US20100222531A1 - Catalysts for olefin polymerization - Google Patents

Catalysts for olefin polymerization Download PDF

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US20100222531A1
US20100222531A1 US12/779,182 US77918210A US2010222531A1 US 20100222531 A1 US20100222531 A1 US 20100222531A1 US 77918210 A US77918210 A US 77918210A US 2010222531 A1 US2010222531 A1 US 2010222531A1
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hydrocarbyl
hydrogen
substituted
independently
substituted hydrocarbyl
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Lin Wang
Elisabeth M. Hauptman
Lynda Kaye Johnson
Elizabeth Forrester McCord
Stephan J. McLain
Ying Wang
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EIDP Inc
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EI Du Pont de Nemours and Co
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    • C07F9/02Phosphorus compounds
    • C07F9/28Phosphorus compounds with one or more P—C bonds
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    • B01J2231/10Polymerisation reactions involving at least dual use catalysts, e.g. for both oligomerisation and polymerisation
    • B01J2231/12Olefin polymerisation or copolymerisation
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    • C08F4/60Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
    • C08F4/619Component covered by group C08F4/60 containing a transition metal-carbon bond

Definitions

  • Transition metal complexes of selected monoanionic phosphine ligands which also contain a selected Group 15 or 16 (IUPAC) element and which are coordinated to a Group 3 to 11 (IUPAC) transition metal or a lanthanide metal, are polymerization catalysts for the (co)polymerization of olefins such as ethylene and ⁇ -olefins, and the copolymerization of such olefins with polar group-containing olefins.
  • nickel complexes of neutral and monoanionic bidentate ligands copolymerize ethylene and polar comonomers at relatively high ethylene pressures and surprisingly high temperatures.
  • Polyolefins are very important items of commerce, large quantities of various grades of these polymers being produced annually for a large number of uses, such as packaging films, elastomers and moldings.
  • There are many different methods for making such polymers including many used commercially, such as free radical polymerization, and many so-called coordination catalysts such as Ziegler-Natta-type and metallocene-type catalysts.
  • Each of these catalyst systems has its advantages and disadvantages, including cost of the polymerization and the particular monomers (co) polymerized, and structure of the polyolefin produced. Due to the importance of polyolefins, new catalyst systems, which are economical and/or produce new types of polyolefins are constantly being sought.
  • Some late transition metal catalysts can incorporate polar comonomers, for example olefinic esters, in copolymerizations with hydrocarbon olefins, especially ethylene.
  • Palladium complexes are particularly noted for this ability, while nickel complexes often do not copolymerize polar comonomers or do so only very poorly, see for example U.S. Pat. No. 5,866,663.
  • JP-A-11292918 reports the copolymerization of methyl acrylate and ethylene using certain nickel complexes as polymerization catalysts. These polymerization are carried out at low temperatures and pressures, and mostly the incorporation of methyl acrylate is reported to be very low, and the polymers have low branching levels.
  • This invention concerns a “first” process for the polymerization of olefins, comprising the step of contacting, at a temperature of about ⁇ 100° C. to about +200° C., at least one polymerizable olefin with an active polymerization catalyst comprising a Group 3 through 11 (IUPAC) transition metal or a lanthanide metal complex of a ligand of the formula (I), (II) or (XII)
  • R 1 and R 2 are each independently hydrocarbyl, substituted hydrocarbyl or a functional group
  • Y is CR 11 R 12 , S(T), S(T) 2 , P(T)Q, NR 36 or NR 36 NR 36 ;
  • X is O, CR 5 R 6 or NR 5 ;
  • A is O, S, Se, N, P or As;
  • Z is O, Se, N, P or As
  • each Q is independently hydrocarbyl or substituted hydrocarbyl
  • R 3 , R 4 , R 5 , R 6 , R 11 and R 12 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
  • R 7 is hydrogen, hydrocarbyl;substituted hydrocarbyl or a functional group, provided that when Z is O or Se, R 7 is not present;
  • R 8 and R 9 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group
  • R 10 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group
  • each T is independently ⁇ O or ⁇ NR 30 ;
  • R 30 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group
  • R 31 and R 32 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group
  • R 33 and R 34 are each independently hydrocarbyl or substituted hydrocarbyl, provided that each is independently an aryl substituted in at least one position vicinal to the free bond of the aryl group, or each independently has an E s of ⁇ 1.0 or less;
  • R 35 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group, provided that when A is O, S or Se, R 35 is not present;
  • each R 36 is independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group
  • n 0 or 1
  • s is 0 or 1;
  • n 0 or 1
  • q is 0 or 1
  • any two of R 3 , R 4 , R 5 , R 6 , R 8 , R 9 , R 11 and R 12 bonded to the same carbon atom taken together may form a functional group
  • any two R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 11 , R 12 , R 31 , R 32 , R 33 , R 34 , R 35 , and R 36 bonded to the same atom or vicinal to one another taken together may form a ring;
  • R 1 and R 2 are each independently hydrocarbyl, then R 1 and R 2 are each independently an aryl substituted in one position vicinal to the free bond of the aryl group, or R 1 and R 2 each independently have an E s of ⁇ 1.0 or less.
  • a “second” process for the polymerization of olefins comprising the step of contacting, at a temperature of about ⁇ 100° C. to about +200° C., at least one polymerizable olefin with a compound of the formula (IV), (V) or (XIII)
  • R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , R 30 , R 31 , R 32 , R 33 , R 34 , R 35 , R 36 , Y, X, A, Z, Q, T, m, s, n and q are as defined above;
  • M is a Group 3 through Group 11 transition metal or a lanthanide metal
  • L 1 is a monodentate monoanionic ligand into which an ethylene molecule may insert between L 1 and M
  • L 2 is a monodentate neutral ligand which may be displaced by ethylene or an empty coordination site
  • L 1 and L 2 taken together are a monoanionic bidentate ligand into which ethylene may insert between said monoanionic bidentate ligand and said nickel atom
  • each L 3 is independently a monoanionic ligand and z is the oxidation state of M minus 2; and provided that;
  • any two of R 3 , R 4 , R 5 , R 6 , R 8 , R 9 , R 11 and R 12 bonded to the same carbon atom taken together may form a functional group
  • any two R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 11 , R 12 , R 31 , R 32 , R 34 , R 35 and R 36 bonded to the same atom or vicinal to one another taken together may form a ring;
  • R 1 and R 2 are each independently hydrocarbyl, then R 1 and R 2 are each independently an aryl substituted in one position vicinal to the free bond of the aryl group, or R 1 and R 2 each independently have an E s of ⁇ 1.0 or less.
  • (IV), (V) and (XIII) and/or the transition metal complexes of (I), (II) or (XII) may in and of themselves be active catalysts, or may be “activated” by contact with a cocatalyst/activator as further described below.
  • the present invention also concerns the ligands of the formulas (I), (II) and (XII) above, transition metal complexes thereof, and polymerization catalyst components comprising these transition metal complexes.
  • a “third” process for forming an ethylene/polar monomer copolymer comprising the step of contacting, under polymerizing conditions, a nickel complex of a bidentate neutral ligand or a bidentate monoanionic ligand, with a monomer component comprising one or more hydrocarbon olefins and one or more polar comonomers (and other optional components such as, for example, one or more cocatalysts and/or other additives), at a temperature of about 60° C. to about 170° C., provided that when CO is present, at least one other polar monomer is present.
  • This third process also relates to an improved process for forming an ethylene/polar monomer copolymer, said process comprising the step of contacting, under polymerizing conditions, a transition metal complex of a bidentate neutral ligand or a bidentate monoanionic ligand, with a monomer component comprising one or more hydrocarbon olefins and one or more polar comonomers (and other optional components such as, for example, one or more cocatalysts and/or other additives), wherein the improvement comprises that the transition metal is nickel, and that the monomer component and complex are contacted at a temperature of about 60° C. to about 170° C., provided that when CO is present, at least one other polar monomer is present.
  • This invention further concerns a “first” polymer, consisting essentially of repeat units derived from ethylene, and one or more polar olefins of the formula H 2 C ⁇ CHC(O)R 32 , wherein R 32 is —OR 34 or any group readily derivable from it, and R 34 is hydrocarbyl or substituted hydrocarbyl, wherein:
  • said polymer contains “first branches” of the formula —(CH 2 ) n CH 3 and “second branches” of the formula —(CH 2 ) m C(O)R 32 , wherein m and n are independently zero or an integer of 1 or more; and
  • This invention also concerns a “second” polymer, consisting essentially of repeat units derived from:
  • hydrocarbon olefins such as ethylene
  • polar olefins of the formula H 2 C ⁇ CHC(O)R 32 , wherein R 32 is —OR 34 , or any group readily derivable from it, and R 34 is hydrocarbyl or substituted hydrocarbyl;
  • said end groups are at least 0.001 mole percent of the total repeat units in said polymer
  • This invention still further concerns a “third” polymer, consisting essentially of:
  • each R 32 is independently —OR 34 or any group readily derivable from it, and each R 34 is independently hydrocarbyl or substituted hydrocarbyl, and
  • FIG. 1 shows the 13 C NMR of a copolymer of ethylene and 2-phenoxyethyl acrylate (EGPEA) which also contains some homopolymer of EGPEA, and which shows assignments of various NMR peaks.
  • EGPEA 2-phenoxyethyl acrylate
  • FIG. 2 shows the 13 C NMR of a copolymer of ethylene and hexyl acrylate (HA) which also contains some homopolymer of HA, and which shows assignments of various NMR peaks.
  • HA hexyl acrylate
  • FIG. 3 shows the 13 C NMR of a copolymer of ethylene and methyl acrylate (MA) which also contains some homopolymer of MA, and which shows assignments of various NMR peaks. Also shown are formulas for calculations of the amount of homopolymer present and the amount of MA incorporated in the copolymer.
  • MA ethylene and methyl acrylate
  • hydrocarbyl group is a univalent group containing only carbon and hydrogen.
  • hydrocarbyls may be mentioned unsubstituted alkyls, cycloalkyls and aryls. If not otherwise stated, it is preferred that hydrocarbyl groups (and alkyl groups) herein contain 1 to about 30 carbon atoms.
  • substituted hydrocarbyl herein is meant a hydrocarbyl group that contains one or more substituent groups that are inert under the process conditions to which the compound containing these groups is subjected (e.g., an inert functional group, see below).
  • the substituent groups also do not substantially detrimentally interfere with the polymerization process or operation of the polymerization catalyst system. If not otherwise stated, it is preferred that substituted hydrocarbyl groups herein contain 1 to about 30 carbon atoms. Included in the meaning of “substituted” are chains or rings containing one or more heteroatoms, such as nitrogen, oxygen and/or sulfur, and the free valence of the substituted hydrocarbyl may be to the heteroatom. In a substituted hydrocarbyl, all of the hydrogens may be substituted, as in trifluoromethyl.
  • (inert) functional group herein is meant a group other than hydrocarbyl or substituted hydrocarbyl that is inert under the process conditions to which the compound containing the group is subjected.
  • the functional groups also do not substantially interfere with any process described herein that the compound in which they are present may take part in.
  • Examples of functional groups include halo (fluoro, chloro, bromo and iodo), and ether such as —OR 22 wherein R 22 is hydrocarbyl or substituted hydrocarbyl.
  • R 22 is hydrocarbyl or substituted hydrocarbyl.
  • a “cocatalyst” or a “catalyst activator” is meant a compound that reacts with a transition metal compound to form an activated catalyst species.
  • One such catalyst activator is an “alkyl aluminum compound” which, herein, is meant a compound in which at least one alkyl group is bound to an aluminum atom.
  • Other groups such as, for example, alkoxide, hydride and halogen may also be bound to aluminum atoms in the compound.
  • neutral Lewis base is meant a compound, which is not an ion that can act as a Lewis base.
  • examples of such compounds include ethers, amines, sulfides and organic nitriles.
  • neutral Lewis acid is meant a compound, which is not an ion that can act as a Lewis acid.
  • examples of such compounds include boranes, alkylaluminum compounds, aluminum halides and antimony [V] halides.
  • cationic Lewis acid is meant a cation that can act as a Lewis acid. Examples of such cations are lithium, sodium and silver cations.
  • an “empty coordination site” is meant a potential coordination site on a transition metal atom that does not have a ligand bound to it.
  • an olefin molecule such as an ethylene molecule
  • the olefin molecule may coordinate to the metal atom.
  • a “ligand into which an olefin molecule may insert between the ligand and a metal atom”, or a “ligand that may add to an olefin”, is meant a ligand coordinated to a metal atom which forms a bond (L-M) into which an olefin molecule (or a coordinated olefin molecule) may insert to start or continue a polymerization.
  • L-M metal atom which forms a bond
  • an olefin molecule or a coordinated olefin molecule
  • a “ligand which may be displaced by an olefin” is meant a ligand coordinated to a transition metal which, when exposed to the olefin (such as ethylene), is displaced as the ligand by the olefin.
  • a “monoanionic ligand” is meant a ligand with one negative charge.
  • neutral ligand a ligand that is not charged.
  • aryl is meant a monovalent aromatic group in which the free valence is to the carbon atom of an aromatic ring.
  • An aryl may have one or more aromatic rings that may be fused, connected by single bonds or other groups.
  • substituted aryl is meant a monovalent aromatic group substituted as set forth in the above definition of “substituted hydrocarbyl”. Similar to an aryl, a substituted aryl may have one or more aromatic rings that may be fused, connected by single bonds or other groups; however, when the substituted aryl has a heteroaromatic ring, the free valence in the substituted aryl group can be to a heteroatom (such as nitrogen) of the heteroaromatic ring instead of a carbon.
  • aryl substituted in at least one position vicinal to the free bond of the aryl group is meant the bond to one of the carbon atoms next to the free valence of the aryl group is something other than hydrogen.
  • a phenyl group it would mean the 2 position of the phenyl group would have something other than hydrogen attached to it.
  • a 1-naphthyl group already has something other than hydrogen attached to one of the vicinal carbon atoms at the fused ring junction, while a 2-napthyl group would have to be substituted in either the 1 or 3 positions to meet this limitation.
  • a preferred aryl substituted in at least one position vicinal to the free bond of the aryl group is a phenyl group substituted in the 2 and 6 positions, and optionally in the other positions.
  • alkyl group and “substituted alkyl group” have their usual meaning (see above for substituted under substituted hydrocarbyl). Unless otherwise stated, alkyl groups and substituted alkyl groups preferably have 1 to about 30 carbon atoms.
  • styrene herein is meant a compound of the formula
  • R 43 , R 44 , R 45 , R 46 and R 47 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group, all of which are inert in the polymerization process. It is preferred that all of R 43 , R 44 , R 45 , R 46 and R 47 are hydrogen. Styrene (itself) is a preferred styrene.
  • R 40 is hydrogen or hydrocarbyl containing 1 to 20 carbon atoms. It is preferred that R 40 is hydrogen or alkyl, more preferably hydrogen or n-alkyl, and especially preferably hydrogen.
  • the norbornene may be substituted by one or more hydrocarbyl, substituted hydrocarbyl or functional groups in the R 40 or other positions, with the exception of the vinylic hydrogens, which remain.
  • Norbornene (itself), dimethyl endo-norbomene-2,3-dicarboxylate and t-butyl 5-norbomene-2-carboxylate are preferred norbomenes, with norbomene (itself) being especially preferred.
  • ⁇ -allyl group a monoanionic ligand comprised of 1 sp 3 and two sp 2 carbon atoms bound to a metal center in a delocalized ⁇ 3 fashion indicated by
  • the three carbon atoms may be substituted with other hydrocarbyl groups or functional groups.
  • hydrocarbon olefin an olefin containing only carbon and hydrogen.
  • polar (co)monomer or “polar olefin” is meant an olefin that contains elements other than carbon and hydrogen.
  • polar comonomer the polar group is attached directly to a vinylic carbon atom, as in acrylic monomers. When copolymerized into a polymer the polymer is termed a “polar copolymer”.
