Metallocene Supported Catalyst Molecular Weight Distribution

Solution Overview

Problem

Existing methods for preparing polyolefins using metallocene catalysts face challenges such as complex supporting procedures, poor polymer morphology, and limitations in achieving desired physical properties due to broad molecular weight distributions and non-uniform comonomer distributions.

Innovation Solution

A metallocene supported catalyst system comprising a specific metallocene compound with a silylalkyl group at the 2-position carbon of the indene derivative, a cocatalyst compound, and a support, which maintains high polymerization activity and allows for the production of polyolefins with high molecular weight and controlled molecular weight distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple metallocene compounds are separately supported on different supports, then molecular weight distribution can be controlled, but the supporting procedure becomes complex and time-consuming

Engineering Contradiction:

Improvemolecular weight distribution controlVSAvoidsupporting procedure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines multiple metallocene compounds (specifically a metallocene compound and a non-metallocene compound) on a single support material, eliminating the need for separate supporting procedures for each catalyst. This merging approach maintains the ability to control molecular weight distribution while significantly simplifying the catalyst preparation process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single support material serves multiple functions by simultaneously carrying different types of metallocene compounds that produce polymers with different molecular weights. This multi-functional support eliminates the need for multiple specialized supports while achieving the same molecular weight distribution control.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If multiple metallocene compounds are separately supported on different supports, then molecular weight distribution can be controlled, but the preparation time increases

Engineering Contradiction:

Improvemolecular weight distribution controlVSAvoidcatalyst preparation time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent combines multiple metallocene compounds (specifically a metallocene compound and a non-metallocene compound) on a single support material, eliminating the need for separate supporting procedures for each catalyst. This merging approach maintains the ability to control molecular weight distribution while significantly simplifying the catalyst preparation process.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If metallocene catalysts are used to produce narrow molecular weight distribution, then polymer quality improves, but catalyst activity and polymer morphology deteriorate

Engineering Contradiction:

Improvemolecular weight distribution uniformityVSAvoidcatalyst activity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent creates a composite catalyst system comprising both metallocene compounds (which provide narrow molecular weight distribution) and non-metallocene compounds (which provide high catalytic activity and good polymer morphology). This composite approach allows the final polymer to exhibit both narrow molecular weight distribution and high catalyst activity with good morphology.

Inventive Principle:

Principle #40Composite materials

4Productivity

If Ziegler-Natta catalyst is used to achieve high catalytic activity, then productivity improves, but molecular weight distribution becomes broad and compositional uniformity deteriorates

Engineering Contradiction:

Improvecatalytic activityVSAvoidmolecular weight distribution uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent creates a composite catalyst system comprising both metallocene compounds (which provide narrow molecular weight distribution) and non-metallocene compounds (which provide high catalytic activity and good polymer morphology). This composite approach allows the final polymer to exhibit both narrow molecular weight distribution and high catalyst activity with good morphology.

Inventive Principle:

Principle #40Composite materials

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 molecular weight polyolefins with improved processability and maintains activity over a long residence time in a reactor, enabling the production of polymers with desired physical properties.

Implementation Method 1

A metallocene compound and a non-metallocene compound are simultaneously supported on a support to conduct simultaneous polymerization of a high molecular weight polymer and a low molecular weight polymer

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

a metallocene compound and a non-metallocene compound are simultaneously supported on a support

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentEP3255069B1Metallocene supported catalyst and method for preparing polyolefin using the same

Publication Date: 2024.01.10 LG CHEM LTD

AI summary

The present disclosure relates to a novel metallocene supported catalyst, and a method for preparing a polyolefin using the same. The metallocene supported catalyst according to the present disclosure exhibits a high polymerization activity even when the metallocene compound is supported on a support, thereby showing an excellent activity and preparing a polyolefin having a high molecular weight.