MgCl2/R'nAl(OR)3-n: an excellent activator/support for transition-metal complexes for olefin polymerization.

ABSTRACT

A new and effective method for the activation, and simultaneously, immobilization of bis(phenoxyimine) early-transition-metal complexes for olefin polymerization (known as FI catalysts), which makes use of MgCl(2)/R'(n)Al(OR)(3-n) as an activator/support, has been developed. Ti-, Zr-, and V-FI catalysts combined with this MgCl(2)-based compound can form highly active MgCl(2)-supported single-site catalysts capable of demonstrating superior catalytic properties, compared to the corresponding homogeneous methylaluminoxane- (Ti- and Zr-FI catalysts) or alkylaluminum-activation systems (V-FI catalysts), in terms of their catalytic activity, molecular weight, stereoselectivity, and comonomer incorporation. Additionally, these new catalysts can produce polymers of significant morphology with high efficiency. Notably, the MgCl(2)-based compounds can also effectively activate and immobilize the early-to-late transition-metal complexes that have emerged recently. Thus, the application of MgCl(2)-based compounds as activators/supports for transition-metal complexes for olefin polymerization provides a conceptually new strategy for the development of methylaluminoxane- and borate-free, high-performance, single-site catalysts capable of controlling polymer morphology.