  • Useful polar comonomers are found in U.S. Pat. No. 5,866,663, WO9905189, WO9909078 and WO9837110, and S. D. Mel, et al., Chem. Rev., vol. 100, p. 1169-1203(2000), all of which are incorporated by reference herein for all purposes as if fully set forth.
  • CO carbon monoxide
  • a “bidentate” ligand is meant a ligand that occupies two coordination sites of the same transition metal atom in a complex.
  • under polymerization conditions is meant the conditions for a polymerization that are usually used for the particular polymerization catalyst system being used. These conditions include things such as pressure, temperature, catalyst and cocatalyst (if present) concentrations, the type of process such as batch, semi batch, continuous, gas phase, solution or liquid slurry etc., except as modified by conditions specified or suggested herein. Conditions normally done or used with the particular polymerization catalyst system, such as the use of hydrogen for polymer molecular weight control, are also considered “under polymerization conditions”. Other polymerization conditions such as presence of hydrogen for molecular weight control, other polymerization catalysts, etc., are applicable with this polymerization process and may be found in the references cited herein.
  • E s is meant a parameter to quantify steric effects of various groupings, see R. W. Taft, Jr., J. Am. Chem. Soc., vol. 74, p. 3120-3128 (1952), and M. S. Newman, Steric Effects in Organic Chemistry, John Wiley & Sons, New York, 1956, p. 598-603, which are both hereby included by reference.
  • the E s values are those described for o-substituted benzoates in these publications. If the value of E s for a particular group is not known, it can be determined by methods described in these references.
  • the transition metals preferred herein in the first and second processes are in Groups 3 through 11 of the periodic table (IUPAC) and the lanthanides, especially those in the 4 th , 5 th , 6 th and 10 th periods.
  • Suitable transition metals include Ni, Pd, Cu, Pt, Fe, Co, Ti, Zr, V, Hf, Cr, Ru, Rh and Re, with Ni, Ti, Zr, Cu and Pd being more preferred, and Ni, Ti and Zr being especially preferred.
  • Preferred oxidation states for some of the transition metals are Ni[II], Ti[IV], Zr[IV], and Pd[II].
  • ligand (I) Table 1 gives preferred structures.
  • ligand (II) Table 2 gives preferred structures.
  • H is hydrogen
  • HC is hydrocarbyl
  • SHC is substituted hydrocarbyl
  • FG is functional group.
  • R 1 and R 2 are t-butyl, aryl or substituted aryl, more preferably t-butyl, and 2,6-disubstituted phenyl, especially 2,6-dimethoxyphenyl. It is believed that in most of the ligands it is preferred that R 1 and R 2 be relatively sterically bulky groups, for example t-butyl. Thus, for instance, 2,6-dimethylphenyl to would often be favored over phenyl for R 1 and R 2 .
  • R 1 and R 2 may, for example, be isopropyl, phenyl, substituted phenyl, aryl, substituted aryl, cyclohexyl, t-butyl or 2-octyl.
  • R 1 and R 2 are independently aryl substituted in one position vicinal to the free bond of the aryl group, or R 1 and R 2 each independently have an E s of ⁇ 1.0 or less, or both. By both means they may be aryl substituted in one position vicinal to the free bond of the aryl group, and also have an E s of ⁇ 1.0 or less.
  • R 3 , R 4 , R 5 , R 6 , R 8 , R 9 , R 11 and R 12 bonded to the same carbon atom taken together may form a functional group.
  • two of these bonds may form part of an oxo (keto) group, ⁇ O, or an imino ⁇ N—R, wherein R is hydrocarbyl group.
  • Preferred types of functional groups include oxo, —C(O)R 13 and —CO 2 R 13 , wherein R 13 is hydrocarbyl or substituted hydrocarbyl.
  • the transition metal is Ni
  • m is 0, n is 1, R 3 and R 4 are hydrogen
  • Y is CR 11 R 12
  • R 11 is hydrocarbyl or substituted hydrocarbyl
  • R 12 is hydrocarbyl, substituted hydrocarbyl or a functional group
  • Z is O; or
  • the transition metal is Ti
  • m is 0, n is 1, R 3 and R 4 are hydrogen
  • Y is CR 11 R 12
  • R 11 is hydrocarbyl or substituted hydrocarbyl
  • R 12 is hydrocarbyl, substituted hydrocarbyl or a functional group
  • Z is O; or
  • the transition metal is Zr, m is 0, n is 1, R 3 and R 4 are hydrogen, Y is CR 11 R 12 , R 11 is hydrocarbyl or substituted hydrocarbyl, R 12 is hydrocarbyl, substituted hydrocarbyl or a functional group, and Z is O; or
  • the transition metal is Ni, m is 0, n is 1, R 3 and R 4 are hydrogen, R 7 is hydrocarbyl or substituted hydrocarbyl, Y is CR 11 R 12 , R 11 is hydrogen, R 12 is hydrocarbyl or substituted hydrocarbyl, and Z is N; or
  • the transition metal is Ni, m is 0, n is 1, R 3 and R 4 are hydrogen, Y is CR 11 R 12 , R 11 and R 12 taken together are oxo, and Z is O; or
  • the transition metal is Ni, m is 0, n is 1, R 3 and R 4 are hydrogen, R 7 is hydrocarbyl or substituted hydrocarbyl, Y is CR 11 R 12 , R 11 and R 12 taken together are oxo, and Z is N; or
  • the transition metal is Ni, m is 0, n is 1, R 3 and R 4 are hydrogen, Y is S(T), T is ⁇ O and Z is O; or
  • the transition metal is Ni, m is 0, n is 1, R 3 and R 4 are hydrogen, Y is S(T), T is ⁇ N-silyl, Z is N and R 7 is silyl; or
  • the transition metal is Ni, m is 0, n is 1, R 3 and R 4 are hydrogen, Y is S(T), T is ⁇ O, Z is N, and R 7 is hydrocarbyl or substituted hydrocarbyl; or
  • the transition metal is Ni, m is 0, n is 1, R 3 and R 4 are hydrogen, Y is CR 11 R 12 , R 11 and R 12 taken together are a ring and Z is O; or
  • the transition metal is Ni
  • m is 0, n is 1, R 3 and R 4 are hydrogen
  • Y is CR 11 R 12 , R 11 and R 12 taken together are N-hydrocarbyl- or N-substituted hydrocarbylimino
  • Z is N and R 7 is hydrocarbyl or substituted hydrocarbyl; or
  • the transition metal is Ni, m is 0, n is 1, R 3 and R 4 are hydrogen, Y is S(T), T is ⁇ O and Z is 0; or
  • the transition metal is Ni
  • m is 0, n is 1, R 3 and R 4 are hydrogen
  • Y is CR 11 R 12 , R 11 and R 12 taken together are sulfo
  • Z is N and R 7 is hydrocarbyl or substituted hydrocarbyl.
  • the transition metal is Ni, q is 0 or 1, R 8 and R 9 are hydrogen and R 10 is hydrocarbyl or substituted hydrocarbyl.
  • R 33 and R 34 are preferably t-butyl, aryl (other than phenyl) or substituted aryl, more preferably t-butyl and 2,6-disubstituted phenyl, especially 2,6-dimethoxyphenyl. It is believed that in most of the ligands it is preferred that R 33 and R 34 be relatively sterically bulky groups, for example t-butyl. Thus, for instance, 2,6-dimethylphenyl would often be favored over 2-methylphenyl for R 33 and R 34 .
  • R 33 and R 34 may, for example, be isopropyl, aryl (other than phenyl), substituted aryl, cyclohexyl, t-butyl or 2-octyl.
  • R 33 and R 34 are independently aryl substituted in one position vicinal to the free bond of the aryl group, or R 33 and R 34 each independently have an E s of ⁇ 1.0 or less, or both. By both means they may be aryl substituted in one position vicinal to the free bond of the aryl group, and also have an E s of ⁇ 1.0 or less.
  • R 31 and R 32 may be mentioned hydrogen, aryl, substitued aryl, oxygen and nitrogen based functional groups and SO 3 Na, as well as when R 31 and R 32 taken together form a ring, for example, an aromatic or non-aromatic ring, which may include one or more heteroatoms.
  • useful groups L 1 include hydrocarbyl and substituted hydrocarbyl (especially phenyl and alkyl, and particularly phenyl, methyl, hydride and acyl).
  • Useful groups for L 2 include phosphine such as triphenylphosphine, nitrile such as acetonitrile, ethers such as ethyl ether, pyridine, and tertiary alkylamines such as triethylamine and TMEDA (N,N,N′,N′-tetramethyl-1,2-ethylenediamine).
  • L 1 and L 2 taken together may be a ⁇ -allyl or ⁇ -benzyl group such as
  • R is hydrocarbyl, and ⁇ -allyl and ⁇ -benzyl groups are preferred.
  • L 1 which form a bond with the metal into which ethylene may insert between it and the transition metal atom are hydrocarbyl and substituted hydrocarbyl, especially phenyl and alkyl, and particularly methyl, hydride and acyl.
  • Ligands L 2 which ethylene may displace include phosphine such as triphenylphosphine, nitrile such as acetonitrile, ether such as ethyl ether, pyridine, tertiary alkylamines such as TMEDA, and other olefins.
  • Ligands in which L 1 and L 2 taken together are a bidentate monoanionic ligand into which ethylene may insert between that ligand and the transition metal atom include ⁇ -allyl- or ⁇ -benzyl-type ligands (in this instance, sometimes it may be necessary to add a neutral Lewis acid cocatalyst such as triphenylborane or tris(pentafluoro-phenyl)borane of a cationic Lewis acid such as Li 30 to initiate the polymerization, see for instance previously incorporated U.S. Pat. No. 6,174,975).
  • a neutral Lewis acid cocatalyst such as triphenylborane or tris(pentafluoro-phenyl)borane of a cationic Lewis acid such as Li 30
  • the ligand in the location of L 1 is not a ligand into which ethylene may insert between it and the transition metal atom, it may be possible to add a cocatalyst which may convert it into L 1 a ligand which will undergo such an insertion.
  • the ligand in the location of L 1 is halo such as chloride or bromide, a carboxylate, acetylacetonate or an alkoxide, it may be converted to hydrocarbyl such as alkyl by use of a suitable alkylating agent such as an alkylaluminum compound, a Grignard reagent or an alkyllithium compound. It may be converted to hydride by use of a compound such as sodium borohydride.
  • a cocatalyst (sometimes also called an activator) which is an alkylating or hydriding agent is also typically present in the olefin polymerization.
  • a preferred cocatalyst is an alkylaluminum compound, and useful alkylaluminum compounds include trialkylaluminum compounds such as triethylaluminum, trimethylaluminum and tri-i-butylaluminum, alkyl aluminum halides such as diethylaluminum chloride and ethylaluminum dichloride, and aluminoxanes such as methylaluminoxane. More than one such cocatalyst may be used in combination.
  • L 3 Preferred for L 3 are ligands of the type above described for L 1 .
  • the ligands (I), (II) and (XIII) may be synthesized by a variety of methods, depending on the particular ligand desired. The synthesis of many specific ligands is illustrated in the Examples. Many of these syntheses are accomplished through the use of R 2 PLi or R 2 PCH 2 Li. More generally speaking, the synthesis of various types of ligands is illustrated in the schemes shown below. In these schemes, each R independently represents hydrocarbyl or substituted hydrocarbyl, and each R′ independently represent hydrogen, hydrocarbyl or substituted hydrocarbyl.
  • Scheme 2 shows the synthesis of (II). Appropriate substitution (as in all these synthesis schemes) in these compounds may be obtained by using appropriately substituted starting materials.
  • Scheme 3 shows the synthesis of 4-membered (or isomeric) metallocycles.
  • isomeric is meant (and included in the definition of) that 4-membered heterocycles such as those shown in Scheme 3 may also be in the form of bridged dimers and/or oligomers.
  • Z may be changed by using the appropriate starting material.
  • Scheme 4 illustrates the synthesis of a 6-membered metallocycle.
  • the corresponding nitrogen compound may be made by using an aziridine as a starting material.
  • Scheme 5 illustrates a method for making (I) in which X is —O—.
  • TMEDA is tetramethylethylenediamine.
  • Ni complexes are prepared, and for making late transition metal complexes other than Ni, similar reactions of metal compounds with an appropriate anion may be used to prepare the complex.
  • metal compounds with an appropriate anion may be used to prepare the complex.
  • Useful types of Ni compounds are listed below.
  • the anion may be reacted with a simple metal compound such as a halide, for example ZrCl 4 or TiCl 4 .
  • Useful monomers include hydrocarbon olefins such as ethylene and ⁇ -olefins of the formula H 2 C ⁇ CH(CH 2 ) t H (III) wherein t is an integer of 1 to 20, a styrene, a norbornene and cyclopentene; and polar comonomers such as CO and polar olefins.
  • Useful polar olefins include those of the formula H 2 C ⁇ CHR 13 E, wherein R 13 is alkylene, alkylidene or a covalent bond, especially —(CH 2 ) x — wherein x is 0 or an integer of 1 to 20 and E is a polar group.
  • Useful polar groups E include —CO 2 R 14 , —OC(O)R 14 , —CO 2 H, —C(O)NR 14 2 and —OR 14 , and —CO 2 R 14 and —OR 14 are more preferred, wherein each R 14 is hydrogen, hydrocarbyl or substituted hydrocarbyl, preferably alkyl or substituted alkyl.
  • R 14 is hydrogen, hydrocarbyl or substituted hydrocarbyl, preferably alkyl or substituted alkyl.
  • An especially preferred olefin is ethylene (alone).
  • CO and polar comonomers will be used with a hydrocarbon olefin such as ethylene to form a copolymer, and often when CO is used at least one other polar monomer will also be present.
  • the polymer produced by the first and second processes herein have a degree of polymerization (average number of monomer units in a polymer molecule) of at least about 20, more preferably at least about 40, and especially preferably at least about 100.
  • the temperature at which the polymerization is carried out is generally about ⁇ 100° C. to about +200° C., preferably about ⁇ 60° C. to about 150° C., and more preferably about ⁇ 20° C. to about 100° C.
  • the pressure of the olefin (if it is a gas) at which the polymerization is carried out is preferably atmospheric pressure to about 275 MPa.
  • the first and second polymerization processes herein may be run in the presence of various liquids, particularly aprotic organic liquids.
  • the catalyst system, monomer(s), and polymer may be soluble or insoluble in these liquids, but obviously these liquids should not prevent the polymerization from occurring.
  • Suitable liquids include alkanes, cycloalkanes, selected halogenated hydrocarbons, and aromatic hydrocarbons.
  • Specific useful solvents include hexane, toluene, benzene, methylene chloride, chlorobenzene, p-xylene, and 1,2,4-trichlorobenzene.
  • Cocatalysts such as alkylaluminum compounds and/or boranes and/or other Lewis acids may optionally be present in the first and second processes. It is believed that the presence of certain Lewis acids may enhance the productivity of the catalyst and/or the rate of polymerization of the olefin(s). Also Lewis acids may form so-called Zwitterionic complexes which are also useful in these processes. For an explanation of Zwitterionic complexes, see U.S. patent application Ser. No. ______ (filed concurrently on 31 May 2001, Applicant's reference CL1655 US NA), which is hereby incorporated by reference herein for all purposes as if fully set forth.
  • one or more polar comonomers are used with one or more hydrocarbon olefins, and preferably ethylene, to form a polar copolymer.
  • Useful polar comonomers include, but are not limited to compounds of the formula H 2 C ⁇ CHR 20 C(O)Y (X), H 2 C ⁇ CHR 20 CN (XI), H 2 C ⁇ CR 25 C(O)Y (XII), or H 2 C ⁇ CHR 20 CCN, wherein R 20 is alkylene or substituted alkylene, R 25 is hydrogen, and Y is —OH, —NR 21 R 22 , —OR 23 , and —SR 24 , wherein R 21 and R 22 are each independently hydrogen, hydrocarbyl or substituted hydrocarbyl, R 23 and R 24 are each hydrocarbyl or substituted hydrocarbyl, and R 25 is hydrogen.
