Fluorene Donor Catalysts for Olefin Polymerization Activity
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Solution Overview
Problem
Current Ziegler-Natta catalyst systems for olefin polymerization suffer from low activity and high residues in polymers, requiring additional electron donor compounds to achieve desired crystallinity and isotacticity.
Innovation Solution
Development of solid catalyst components comprising titanium, magnesium, halogen, and internal electron donor compounds containing 9-(alkoxymethyl)-9H-fluorene compounds, which enhance catalyst activity and polymer properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional Ziegler-Natta catalyst systems are used, then polymerization can occur, but catalyst activity is low and polymer residues are high
Solution Approach 1:
The patent changes the chemical parameters of the catalyst system by introducing specific internal electron donor compounds (cyclic carboxylic acid esters with 5-7 membered rings) and external electron donor compounds (silicon compounds). These parameter changes in catalyst composition lead to significantly improved catalyst activity and reduced polymer residues, resolving the contradiction between productivity and harmful factors.
Solution Approach 2:
The patent creates a composite catalyst system combining titanium halide, magnesium halide, internal electron donor compounds (cyclic carboxylic acid esters), and external electron donor compounds (silicon compounds). This composite material approach synergistically improves catalyst activity while reducing polymer residues, addressing both aspects of the contradiction simultaneously.
2Manufacturing precision
If internal and external electron donor compounds are added to maintain high selectivity for isotactic polymer, then polymer crystallinity is improved, but catalyst system complexity increases
Solution Approach 1:
The patent optimizes the molecular structure parameters of electron donor compounds by selecting cyclic carboxylic acid esters with 5-7 membered rings for internal donors and specific silicon compounds for external donors. These parameter optimizations achieve high polymer crystallinity and isotacticity while keeping the catalyst system relatively simple and manageable.
3Manufacturing precision
If higher crystallinity of polymer is required, then external donor compound is added during polymerization, but catalyst component complexity increases
Solution Approach 1:
The patent changes the parameters of external donor compounds by selecting specific silicon compounds with optimized structures. This parameter optimization achieves the desired polymer crystallinity while maintaining catalyst system simplicity, resolving the contradiction between manufacturing precision and device complexity.
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 catalyst system achieves high activity, controlled crystallinity, and molecular weight, producing polymers with improved isotacticity and reduced residues.
Implementation Method 1
Ziegler-Natta catalysts can polymerize vinyl monomers using a transition metal halide to provide a polymer with an isotactic stereochemical configuration
Data Source
AI summary
The present disclosure relates to solid catalyst components comprising titanium, magnesium, halogen and an internal electron donor compound containing at least one 9-(alkoxymethyl)-9H-fluorene compound. The 9-(alkoxymethyl)-9H-fluorene compound include octyl-9-(methoxymethyl)-9H-fluorene-9-carboxylate; 7-methyloctyl-9-(methoxymethyl)-9H-fluorene-9-carboxylate; 2-ethylhexyl-9-(methoxymethyl)-9H-fluorene-9-carboxylate; and 9-(methoxymethyl)-9H-fluorene-9-yl benzoate. The present disclosure further relates to catalyst systems containing the catalyst solid components, organoaluminum compounds, and organosilicon compounds. The present disclosure also relates to methods of making the solid catalyst components and the catalyst systems, and methods of polymerizing or copolymerizing alpha-olefins using the catalyst systems.