Imine Bisphenolate Catalyst for High-Density Polyethylene
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Solution Overview
Problem
There is a need for improved catalyst systems to produce high-density polyethylene (PE) with enhanced barrier properties and processing characteristics, as existing systems do not adequately meet the requirements for high-performance polymeric compositions.
Innovation Solution
The use of an imine bis(phenol) compound and its metal salt complex, specifically a metal salt complex of an imine (bis)phenolate compound, in conjunction with a solid oxide and optional metal alkyl, to catalyze the polymerization of olefin monomers, resulting in high-density polymers with improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing catalyst systems are used for polyethylene production, then the basic polymerization function is achieved, but the barrier properties and processing characteristics of the resulting polyethylene are insufficient
Solution Approach 1:
The patent modifies the chemical structure of the catalyst ligand by introducing specific substituent groups (R, R2, R3) at defined positions on the phenol rings. These structural parameter changes in the catalyst composition directly influence the polymerization mechanism to produce polyethylene with enhanced barrier properties and improved processing characteristics, resolving the contradiction between performance and manufacturability
Solution Approach 2:
The catalyst system employs a composite structure combining a metal salt (Mg, Ca, Sr, or Ba) with a specifically designed imine bis(phenol) ligand framework. This composite catalyst architecture enables simultaneous optimization of polymerization activity and polymer product quality, achieving both superior barrier properties and processing characteristics that neither component could achieve alone
2Manufacturing precision
If conventional catalyst compositions are employed, then the polymerization process is simple, but the density and performance of the polyethylene product are insufficient
Solution Approach 1:
The patent introduces specific substituent groups (R, R2, R3) at localized positions on the phenol ligand structure. These local structural modifications create specific active sites on the catalyst surface that control polymer chain growth and folding, thereby achieving precise control over polyethylene density and crystallinity without requiring complex overall catalyst architecture
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 described catalyst composition enables the production of high-density polymers with superior barrier properties and processing characteristics, addressing the limitations of existing systems by enhancing the density and performance of polyethylene products.
Implementation Method 1
a catalyst composition comprises a metal salt complex of an imine (bis)phenolate compound, a solid oxide, and an optional metal alkyl
Data Source
AI summary
An imine phenol compound having Structure I:wherein O and N represent oxygen and nitrogen respectively; R comprises a halogen, a hydrocarbyl group, or a substituted hydrocarbyl group; R2 and R3 can each independently be hydrogen, a halogen, a hydrocarbyl group, or a substituted hydrocarbyl group; and Q is a donor group. A method comprising contacting a catalyst composition with a monomer under conditions suitable for the formation of a polymer wherein the catalyst composition comprises a metal salt complex of an imine (bis)phenolate compound, a solid oxide, and an optional metal alkyl and wherein the metal salt complex of an imine (bis)phenolate compound has Structure XIVwhere M is titanium, zirconium, or hafnium; OEt2 is ethoxide, R comprises a halogen, a hydrocarbyl group, or a substituted hydrocarbyl group; and R2 comprises hydrogen, a halogen, a hydrocarbyl group, or a substituted hydrocarbyl group.