Olefin Polymerization Activators for High-Temperature Efficiency
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Solution Overview
Problem
Existing olefin polymerization catalyst systems face challenges in achieving high catalyst efficiency, consistent polymer composition, and selective deactivation of activators, particularly at high temperatures, while minimizing the impact of residual activator ions on the electrical properties of the polymer.
Innovation Solution
The use of a catalyst system that combines Group IV metal-ligand complexes with specific activators or co-catalysts that efficiently activate the catalyst, decompose readily, and perform well at high temperatures, thereby producing polyolefin resins with desirable polymer composition and electrical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional non-coordinating anion activators are used to increase catalytic efficiency, then the rate of procatalyst activation and overall catalyst efficiency improve, but the residual activator anion in the polymer lowers electrical resistance and increases electrical loss
Solution Approach 1:
The patent changes the chemical parameters of the anion by introducing fluorinated alkyl groups with specific chain lengths (C1-C20) and structures. This modifies the anion's coordination ability and diffusion characteristics, allowing it to maintain weak coordination for catalytic efficiency while reducing diffusion into the polymer bulk, thereby lowering electrical loss.
Solution Approach 2:
The activator uses a composite anion structure combining fluorinated alkyl groups with aromatic rings (such as perfluorophenyl groups). This composite structure provides both the weak coordination needed for high catalytic efficiency and the appropriate size/interaction characteristics to limit diffusion into the polymer, reducing electrical conductivity improvements.
2Stability of the object's composition
If activators with strong coordination ability are used to maintain polymer composition consistency, then polymer composition consistency improves, but catalytic efficiency and activation rate decrease
Solution Approach 1:
The patent optimizes the coordination strength parameter by carefully designing the anion's fluorinated alkyl chain length and structure. The fluorinated groups provide electron-withdrawing effects that tune the anion's donor ability, achieving a balance where coordination is strong enough to stabilize the cationic catalyst and ensure consistent polymer composition, but weak enough to maintain high catalytic efficiency.
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 proposed catalyst system enhances the production of α-olefin polymers, increases the rate of procatalyst activation, improves high-temperature catalyst efficiency, maintains consistent polymer composition, and enables selective deactivation of activators, resulting in polymers with improved electrical properties.
Implementation Method 1
Brønsted acid salts that are fully ionized are capable of transferring a proton to form a cationic derivative of such Group IV metal complexes
Implementation Method 2
the molecular polymerization procatalyst is activated to generate the catalytically active species for polymerization
Implementation Method 3
the size of the ion and the charge of the ion, the interaction of the ion with the surrounding medium, and the dissociation energy of the ion with available counterions will affect the ion's ability to diffuse through a surrounding medium, such as a solvent, a gel, or a polymer material
Data Source
AI summary
Embodiments of this disclosure include processes of polymerizing olefins, the process comprising contacting ethylene and a (C3-C40)alpha-olefin comonomer in the presence of a catalyst system, the catalyst system comprising a Group IV metal-ligand complex and an ionic metallic activator complex, the ionic metallic activator complex comprising an anion and a countercation, the anion having a structure according to formula (I):formula (I)