  • Other more specific preferred polar comonomers are (X) wherein R 20 is —(CH 2 ) q — wherein q is 0 or an integer of 1 to 20 and Y is —OR 23 , and (XII), wherein it is especially preferred that q is zero.
  • Norbornenes containing functional groups are also useful polar comonomers.
  • Ni complexes which may contain bidentate ligands and may be useful in the third process herein may be found in JP-A-11158214, JP-A-11158213, JP-A-10017617, JP-A-09255713, JP-A-11180991, JP-A-256414(2000), JP-A-10007718, JP-A-10182679, JP-A-128922(2000), JP-A-10324709, JP-A-344821(2000), JP-A-11292917, JP-A-11181014, WO00/56744, WO96/37522, WO96/37523, WO98/49208, WO00/18776, WO00/56785, WO00/06620, WO99/50320, WO00/68280, WO00/59956, WO00/50475, WO00/50470, WO98/42665, WO99/54364, WO98/33823, WO99/3
  • a preferred low temperature is about 80° C., more preferably about 90° C.
  • a preferred high temperature is about 150° C., more preferably about 130° C.
  • a preferred lower ethylene pressure is about 5 MPa or more.
  • a preferred upper limit on ethylene pressure is about 200 MPa, more preferably about 20 MPa.
  • Preferred bidentate ligands in the third process herein are:
  • R 26 and R 27 are each independently hydrocarbyl or substituted hydrocarbyl, provided that the carbon atom bound to the imino nitrogen atom has at least two carbon atoms bound to it;
  • R 28 and R 29 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl, or R 28 and R 29 taken together are hydrocarbylene or substituted hydrocarbylene to form a carbocyclic ring;
  • R 60 and R 61 are each independently functional groups bound to the rest of (XV) through heteroatoms (for example O, S or N), or R 60 and R 61 (still containing their heteroatoms) taken together form a ring.
  • each R 50 is independently hydrocarbyl or substituted hydrocarbyl
  • each R 51 is independently hydrogen, hydrocarbyl or substituted hydrocarbyl
  • each R 52 is hydrocarbyl, substituted hydrocarbyl, hydrocarbyloxy, or substituted hydrocarbyloxy.
  • (XVI), (XVII) and (XVIII) are used as the complexes, especially as their nickel complexes it is preferred that they be used as their complexes with Lewis acids (“Zwitterionic complexes”) such as tris(pentafluorophenyl)borane. These Zwitterionic complexes are sometimes better polymerization catalysts than the complexes which are do not contain the Lewis acid. These Zwitterionic compounds may be formed before the complex is added to the polymerization process, or may be formed in situ by reaction with Lewis acid which is present.
  • Lewis acids such as tris(pentafluorophenyl)borane.
  • copolymerizable olefins may also be present in the third process.
  • ⁇ -Olefins of the formula H 2 C ⁇ CH(CH 2 ) z CH 3 wherein z is 0 or an integer of 1 to 21, for example propylene or 1-butene, may be used. It is preferred that any other comonomers present constitute less than 50 mole percent, more preferably less than 25 mole percent of the product copolymer.
  • polar comonomers for example acrylate-type comonomers
  • these homopolymers arise from a “competitive” free radical-type polymerization “originating” from some free radicals which may be present or generated in the third process polymerization.
  • Some types of polar comonomers such as acrylates are well known to readily undergo such polymerizations. These usually unwanted free radical polymerizations may be suppressed to varying extents by the presence of free radical polymerization inhibitors such as phenothiazine in the third polymerization process, but these may interfere with the desired polymerization process, or cause other problems.
  • alkali metal or ammonium salts preferably alkali metal salts
  • of relatively noncoordinating anions retards or eliminates the formation of homopolymer of the polar comonomer (or copolymers containing only polar comonomers if more than one polar comonomer is used).
  • alkali metal cations are Li, Na and K, and Li and Na are especially preferred.
  • Useful weakly coordinating anions include BAF, tetrakis(pentafluorophenyl)borate, N(S(O) 2 CF 3 ) 2 31 , tetraphenylborate, trifluoromethanesulfonate, and hexafluoroantimonate, and preferred anions are BAF, tetrakis(pentafluorophenyl)-borate, and N(S(O) 2 CF 3 ) 2 ⁇ .
  • a useful molar ratio of these salts to the number of moles of Ni compounds present is about 10,000 to about 5 to 1.0, more preferably about 1,000 to about 50 to 1.0.
  • These salts will preferably be used in a third polymerization process in which there is a liquid phase present, for example a polymerization which is a solution or liquid suspension polymerization.
  • the molar ratio of the total of the polar comonomers present to any added Lewis acid is at least 2:1, preferably at least 10:1.
  • Polar comonomers such acrylic-type monomers, have been copolymerized in certain situations by destroying their Lewis basic (or coordinating) character by reacting them with a Lewis acid, to form a Lewis acid “salt” of the polar comonomer. While this may often help to form the polar copolymer, later removal of the stoichiometric amount (of polar comonomer) of Lewis acid is difficult and expensive.
  • the olefin polymerizations herein may also initially be carried out in the “solid state” by, for instance, supporting the transition metal compound on a substrate such as silica or alumina, activating it if necessary with one or more cocatalysts and contacting it with the olefin(s).
  • the support may first be contacted (reacted) with one or more cocatalysts (if needed) such as an alkylaluminum compound, and then contacted with an appropriate Ni compound.
  • the support may also be able to take the place of a Lewis or Bronsted acid, for instance, an acidic clay such as montmorillonite, if needed.
  • Another method of making a supported catalyst is to start a polymerization or at least make a transition metal complex of another olefin or oligomer of an olefin such as cyclopentene on a support such as silica or alumina.
  • These “heterogeneous” catalysts may be used to catalyze polymerization in the gas phase or the liquid phase.
  • gas phase is meant that a gaseous olefin is transported to contact with the catalyst particle.
  • a preferred case is when the ligand is covalently attached to the supports, which helps prevent leaching of the transition metal complex from the support.
  • oligomers and polymers of the various olefins are made. They may range in molecular weight from oligomeric olefins, to lower molecular weight oils and waxes, to higher molecular weight polyolefins.
  • One preferred product is a polymer with a degree of polymerization (DP) of about 10 or more, preferably about 40 or more.
  • DP degree of polymerization
  • DP is meant the average number of repeat (monomer) units in a polymer molecule.
  • the polymers made by the first and second processes described herein are useful in many ways. For instance if they are thermoplastics, they may be used as molding resins, for extrusion, films, etc. If they are elastomeric, they may be used as elastomers. If they contain functionalized monomers such as acrylate esters, they are useful for other purposes, see for instance previously incorporated U.S. Pat. No. 5,880,241.
  • polymers even those made from the same monomer(s) may have varying properties. Some of the properties that may change are molecular weight and molecular weight distribution, crystallinity, melting point, and glass transition temperature. Except for molecular weight and molecular weight distribution, branching can affect all the other properties mentioned, and branching may be varied (using the same transition metal compound) using methods described in previously incorporated U.S. Pat. No. 5,880,241.
  • blends of distinct polymers may have advantageous properties compared to “single” polymers.
  • polymers with broad or bimodal molecular weight distributions may be melt processed (be shaped) more easily than narrower molecular weight distribution polymers.
  • Thermoplastics such as crystalline polymers may often be toughened by blending with elastomeric polymers.
  • the transition metal containing polymerization catalyst disclosed herein can be termed the first active polymerization catalyst.
  • Monomers useful with these catalysts are those described (and also preferred) above.
  • a second active polymerization catalyst (and optionally one or more others) is used in conjunction with the first active polymerization catalyst.
  • the second active polymerization catalyst may be a late transition metal catalyst, for example as described herein, in previously incorporated U.S. Pat. No. 5,880,241, U.S. Pat. No. 6,060,569, U.S. Pat. No. 6,174,975 and U.S. Pat. No. 5,714,556, and/or in U.S. Pat. No. 5,955,555 (also incorporated by reference herein for all purposes as if fully set forth).
  • catalysts may also be used for the second active polymerization catalyst.
  • so-called Ziegler-Natta and/or metallocene-type catalysts may also be used.
  • These types of catalysts are well known in the polyolefin field, see for instance Angew. Chem., Int. Ed. Engl., vol. 34, p. 1143-1170 (1995), EP-A-0416815 and U.S. Pat. No. 5,198,401 for information about metallocene-type catalysts; and J. Boor Jr., Ziegler - Natta Catalysts and Polymerizations, Academic Press, New York, 1979 for information about Ziegler-Natta-type catalysts, all of which are hereby included by reference.
  • the first olefin(s) (the monomer(s) polymerized by the first active polymerization catalyst) and second olefin(s) (the monomer(s) polymerized by the second active polymerization catalyst) are identical, and preferred olefins in such a process are the same as described immediately above.
  • the first and/or second olefins may also be a single olefin or a mixture of olefins to make a copolymer. Again it is preferred that they be identical particularly in a process in which polymerization by the first and second active polymerization catalysts make polymer simultaneously.
  • the first active polymerization catalyst may polymerize a monomer that may not be polymerized by said second active polymerization catalyst, and/or vice versa. In that instance two chemically distinct polymers may be produced. In another scenario two monomers would be present, with one polymerization catalyst producing a copolymer, and the other polymerization catalyst producing a homopolymer, or two copolymers may be produced which vary in the molar proportion or repeat units from the various monomers. Other analogous combinations will be evident to the artisan.
  • one of the polymerization catalysts makes an oligomer of an olefin, preferably ethylene, which oligomer has the formula R 70 CH ⁇ CH 2 , wherein R 70 is n-alkyl, preferably with an even number of carbon atoms.
  • the other polymerization catalyst in the process then (co)polymerizes this olefin, either by itself or preferably with at least one other olefin, preferably ethylene, to form a branched polyolefin.
  • Preparation of the oligomer (which is sometimes called an ⁇ -olefin) by a second active polymerization-type of catalyst can be found in previously incorporated U.S. Pat. No. 5,880,241, as well as in WO99/02472 (also incorporated by reference herein).
  • the first active polymerization catalyst is described in detail above.
  • the second active polymerization catalyst may also meet the limitations of the first active polymerization catalyst, but must be chemically distinct. For instance, it may have a different transition metal present, and/or utilize a different type of ligand and/or the same type of ligand that differs in structure between the first and second active polymerization catalysts. In one preferred process, the ligand type and the metal are the same, but the ligands differ in their substituents.
  • two active polymerization catalysts include systems in which a single polymerization catalyst is added together with another ligand, preferably the same type of ligand, which can displace the original ligand coordinated to the metal of the original active polymerization catalyst, to produce in situ two different polymerization catalysts.
  • the molar ratio of the first active polymerization catalyst to the second active polymerization catalyst used will depend on the ratio of polymer from each catalyst desired, and the relative rate of polymerization of each catalyst under the process conditions. For instance, if one wanted to prepare a “toughened” thermoplastic polyethylene that contained 80% crystalline polyethylene and 20% rubbery polyethylene, and the rates of polymerization of the two catalysts were equal, then one would use a 4:1 molar ratio of the catalyst that gave crystalline polyethylene to the catalyst that gave rubbery polyethylene. More than two active polymerization catalysts may also be used if the desired product is to contain more than two different types of polymer.
  • the polymers made by the first active polymerization catalyst and the second active polymerization catalyst may be made in sequence, i.e., a polymerization with one (either first or second) of the catalysts followed by a polymerization with the other catalyst, as by using two polymerization vessels in series. However it is preferred to carry out the polymerization using the first and second active polymerization catalysts in the same vessel(s), i.e., simultaneously. This is possible because in most instances the first and second active polymerization catalysts are compatible with each other, and they produce their distinctive polymers in the other catalyst's presence. Any of the processes applicable to the individual catalysts may be used in this polymerization process with 2 or more catalysts, i.e., gas phase, liquid phase, continuous, etc.
  • Catalyst components which include transition metal complexes of (I), (II) or (XII), with or without other materials such as one or more cocatalysts and/or other polymerization catalysts are also disclosed herein.
  • a catalyst component could include the transition metal complex supported on a support such as alumina, silica, a polymer, magnesium chloride, sodium chloride, etc., with or without other components being present. It may simply be a solution of the transition metal complex, or a slurry of the transition metal complex in a liquid, with or without a support being present.
  • the polymers produced by this process may vary in molecular weight and/or molecular weight distribution and/or melting point and/or level of crystallinity, and/or glass transition temperature and/or other factors.
  • the polymers may differ in ratios of comonomers if the different polymerization catalysts polymerize the monomers present at different relative rates.
  • the polymers produced are useful as molding and extrusion resins and in films as for packaging. They may have advantages such as improved melt processing, toughness and improved low temperature properties.
  • Hydrogen or other chain transfer agents such as silanes (for example trimethylsilane or triethylsilane) may be used to lower the molecular weight of polyolefin produced in the polymerization process herein. It is preferred that the amount of hydrogen present be about 0.01 to about 50 mole percent of the olefin present, preferably about 1 to about 20 mole percent.
  • silanes for example trimethylsilane or triethylsilane
  • the amount of hydrogen present be about 0.01 to about 50 mole percent of the olefin present, preferably about 1 to about 20 mole percent.
  • liquid monomers (olefins) one may need to experiment briefly to find the relative amounts of liquid monomers and hydrogen (as a gas). If both the hydrogen and monomer(s) are gaseous, their relative concentrations may be regulated by their partial pressures.
  • Copolymers of ethylene and certain polar comonomers such as H 2 C ⁇ CHC(O)R 32 are described herein (first and second polymers), and they contain first branches of the formula —(CH 2 ) n CH 3 and second branches of the formula —(CH 2 ) m C(O)R 33 , wherein R 32 is —OR 34 or any group readily derivable from it, R 33 is R 32 or any group readily derivable from it, R 34 is hydrocarbyl or substituted hydrocarbyl, and each R 35 is hydrogen, hydrocarbyl or substituted hydrocarbyl.
  • any group readily derivable from it is meant any derivative of a carboxylic acid which is readily interconverted from the carboxylic acid itself or a derivative of a carboxylic acid.
  • a carboxylic acid ester may be converted to a carboxylic acid by hydrolysis, an amide by reaction with a primary or secondary amine, a carboxylate salt (for example with an alkali or alkaline earth metal) by hydrolysis and neutralization, an acyl halide by hydrolysis and reaction with a compound such as thionyl chloride, nitriles, and others.
  • the first and/or second polymers, and/or third polymers in some instances have the following characteristics in various combinations that separates them from other copolymers made from the same monomers. These characteristics are:
  • the ratio of first branches wherein n is 0 to first branches wherein n is 1 is about 3.0 or more, preferably about 4.0 or more;
  • the ratio of first branches wherein n is 0 to first branches wherein n is 3 is 1.0 or more, preferably 1.5 or more;
  • the ratio of second branches wherein m is 0 to second branches wherein m is one or more is at least about 3.0, more preferably at least about 5.0;
  • the total number of first branches where n is 0, 1, 2 and 3 in said polymer is about 10 or more per 1000 CH 2 groups, preferably about 20 or more;
  • repeat units derived from H 2 C ⁇ CHC(O)R 33 is 0.3 mole percent or more based on the total repeat units derived from ethylene and H 2 C ⁇ CHC(O)R 33 , preferably about 0.5 mole percent or more, especially preferably 1.1 mole percent or more, and very preferably about 1.5 mole percent or more (if there are repeat units in which R 33 vanes, the total of such units shall be used);
  • the polymers have end groups of the formula ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ -HC ⁇ CH—C(O)—R 32 and at least about 5 mole percent, preferably at least about 10 mole percent, of said monomer incorporated is present in said polymer as end groups of the formula ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ -HC ⁇ CH—C(O)—R 33 , wherein ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ is the remainder of the polymer chain of said end group (the polymer chain the end group is attached to); and/or
  • the said unsaturated end groups are at least 0.001 mole percent, preferably at least about 0.01 mole percent, and more preferably at least 0.1 mole percent, of the total repeat units (ethylene and polar comonomer(s)) in said polymer.
