Linear Copolymers via Transition Metal Catalyst

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Solution Overview

Problem

Current commercial processes for copolymerizing ethylene with polar monomers using free radical processes lack control over polymer architecture, resulting in high capital investment, safety concerns, and limited range of material properties due to random incorporation of polar functionality.

Innovation Solution

A process involving a catalyst composition with a metal center complexed to a specific ligand structure, using acyclic aliphatic olefins and nitrogen-containing vinyl monomers to produce substantially linear copolymers under mild conditions, allowing for controlled incorporation of polar groups and stereoregularity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If free radical processes are used for copolymerization of ethylene with polar monomers, then copolymerization can be achieved, but control over polymer architecture is lost and capital investment and manufacturing costs increase

Engineering Contradiction:

Improvecontrol over polymer architectureVSAvoidcapital investment and manufacturing costs

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent changes the fundamental parameter of the polymerization mechanism from free radical to coordination polymerization using transition metal catalysts. This enables precise control over polymer architecture (linearity, branching, tacticity, molecular weight distribution) while operating under mild conditions (low pressure, moderate temperature), thereby resolving the contradiction between manufacturing precision and ease of manufacture

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical/high-pressure free radical process with a chemical catalyst-based coordination polymerization system. The transition metal catalysts ( Groups 4-10) provide a controlled mechanism that substitutes the need for extreme pressures and temperatures, reducing capital investment while maintaining or improving polymer architecture control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If free radical initiators are used, then copolymerization occurs, but control over tacticity, crystallinity, blockiness, and molecular weight is limited

Engineering Contradiction:

Improvecontrol over tacticity, crystallinity, blockiness, and molecular weightVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent changes the polymerization mechanism parameter from uncontrolled free radical to controlled coordination polymerization. The transition metal catalysts enable independent control over multiple parameters simultaneously: tacticity (stereoregularity), crystallinity (through linearity control), blockiness (comonomer distribution), and molecular weight (through catalyst deactivation control), thereby resolving the contradiction without significantly increasing process complexity

Inventive Principle:

Principle #35Parameter changes

3Reliability

If extreme pressures are used for free radical copolymerization, then copolymerization of ethylene with polar monomers is achieved, but safety concerns increase

Engineering Contradiction:

ImprovesafetyVSAvoidreaction pressure

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The patent changes the pressure parameter from extreme (free radical) to mild (coordination polymerization). The transition metal catalysts enable copolymerization of ethylene with polar monomers at low pressures by providing a coordinated insertion mechanism that is not dependent on high pressure, thereby resolving the contradiction between reliability (safety) and reaction pressure conditions

Inventive Principle:

Principle #35Parameter changes

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 enables the production of copolymers with enhanced properties such as toughness, adhesion, and surface properties, maintaining important crystallinity and solvent resistance while introducing new properties like biocidal activity or enhanced biodegradability.

Implementation Method 1

a catalyst composition comprising a metal center, M, complexed with at least one ligand

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS7524905B2Substantially linear copolymers and methods of making the same

Publication Date: 2009.04.28 ROHM & HAAS CO

AI summary

Substantially linear copolymers derived from at least one acyclic aliphatic olefin monomer and at least one nitrogen containing vinyl monomer, wherein the at least one nitrogen containing vinyl monomer is according to Formula (I)wherein R19 is selected —C═C; and —C(O)—C═C; wherein R20 and R21 are independently selected from H, an alkyl group, an alkenyl group, an alkynyl group, an aryl group, a biphenyl group, a carboxylate group, a carboxyalkyl group, a carboxyarylalkyl group, an alkoxy group, an alkenyloxy group, an alkynyloxy group, an aryloxy group, an alkoxycarbonyl group, and derivatives thereof. Also disclosed are methods of making such copolymers using late transition metal catalyst complexes.