Hybrid Supported Metallocene Catalyst for Bimodal Polyolefin
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Solution Overview
Problem
Existing methods for preparing hybrid supported metallocene catalysts face challenges in achieving high molecular weight and uniform polymer properties due to complex supporting procedures and limited simultaneous implementation of catalyst properties, leading to poor polymer morphology and molecular weight distribution.
Innovation Solution
A hybrid supported metallocene catalyst system comprising two different metallocene compounds, one with a quinoline-based amido group-introduced monocyclopentadienyl ligand and another with a specific electronic and steric environment, supported on a hydroxyl-containing surface, along with a co-catalyst, to produce olefin-based polymers with high molecular weight and desired physical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two different metallocene catalysts are supported on one support to achieve bimodal molecular weight distribution, then molecular weight distribution is improved, but the supporting procedure becomes complicated and polymer morphology deteriorates
Solution Approach 1:
The patent combines two different metallocene catalysts (Ti-based for high molecular weight and Zr-based for low molecular weight) into a single supported catalyst system, merging their functions to achieve bimodal molecular weight distribution in one step rather than through separate supporting procedures
Solution Approach 2:
The catalyst system is segmented into distinct functional components: Ti-based metallocene for high molecular weight polymer production and Zr-based metallocene for low molecular weight polymer production, with each component maintaining its specific catalytic characteristics on the support
2Manufacturing precision
If metallocene compound and non-metallocene compound are separately supported to simultaneously polymerize high and low molecular weight polymers, then molecular weight control is improved, but the supporting process becomes troublesome and requires pretreatment with various compounds
Solution Approach 1:
The patent merges the supporting processes for metallocene and non-metallocene compounds into a single unified procedure, eliminating the need for separate supporting steps and pretreatment with various compounds while maintaining the ability to produce both high and low molecular weight polymers
Solution Approach 2:
The support structure is designed to universally accommodate both metallocene and non-metallocene compounds with different chemical requirements, providing a multi-functional platform that eliminates the need for compound-specific pretreatment procedures
3Weight of moving object
If Ziegler-Natta catalyst is used to achieve high molecular weight polymer, then molecular weight is improved, but molecular weight distribution becomes broad and compositional distribution of comonomers becomes non-uniform
Solution Approach 1:
The patent applies local quality by assigning specific catalytic functions to specific metal centers: Ti-based sites are optimized for high molecular weight polymer production while Zr-based sites are optimized for narrow molecular weight distribution and uniform comonomer incorporation, allowing each component to excel at its specific function
4Manufacturing precision
If dinuclear metallocene catalyst and mononuclear metallocene catalyst are supported with activating agent to control molecular weight distribution, then molecular weight distribution is improved, but catalyst properties cannot be simultaneously implemented and metallocene catalyst departs from support causing fouling
Solution Approach 1:
The patent creates a composite catalyst system combining Ti-based and Zr-based metallocenes on a single support matrix, where the support acts as an integrating framework that maintains both catalyst types in stable positions, preventing departure and fouling while enabling simultaneous implementation of their respective catalytic properties
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 and produces olefin-based polymers with controlled molecular weight distribution and short chain branch content, enhancing polymer processability and physical properties.
Implementation Method 1
the metallocene catalyst system comprises a main catalyst whose main component is a transition metal compound and an organometallic compound cocatalyst whose main component is aluminum
Implementation Method 2
a hybrid supported metallocene catalyst comprising a metallocene compound represented by the following Formula 1, a metallocene compound represented by the following Formula 2, a co-catalyst compound, and a support
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a hybrid supported metallocene catalyst and a method for preparing an olefin-based polymer using the same. More particularly, the present invention provides a hybrid supported metallocene catalyst comprising two different kinds of metallocene compounds, in which one kind of the metallocene compound is a transition metal compound coordinated with quinoline-based amido group-introduced monocyclopentadienyl ligand, and a method for preparing an olefin-based polymer using the same.