  • the first, second and third polymers may also contain “saturated” end groups of the formula ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ C(O)R 33 , which with present analytical techniques may be indistinguishable from second branches where m is ⁇ 5.
  • end groups may have the formula ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ CH ⁇ CH 2 (a vinyl end group).
  • Such end groups may sometimes be polymerizable, and therefore polymers with such end groups may be useful as macromonomers.
  • ester groups which are saturated polymer ends (no olefin bond associated with the end group), and ester groups at the ends of long branches by 13 C NMR spectroscopy (created by chain walking event, a CWE).
  • the carbonyl group is shifted from about 175.5 ppm for the in-chain comonomer to 170-174 ppm for the saturated end group or CWE.
  • the saturated ester end group or CWE peak in the region 170-174 ppm is very small and present in only trace quantities. Because of the very low levels of this peak, it is difficult to confirm by 2D NMR this hypothesis, and the assignment should be considered tentative.
  • the first, second and third polymers are useful in many ways, for instance,
  • Tackifiers for low strength adhesives (U, vol. A1, p. 235-236) are a use for these polymers. Elastomeric and/or relatively low molecular weight polymers are preferred.
  • the polymers are useful as base resins for hot melt adhesives (U, vol. A1, p. 233-234), pressure sensitive adhesives (U, vol. A1, p. 235-236) or solvent applied adhesives.
  • Thermoplastics are preferred for hot melt adhesives.
  • the polymers may also be used in a carpet installation adhesive.
  • Base polymer for caulking of various kinds is another use.
  • An elastomer is preferred.
  • Lower molecular weight polymers are often used.
  • the polymers may be used for modifying asphalt, to improve the physical properties of the asphalt and/or extend the life of asphalt paving, see U.S. Pat. No. 3,980,598.
  • Wire insulation and jacketing may be made from any of the polymers (see EPSE, vol. 17, p. 828-842). In the case of elastomers it may be preferable to crosslink the polymer after the insulation or jacketing is formed, for example by free radicals.
  • the polymers, especially the branched polymers, are useful as base resins for carpet backing, especially for automobile carpeting.
  • the polymers may be used for extrusion or coextrusion coatings onto plastics, metals, textiles or paper webs.
  • the polymers may be used as a laminating adhesive for glass.
  • the polymers are useful for blown or cast films or as sheet (see EPSE, vol. 7 p. 88-106; ECT4, vol. 11, p. 843-856; PM, p. 252 and p. 432ff).
  • the films may be single layer or multilayer, the multilayer films may include other polymers, adhesives, etc.
  • the films may be stretch-wrap, shrink-wrap or cling wrap.
  • the films are useful for many applications such as packaging foods, geomembranes and pond liners. It is preferred that these polymers have some crystallinity.
  • the polymers may be used to form flexible or rigid foamed objects, such as cores for various sports items such as surf boards and liners for protective headgear. Structural foams may also be made. It is preferred that the polymers have some crystallinity.
  • the polymer of the foams may be crosslinked.
  • the polymers may be used to coat objects by using plasma, flame spray or fluidized bed techniques.
  • Extruded films may be formed from these polymers, and these films may be treated, for example drawn. Such extruded films are useful for packaging of various sorts.
  • the polymers especially those that are elastomeric, may be used in various types of hoses, such as automotive heater hose.
  • the polymers may be used as reactive diluents in automotive finishes, and for this purpose it is preferred that they have a relatively low molecular weight and/or have some crystallinity.
  • the polymers can be converted to ionomers, which when they possess crystallinity can be used as molding resins.
  • ionomeric molding resins are golf ball covers, perfume caps, sporting goods, film packaging applications, as tougheners in other polymers, and usually extruded) detonator cords.
  • the functional groups on the polymers can be used to initiate the polymerization of other types of monomers or to copolymerize with other types of monomers. If the polymers are elastomeric, they can act as toughening agents.
  • the polymers can act as compatibilizing agents between various other polymers.
  • the polymers can act as tougheners for various other polymers, such as thermoplastics and thermosets, particularly if the olefin/polar monomer polymers are elastomeric.
  • the polymers may act as internal plasticizers for other polymers in blends.
  • a polymer which may be plasticized is poly(vinyl chloride).
  • the polymers can serve as adhesives between other polymers.
  • the polymers may serve as curing agents for other polymers with complimentary functional groups (i.e., the functional groups of the two polymers react with each other).
  • the polymers are useful as pour point depressants for fuels and oils.
  • Lubricating oil additives as Viscosity Index Improvers for multigrade engine oil (ECT3, Vol 14, p. 495-496) are another use. Branched polymers are preferred. Ethylene copolymer with acrylates or other polar monomers will also function as Viscosity Index Improvers for multigrade engine oil with the additional advantage of providing some dispersancy.
  • the polymers may be used for roofing membranes.
  • the polymers may be used as additives to various molding resins such as the so-called thermoplastic olefins to improve paint adhesion, as in automotive uses.
  • a flexible pouch made from a single layer or multilayer film (as described above) which may be used for packaging various liquid products such as milk, or powder such as hot chocolate mix.
  • the pouch may be heat sealed. It may also have a barrier layer, such as a metal foil layer.
  • a wrap packaging film having differential cling is provided by a film laminate, comprising at least two layers; an outer reverse which is a polymer (or a blend thereof) described herein, which contains a tackifier in sufficient amount to impart cling properties; and an outer obverse which has a density of at least about 0.916 g/mL which has little or no cling, provided that a density of the outer reverse layer is at least 0.008 g/mL less than that of the density of the outer obverse layer. It is preferred that the outer obverse layer is linear low density polyethylene, and the polymer of the outer obverse layer have a density of less than 0.90 g/mL. All densities are measured at 25° C.
  • Fine denier fibers and/or multifilaments These may be melt spun. They may be in the form of a filament bundle, a non-woven web, a woven fabric, a knitted fabric or staple fiber.
  • a composition comprising a mixture of the polymers herein and an antifogging agent. This composition is especially useful in film or sheet form because of its antifogging properties.
  • polymers are functionalized with monomers such as fluoroalkyl acrylate esters or other fluorine-containing monomers, they are useful for selectively imparting surface activity to polyolefins. This would be of use reducing fluid penetration in flash-spun polyolefin films for medical and other applications.
  • the fluoro-functionalized polyolefins would also be useful for dispersing fluoropolymers in lubricant applications.
  • EG—end-group refers to the ester group of the acrylate being located in an unsaturated end group of the ethylene copolymer
  • Et sBu percent of ethyl branches occurring in sec-butyl ended branches
  • IC—in-chain refers to the ester group of the acrylate being bound to the main-chain of the ethylene copolymer
  • Me sBu percent of methyl branches occurring in sec-butyl ended branches
  • (Tert-butyl) 2 PCH 2 Li was synthesized by reacting (tert-butyl) 2 PCH 3 with tert-butyl lithium in heptane in a 109° C. bath for a few hours. The product was filtered and washed with pentane.
  • (Tert-butyl) 2 PLi was synthesized by reacting (tert-butyl) 2 PH with n-butyl lithium in heptane at 90° C. for 6 h. Ph 2 PLi was made by reacting Ph 2 PH with n-butyl lithium at RT for 3 d at RT.
  • the NMR spectra were recorded using a Bruker 500 MHz spectrometer or a Bruker 300 MHz spectrometer.
  • a single red-orange crystal was grown from CH 2 Cl 2 /hexane at ambient temperature, and X-ray diffraction data confirmed the structure. No LiCl was present in the structure based X-ray single crystal diffraction analysis.
  • Electron spray mass spectroscopy showed major peaks at 468 and 470 (due to 58 Ni and 60 Ni isotopes); which indicated that the desired product picked up a proton in the spray process.
  • X-ray single crystal diffraction analysis confirmed the structure. No LiCl was present in the structure.
  • the product was mixed with 0.2796 g ((allyl)NiCl) 2 and 25 mL THF in a RB flask. The mixture was allowed to stir for 2 h at RT. The mixture was evaporated to dryness. The residue was extracted with toluene, filtered and washed with toluene. Solvent was evaporated. The product was dried in vacuo.
  • the mixture was evaporated to dryness.
  • the solid product was mixed with 10 mL toluene first and then 90 mL pentane. The solid was filtered, followed by 3 ⁇ pentane wash and dried in vacuo overnight. Light brown solid (0.59 g) was obtained.
  • Example 20B The in-situ prepared Catalyst 20 (0.05 mmol, see Example 20B) was screened for ethylene polymerization at 6.9 MPa of ethylene at 50° C. for 18 h in a shaker tube. Polyethylene (0.067 g) was obtained. It had melting points of 131° C. (166.7 J/g) and 114° C. (33.5 J/g).
  • a glass insert was loaded with the isolated Ni catalysts (except Catalyst 20 in Example 20, which was generated in-situ). Solvent (TCB or chlorobenzene), optionally comonomers were added to the glass insert. A Lewis acid cocatalyst (typically BPh 3 or B(C 6 F 5 ) 3 ) was often added to the solution. The insert was then capped and sealed. Outside of the drybox, the tube was placed under ethylene and was shaken mechanically at desired temperature listed in Table 3 for about 18 h. Sometimes an aliquot of the solution was used to acquire a 1 HNMR spectrum. The remaining portion was added to about 20 mL of methanol in order to precipitate the polymer. The polymer was isolated, washed with methanol several times and dried in vacuo.
  • Solvent TCB or chlorobenzene
  • a Lewis acid cocatalyst typically BPh 3 or B(C 6 F 5 ) 3
  • a glass insert was loaded with 0.02 mmol of the isolated Zr or Ti catalyst and 9 mL of 1,2,4-trichlorobenzene. It was then cooled to ⁇ 30° C. PMAO-IP (1 mL 12.9 wt % (in Al) toluene solution) was added to the frozen solution. It was put in a ⁇ 30° C. freezer. The insert was then capped and sealed. Outside of the drybox, the cold tube was placed under ethylene and was shaken mechanically at desired temperature listed in Table 3, condition V, for about 18 h. Methanol (about 15 mL) and 2 mL conc. hydrochloric acid was added to the mixture. The polymer was isolated, washed with methanol several times and dried in vacuo.
  • Total methyls per 1000 CH 2 are measured using different NMR resonances in 1H and 13C NMR. Because of accidental overlaps of peaks and different methods of correcting the calculations, the values measured by 1 H and 13 C NMR will usually not be exactly the same, but they will be close, normally within 10-20% at low levels of acrylate comonomer.
  • 13 C NMR the total methyls per 1000 CH2 are the sums of the 1B 1 , 1B 2 , 1B 3 , and 1B 4+ , EOC resonances per 1000 CH 2 , where the CH 2 's do not include the CH 2 's in the alcohol portions of the ester group.
  • the total methyls measured by 13C NMR do not include the minor amounts of methyls from the methyl vinyl ends or the methyls in the alcohol portion of the ester group.
  • the total methyls are measured from the integration of the resonances from 0.6 to 1.08 and the CH 2 's are determined from the integral of the region from 1.08 to 2.49 ppm. It is assumed that there is 1 methine for every methyl group, and 1 ⁇ 3 of the methyl integral is subtracted from the methylene integral to remove the methine contribution.
  • the methyl and methylene integrals are also usually corrected to exclude the values of the methyls and methylenes in the alcohol portion of the ester group, if this is practical. Because of the low levels of incorporation, this is usually a minor correction.
  • the spectrum was obtained on a 500 MHz Bruker Avance spectrometer on a 5 mm QNP probe on samples diluted ⁇ 10 mg/0.5 ml in tce-d2 at 120° C. using a 90 degree pulse of 14 ⁇ sec, a spectral width of 12.8 kHz, an acquisition time of 2.6 sec and a recycle delay of 30 sec. A total of 8 transients were acquired. Spectra were referenced to tce-d2 at 5.928 ppm.
  • FIG. 1 also indicates the assignments of the various peaks. Using EGPEA (and other acrylates described above) separation of the homopolymer and copolymer peaks is clear and quantitative analysis of the mixture is possible.
  • a typical sample contained 310 mg polymer and 60 mg CrAcAc in TCB with a total volume of 3.1 mL (Varian recommended volume) in a 10 mm NMR tube; care was taken that the sample was very well mixed and uniform in consistency. Samples were preheated for at least 15 min. in the NMR before acquiring data. Data acquisition time was typically 10.5 hr per sample. The T1 values of the carbons of an ethylene/methyl acrylate copolymer sample were measured under these conditions to be all less than 0.9 s. The longest T1 measured was for the Bu+, EOC resonance at 14 ppm, which was 0.84 s. Spectra are referenced to the solvent—the TCB high field resonance at 127.918 ppm.
  • Integrals of unique carbons in each branch were measured and were reported as number of branches per 1000 methylenes. Counted in these methylenes are those in the backbone (main chain) and branches, but not methylenes in the alcohol portions of esters, for example the —O CH 2 CH 3 methylene in an ethyl ester. These integrals are accurate to +/ ⁇ 5% relative for abundant branches and +/ ⁇ 10 or 20% relative for branches present at less than 10 per 1000 methylenes.
  • FIG. 2 shows such a spectrum together with assignments of various carbon atoms.
  • GPC molecular weights are reported versus polystyrene standards. Unless noted otherwise, GPC's were run with RI detection at a flow rate of 1 mL/min at 135° C. with a run time of 30 min. Two columns were used: AT-806MS and WA/P/N 34200. A Waters RI detector was used and the solvent was TCB with 5 grams of BHT per 3.79 L. Dual UV/RI detection GPC was run in THF at rt using a Waters 2690 separation module with a Waters 2410 RI detector and a Waters 2487 dual absorbance detector. Two Shodex columns, KF-806M, were used along with one guard column, KF-G. In addition to GPC, molecular weight information was at times determined by 1 H NMR spectroscopy (olefin end group analysis) and by melt index measurements (g/10 min at 190° C.).
  • 0.0814 g (0.154 mmole) of the ligand precursor and 0.0366 g (0.077 mmole) of the allyl-Ni-bromide dimer (((2-MeO 2 C—C 3 H 4 )NiBr) 2 ) were mixed in 10 mL THF in a 50 ml RB flask and the mixture was stirred for 1 h. THF was removed in vacuo and the residue was extracted with ether. Upon removal of the ether, the product was washed with pentane. Yellow powder (0.0906 g, 0.133 mmole) was obtained in 87% yield.
  • benzoylisocyanate (0.1966 g, 1.336 mmole) was dissolved in 20 mL THF in a 100 mL RB flask. The solution was cooled to ca. ⁇ 30° C. in a freezer. (t-Bu) 2 PCH 2 Li (0.2220 g, 1.336 mmole) was added to the above cold solution under stirring. The mixture turned dark red. It was allowed to stir at RT for 4 h. The solution was then evaporated to dryness. To the ligand precursor (ca. 1.300 mmole) was added 20 mL THF. Under stirring, nickel allyl chloride dimer (0.1760 g, 0.6500 mmole) was added to the mixture.
  • Examples 121-150 are listed in Tables 16-20 below.
  • the structures for these compounds illustrate just one of the possible products and binding modes that may have formed during the synthesis of the ligand and the subsequent synthesis of the nickel compound and are not meant to be restrictive.
  • the polymerizations were carried out according to General Polymerization Procedure A. Varying amounts of acrylate homopolymer are present in some of the samples.
  • Tables 16-20 the yield of the polymer is reported in grams and includes the yield of the dominant ethylene/acrylate copolymer as well as the yield of any acrylate homopolymer that was formed. Molecular weights were determined by GPC, unless indicated otherwise. All copolymerizations were run for 18 h, unless otherwise noted.
  • a glass insert was loaded with the nickel compound and, optionally, a Lewis acid (e.g., BPh 3 or B(C 6 F 5 ) 3 ) and borate (e.g., NaBAF or LiBArF) and any other specified cocatalysts.
  • a Lewis acid e.g., BPh 3 or B(C 6 F 5 ) 3
  • borate e.g., NaBAF or LiBArF
  • Examples 151-439 are listed in Tables 21-57 below. They were carried out with nickel complexes 45-97 shown above. For each of 45-97 the counterion is BAF.
