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We make use of a specially synthesized linear high density polyethylene with a bimodal molecular weight distribution (MWD) to demonstrate that it is possible to produce a suspension of extended-chain (shish) crystals only. Such a suspension can be generated at high temperatures, above but close to the equilibrium melting temperature of the unconstrained extended-chain crystals (T(m)(0)=141.2 degrees C) and requires stretch of the longest chains of the MWD. After the application of a shear flow of 120 s(-1) for 1 s at 142 degrees C, x-ray scattering suggests the presence of a large number of metastable needlelike precursors with limited or no crystallinity. Precursors that are too small dissolve on a timescale that correlates perfectly with the reptation time of the longest polymer molecules. Whereas, precursors that exceed a critical size crystallize forming extended-chain shishes.

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Polymer particle growth in the early stages of olefin polymerization has been investigated using metallocene/methylaluminoxane (MAO)/silica catalyst systems. Scanning electron microscopy (SEM) has been used to characterize the surface and cross-sectional morphology of polymer particles at different stages of particle growth. The aluminum distribution in various MAO-impregnated supports has been determined by energy-dispersive X-ray (EDX) analysis, revealing that the homogeneity of the distribution is dependent on both the silica calcination temperature and the impregnation conditions used. Depending on the impregnation routes and polymerization conditions applied, two fragmentation behaviors have been observed:  main polymerization at the surface with coarse fragmentation at the core of the support particles in the case of propylene polymerization and a heterogeneous (co)catalyst distribution, and a layer-by-layer fragmentation of the support in ethylene polymerization using a homogeneously immobilized catalyst.

The activity and stability of homogeneous olefin polymerisation catalysts, when immobilised on a support, are dependent on both chemical and physical effects. Chemical factors affecting catalyst activity include the ease of formation of the active species, which is strongly dependent on the transition metal. Catalyst productivity is dependent on the balance between activity and stability. Immobilisation can lead to a lower proportion of active species and therefore lower initial polymerisation activity, but nevertheless give higher polymer yields in cases where increased catalyst stability is obtained. Important physical factors are support porosity and the ability of a support to undergo progressive fragmentation during polymerisation, facilitating monomer diffusion through the growing catalyst/polymer particle. This article illustrates the importance of these factors in olefin polymerisation with both early- and late-transition metal catalysts, with particular reference to the use of silica and magnesium chloride supports as well as to effects of immobilisation on polymer structure and properties.

Investigation of the characteristics and performance in propylene polymerization of silica-immobilized methylaluminoxane (MAO), in combination with a moderately and a highly isospecific zirconocene catalyst, has revealed that a simple impregnation of silica with MAO at ambient temperature is insufficient to obtain uniform distribution of MAO throughout the support particle. Homogeneous Al distribution throughout the support, giving increased catalyst activity, was achieved by a more rigorous impregnation of silica with MAO at elevated temperatures. The highest catalyst activities were obtained by precontacting the MAO with the zirconocene to generate the activated species before immobilization on silica. Polymer particle morphology was strongly dependent on the characteristics of the silica used for catalyst immobilization. V V C 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43

A method for the preparation of well‐defined crystallites of MgCl2‐supported Ziegler‐Natta catalysts on Si wafers has been developed. This has been achieved by the spin‐coating of a MgCl2 solution onto a flat Si wafer, followed by controlled crystal growth to give well‐defined MgCl2 · nEtOH crystallites. The growth of the crystallites on the flat silica facilitates their characterization using electron and scanning probe microscopy. The relative proportions of 120° and 90° edge angles indicate the preference for the formation of a particular crystallite face for the MgCl2. Polyethylene has been identified to be formed on the lateral faces of the crystallite.magnified image

Significant increases in the productivity of iron-, chromium-, and titanium-based MgCl2-supported catalysts for ethylene polymerization have been obtained by incorporation of a limited amount of a nickel diimine catalyst giving branched polyethylene. Formation of the latter during the early stages of polymerization reduces the monomer diffusion limitation inherent in ethylene homopolymerization, thereby increasing the productivity of the main catalyst component. The final products are essentially linear, high-density polyethylenes containing very small amounts of branched polymer. As well being effective for catalysts prepared by coimmobilization of the Ni and Fe, Cr, or Ti component on the MgCl2 support, it is also shown that the productivity of preformed Ziegler−Natta catalysts can be improved significantly by impregnation with the nickel diimine component. In the latter case, more rapid increases in rate throughout the polymerization indicated easier fragmentation of the support in the presence of the nickel complex.