Synthesis of Long-Chain Branched Polyolefins by Coordinative Chain Transfer Polymerization

Advances in Nonreactive Polymer Compatibilizers for Commodity Polyolefin Blends

Recycling mixed polyolefin plastics is a significant challenge due to the limitations in sorting and degraded mechanical properties of blends. Nonreactive compatibilization by adding a small amount of polymeric additive is a widespread approach to restoring the performance and value of recycled plastics. Over the past several decades, synthetic advances have enabled access to low-cost copolymers and precision architectures for deepening the understanding of compatibilization mechanisms in semicrystalline polyolefins. This review covers the design parameters of a polymeric compatibilizer, the testing of blends, the synthetic methods of producing economically viable additives, and surveys the literature of blends of compatibilized HDPE, LLDPE, LDPE, and iPP. From this, readers should gain a comprehension of the polymer mechanics, synthesis, and macromolecular engineering of processable polyolefin blends, along with the field's future directions.

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.

Ammonium Tetrakis(pentafluorophenyl)borate: Preparation and Application in Olefin Coordination Polymerization as the Cocatalyst Compound

Metallocene catalysts have attracted much attention from academia and industry for their excellent catalytic activity in the field of olefin polymerization. Cocatalysts play a key role in metallocene catalytic systems, which can not only affect the overall catalytic activity, but also have an obvious influence on the structure and properties of the polymer. Although methylaluminoxane (MAO) is currently the most widely used cocatalyst, its price increases the production cost of polyolefin materials. Ammonium tetrakis(pentafluorophenyl)borate has shown excellent performance in polymerization, being one of the best substitutes for the traditional cocatalyst MAO. Compared with the main catalyst, whose composition and structure are relatively complex, the research on cocatalyst is very limited. This review mainly introduces the research history, preparation methods, and application progress in polymerization of ammonium tetrakis(pentafluorophenyl)borate, deepening our understanding of the role of cocatalyst in polymerization, with the hope of inspiring brand-new thinking on improving and enhancing the overall performance of catalyst systems.

Recent Advances in Controlled Production of Long-Chain Branched Polyolefins

Polyolefins, composed of carbon and hydrogen atoms, dominate global polymer production. This stems from the wide range of physical and mechanical properties that various polyolefins can cover. Their versatile properties are largely tuned by chain microstructure, including molar mass distribution, comonomer content, and long-chain branching (LCB). Specifically, LCB imparts unique characteristics, notably enhances processability crucial for downstream applications. Tailoring LCB structural features has encouraged academic and industrial efforts, chronicle in this review from a chemistry standpoint. While encompassing post-reaction modification based traditional methods like peroxide grafting, ionizing beam irradiation, and coupling reactions, the main focus is given to catalyst-centric strategies and innovative polymerization schemes. The advent of single-site catalysts-metallocenes and late transition metals catalysts-amplifies interest in tailored chemical methods, but the progress in LCB formation flourishes via tandem catalytic systems and bimetallic catalysts under controlled reaction conditions. Specifically, the breakthrough in coordinative chain transfer polymerization unveils a novel avenue for controlled LCB synthesis by sequential chain propagation, transfer, liberation, and enchainment. This short review highlights recent approaches for the production of LCB polyolefins that can provide a roadmap crucial for researchers in academia and industry, steering their efforts toward further advancements in the production of tailored polyolefin.

Ductile Copolyesters Prepared Using Succinic Acid, 1,4-Butanediol, and Bis(2-hydroxyethyl) Terephthalate with Minimizing Generation of Tetrahydrofuran

Poly(1,4-butylene succinate) (PBS) is a promising sustainable and biodegradable synthetic polyester. In this study, we synthesized PBS-based copolyesters by incorporating 5-20 mol% of -O2CC6H4CO2- and -OCH2CH2O- units through the polycondensation of succinic acid (SA) with 1,4-butanediol (BD) and bis(2-hydroxyethyl) terephthalate (BHET). Two different catalysts, H3PO4 and the conventional catalyst (nBuO)4Ti, were used comparatively in the synthesis process. The copolyesters produced using the former were treated with M(2-ethylhexanoate)2 (M = Mg, Zn, Mn) to connect the chains through ionic interactions between M2+ ions and either -CH2OP(O)(OH)O- or (-CH2O)2P(O)O- groups. By incorporating BHET units (i.e., -O2CC6H4CO2- and -OCH2CH2O-), the resulting copolyesters exhibited improved ductile properties with enhanced elongation at break, albeit with reduced tensile strength. The copolyesters prepared with H3PO4/M(2-ethylhexanoate)2 displayed a less random distribution of -O2CC6H4CO2- and -OCH2CH2O- units, leading to a faster crystallization rate, higher Tm value, and higher yield strength compared to those prepared with (nBuO)4Ti using the same amount of BHET. Furthermore, they displayed substantial shear-thinning behavior in their rheological properties due to the presence of long-chain branches of (-CH2O)3P=O units. Unfortunately, the copolyesters prepared with H3PO4/M(2-ethylhexanoate)2, and hence containing M2+, -CH2OP(O)(OH)O-, (-CH2O)2P(O)O- groups, did not exhibit enhanced biodegradability under ambient soil conditions.