  • the polymerizations were carried out according to General Polymerization Procedure A. Varying amounts of acrylate homopolymer are present in some of the isolated polymers.
  • Tables 21-58 the yield of the polymer is reported in grams and includes the yield of the dominant ethylene/acrylate copolymer as well as the yield of any acrylate homopolymer that was formed. Molecular weights were determined by GPC, unless indicated otherwise. Mole percent acrylate incorporation and total Me were determined by 1 H NMR spectroscopy, unless indicated otherwise.
  • Mole percent acrylate incorporation is typically predominantly IC, unless indicated otherwise.
  • the LiB(C 6 F 5 ) 4 used included 2.5 equiv of Et 2 O. All copolymerizations were run for 18 h, unless otherwise noted.
  • the isolated polymers Due to the high acrylate concentration, the isolated polymers all contained some homopolymer.
  • the EGPEA used contained 100 ppm hydroquinone in addition to the NaBAF and 1,4-benzoquinone (BQ) inhibitors that were added to the individual runs.
  • alkylaluminum compounds are used as cocatalysts.
  • These alkylaluminums were purchased from commercial sources, PMAO-IP (97) (polymethylaluminoxane from Akzo-Nobel, Inc., 12.7 wt % aluminum in toluene, (0.88 g/ml at 30° C.)) or synthesized by literature methods, (AlMe 2 (Et 2 O) 2 )(MeB(C 6 F 5 ) 3 ) (98) (WO0011006), AlMe(2,6-t-Bu-4-Me(OC 6 H 2 )) 2 (99) (A. P. Shreve, et al., Organometallics, vol. 7, p. 409 (1988)). and (Al-i-Bu 2 (OC 6 F 5 )) 2 (100) (D. G. Hendershot, et al., Organometallics, vol. 10 p. 1917 (1991)).
  • transition metal complexes (101-117) are either isolated compounds or in situ generated from a combination of compounds. Such combinations are shown under the compound designation (number). Syntheses of compounds other than ⁇ -diimines or their complexes are described in the following references:
  • the solution was added to the glass insert and then cooled to ⁇ 30° C.
  • the insert was capped and placed into double ziplock bags. Outside the drybox the rack was transferred to a pressure tube and flushed with ethylene.
  • the pressure tube was pressurized with ethylene and heated to the desired temperature and mechanically shaken for the duration of time listed in the table.
  • the reaction solution was quenched with 30 mL of methanol or acidic methanol (10:90 HCl methanol solution) and the polymer was isolated by filtration, rinsed with additional methanol and dried under vacuum.
  • Table 58 contains examples with Ni catalysts, diimine with Ni(acac) 2 , and alkylaluminum cocatalysts for EGPEA and ethylene copolymerization. At these high ratios of Ni to salt and Al cocatalysts we had some significant acrylate homopolymerization.
  • the acrylate homopolymer was found in two forms, a powder which was a mixture of copolymer with some acrylate homopolymer as identified by 1 H NMR, and a gelatin consisting of acrylate homopolymer which was physically separated and not included in the polymer weight in the tables.
  • the solution volume was approximately 10 mL in each case, therefore, the solvent added was 10 mL minus the volume added for the liquid comonomer.
  • Table 59 shows examples of some of the better catalysts under conditions with low concentration of Ni and high concentration of salt and Al cocatalysts. In these examples consistently good yields of EGPEA/ethylene copolymer were obtained. Further characterization of these polymers is indicated by Mw from GPC as well as incorporation of acrylate (mole %) in the copolymer that was calculated from 1 H NMR spectra of the polymer.
  • Table 60 This table has very low Ni concentrations and more acrylate homopolymer and low yields of polymer are obtained overall.
  • Table 62 Examples for E-10-U copolymerizations with ethylene.
  • Table 64 Other catalysts for EGPEA copolymerization.
  • ND (not determined) indicates that the formation of excess acrylate homopolymer overlaps the region for determining copolymer content.
  • acrylate in the ethylene copolymer (Mol % Ac) the in chain (i) and end of chain (e) position is indicated.
  • THF solutions 0.0500 M
  • Table 65 Ninety-five isocyanates were prepared as THF solutions (0.0500 M) and are listed in Table 65. These solutions were prepared in glass vials capped with Teflon® lined silicone septa to maintain an inert atmosphere and prevent evaporation.
  • each sample was prepared by adding sequentially 150( ⁇ 3) ⁇ L of an isocyanate solution (0.0500 M in THF) followed by 150( ⁇ 3) ⁇ L of a solution of (t-Bu) 2 PCH 2 Li (0.0500 M in THF), followed by 150( ⁇ 3) ⁇ L of a solution of (NiCl( ⁇ 3 -C 3 H 5 )) 2 (0.0250 M in THF) to a septa sealed 2 mL glass vial. The solvent was then removed from each vial by purging with a nitrogen gas stream and each vial was then dried for 2 h in a vacuum chamber.
  • Each vial was placed in a high-pressure reactor. The reactor was pressurized to the desired pressure (typically 6.9 MPa or 1.0 MPa) with ethylene and kept at that pressure for 18 h. At the end of the run, the solvent was removed from each vial under vacuum. After this operation each vial was weighed to obtain a polymer yield.
  • Toluene was purified according to R. H. Grubbs et. al., Organometallics, 1996, 15, p. 1518-1520. Methyl acrylate was sparged with nitrogen and passed through a column of activated neutral alumina in the drybox before use. In a drybox 1.77 g NaBAF, B(C 6 F 5 ) 3 (see Table 66), methyl acrylate (see Table 66) and all but 20 mL of the toluene were combined. The total volume of the reaction mixture was 100 mL and the amount of methyl acrylate and toluene were calculated on this basis.
  • the autoclave was pressurized with ethylene to 350 to 690 kPa below the desired operating pressure (Table 66).
  • the catalyst addition cylinder was charged with ethylene to the desired operating pressure, and the catalyst solution was then pressure injected to begin the polymerization. Ethylene was fed to maintain a constant pressure.
  • the reaction was cooled to RT. All volatiles were removed from the reaction solution using a rotary evaporator. The evaporated residue was washed with three 50-100 mL portions of methanol with decanting of the methanol into a fritted glass filter after each wash. The methanol insoluble solids were then transferred to the filter with methanol and washed on the filter with additional methanol.
  • the solids were dried for 18 hours at 60° C. in a vacuum oven. Molecular weights of the isolated polymer samples were determined by GPC. 13 C NMR of the dried polymers was used to calculate the weight % of homopoly(methyl acrylate), the mole % MA content of the ethylene/methyl acrylate copolymer, and the amount of branching in the polymer. (See FIG. 3 for 13 C peak assignments and formulas for the mole % calculations.) Weight % calculations were done using the mole % values and the molecular weights of the components.
  • the additives were prepared as solutions (0.0375 M) in THF (Ex. 674-722), acetonitrile (Ex. 723-739), methanol (Ex. 740-754) and water (Ex. 755-758). These solutions were prepared in glass vials capped with Teflon® lined silicone to septa to maintain inert atmosphere and prevent evaporation.
  • the nickel compounds used are shown below.
  • Catalysts B and C may contain 0-2 equiv of LiCl and we have assumed 1 equiv for the purposes of calculating a molecular weight.
  • the septum cap was removed and the solvent was removed under a nitrogen gas stream and the sample was dried for 20 min in a vacuum chamber.
  • the vial was recapped with a septum cap.
  • Each vial was placed into a high-pressure reactor and pressurized with ethylene to the desired pressure and temperature for a total of 18 h. For ethylene polymerization experiments the volatiles were removed from each vial in a heated (approx.
  • Condition 1 Catalyst B with 5 equiv of additive and 0.300 mL of chlorobenzene. The polymerization was conducted at 6.9 MPa of ethylene at RT for 18 h.
  • Condition 4 Catalyst A with 1 equiv of additive, 5 equiv of B(C 6 F 5 ) 3 , 5 equiv of LiB(C 6 F 5 ) 4 and 0.300 mL of TCB solution (the TCB solution contained 20 volume % of EGPEA). The polymerization was conducted at 6.9 MPa of ethylene at 100° C. for 18 h.
  • Condition 7 Catalyst C with 1 equiv of additive, 5 equiv of B(C 6 F 5 ) 3 and 0.300 mL of chlorobenzene. The polymerization was conducted at 3.5 MPa of ethylene at RT for 18 h.
  • g Conditions 4-7 additive is Li[Al(OCPh(CF 3 ) 2 ) 4 ] synthesized by a literature method, T. J. Barbarich, Thesis, 1998, Colorado State University; h Conditions 5-7.
  • reaction mixture including catalyst, solvent, acrylate and cocatalysts was assembled inside a nitrogen filled drybox and placed in a 50 mL stainless steel pressure vessel. A stir bar was added and the vessel sealed and removed from the drybox where it was pressurized with ethylene to the desired pressure. The vessel was heated and stirred with a constant pressure of ethylene for the duration of the reaction.
  • Support A Inside a nitrogen filled drybox, dehydrated, spray-dried spherical silica (2 g, Grace XPO-2402, dehydrated to ⁇ 1 mmol OH/g silica) was placed in 6 mL dry toluene and AlMe3 (3 mL, 2M in hexane, Aldrich) added. The slurry was agitated by shaking for 30 min after which the solids were filtered, washed with pentane and dried under vacuum.
  • spherical silica 2 g, Grace XPO-2402, dehydrated to ⁇ 1 mmol OH/g silica
  • Support B Inside a nitrogen filled drybox, spray-dried spherical silica-alumina (1 g, Grace MS 13-1.10, dehydrated at 500° C.) was placed in 6 mL dry toluene and AlMe 3 (1.8 mL, 2M in hexane, Aldrich) added. The slurry was agitated by shaking for 30 min after which the solids were filtered, washed with pentane and dried under vacuum.
  • spherical silica-alumina 1 g, Grace MS 13-1.10, dehydrated at 500° C.
  • Catalyst I Support A (0.5 g) was added to a solution of 45 (76 mg, 0.05 mmol) in anhydrous toluene. The slurry was agitated by shaking for 30 min after which the solids were filtered away from the brown filtrate and dried under vacuum.
  • Catalyst VI Support B (0.25 g) was added to a solution of 45 (19 mg, 0.013 mmol) in anhydrous toluene. The slurry was agitated by shaking for 45 min after which the solids were filtered away from the dark green filtrate, washed with toluene and dried under vacuum.
  • Catalyst VII Support A (0.25 g) was added to a solution of 45 (19 mg, 0.013 mmol in anhydrous toluene. The slurry was agitated by shaking for 45 min after which the solids were filtered away from the light brown filtrate, washed with toluene and dried under vacuum.
  • Catalyst X Support A (0.25 g) was added to a solution of 45 (19 mg, 0.013 mmol) in anhydrous toluene. The slurry was agitated by shaking for 60 min after which the brown solids were filtered away from the green filtrate, washed with toluene and dried under vacuum.
  • Catalyst XI Support A was added to a solution of 45 (19 mg, 0.013 mmol) in anhydrous toluene. The slurry was agitated by shaking for 60 min after which the orange solids were filtered away from the orange filtrate, washed with toluene and dried under vacuum.
  • Catalyst XII Support A (0.25 g) was added to a solution of 129 (9.6 mg, 0.013 mmol) in anhydrous toluene. The slurry was agitated by shaking for 60 min after which the gray solids were filtered away from the purple filtrate, washed with toluene and dried under vacuum.
  • Catalyst XIII Support A (0.25 g) was added to a solution of 40 (5.6 mg, 0.013 mmol) in anhydrous toluene. The slurry was agitated by shaking for 60 min after which the orange solids were filtered away from the orange filtrate, washed with toluene and dried under vacuum.
  • Catalyst XIV Support A (0.25 g) was added to a solution of 21 (4.5 mg, 0.013 mmol) in anhydrous toluene. The slurry was agitated by shaking for 60 min after which the beige solids were filtered away from the filtrate, washed with toluene and dried under vacuum.
  • the solid catalyst and cocatalyst components (catalyst ⁇ 0.004 mmol, 0.177 g NaBAF, and optionally B(C 6 F 5 ) 3 ) were added to a glass insert.
  • Solvent anhydrous chlorobenzene, 9 mL
  • EGPEA (1 mL, filtered through basic alumina, Aldrich) were added last and the insert placed in a metal pressure vessel.
  • Some ethylene was admitted and the vessel was heated to 120° C. and then pressurized to 6.9 MPa with ethylene and agitated for 18 h. After this time the reactor was cooled, the pressure released and the contents of the insert placed in stirring methanol to precipitate polymer product. The polymeric product was then filtered, washed well and dried. Results are given in Table 79.
  • the polymerizations were carried out according to General Polymerization Procedure A. Varying amounts of acrylate homopolymer are s present in some of the isolated polymers. For acrylate copolymers, the yield of the polymer is reported in grams and includes the yield of the dominant ethylene/acrylate copolymer as well as the yield of any acrylate homopolymer that was formed. Molecular weights were determined by GPC, unless indicated otherwise. Mole percent acrylate incorporation and total Me were determined by 1 H NMR spectroscopy, unless indicated otherwise. Mole percent acrylate incorporation is typically predominantly IC, unless indicated otherwise. The LiB(C 6 F 5 ) 4 used (LiBArF) included 2.5 equiv of Et 2 O.
  • 2,6-Bis-dimethoxyphenyllithium was prepared from 14.18 g (0.103 mole) of 1,3-dimethoxybenzene, 77 mL of a 1.6 M solution of BuLi in hexanes and 0.23 mL of N,N,N′,N′-tetramethylethylenediamine in dry diethyl ether (72 mL).
  • Dichloromethylphosphine (5.0 g, 0.04276 mole) was added at 0° C., and the reaction mixture was stirred at room temperature overnight. Methanol (20 mL) was added, and the mixture was concentrated to about half its original volume under reduced pressure.
  • acrylate incorporation was determined by assuming that the copolymer was derived from just ethylene and acrylate.
  • b The larger number of butyl branches relative to ethyl branches is consistent with 1-hexene incorporation.
  • the ligand 7 (0.1102 g, 0.212 mmol), allyl-Ni dimer ([(2-MeO 2 C—C 3 H 4 )NiBr] 2 ) (0.0505 g, 0.106 mmol) and Na(tetra[3,5-bis(trifluoromethyl)]-phenylborane) (0.1879 g, 0.212 mmol) were mixed in 20 mL of ether in a 50 mL of round bottom flask. The reaction mixture was stirred at room temperature for one hour and filtered through a Celite plug on a frit. Removal of the solvent yields a brown powder that was then rinsed with pentane and dried under high vacuum.
  • Reaction conditions for polymerization were: 1000 psi ethylene, 120° C., 18 hours.

Abstract

Transition metal complexes of selected monoanionic phosphine ligands, which also contain a selected Group 15 or 16 (IUPAC) element and which are coordinated to a Group 3 to 11 (IUPAC) transition metal or a lanthanide metal, are polymerization catalysts for the (co)polymerization of olefins such as ethylene and α-olefins, and the copolymerization of such olefins with polar group-containing olefins. These and other nickel complexes of neutral and monoanionic bidentate ligands copolymerize ethylene and polar comonomers, especially acrylates, at relatively high ethylene pressures and surprisingly high temperatures, and give good incorporation of the polar comonomers and good polymer productivity. These copolymers are often unique structures, which are described.

Description

    CROSS-REFERENCE TO RELATED APPLICATION
  • This application claims priority under 35 U.S.C. §119 from U.S. National application Ser. No. 09/871,099 (filed May 31, 2001), U.S. Provisional Application Ser. Nos. 60/208,087 (filed May 31, 2000), 60/211,601 (filed Jun. 15, 2000), 60/214,036 (filed Jun. 23, 2000) and 60/264,537 (filed Jan. 25, 2001), all of which are incorporated by reference herein as if fully set forth.
