Bimetallic Activator Complex for Olefin Polymerization
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Solution Overview
Problem
Conventional olefin polymerization catalyst systems face challenges in achieving rapid procatalyst activation, high temperature capability, consistent polymer composition, and efficient decomposition of activators, which affects the electrical properties of the final polymer products.
Innovation Solution
The use of a bimetallic activator complex with a specific anion and countercation structure, which includes a procatalyst and a Group IV metal-ligand complex, enables efficient activation and decomposition of the catalyst system, improving the production of polyolefin resins with superior polymer composition and electrical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If weakly-coordinating or non-coordinating anions are used as activators, then catalytic efficiency is increased, but electrical resistance of the polymer decreases (electrical loss increases)
Solution Approach 1:
The patent changes the chemical parameters of the anion by introducing fluorinated alkyl groups with specific chain lengths and branching patterns. This modifies the anion's coordination strength and diffusion characteristics, allowing it to maintain catalytic efficiency while reducing ion diffusion and improving electrical resistance of the final polymer.
Solution Approach 2:
The activator is designed as a composite structure combining a cationic component (ammonium, sulfonium, phosphonium, ferrocenium, silver, or lead) with a specially designed anionic component containing fluorinated alkyl groups. This composite structure allows optimization of both catalytic performance and electrical properties through the synergistic interaction between cation and anion.
2Productivity
If the anion has non-nucleophilic character to increase catalytic efficiency, then diffusion of the anion increases, but electrical resistance of the polymer decreases
Solution Approach 1:
The patent modifies the anion's physical and chemical parameters by incorporating fluorinated alkyl groups with controlled chain lengths (C1-C40) and branching. This changes the anion's diffusion coefficient and interaction with the polymer matrix, reducing ion mobility while maintaining catalytic activity, thereby improving insulation ability.
Solution Approach 2:
The anion is designed with localized fluorinated alkyl groups that create specific interaction zones within the polymer matrix. These localized regions with high fluorine content create zones of reduced ion diffusion while maintaining overall catalytic functionality, effectively separating the catalytic function from the electrical insulation function.
3Productivity
If conventional activators are used, then procatalyst activation occurs, but activation rate is slow and catalyst efficiency at high temperature is poor
Solution Approach 1:
The patent optimizes the activator's thermal stability parameters by selecting cations and anions with appropriate thermal resistance. The fluorinated alkyl groups provide thermal stability while the cation-anion pairing is designed to maintain dissociation equilibrium at elevated temperatures, enabling rapid activation and sustained catalytic efficiency from ambient to high temperatures.
Solution Approach 2:
The activator system is designed with dynamic equilibrium between associated and dissociated forms. The cation-anion pairing allows reversible dissociation that adapts to temperature changes, providing rapid activation at lower temperatures and maintaining catalytic activity at high temperatures through controlled dissociation, rather than fixed stoichiometric ratios.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The bimetallic activator complex enhances the production of polyolefin resins by facilitating rapid procatalyst activation, maintaining high catalyst efficiency at elevated temperatures, and ensuring consistent polymer composition, while also improving the electrical properties by reducing ion diffusion and energy loss.
Implementation Method 1
Brønsted acid salts that are fully ionized are capable of transferring a proton to form a cationic derivative of such Group IV metal complexes
Implementation Method 2
the size of the ion, the charge of the ion, the interaction of the ion with the surrounding medium, and the dissociation energy of the ion with available counterions will affect the ion's ability to diffuse through a surrounding medium such as a solvent, a gel, or a polymer material
Implementation Method 3
the catalyst systems for producing polyethylene-based polymers may include a chromium-based catalyst system, a Ziegler-Natta catalyst system, or a molecular (either metallocene or non-metallocene) catalyst system
Data Source
AI summary
Embodiments of the disclosure include processes of polymerizing olefins. The process includes contacting ethylene and a (C3-C40)alpha-olefin comonomer in the presences of a catalyst system. The catalyst system comprises a procatalyst and a bimetallic activator complex. The bimetallic activator complex comprises an anion and a countercation, and the anion has a structure according to formula (I).