Glycerol-derived organic carbonates: environmentally friendly plasticizers for PLA

Polylactic acid (PLA) stands as a promising material, sourced from renewables and exhibiting biodegradability-albeit under stringent industrial composting settings. A primary challenge impeding PLA's broad applications is its inherent brittleness, as it fractures with minimal elongation despite its commendable tensile strength. A well-established remedy involves blending PLA with plasticizers. In this study, a range of organic carbonates-namely, 4-ethoxycarbonyloximethyl-[1,3]dioxolan-2-one (1), 4-methoxycarbonyloximethyl-[1,3]dioxolan-2-one (2), glycerol carbonate (3), and glycerol 1-acetate 2,3-carbonate (4)-were synthesized on a preparative scale (∼100 g), using renewable glycerol and CO2-derived diethyl carbonate (DEC) or dimethyl carbonate (DMC). Significantly, 1-4 exhibited biodegradability under ambient conditions within a week, ascertained through soil exposure at 25 °C-outpacing the degradation of comparative cellulose. Further investigations revealed 1's efficacy as a PLA plasticizer. Compatibility with PLA, up to 30 phr (parts per hundred resin), was verified using an array of techniques, including DSC, DMA, SEM, and rotational rheometry. The resulting blends showcased enhanced ductility, evident from tensile property measurements. Notably, the novel plasticizer 1 displayed an advantage over conventional acetyltributylcitrate (ATBC) in terms of morphological stability. Slow crystallization, observed in PLA/ATBC blends over time at room temperature, was absent in PLA/1 blends, preserving amorphous domain dimensions and mitigating plasticizer migration-confirmed through DMA assessments of aged and unaged specimens. Nevertheless, biodegradation assessments of the blends revealed that the biodegradable organic carbonate plasticizers did not augment PLA's biodegradation. The PLA in the blends remained mostly unchanged under ambient soil conditions of 25 °C over a 6 month period. This work underscores the potential of organic carbonates as both eco-friendly plasticizers for PLA and as biodegradable compounds, contributing to the development of environmentally conscious polymer systems.

Coordinative Chain Transfer and Chain Shuttling Polymerization

Coordinative chain transfer polymerization, CCTP, is a degenerative chain transfer polymerization process that has a wide range of applications. It allows a highly controlled synthesis of polyolefins, stereoregular polydienes, and stereoregular polystyrene, including (stereo)block as well as statistical copolymers thereof. It also shows a green character by allowing catalyst economy during the synthesis of such polymers. CCTP notably allows the end functionalization of both the commodity and stereoregular specialty polymers aforementionned, control of the composition of statistical copolymers without adjusting the feed, and quantitative formation of 1-alkenes from ethene. A one-pot one-step synthesis of the original multiblock microstructures and architectures by chain shuttling polymerization (CSP) is also an asset of CCTP. This methodology takes advantage of the simultaneous presence of two catalysts of different selectivity toward comonomers that produce blocks of different composition/microstructure, while still allowing the chain transfer. This affords the production of highly performant functional polymers, such as thermoplastic elastomers and adhesives, among others. This approach has been extended to cyclic esters' and ethers' ring-opening polymerization, providing new types of multiblock microstructure. The present Review provides the state of the art in the field with a focus on the last 10 years.