  • FIELD OF THE INVENTION
  • Transition metal complexes of selected monoanionic phosphine ligands, which also contain a selected Group 15 or 16 (IUPAC) element and which are coordinated to a Group 3 to 11 (IUPAC) transition metal or a lanthanide metal, are polymerization catalysts for the (co)polymerization of olefins such as ethylene and α-olefins, and the copolymerization of such olefins with polar group-containing olefins. In general, nickel complexes of neutral and monoanionic bidentate ligands copolymerize ethylene and polar comonomers at relatively high ethylene pressures and surprisingly high temperatures.
  • TECHNICAL BACKGROUND
  • Polyolefins are very important items of commerce, large quantities of various grades of these polymers being produced annually for a large number of uses, such as packaging films, elastomers and moldings. There are many different methods for making such polymers, including many used commercially, such as free radical polymerization, and many so-called coordination catalysts such as Ziegler-Natta-type and metallocene-type catalysts. Each of these catalyst systems has its advantages and disadvantages, including cost of the polymerization and the particular monomers (co) polymerized, and structure of the polyolefin produced. Due to the importance of polyolefins, new catalyst systems, which are economical and/or produce new types of polyolefins are constantly being sought.
  • U. Klabunde, et al., J. Mol. Cat., vol. 41, p. 123-134 (1987) describes the polymerization of ethylene with nickel complex catalysts having certain phosphorous-oxygen ligands. The catalysts and processes of this reference are different than those of the present invention.
  • U. Muller, et al., Angew. Chem. Int. Ed. Eng., vol. 28, p. 1011-1013 report on the interaction of Ni(COD)2 (COD is cyclooctadiene), ethylene and a phosphorous-oxygen compound which may be a ligand. There is no evidence for polymerization.
  • K. A. Ostoja Starzewski, et al., Angew. Chem., Intl. Ed. Engl., vol. 26, p. 63 (1987) reports on the polymerization of ethylene using certain phosphorous-oxygen ylides and Ni(COD)2. Ylides are not used herein.
  • W. Keim, Angew. Chem. Int. Ed. Engl., vol. 22, p. 503 (1983) reports the use of nickel complexes of certain arsenic-oxygen compounds to oligomerize ethylene. Higher molecular weight polymers are not reported.
  • P. Braunstein, et al., J. Chem. Soc., Dalton Trans., 1996, p. 3571-3574 report that nickel complexes of certain phosphorous-nitrogen compounds oligomerize ethylene to low molecular weight olefins. Higher molecular weight polymers are not reported.
  • U.S. Pat. No. 5,714,556, U.S. Pat. No. 6,060,569, U.S. Pat. No. 6,174,975 and S. D. Ittel, et al., Chem. Rev., vol. 100, p. 1169-1203 (2000) (and references therein), report the use of transition metal complexes of various phosphorous-containing ligands as catalysts for olefin polymerizations. The catalysts and processes of these references are different than those of the present invention.
  • One of the advantages of some late transition metal catalysts is that they can incorporate polar comonomers, for example olefinic esters, in copolymerizations with hydrocarbon olefins, especially ethylene. Palladium complexes are particularly noted for this ability, while nickel complexes often do not copolymerize polar comonomers or do so only very poorly, see for example U.S. Pat. No. 5,866,663.
  • It has also been discovered that using relatively high temperatures and high hydrocarbon olefin (ethylene) pressures often improves the incorporation of the polar comonomer in the polymer formed as well as increasing the productivity of the polymerization catalyst. This is surprising in view of the observations in the literature that increasing temperatures usually decrease the productivity of many nickel polymerization catalysts; see for instance U.S. Pat. No. 6,127,497 and WO00/50470.
  • JP-A-11292918 reports the copolymerization of methyl acrylate and ethylene using certain nickel complexes as polymerization catalysts. These polymerization are carried out at low temperatures and pressures, and mostly the incorporation of methyl acrylate is reported to be very low, and the polymers have low branching levels.
  • A. Michalak, et al., Organometallics, vol. 20, p. 1521-1532 (2001) conclude that, using computational methods, nickel complexes having neutral bidentate ligands such as α-dimines should not copolymerize ethylene and polar comonomers such as methyl acrylate.
  • Other references of interest concerning transition metal complexes and/or their use as polymerization catalysts are Keim, Organometallics, vol. 2, p. 594 (1983); I. Hirose, et al., J. Mol. Cat., vol. 73, p. 271 (1992); and R. Soula, et al., Macromolecules, vol. 34, p. 2438-2442. None of the complexes or processes with them is claimed herein.
  • Other references of interest concerning polar copolymers include U.S. Pat. No. 3,481,908, U.S. Pat. No. 3,278,495 and M. M. Marques, et al., Poly. Int., 50, 579-587 (2001).
  • All of the above publications are incorporated by reference herein for all purposes as if fully set forth.
  • SUMMARY OF THE INVENTION
  • This invention concerns a “first” process for the polymerization of olefins, comprising the step of contacting, at a temperature of about −100° C. to about +200° C., at least one polymerizable olefin with an active polymerization catalyst comprising a Group 3 through 11 (IUPAC) transition metal or a lanthanide metal complex of a ligand of the formula (I), (II) or (XII)
  • Figure US20100222531A1-20100902-C00001
  • wherein:
  • R1 and R2 are each independently hydrocarbyl, substituted hydrocarbyl or a functional group;
  • Y is CR11R12, S(T), S(T)2, P(T)Q, NR36 or NR36NR36;
  • X is O, CR5R6 or NR5;
  • A is O, S, Se, N, P or As;
  • Z is O, Se, N, P or As;
  • each Q is independently hydrocarbyl or substituted hydrocarbyl;
  • R3, R4, R5, R6, R11 and R12 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
  • R7 is hydrogen, hydrocarbyl;substituted hydrocarbyl or a functional group, provided that when Z is O or Se, R7 is not present;
  • R8 and R9 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
  • R10 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
  • each T is independently ═O or ═NR30;
  • R30 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
  • R31 and R32 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
  • R33 and R34 are each independently hydrocarbyl or substituted hydrocarbyl, provided that each is independently an aryl substituted in at least one position vicinal to the free bond of the aryl group, or each independently has an Es of −1.0 or less;
  • R35 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group, provided that when A is O, S or Se, R35 is not present;
  • each R36 is independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
  • m is 0 or 1;
  • s is 0 or 1;
  • n is 0 or 1; and
  • q is 0 or 1;
  • and provided that:
  • any two of R3, R4, R5, R6, R8, R9, R11 and R12 bonded to the same carbon atom taken together may form a functional group;
  • any two R1, R2, R3, R4, R5, R6, R7, R8, R9, R11, R12, R31, R32, R33, R34, R35, and R36 bonded to the same atom or vicinal to one another taken together may form a ring; and
  • when said ligand is (I), Y is C(O), Z is O, and R1 and R2 are each independently hydrocarbyl, then R1 and R2 are each independently an aryl substituted in one position vicinal to the free bond of the aryl group, or R1 and R2 each independently have an Es of −1.0 or less.
  • Also described herein is a “second” process for the polymerization of olefins, comprising the step of contacting, at a temperature of about −100° C. to about +200° C., at least one polymerizable olefin with a compound of the formula (IV), (V) or (XIII)
  • Figure US20100222531A1-20100902-C00002
  • wherein R1, R2, R3, R4, R5, R6, R7, R8, R9, R10, R11, R12, R30, R31, R32, R33, R34, R35, R36, Y, X, A, Z, Q, T, m, s, n and q are as defined above;
  • M is a Group 3 through Group 11 transition metal or a lanthanide metal; and
  • L1 is a monodentate monoanionic ligand into which an ethylene molecule may insert between L1 and M, and L2 is a monodentate neutral ligand which may be displaced by ethylene or an empty coordination site, or L1 and L2 taken together are a monoanionic bidentate ligand into which ethylene may insert between said monoanionic bidentate ligand and said nickel atom, and each L3 is independently a monoanionic ligand and z is the oxidation state of M minus 2; and provided that;
  • any two of R3, R4, R5, R6, R8, R9, R11 and R12 bonded to the same carbon atom taken together may form a functional group;
  • any two R1, R2, R3, R4, R5, R6, R7, R8, R9, R11, R12, R31, R32, R34, R35 and R36 bonded to the same atom or vicinal to one another taken together may form a ring; and
  • when said compound is (IV), Y is C(O), Z is O, and R1 and R2 are each independently hydrocarbyl, then R1 and R2 are each independently an aryl substituted in one position vicinal to the free bond of the aryl group, or R1 and R2 each independently have an Es of −1.0 or less.
  • In the above-mentioned processes, (IV), (V) and (XIII) and/or the transition metal complexes of (I), (II) or (XII) may in and of themselves be active catalysts, or may be “activated” by contact with a cocatalyst/activator as further described below.
  • The present invention also concerns the ligands of the formulas (I), (II) and (XII) above, transition metal complexes thereof, and polymerization catalyst components comprising these transition metal complexes.
  • Also disclosed herein is a “third” process for forming an ethylene/polar monomer copolymer, comprising the step of contacting, under polymerizing conditions, a nickel complex of a bidentate neutral ligand or a bidentate monoanionic ligand, with a monomer component comprising one or more hydrocarbon olefins and one or more polar comonomers (and other optional components such as, for example, one or more cocatalysts and/or other additives), at a temperature of about 60° C. to about 170° C., provided that when CO is present, at least one other polar monomer is present.
  • This third process also relates to an improved process for forming an ethylene/polar monomer copolymer, said process comprising the step of contacting, under polymerizing conditions, a transition metal complex of a bidentate neutral ligand or a bidentate monoanionic ligand, with a monomer component comprising one or more hydrocarbon olefins and one or more polar comonomers (and other optional components such as, for example, one or more cocatalysts and/or other additives), wherein the improvement comprises that the transition metal is nickel, and that the monomer component and complex are contacted at a temperature of about 60° C. to about 170° C., provided that when CO is present, at least one other polar monomer is present.
  • This invention further concerns a “first” polymer, consisting essentially of repeat units derived from ethylene, and one or more polar olefins of the formula H2C═CHC(O)R32, wherein R32 is —OR34 or any group readily derivable from it, and R34 is hydrocarbyl or substituted hydrocarbyl, wherein:
  • said polymer contains “first branches” of the formula —(CH2)nCH3 and “second branches” of the formula —(CH2)mC(O)R32, wherein m and n are independently zero or an integer of 1 or more; and
  • said polymer has the following structural characteristics:
      • (a) one or both of:
        • (1) the ratio of first branches wherein n is 0 to first branches wherein n is 1 is about 3.0 or more; and
        • (2) the ratio of first branches wherein n is 0 to first branches wherein n is 3 is 1.0 or more; and
      • (b) one or both of:
        • (1) the total number of first branches in which n is 0, 1, 2 and 3 in said polymer is about 10 or more per 1000 CH2 groups; and
        • (2) the incorporation of repeat units derived from H2C═CHC(O)R32 is 0.3 mole percent or more based on the total repeat units derived from the hydrocarbonolefin and H2C═CHC(O)R32.
  • This invention also concerns a “second” polymer, consisting essentially of repeat units derived from:
  • one or more hydrocarbon olefins, such as ethylene, and
  • one or more polar olefins of the formula H2C═CHC(O)R32, wherein R32 is —OR34, or any group readily derivable from it, and R34 is hydrocarbyl or substituted hydrocarbyl;
  • wherein in said polymer incorporation of repeat units derived from H2C═CHC(O)R32 is 0.3 mole percent or more based on the total repeat units; and
  • wherein said polymer has one or both of the following structural characteristics:
  • at least 5 mole percent of said repeat units derived from H2C═CHC(O)R32 are present in said polymer as end groups; and
  • said end groups are at least 0.001 mole percent of the total repeat units in said polymer;
  • and provided that said end groups have the formula

  • ˜˜˜˜˜˜˜-HC═CH—C(O)—R32
  • wherein ˜˜˜˜˜˜˜ is the remainder of the polymer chain of said end group.
  • This invention still further concerns a “third” polymer, consisting essentially of:
  • repeat units derived from ethylene;
  • repeat units derived from one or more monomers of the formula H2C═CHC(O)R32, wherein each R32 is independently —OR34 or any group readily derivable from it, and each R34 is independently hydrocarbyl or substituted hydrocarbyl, and
  • repeat units derived from one or more alpha-olefins of formulas H2C═CH—(CH2)t—H and/or H2C═CH—R75-G, wherein t is an integer of 1 to 20, R75 is alkylene or substituted alkylene, and G is an inert functional group.
  • These and other features and advantages of the present invention will be more readily understood by those of ordinary skill in the art from a reading of the following detailed description. It is to be appreciated that certain features of the invention, which are, for clarity, described below in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 shows the 13C NMR of a copolymer of ethylene and 2-phenoxyethyl acrylate (EGPEA) which also contains some homopolymer of EGPEA, and which shows assignments of various NMR peaks.
  • FIG. 2 shows the 13C NMR of a copolymer of ethylene and hexyl acrylate (HA) which also contains some homopolymer of HA, and which shows assignments of various NMR peaks.
  • FIG. 3 shows the 13C NMR of a copolymer of ethylene and methyl acrylate (MA) which also contains some homopolymer of MA, and which shows assignments of various NMR peaks. Also shown are formulas for calculations of the amount of homopolymer present and the amount of MA incorporated in the copolymer.
  • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • Herein, certain terms are used. Some of them are:
  • A “hydrocarbyl group” is a univalent group containing only carbon and hydrogen. As examples of hydrocarbyls may be mentioned unsubstituted alkyls, cycloalkyls and aryls. If not otherwise stated, it is preferred that hydrocarbyl groups (and alkyl groups) herein contain 1 to about 30 carbon atoms.
  • By “substituted hydrocarbyl” herein is meant a hydrocarbyl group that contains one or more substituent groups that are inert under the process conditions to which the compound containing these groups is subjected (e.g., an inert functional group, see below). The substituent groups also do not substantially detrimentally interfere with the polymerization process or operation of the polymerization catalyst system. If not otherwise stated, it is preferred that substituted hydrocarbyl groups herein contain 1 to about 30 carbon atoms. Included in the meaning of “substituted” are chains or rings containing one or more heteroatoms, such as nitrogen, oxygen and/or sulfur, and the free valence of the substituted hydrocarbyl may be to the heteroatom. In a substituted hydrocarbyl, all of the hydrogens may be substituted, as in trifluoromethyl.
  • By “(inert) functional group” herein is meant a group other than hydrocarbyl or substituted hydrocarbyl that is inert under the process conditions to which the compound containing the group is subjected. The functional groups also do not substantially interfere with any process described herein that the compound in which they are present may take part in. Examples of functional groups include halo (fluoro, chloro, bromo and iodo), and ether such as —OR22 wherein R22 is hydrocarbyl or substituted hydrocarbyl. In cases in which the functional group may be near a transition metal atom the functional group should not coordinate to the metal atom more strongly than the groups in those compounds are shown as coordinating to the metal atom, that is they should not displace the desired coordinating group.
  • By a “cocatalyst” or a “catalyst activator” is meant a compound that reacts with a transition metal compound to form an activated catalyst species. One such catalyst activator is an “alkyl aluminum compound” which, herein, is meant a compound in which at least one alkyl group is bound to an aluminum atom. Other groups such as, for example, alkoxide, hydride and halogen may also be bound to aluminum atoms in the compound.
  • By “neutral Lewis base” is meant a compound, which is not an ion that can act as a Lewis base. Examples of such compounds include ethers, amines, sulfides and organic nitriles.
  • By “neutral Lewis acid” is meant a compound, which is not an ion that can act as a Lewis acid. Examples of such compounds include boranes, alkylaluminum compounds, aluminum halides and antimony [V] halides.
  • By “cationic Lewis acid” is meant a cation that can act as a Lewis acid. Examples of such cations are lithium, sodium and silver cations.
  • By an “empty coordination site” is meant a potential coordination site on a transition metal atom that does not have a ligand bound to it. Thus if an olefin molecule (such as an ethylene molecule) is in the proximity of the empty coordination site, the olefin molecule may coordinate to the metal atom.
