A commercially viable solution process to control long-chain branching in polyethylene.

In polyolefins, long-chain branching is introduced through an energy-intensive, high-pressure radical process to form low-density polyethylene (LDPE). In the current work, we demonstrated a ladder-like polyethylene architecture through solution polymerization of ethylene and less than 1 mole % of α,ω-dienes, using a dual-chain catalyst. The ladder-branching mechanism requires catalysts with two growing polymer chains on the same metal center, thus enchaining the diene without the requirement of a steady-state concentration of pendant vinyl groups. Molecular weight distributions lacking a high-molecular weight tail, distinctive Mark-Houwink signatures, nuclear magnetic resonance characterization, and shear and extensional rheology consistent with highly branched polyethylene architectures are described. This approach represents an industrially viable solution-polymerization process capable of producing controlled long-chain branched polyethylene with rheological properties comparable to those of LDPE or its blends with linear low-density polyethylene (LLDPE).

Computational and Experimental Studies of Regioselective SNAr Halide Exchange (Halex) Reactions of Pentachloropyridine.

The Halex reaction of pentachloropyridine with fluoride ion was studied experimentally and computationally with a modified ab initio G3MP2B3 method. The G3 procedure was altered, as the anionic transition state optimizations failed due to the lack of diffuse functions in the small 6-31G* basis set. Experimental Halex regioselectivities were consistent with kinetic control at the 4-position. The reverse Halex reaction of fluoropyridines with chloride sources was demonstrated using precipitation of LiF in DMSO as a driving force. Reverse Halex regioselectivity at the 4-position was predicted by computations and was consistent with kinetic control. Scrambling of halide ions between chlorofluoropyridines was catalyzed by n-Bu4PCl, and the products of these reactions were shown to result from a combination of kinetic and thermodynamic control. Comparison of the C-F and C-Cl homolytic bond dissociation energies suggests that an important thermodynamic factor which controls regioselectivity in this system is the weak C2-Cl bond. The differences between ΔH° values of chlorofluoropyridines can be explained by a combination of three factors: (1) the number of fluorine atoms in the molecule, (2) the number of fluorine atoms at the C2 and C6 positions, and (3) the number of pairs of fluorine atoms which are ortho to one another.

Penultimate effect in ethylene-styrene copolymerization and the discovery of highly active ethylene-styrene catalysts with increased styrene reactivity.

For the first time commercially relevant catalysts for the copolymerization of ethylene and styrene have been identified. The catalysts maintain very high copolymer efficiencies at relatively high reactor temperatures without sacrificing styrene comonomer reactivity. The observations which led to this discovery are based upon the kinetic analysis of ethylene-styrene copolymerization using constrained geometry catalyst (eta5-C5Me4)(SiMe2-N-t-Bu)TiMe2 (1). This analysis revealed a substantial styrene penultimate monomer effect. Inherent reactivity of 1 toward styrene is greatly improved when the penultimate monomer on the growing polymer chain is styrene rather than ethylene. The presence of a penultimate styrene effect led to the hypothesis that catalysts bearing aromatic moieties in close proximity to the active site could lead to enhancement of styrene reactivity for this catalyst family. This hypothesis was born out by two new constrained geometry catalysts, one having two phenyl substituents placed in the 3 and 3' positions of the Cp ring (2) and the other with a 2,2'-biphenyl fragment attached to the Cp ring (3). Both catalysts exhibit higher activity than that of 1 and, more importantly, much higher styrene reactivity leading to copolymers with substantially increased styrene content (21.5% for 2, 30.6% for 3) as compared to 1 (11%) under the same polymerization conditions. Analysis of the X-ray crystal structures of 2 and 3 shows no overriding structural arguments for the increased performance. Outstanding polymerization characteristics achieved with 3 make this catalyst a candidate for commercial production of ethylene-styrene resins in a solution process.

Catalytic production of olefin block copolymers via chain shuttling polymerization.

We report a catalytic system that produces olefin block copolymers with alternating semicrystalline and amorphous segments, achieved by varying the ratio of alpha-olefin to ethylene in the two types of blocks. The system uses a chain shuttling agent to transfer growing chains between two distinct catalysts with different monomer selectivities in a single polymerization reactor. The block copolymers simultaneously have high melting temperatures and low glass transition temperatures, and therefore they maintain excellent elastomeric properties at high temperatures. Furthermore, the materials are effectively produced in economically favorable, continuous polymerization processes.