High temperature-size exclusion chromatography with triple detection to assess the molecular architecture of low-density polyethylene: Insight into branching and processability correlations

In this study, three commercially available low-density polyethylene (LDPE) polymers produced via a tubular reactor process, with varying melt flow rates at 190°C/2.16 kg (4.0, 1.9, and 0.75 g/10 min), have been selected and subjected to high temperature-size exclusion chromatography (SEC) analysis coupled with an infrared-5 (IR-5), viscometer (VISCO), and multiangle laser light-scattering detectors. The molecular weight (MW), MW distribution, short-chain branching (SCB), and long-chain branching parameters were investigated. It was found that MW obtained by the universal technique (∼1.57-1.7 times) and multiangle laser light-scattering detection technique is (∼1.43-1.55 times) higher than that of the conventional calibration technique, which could be attributed to structural complexity associated with LDPEs which is not clearly understood by conventional SEC mode alone. The bulk SCB per 1000 total carbon atoms estimated by IR-5 detection was found to range from 16.50 to 17.80. On the other hand, long chain branching frequency per 1000 total carbon atoms obtained by online VISCO and multiangle laser light-scattering detection ranged from 0.46 to 0.54 and 0.65 to 0.94, respectively. Further, the significance of long chain branching parameters on the polymer processing behavior was studied in correlation with rheological property (Die swell ratio).

Synthesis of α,ω-End Functionalized Polydienes: Allylic-Bearing Heteroleptic Aluminums for Selective Alkylation and Transalkylation in Coordinative Chain Transfer Polymerization

There are still challenges in the preparation of difunctional stereoregular polydienes, especially for the construction of initiating chain-end functionalization. Coordinative chain transfer polymerization (CCTP) provides a way to achieve the goal but usually requires sophisticated functionalized catalysts as well as expensive chain transfer agents (CTAs). In this work, heteroleptic aluminum with oligo(dienyl) substituents (oligo-Al agents) were readily prepared by living anionic polymerization (LAP) technique. The oligo-Al agents used in Nd-mediated CCTPs of dienes exhibit highly selective alkylation and transalkylation features. Kinetics and transfer efficiency studies using 1 H NMR, 13 C NMR, 1 H-13 C HSQC, and Dosy NMR analyses revealed that the resulting polydienes possess substituents at the initiating chain-end that have transferred from the oligo-Al agents. The functionalization efficiency of the initiating chain-end is up to 99 %, and the molar mass regulation efficiency of heteroleptic aluminum is higher than that of the traditional CTA Ali Bu2 H (0.608 vs. 0.410). Based on the experimental results and density functional theory (DFT) calculations, we propose a mechanism in which allylic-Al acts as an efficient alkylating moiety in catalyst preformation and also as an effective transfer agent in polymerization. Taking advantage of these features, di-functionalized polyisoprene, polybutadiene, and poly(isoprene-co-butadiene) can be facilely synthesized.

The Highly Controlled and Efficient Polymerization of Ethylene

The highly controlled and efficient polymerization of ethylene is a very attractive but challenging target. Herein we report on a Coordinative Chain Transfer Polymerization catalyst, which combines a high degree of control and very high activity in ethylene oligo- or polymerization with extremely high chain transfer agent (triethylaluminum) to catalyst ratios (catalyst economy). Our Zr catalyst is long living and temperature stable. The chain length of the polyethylene products increases over time under constant ethylene feed or until a certain volume of ethylene is completely consumed to reach the expected molecular weight. Very high activities are observed if the catalyst elongates 60 000 or more alkyl chains and the polydispersity of the strictly linear polyethylene materials obtained are very low. The key for the combination of high control and efficiency seems to be a catalyst stabilized by only one strongly bound monoanionic N-ligand.

Rapid Biodegradable Ionic Aggregates of Polyesters Constructed with Fertilizer Ingredients

Synthetic biodegradable polyesters tend to undergo slow biodegradation under ambient natural conditions and, hence, have been rejected or even banned recently in ecofriendly applications. Here, we demonstrate the preparation of polyesters exhibiting enhanced biodegradability, which were generated through a combination of old controversial macromolecules and aggregate theories. H₃PO₄-catalyzed diacid/diol polycondensation afforded polyester chains bearing chain-end -CH₂OP(O)(OH)₂ and inner-chain (-CH₂O)₂P(O)(OH) groups, which were subsequently treated with M(2-ethylhexanoate)₂ (M = Zn, Mg, Mn, and Ca) to form ionic aggregates of polyesters. The prepared ionic aggregates of polyesters, which were constructed with fertilizer ingredients (such as M²⁺ and phosphate), exhibit much faster biodegradability than that of the conventional polyesters under controlled soil conditions at 25 °C, while displaying comparable or superior rheological and mechanical properties.

Cyclic olefin copolymers containing both linear polyethylene and poly(ethylene-co-norbornene) segments prepared from chain shuttling copolymerization of ethylene and norbornene

A series of novel HDPE/COC multiblock copolymers have been effectively obtained via chain shuttling copolymerization of ethylene and NBE. These promising copolymers exhibit excellent clarity, high heat resistance and balanced mechanical properties.