  • By a “ligand into which an olefin molecule may insert between the ligand and a metal atom”, or a “ligand that may add to an olefin”, is meant a ligand coordinated to a metal atom which forms a bond (L-M) into which an olefin molecule (or a coordinated olefin molecule) may insert to start or continue a polymerization. For instance, with ethylene this may take the form of the reaction (wherein L is a ligand):
  • Figure US20100222531A1-20100902-C00003
  • By a “ligand which may be displaced by an olefin” is meant a ligand coordinated to a transition metal which, when exposed to the olefin (such as ethylene), is displaced as the ligand by the olefin.
  • By a “monoanionic ligand” is meant a ligand with one negative charge.
  • By a “neutral ligand” is meant a ligand that is not charged.
  • By “aryl” is meant a monovalent aromatic group in which the free valence is to the carbon atom of an aromatic ring. An aryl may have one or more aromatic rings that may be fused, connected by single bonds or other groups.
  • By “substituted aryl” is meant a monovalent aromatic group substituted as set forth in the above definition of “substituted hydrocarbyl”. Similar to an aryl, a substituted aryl may have one or more aromatic rings that may be fused, connected by single bonds or other groups; however, when the substituted aryl has a heteroaromatic ring, the free valence in the substituted aryl group can be to a heteroatom (such as nitrogen) of the heteroaromatic ring instead of a carbon.
  • By “aryl substituted in at least one position vicinal to the free bond of the aryl group,” is meant the bond to one of the carbon atoms next to the free valence of the aryl group is something other than hydrogen. For example for a phenyl group, it would mean the 2 position of the phenyl group would have something other than hydrogen attached to it. A 1-naphthyl group already has something other than hydrogen attached to one of the vicinal carbon atoms at the fused ring junction, while a 2-napthyl group would have to be substituted in either the 1 or 3 positions to meet this limitation. A preferred aryl substituted in at least one position vicinal to the free bond of the aryl group is a phenyl group substituted in the 2 and 6 positions, and optionally in the other positions.
  • “Alkyl group” and “substituted alkyl group” have their usual meaning (see above for substituted under substituted hydrocarbyl). Unless otherwise stated, alkyl groups and substituted alkyl groups preferably have 1 to about 30 carbon atoms.
  • By a “styrene” herein is meant a compound of the formula
  • Figure US20100222531A1-20100902-C00004
  • wherein R43, R44, R45, R46 and R47 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group, all of which are inert in the polymerization process. It is preferred that all of R43, R44, R45, R46 and R47 are hydrogen. Styrene (itself) is a preferred styrene.
  • By a “norbomene” is meant a compound of the formula
  • Figure US20100222531A1-20100902-C00005
  • wherein R40 is hydrogen or hydrocarbyl containing 1 to 20 carbon atoms. It is preferred that R40 is hydrogen or alkyl, more preferably hydrogen or n-alkyl, and especially preferably hydrogen. The norbornene may be substituted by one or more hydrocarbyl, substituted hydrocarbyl or functional groups in the R40 or other positions, with the exception of the vinylic hydrogens, which remain. Norbornene (itself), dimethyl endo-norbomene-2,3-dicarboxylate and t-butyl 5-norbomene-2-carboxylate are preferred norbomenes, with norbomene (itself) being especially preferred.
  • By a “π-allyl group” is meant a monoanionic ligand comprised of 1 sp3 and two sp2 carbon atoms bound to a metal center in a delocalized η3 fashion indicated by
  • Figure US20100222531A1-20100902-C00006
  • The three carbon atoms may be substituted with other hydrocarbyl groups or functional groups.
  • “Vinyl group” has its usual meaning.
  • By a “hydrocarbon olefin” is meant an olefin containing only carbon and hydrogen.
  • By a “polar (co)monomer” or “polar olefin” is meant an olefin that contains elements other than carbon and hydrogen. In a “vinyl polar comonomer,” the polar group is attached directly to a vinylic carbon atom, as in acrylic monomers. When copolymerized into a polymer the polymer is termed a “polar copolymer”. Useful polar comonomers are found in U.S. Pat. No. 5,866,663, WO9905189, WO9909078 and WO9837110, and S. D. Mel, et al., Chem. Rev., vol. 100, p. 1169-1203(2000), all of which are incorporated by reference herein for all purposes as if fully set forth. Also included as a polar comonomer is CO (carbon monoxide).
  • By a “bidentate” ligand is meant a ligand that occupies two coordination sites of the same transition metal atom in a complex.
  • By “under polymerization conditions” is meant the conditions for a polymerization that are usually used for the particular polymerization catalyst system being used. These conditions include things such as pressure, temperature, catalyst and cocatalyst (if present) concentrations, the type of process such as batch, semi batch, continuous, gas phase, solution or liquid slurry etc., except as modified by conditions specified or suggested herein. Conditions normally done or used with the particular polymerization catalyst system, such as the use of hydrogen for polymer molecular weight control, are also considered “under polymerization conditions”. Other polymerization conditions such as presence of hydrogen for molecular weight control, other polymerization catalysts, etc., are applicable with this polymerization process and may be found in the references cited herein.
  • By “Es” is meant a parameter to quantify steric effects of various groupings, see R. W. Taft, Jr., J. Am. Chem. Soc., vol. 74, p. 3120-3128 (1952), and M. S. Newman, Steric Effects in Organic Chemistry, John Wiley & Sons, New York, 1956, p. 598-603, which are both hereby included by reference. For the purposes herein, the Es values are those described for o-substituted benzoates in these publications. If the value of Es for a particular group is not known, it can be determined by methods described in these references.
  • The transition metals preferred herein in the first and second processes are in Groups 3 through 11 of the periodic table (IUPAC) and the lanthanides, especially those in the 4th, 5th, 6th and 10th periods. Suitable transition metals include Ni, Pd, Cu, Pt, Fe, Co, Ti, Zr, V, Hf, Cr, Ru, Rh and Re, with Ni, Ti, Zr, Cu and Pd being more preferred, and Ni, Ti and Zr being especially preferred. Preferred oxidation states for some of the transition metals are Ni[II], Ti[IV], Zr[IV], and Pd[II].
  • For ligand (I), Table 1 gives preferred structures. For ligand (II), Table 2 gives preferred structures. In both tables, H is hydrogen, HC is hydrocarbyl, SHC is substituted hydrocarbyl and FG is functional group.
  • TABLE 1
    m n X Z R3 R4 R5 R6 R7 R11 R12
    Zero Zero N HC, SHC HC, SHC H, HC,
    SHC
    Zero Zero O HC, SHC HC, SHC,
    FG
    Zero 1 O H H HC, SHC, HC, SHC,
    FG FG
    Zero 1 N H H HC, SHC H, HC, H, HC,
    SHC, FG SHC, FG
    Zero 1 S H H HC, SHC, HC, SHC,
    FG FG
    1 Zero O O H, HC, H, HC, H, HC, H, HC,
    SHC SHC SHC SHC
    1 1 CR5R6 O H, HC, H, HC, H H H, HC, H, HC,
    SHC SHC SHC SHC
    1 1 CR5R6 N H, HC, H, HC, H H HC, SHC H, HC, H, HC,
    SHC SHC SHC SHC
  • TABLE 2
    q R8 R9 R10
    Zero HC, SHC
    1 H, HC H, HC HC, SHC
  • In all preferred (I) and (II) (and by reference corresponding structures (IV) and (V), respectively), R1 and R2 are t-butyl, aryl or substituted aryl, more preferably t-butyl, and 2,6-disubstituted phenyl, especially 2,6-dimethoxyphenyl. It is believed that in most of the ligands it is preferred that R1 and R2 be relatively sterically bulky groups, for example t-butyl. Thus, for instance, 2,6-dimethylphenyl to would often be favored over phenyl for R1 and R2. Thus R1 and R2 may, for example, be isopropyl, phenyl, substituted phenyl, aryl, substituted aryl, cyclohexyl, t-butyl or 2-octyl. In another preferred form, R1 and R2 are independently aryl substituted in one position vicinal to the free bond of the aryl group, or R1 and R2 each independently have an Es of −1.0 or less, or both. By both means they may be aryl substituted in one position vicinal to the free bond of the aryl group, and also have an Es of −1.0 or less.
  • Any two of R3, R4, R5, R6, R8, R9, R11 and R12 bonded to the same carbon atom taken together may form a functional group. By this is meant, for instance, two of these bonds may form part of an oxo (keto) group, ═O, or an imino ═N—R, wherein R is hydrocarbyl group. Preferred types of functional groups (single or double bonded) include oxo, —C(O)R13 and —CO2R13, wherein R13 is hydrocarbyl or substituted hydrocarbyl.
  • In (I) or (IV) the following structures are preferred:
  • the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 is hydrocarbyl or substituted hydrocarbyl, R12 is hydrocarbyl, substituted hydrocarbyl or a functional group, and Z is O; or
  • the transition metal is Ti, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 is hydrocarbyl or substituted hydrocarbyl, R12 is hydrocarbyl, substituted hydrocarbyl or a functional group, and Z is O; or
  • the transition metal is Zr, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 is hydrocarbyl or substituted hydrocarbyl, R12 is hydrocarbyl, substituted hydrocarbyl or a functional group, and Z is O; or
  • the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, R7 is hydrocarbyl or substituted hydrocarbyl, Y is CR11R12, R11 is hydrogen, R12 is hydrocarbyl or substituted hydrocarbyl, and Z is N; or
  • the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 and R12 taken together are oxo, and Z is O; or
  • the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, R7 is hydrocarbyl or substituted hydrocarbyl, Y is CR11R12, R11 and R12 taken together are oxo, and Z is N; or
  • the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is S(T), T is ═O and Z is O; or
  • the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is S(T), T is ═N-silyl, Z is N and R7 is silyl; or
  • the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is S(T), T is ═O, Z is N, and R7 is hydrocarbyl or substituted hydrocarbyl; or
  • the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 and R12 taken together are a ring and Z is O; or
  • the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 and R12 taken together are N-hydrocarbyl- or N-substituted hydrocarbylimino, Z is N and R7 is hydrocarbyl or substituted hydrocarbyl; or
  • the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is S(T), T is ═O and Z is 0; or
  • the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 and R12 taken together are sulfo, Z is N and R7 is hydrocarbyl or substituted hydrocarbyl.
  • In (II) or (V), it is preferred that the transition metal is Ni, q is 0 or 1, R8 and R9 are hydrogen and R10 is hydrocarbyl or substituted hydrocarbyl.
  • In (XII) (and by reference corresponding structure (XIII)), R33 and R34 are preferably t-butyl, aryl (other than phenyl) or substituted aryl, more preferably t-butyl and 2,6-disubstituted phenyl, especially 2,6-dimethoxyphenyl. It is believed that in most of the ligands it is preferred that R33 and R34 be relatively sterically bulky groups, for example t-butyl. Thus, for instance, 2,6-dimethylphenyl would often be favored over 2-methylphenyl for R33 and R34. Thus R33 and R34 may, for example, be isopropyl, aryl (other than phenyl), substituted aryl, cyclohexyl, t-butyl or 2-octyl. In another preferred form R33 and R34 are independently aryl substituted in one position vicinal to the free bond of the aryl group, or R33 and R34 each independently have an Es of −1.0 or less, or both. By both means they may be aryl substituted in one position vicinal to the free bond of the aryl group, and also have an Es of −1.0 or less.
  • As examples of useful groups R31 and R32 may be mentioned hydrogen, aryl, substitued aryl, oxygen and nitrogen based functional groups and SO3Na, as well as when R31 and R32 taken together form a ring, for example, an aromatic or non-aromatic ring, which may include one or more heteroatoms.
  • Other preferences include when A is O and s is 0.
  • In (IV), (V) and (XIII), useful groups L1 include hydrocarbyl and substituted hydrocarbyl (especially phenyl and alkyl, and particularly phenyl, methyl, hydride and acyl). Useful groups for L2 include phosphine such as triphenylphosphine, nitrile such as acetonitrile, ethers such as ethyl ether, pyridine, and tertiary alkylamines such as triethylamine and TMEDA (N,N,N′,N′-tetramethyl-1,2-ethylenediamine). Alternatively L1 and L2 taken together may be a π-allyl or π-benzyl group such as
  • Figure US20100222531A1-20100902-C00007
  • wherein R is hydrocarbyl, and π-allyl and π-benzyl groups are preferred.
  • In (IV), (V) and (XIII), when an olefin (such as ethylene) may insert between L1 and the transition metal atom, and L2 is an empty coordination site or is a ligand which may be displaced by an olefin (such as ethylene), or L1 and L2 taken together are a bidentate monoanionic ligand into which an olefin (such as ethylene) may be inserted between that ligand and the transition metal atom, (IV), (V) and (XIII) may by themselves catalyze the polymerization of an olefin.
  • Examples of L1 which form a bond with the metal into which ethylene may insert between it and the transition metal atom are hydrocarbyl and substituted hydrocarbyl, especially phenyl and alkyl, and particularly methyl, hydride and acyl. Ligands L2 which ethylene may displace include phosphine such as triphenylphosphine, nitrile such as acetonitrile, ether such as ethyl ether, pyridine, tertiary alkylamines such as TMEDA, and other olefins. Ligands in which L1 and L2 taken together are a bidentate monoanionic ligand into which ethylene may insert between that ligand and the transition metal atom include π-allyl- or π-benzyl-type ligands (in this instance, sometimes it may be necessary to add a neutral Lewis acid cocatalyst such as triphenylborane or tris(pentafluoro-phenyl)borane of a cationic Lewis acid such as Li30 to initiate the polymerization, see for instance previously incorporated U.S. Pat. No. 6,174,975). For a summary of which ligands ethylene may insert into (between the ligand and transition metal atom) see for instance J. P. Collman, et al., Principles and Applications of Orcianotransition Metal Chemistry, University Science Books, Mill Valley, Calif., 1987, included herein by reference.
  • If for instance the ligand in the location of L1 is not a ligand into which ethylene may insert between it and the transition metal atom, it may be possible to add a cocatalyst which may convert it into L1 a ligand which will undergo such an insertion. Thus if the ligand in the location of L1 is halo such as chloride or bromide, a carboxylate, acetylacetonate or an alkoxide, it may be converted to hydrocarbyl such as alkyl by use of a suitable alkylating agent such as an alkylaluminum compound, a Grignard reagent or an alkyllithium compound. It may be converted to hydride by use of a compound such as sodium borohydride.
  • As indicated above, when L1 and L2 taken together are a monoanionic bidentate ligand, a cocatalyst (sometimes also called an activator) which is an alkylating or hydriding agent is also typically present in the olefin polymerization. A preferred cocatalyst is an alkylaluminum compound, and useful alkylaluminum compounds include trialkylaluminum compounds such as triethylaluminum, trimethylaluminum and tri-i-butylaluminum, alkyl aluminum halides such as diethylaluminum chloride and ethylaluminum dichloride, and aluminoxanes such as methylaluminoxane. More than one such cocatalyst may be used in combination.
  • Preferred for L3 are ligands of the type above described for L1.
  • The ligands (I), (II) and (XIII) may be synthesized by a variety of methods, depending on the particular ligand desired. The synthesis of many specific ligands is illustrated in the Examples. Many of these syntheses are accomplished through the use of R2PLi or R2PCH2Li. More generally speaking, the synthesis of various types of ligands is illustrated in the schemes shown below. In these schemes, each R independently represents hydrocarbyl or substituted hydrocarbyl, and each R′ independently represent hydrogen, hydrocarbyl or substituted hydrocarbyl.
  • Figure US20100222531A1-20100902-C00008
  • In Scheme 1 one may substitute an imine for the ketone R′2CO and obtain a final product in which Z is nitrogen rather than oxygen. In another variation of Scheme 1 one can react R2PH with an acrylonitrile, followed by reaction with R′MgX (addition across the nitrile bond) and then ((allyl)NiCl)2 to form the 6-membered metallocycle in which Z is nitrogen. To obtain compounds in which Z is not nitrogen or oxygen, one can use analogous compounds containing the appropriate element for Z. As shown in Scheme 2, (II) can exist in isomeric forms, and the formula for any of the forms represents all of the isomeric forms.
