Emulsion Polymerization Strategy for Heterogenization of Olefin Polymerization Catalysts

Heterogenization of homogeneous metal catalysts on solid supports has been widely studied for product morphology control in ethylene polymerization. In this contribution, an emulsion polymerization strategy was introduced to achieve heterogenization of various imino-based nickel olefin polymerization catalysts. A series of polymeric microspheres were prepared through emulsion copolymerization of vinyl-functionalized imino ligands with comonomers such as styrene or methyl methacrylate. The corresponding heterogeneous nickel catalysts demonstrated superior properties in ethylene polymerization and copolymerization with methyl 10-undecylenate. Their catalytic properties can be controlled by tuning the comonomer type, composition, and particle size. Most importantly, this strategy can achieve product morphology control and avoid reactor fouling while generating polyethylene products with minimum inorganic contamination. In addition, the introduction of polymer microspheres can improve the mechanical properties and surface properties of polyolefin products.