Synergistic lignin construction of a long-chain branched polypropylene and its properties

In light of current environmental pressures (referring to its destruction) and the consumption of petrochemical resources, the substitution of chemicals products with renewable natural substances has attracted extensive interest. In this paper, a synergistically constructed lignin polypropylene matrix composite with long-chain branched characteristics was prepared by a pre-irradiation and melt blending method. The effects of lignin on the crystallization, rheological behavior, foaming and aging properties of polypropylene were studied. Differential scanning calorimetry and polarized light microscopy results show that lignin undergoes heterophasic nucleation in a polypropylene matrix; rheological studies show that lignin promotes the formation of a heterogeneous polypropylene network, and thus polypropylene exhibits long-chain branching features; nucleation and a network structure endow the polypropylene-based composites with uniform cell size, thin cell walls, and a foaming ratio of 5–44 times; at the same time, a large number of hindered phenols in lignin can capture free radicals to improve the aging properties of the polypropylene. This research will help to convert industrial waste into functional composite materials.

Polypropylene with long chain branching behavior was constructed by lignin, which foaming property and polarity were improved.

Preparation of Pyridylamido Hafnium Complexes for Coordinative Chain Transfer Polymerization

The pyridylamido hafnium complex (I) discovered at Dow is a flagship catalyst among postmetallocenes, which are used in the polyolefin industry for PO-chain growth from a chain transfer agent, dialkylzinc. In the present work, with the aim to block a possible deactivation process in prototype compound I, the corresponding derivatives were prepared. A series of pyridylamido Hf complexes were prepared by replacing the 2,6-diisopropylphenylamido part in I with various 2,6-R2C6H3N-moieties (R = cycloheptyl, cyclohexyl, cyclopentyl, 3-pentyl, ethyl, or Ph) or by replacing 2-iPrC6H4C(H)- in I with the simple PhC(H)-moiety. The isopropyl substituent in the 2-iPrC6H4C(H)-moiety influences not only the geometry of the structures (revealed by X-ray crystallography), but also catalytic performance. In the complexes bearing the 2-iPrC6H4C(H)-moiety, the chelation framework forms a plane; however, this framework is distorted in the complexes containing the PhC(H)-moiety. The ability to incorporate α-olefin decreased upon replacing 2-iPrC6H4C(H)-with the PhC(H)-moiety. The complexes carrying the 2,6-di(cycloheptyl)phenylamido or 2,6-di(cyclohexyl)phenylamido moiety (replacing the 2,6-diisopropylphenylamido part in I) showed somewhat higher activity with greater longevity than did prototype catalyst I.

Polystyrene Chain Growth Initiated from Dialkylzinc for Synthesis of Polyolefin-Polystyrene Block Copolymers

Polyolefins (POs) are the most abundant polymers. However, synthesis of PO-based block copolymers has only rarely been achieved. We aimed to synthesize various PO-based block copolymers by coordinative chain transfer polymerization (CCTP) followed by anionic polymerization in one-pot via conversion of the CCTP product (polyolefinyl)2Zn to polyolefinyl-Li. The addition of 2 equiv t-BuLi to (1-octyl)2Zn (a model compound of (polyolefinyl)2Zn) and selective removal or decomposition of (tBu)2Zn by evacuation or heating at 130 °C afforded 1-octyl-Li. Attempts to convert (polyolefinyl)2Zn to polyolefinyl-Li were unsuccessful. However, polystyrene (PS) chains were efficiently grown from (polyolefinyl)2Zn; the addition of styrene monomers after treatment with t-BuLi and pentamethyldiethylenetriamine (PMDTA) in the presence of residual olefin monomers afforded PO-block-PSs. Organolithium species that might be generated in the pot of t-BuLi, PMDTA, and olefin monomers, i.e., [Me2NCH2CH2N(Me)CH2CH2N(Me)CH2Li, Me2NCH2CH2N(Me)Li·(PMDTA), pentylallyl-Li⋅(PMDTA)], as well as PhLi⋅(PMDTA), were screened as initiators to grow PS chains from (1-hexyl)2Zn, as well as from (polyolefinyl)2Zn. Pentylallyl-Li⋅(PMDTA) was the best initiator. The Mn values increased substantially after the styrene polymerization with some generation of homo-PSs (27-29%). The Mn values of the extracted homo-PS suggested that PS chains were grown mainly from polyolefinyl groups in [(polyolefinyl)2(pentylallyl)Zn]-[Li⋅(PMDTA)]+ formed by pentylallyl-Li⋅(PMDTA) acting onto (polyolefinyl)2Zn.