Ionic Aluminoxane Catalyst Activators for Olefin Polymerization

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Solution Overview

Problem

Conventional aluminoxane-based catalyst systems for olefin polymerization lack activation efficiency, require high aluminum loading, and are expensive, making them less suitable for commercial applications.

Innovation Solution

The development of compositions derived from an organoaluminum compound, a carrier, and an oxygen source, which increase the quantity of dialkylaluminum cation precursors, enhancing the activation of transition metals for olefin polymerization by forming Lewis acid sites and stabilizing dialkylaluminum cations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional aluminoxane-based catalyst systems are used for olefin polymerization, then the polymerization can proceed, but the activation efficiency is low and high aluminum loading is required

Engineering Contradiction:

Improvealuminum loadingVSAvoidactivation efficiency

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The invention changes the chemical composition parameters by introducing specific Lewis base ligands (such as OMTS, DTBS) to modify the aluminoxane structure, creating ionic aluminoxanate compositions with enhanced dialkylaluminum cation content. This parameter change increases activation efficiency while reducing the quantity of aluminum needed

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates composite material systems by combining organoaluminum compounds with Lewis base ligands to form ionic aluminoxanate compositions. These composite structures provide both the aluminoxane framework and the stabilizing Lewis base environment, achieving high activation efficiency at lower aluminum loadings

Inventive Principle:

Principle #40Composite materials

2Reliability

If methylaluminoxane (MAO) is used as the aluminum co-catalyst/activator, then the polymerization activity is achieved, but the cost is expensive

Engineering Contradiction:

Improvepolymerization activityVSAvoidcost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The invention replaces expensive MAO with more cost-effective ionic aluminoxanate compositions derived from readily available organoaluminum compounds and Lewis base ligands. These alternative compositions maintain polymerization activity while significantly reducing material costs

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention modifies the compositional parameters by varying the Lewis base ligand structure and aluminum compound selection to optimize cost-effectiveness while preserving the essential activation function for polymerization

Inventive Principle:

Principle #35Parameter changes

3Reliability

If ionic aluminoxanate compositions are prepared by contact of MAO with Lewis base ligands, then the activation efficiency is improved, but two-phase clathrate mixtures are formed requiring tedious work-up procedures

Engineering Contradiction:

Improveactivation efficiencyVSAvoidwork-up procedures

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention performs preliminary action by pre-combining the organoaluminum compound with the Lewis base ligand to form the ionic aluminoxanate composition before the actual polymerization process. This pre-preparation eliminates the need for complex post-synthesis work-up procedures while maintaining high activation efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention uses the Lewis base ligand as an intermediary that facilitates the formation of stable ionic aluminoxanate structures. This intermediary approach enables single-phase formation that avoids the two-phase clathrate mixture problem, simplifying the manufacturing process

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This approach significantly improves the activation efficiency of transition metals, reducing the amount of catalyst needed and lowering costs, while maintaining or exceeding the performance of traditional systems.

Implementation Method 1

an intermediate composition derived from i) at least an organoaluminum compound, a carrier, and an oxygen source combined in any order

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 2

increase the quantity of dialkylaluminum cation precursors, enhancing the activation of transition metals

Methodology Applied

Scientific EffectLewis acid-base interaction:

Implementation Method 3

an intermediate composition derived from i) at least an organoaluminum compound, a carrier, and an oxygen source

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentEP2195112B1Aluminoxane catalyst activators derived from dialkylaluminum cation precursor agents and use thereof in catalysts and polymerization of olefins

Publication Date: 2017.03.01 ALBEMARLE CORP

AI summary

Compositions useful for activating catalysts for olefin polymerization, and methods for making same, are provided. Such compositions can be derived from at least: a) an intermediate composition derived from at least an organoaluminium compound, a carrier, and an oxygen source; and b) R2 2 AIY, wherein each R2 independently comprises a hydrocarbyl group having from 1 to 20 carbons, and Y comprises a halide radical, a pseudo halide radical, an alkoxide radical, an aryloxide radical, an alkyl substituted amide radical, an aryl substituted amide radical, a siloxy radical, a boronoxy radical, a diaryl boronoxy radical, or a halogenated diaryl boronoxy radical.