-PS-g-PMMA graft copolymers. 

Syndiotactic Polystyrene. Syndiotactic polystyrene is an interesting material because it has a Tg of 95 °C and a Tm of 260 °C [38], Polystyrene made via radical polymerisation may show some syndiotacticity, but its heat distortion temperature is too low to allow its use in important applications requiring temperatures around 120 °C or higher, such as medical equipment which requires sterilization or hot water storage containers. Idemitsu and Dow have reported titanium-based catalysts such as the one shown in Figure 10.23. We presume that the mechanism is a chain-end controlled "2,1" insertion. 

Figure 10.23. Syndiotactic, chain-end controlled polystyrene catalyst...

For example, it is possible to synthesize isotactic as well as syndiotactic polypropylene in high configurational purity and high yields. The same holds for syndiotactic polystyrene. Furthermore, metallocene catalysts open the possibility to absolutely new homopolymers and copolymers like, e.g., cycloolefin copolymers (COG) and even (co)polymers of polar monomers.The simplest metallocene catalyst consists of two components. The first one is a n-complex (the actual metallocene) that can be bridged via a group X and therefore can become chiral ... 

With conventional polymerization processes, atactic chains are predominantly formed for the formation of isotactic and syndiotactic chains a special catalyst system is required, e.g. Ziegler-Natta catalysts. Such a process is called stereospecific polymerization. It enables the manufacture of, i.a., technically usable PP and also unbranched PE (see 4.1). The newest development is the metallocene katalyst it enables the building-up of chains-to-measure with very high degrees of chain regularity also the manufacture of syndiotactic polystyrene is technically possible in this way (see Qu. 2.47). 

Syndiotactic polystyrene was first obtained only recently by Ishihara et al. [5] in polymerisation with a homogeneous catalyst derived from a transition metal compound such as monocyclopentadienyltitanium trichloride and methylalu-minoxane in toluene. Since then, several authors have reported on the synthesis of syndiotactic polystyrene promoted by different catalysts based on metal hydrocarbyls such as benzyl compounds, half-sandwich metallocenes (e.g. monocyclopentadienyl, monopentamethylcyclopentadienyl and monoindenyl metal derivatives), metal alkoxides, metallocenes and some other compounds. These catalysts are commonly derived from titanium or zirconium compounds, either activated with methylaluminoxane or aluminium-free, such as those activated with tris(pentafluorophenyl)boron, and promote the syndiospecific polymerisation of styrene and substituted styrenes [5-10,21,48-70], Representative examples of the syndiospecific polymerisation of styrene using catalysts based on various titanium compounds and methylaluminoxane are shown in Table 4.2 [6,52,53,56,58],... 

Also, divalent TiPh2 activated with [Al(Me)0]x appeared to be a catalyst for syndiospecific styrene polymerisation [71]. Even 5-TiCh or (Acac)3TiCl3, when activated with [Al(Me)0]x, could yield a mixture of isotactic and syndiotactic polystyrenes. Some other catalysts, such as rare-earth coordination catalysts, have been successfully used to obtain syndiotactic-rich polystyrenes [72],... 

Moreover, polymerisation in the presence of a catalyst with (13C)-enriched triethylaluminium [A1(13CH2CH3)3] as an activator yielded syndiotactic polystyrene, which contained some — CH(Ph)CH213CH2CH3 end groups [9],... 

Methylaluminoxane-free catalysts, such as cationic complexes derived from TiBz4 and tris(pentafluorophenyl)borane [B(C6F5)3], appear to be much less active, poorly stereospecific catalysts for the polymerisation of styrene. Under analogous conditions, the use of N, yV-dimethylanilinium tetrakis(pentafluor-ophenyl)borate [Me2N(Ph)H]+[B(C6F5)4]- instead of B(C6F5)3 does not yield active catalysts only traces of syndiotactic polystyrene were obtained [70]. 

Although there is dispute about the exact oxidation state of titanium in the active species [Ti(III) or Ti(IV)], it was suggested, from the results of ESR measurements, that Ti(III) species form highly active sites for producing syndiotactic polystyrene in styrene polymerisation systems with the TiBz4—[Al(Me)0]x catalyst [50]. The moderately low catalyst activity is attributable to the stability of the benzyl transition metal derivatives towards reduction. 

Catalysts of the Ti(OR)4—[Al(Me)0]x type show greatly inferior activity and syndiospecificity in the polymerisation of styrene by comparison with catalysts of the CpTi(OR)3—[Al(Me)0]x type [54,70]. The activity and syndiospecificity of Ti(OR)4—[Al(Me)0]x catalysts increases when the Al/Ti molar ratio in the polymerisation system is increased. The maximum activity of Ti(OR)4—[A1 (Me)0]x catalysts is observed at an Al/Ti molar ratio of ca 100 [54,55]. It is worth mentioning that, under the same polymerisation conditions, these catalysts yield syndiotactic polystyrene with a higher molecular weight than does the CpTiCl3—[Al(Me)O]x catalyst [71],... 

When supported on AI2O3 as a carrier, half-sandwich metallocenes such as CpTiCl3 and Cp TiCl3 also gave rise to suitable stereospecific catalysts that could even be activated by Al(z -Bu)3 [69]. However, in contrast to the respective homogeneous catalysts (yielding syndiotactic polystyrene), polymerisation with these heterogeneous catalysts afforded isotactic and syndiotactic polystyrenes. 

Table 24. Synthesis of syndiotactic polystyrene using metallocene/MAO catalysts...

Metallocenes are very versatile catalysts for the production of polyolefins, polystyrene and copolymers. Some polymers such as syndiotaetic polypropene, syndiotactic polystyrene, cycloolefin copolymers, optically active oligomers, and polymethylenecycloalkenes can be produced only by metallocene catalysts. It is possible to tailor the microstructure of polymers by changing the ligand structure of the metallocene. The effect and influence of the ligands can more and more be predicted and understood by molecular modeling and other calculations. 

Monocyclopentadienyl complexes of titaninm (Cp TtXs) perform poorly as catalysts for ethylene or propylene polymerization, bnt in the presence of MAO, they polymerize styrene to stereo- and regioregnlar syndiotactic polystyrene, a crystalline material with very high melting point (273 °C) and glass transition temperature (100°C). In this case, the active polymerizing species is a Ti complex (Figure 8). Each styrene monomer inserts in a secondary manner and the stereoregularity is maintained by the conformation of the last inserted unit (chain-end control). 

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