  • Figure US20100222531A1-20100902-C00009
  • is Scheme 2 shows the synthesis of (II). Appropriate substitution (as in all these synthesis schemes) in these compounds may be obtained by using appropriately substituted starting materials.
  • Figure US20100222531A1-20100902-C00010
  • Scheme 3 shows the synthesis of 4-membered (or isomeric) metallocycles. Herein by isomeric is meant (and included in the definition of) that 4-membered heterocycles such as those shown in Scheme 3 may also be in the form of bridged dimers and/or oligomers. Z may be changed by using the appropriate starting material.
  • Figure US20100222531A1-20100902-C00011
  • Scheme 4 illustrates the synthesis of a 6-membered metallocycle. The corresponding nitrogen compound may be made by using an aziridine as a starting material.
  • Figure US20100222531A1-20100902-C00012
  • Scheme 5 illustrates a method for making (I) in which X is —O—. Herein TMEDA is tetramethylethylenediamine.
  • In Schemes 1-5 above Ni complexes are prepared, and for making late transition metal complexes other than Ni, similar reactions of metal compounds with an appropriate anion may be used to prepare the complex. Useful types of Ni compounds are listed below.
      • (Ph3P)2Ni(Ph)(Cl) which gives as ligands (in addition to (I), (II) or (XIII)) Ph and Ph3P.
      • (TMEDA)2Ni(Ph)(Cl) in the presence of a “trapping ligand” L2 such as pyridine, which gives as ligands (in addition to (I), (II) or (XIII)) Ph and pyridine.
      • (Ph3P)2NiCl2 which gives as ligands (in addition to (I), (II) or (XIII)) Cl and Ph3P.
      • ((allyl)Ni(X))2 which gives as a ligand (in addition to (I), (II) or (XII)) π-allyl.
        Other useful Ni precursors and methods of synthesis of these types of nickel complexes may also be found in previously incorporated U.S. Pat. No. 6,060,569, U.S. Pat. No. 6,174,975 and S. D. Mel, et al., Chem. Rev., vol. 100, p. 1169-1203(2000), as well as WO98/42664, and R. H. Grubbs., et al., Organometallics, vol. 17, p. 3149 (1988), which are also incorporated herein by reference for all purposes as if fully set forth.
  • In preparing early transition metal complexes such as Zr and Ti complexes, the anion may be reacted with a simple metal compound such as a halide, for example ZrCl4 or TiCl4.
  • Useful monomers (olefins) include hydrocarbon olefins such as ethylene and α-olefins of the formula H2C═CH(CH2)tH (III) wherein t is an integer of 1 to 20, a styrene, a norbornene and cyclopentene; and polar comonomers such as CO and polar olefins. Useful polar olefins include those of the formula H2C═CHR13E, wherein R13 is alkylene, alkylidene or a covalent bond, especially —(CH2)x— wherein x is 0 or an integer of 1 to 20 and E is a polar group. Useful polar groups E include —CO2R14, —OC(O)R14, —CO2H, —C(O)NR14 2 and —OR14, and —CO2R14 and —OR14 are more preferred, wherein each R14 is hydrogen, hydrocarbyl or substituted hydrocarbyl, preferably alkyl or substituted alkyl. For any olefin other than a norbornene, cyclopentene and a styrene, it is preferred that it be copolymerized with ethylene. An especially preferred olefin is ethylene (alone). Typically CO and polar comonomers will be used with a hydrocarbon olefin such as ethylene to form a copolymer, and often when CO is used at least one other polar monomer will also be present.
  • It will be understood that not every combination of every ligand with every transition metal will polymerize every (type of) olefin or combination of olefins described herein. For instance, late transition metals are believed to be more efficacious for polymerization of polar olefins than are early transition metals. The structure of the polyolefin produced will also vary with the particular transition metal and ligand chosen. For example late transition metals tend to produce polymers with an unusual branching pattern, while early transition metals give polymers with more “normal” branching patterns. For a description of unusual and normal branching patterns see U.S. Pat. No. 5,880,241, which is incorporated by reference herein for all purposes as if fully set forth. The combinations of ingredients to use in the polymerization and the products produced may be readily determined by experimentation.
  • It is preferred that the polymer produced by the first and second processes herein have a degree of polymerization (average number of monomer units in a polymer molecule) of at least about 20, more preferably at least about 40, and especially preferably at least about 100.
  • In the first and second polymerization processes herein, the temperature at which the polymerization is carried out is generally about −100° C. to about +200° C., preferably about −60° C. to about 150° C., and more preferably about −20° C. to about 100° C. The pressure of the olefin (if it is a gas) at which the polymerization is carried out is preferably atmospheric pressure to about 275 MPa.
  • The first and second polymerization processes herein may be run in the presence of various liquids, particularly aprotic organic liquids. The catalyst system, monomer(s), and polymer may be soluble or insoluble in these liquids, but obviously these liquids should not prevent the polymerization from occurring. Suitable liquids include alkanes, cycloalkanes, selected halogenated hydrocarbons, and aromatic hydrocarbons. Specific useful solvents include hexane, toluene, benzene, methylene chloride, chlorobenzene, p-xylene, and 1,2,4-trichlorobenzene.
  • Cocatalysts such as alkylaluminum compounds and/or boranes and/or other Lewis acids may optionally be present in the first and second processes. It is believed that the presence of certain Lewis acids may enhance the productivity of the catalyst and/or the rate of polymerization of the olefin(s). Also Lewis acids may form so-called Zwitterionic complexes which are also useful in these processes. For an explanation of Zwitterionic complexes, see U.S. patent application Ser. No. ______ (filed concurrently on 31 May 2001, Applicant's reference CL1655 US NA), which is hereby incorporated by reference herein for all purposes as if fully set forth.
  • In the third polymerization process described herein one or more polar comonomers are used with one or more hydrocarbon olefins, and preferably ethylene, to form a polar copolymer. Useful polar comonomers include, but are not limited to compounds of the formula H2C═CHR20C(O)Y (X), H2C═CHR20CN (XI), H2C═CR25C(O)Y (XII), or H2C═CHR20CCN, wherein R20 is alkylene or substituted alkylene, R25 is hydrogen, and Y is —OH, —NR21R22, —OR23, and —SR24, wherein R21 and R22 are each independently hydrogen, hydrocarbyl or substituted hydrocarbyl, R23 and R24 are each hydrocarbyl or substituted hydrocarbyl, and R25 is hydrogen. More generally vinyl polar monomers of the formula H2C═CHX, wherein X is a polar group, are preferred. Other more specific preferred polar comonomers are (X) wherein R20 is —(CH2)q— wherein q is 0 or an integer of 1 to 20 and Y is —OR23, and (XII), wherein it is especially preferred that q is zero. Norbornenes containing functional groups are also useful polar comonomers.
  • Some of Ni complexes which may contain bidentate ligands and may be useful in the third process herein may be found in JP-A-11158214, JP-A-11158213, JP-A-10017617, JP-A-09255713, JP-A-11180991, JP-A-256414(2000), JP-A-10007718, JP-A-10182679, JP-A-128922(2000), JP-A-10324709, JP-A-344821(2000), JP-A-11292917, JP-A-11181014, WO00/56744, WO96/37522, WO96/37523, WO98/49208, WO00/18776, WO00/56785, WO00/06620, WO99/50320, WO00/68280, WO00/59956, WO00/50475, WO00/50470, WO98/42665, WO99/54364, WO98/33823, WO99/32226, WO99/49969, WO99/15569, WO99/46271, WO98/03521, WO00/59961, DE-A-19929131, U.S. Pat. No. 5,886,224, U.S. Pat. No. 5,714,556, U.S. Pat. No. 6,060,569, U.S. Pat. No. 6,069,110, U.S. Pat. No. 6,174,976, U.S. Pat. No. 6,103,658, U.S. Pat. No. 6,200,925, U.S. Pat. No. 5,929,181, U.S. Pat. No. 5,932,670, U.S. Pat. No. 6,030.917, U.S. Pat. No. 4,689,437, EP-A-0950667 and EP-A-0942010, and S. D. Mel, et al., Chem. Rev., vol. 100, p. 1169-1203 (2000) (and references therein), all of which are hereby incorporated by reference for all purposes as if fully set forth, as well as the complexes described herein derived from (I), (II) or (XII).
  • All of the complexes mentioned in these publications, and all nickel complexes of bidentate neutral and monoanionic ligands, may not in general be catalysts for the copolymerization of ethylene and one or more polar comonomers, but the conditions described herein give a good chance for them to be such catalysts. To determine whether such a complex is a polar olefin copolymerization catalyst, one may simply try a copolymerization of ethylene and a polar comonomer such as methyl acrylate or ethyl-10-undecylenoate under the conditions described herein. These conditions include principally temperature and ethylene pressure. During most polymerizations there are other conditions usually present, such as activation of the polymerization catalyst, exclusion of polymerization catalyst poisons, use of a molecular weight regulating compound such as hydrogen, agitation, supportation, etc. Except for those conditions specifically described herein for the third polymerization, the other conditions described, for example, in the above references may be used in such test polymerizations and in polymerizations of the third process in general, and reference may be had thereto for further details.
  • In the third process herein a preferred low temperature is about 80° C., more preferably about 90° C., and a preferred high temperature is about 150° C., more preferably about 130° C. A preferred lower ethylene pressure is about 5 MPa or more. A preferred upper limit on ethylene pressure is about 200 MPa, more preferably about 20 MPa.
  • Preferred bidentate ligands in the third process herein are:
  • Figure US20100222531A1-20100902-C00013
  • wherein:
  • R26 and R27 are each independently hydrocarbyl or substituted hydrocarbyl, provided that the carbon atom bound to the imino nitrogen atom has at least two carbon atoms bound to it;
  • R28 and R29 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl, or R28 and R29 taken together are hydrocarbylene or substituted hydrocarbylene to form a carbocyclic ring;
  • R60 and R61 are each independently functional groups bound to the rest of (XV) through heteroatoms (for example O, S or N), or R60 and R61 (still containing their heteroatoms) taken together form a ring.
  • each R50 is independently hydrocarbyl or substituted hydrocarbyl;
  • each R51 is independently hydrogen, hydrocarbyl or substituted hydrocarbyl; and
  • each R52 is hydrocarbyl, substituted hydrocarbyl, hydrocarbyloxy, or substituted hydrocarbyloxy.
  • When (XVI), (XVII) and (XVIII) are used as the complexes, especially as their nickel complexes it is preferred that they be used as their complexes with Lewis acids (“Zwitterionic complexes”) such as tris(pentafluorophenyl)borane. These Zwitterionic complexes are sometimes better polymerization catalysts than the complexes which are do not contain the Lewis acid. These Zwitterionic compounds may be formed before the complex is added to the polymerization process, or may be formed in situ by reaction with Lewis acid which is present.
  • Other copolymerizable olefins may also be present in the third process. α-Olefins of the formula H2C═CH(CH2)zCH3 wherein z is 0 or an integer of 1 to 21, for example propylene or 1-butene, may be used. It is preferred that any other comonomers present constitute less than 50 mole percent, more preferably less than 25 mole percent of the product copolymer.
  • One problem noted with using some polar comonomers, for example acrylate-type comonomers, under certain conditions is the tendency of these comonomers to form homopolymers. It is believed that these homopolymers arise from a “competitive” free radical-type polymerization “originating” from some free radicals which may be present or generated in the third process polymerization. Some types of polar comonomers such as acrylates are well known to readily undergo such polymerizations. These usually unwanted free radical polymerizations may be suppressed to varying extents by the presence of free radical polymerization inhibitors such as phenothiazine in the third polymerization process, but these may interfere with the desired polymerization process, or cause other problems. This may be particularly acute in the third polymerization process herein because of the relatively high process temperatures. It has been found that the presence of alkali metal or ammonium salts, preferably alkali metal salts, of relatively noncoordinating anions in the third polymerization process retards or eliminates the formation of homopolymer of the polar comonomer (or copolymers containing only polar comonomers if more than one polar comonomer is used). Particularly preferred alkali metal cations are Li, Na and K, and Li and Na are especially preferred. Useful weakly coordinating anions include BAF, tetrakis(pentafluorophenyl)borate, N(S(O)2CF3)2 31 , tetraphenylborate, trifluoromethanesulfonate, and hexafluoroantimonate, and preferred anions are BAF, tetrakis(pentafluorophenyl)-borate, and N(S(O)2CF3)2 . A useful molar ratio of these salts to the number of moles of Ni compounds present is about 10,000 to about 5 to 1.0, more preferably about 1,000 to about 50 to 1.0. These salts will preferably be used in a third polymerization process in which there is a liquid phase present, for example a polymerization which is a solution or liquid suspension polymerization.
  • In any of the polymerization processes herein in which a polar comonomer is copolymerized, and any formation of any polar copolymer, it is preferred that the molar ratio of the total of the polar comonomers present to any added Lewis acid is at least 2:1, preferably at least 10:1. Polar comonomers, such acrylic-type monomers, have been copolymerized in certain situations by destroying their Lewis basic (or coordinating) character by reacting them with a Lewis acid, to form a Lewis acid “salt” of the polar comonomer. While this may often help to form the polar copolymer, later removal of the stoichiometric amount (of polar comonomer) of Lewis acid is difficult and expensive.
  • The olefin polymerizations herein may also initially be carried out in the “solid state” by, for instance, supporting the transition metal compound on a substrate such as silica or alumina, activating it if necessary with one or more cocatalysts and contacting it with the olefin(s). Alternatively, the support may first be contacted (reacted) with one or more cocatalysts (if needed) such as an alkylaluminum compound, and then contacted with an appropriate Ni compound. The support may also be able to take the place of a Lewis or Bronsted acid, for instance, an acidic clay such as montmorillonite, if needed. Another method of making a supported catalyst is to start a polymerization or at least make a transition metal complex of another olefin or oligomer of an olefin such as cyclopentene on a support such as silica or alumina. These “heterogeneous” catalysts may be used to catalyze polymerization in the gas phase or the liquid phase. By gas phase is meant that a gaseous olefin is transported to contact with the catalyst particle. For the copolymerization of polar olefins using supported catalysts, especially in a liquid medium, a preferred case is when the ligand is covalently attached to the supports, which helps prevent leaching of the transition metal complex from the support.
  • In all of the polymerization processes described herein oligomers and polymers of the various olefins are made. They may range in molecular weight from oligomeric olefins, to lower molecular weight oils and waxes, to higher molecular weight polyolefins. One preferred product is a polymer with a degree of polymerization (DP) of about 10 or more, preferably about 40 or more. By “DP” is meant the average number of repeat (monomer) units in a polymer molecule.
  • Depending on their properties, the polymers made by the first and second processes described herein are useful in many ways. For instance if they are thermoplastics, they may be used as molding resins, for extrusion, films, etc. If they are elastomeric, they may be used as elastomers. If they contain functionalized monomers such as acrylate esters, they are useful for other purposes, see for instance previously incorporated U.S. Pat. No. 5,880,241.
  • Depending on the process conditions used and the polymerization catalyst system chosen, polymers, even those made from the same monomer(s) may have varying properties. Some of the properties that may change are molecular weight and molecular weight distribution, crystallinity, melting point, and glass transition temperature. Except for molecular weight and molecular weight distribution, branching can affect all the other properties mentioned, and branching may be varied (using the same transition metal compound) using methods described in previously incorporated U.S. Pat. No. 5,880,241.
  • It is known that blends of distinct polymers, varying for instance in the properties listed above, may have advantageous properties compared to “single” polymers. For instance it is known that polymers with broad or bimodal molecular weight distributions may be melt processed (be shaped) more easily than narrower molecular weight distribution polymers. Thermoplastics such as crystalline polymers may often be toughened by blending with elastomeric polymers.
  • Therefore, methods of producing polymers which inherently produce polymer blends are useful especially if a later separate (and expensive) polymer mixing step can be avoided. However in such polymerizations one should be aware that two different catalysts may interfere with one another, or interact in such a way as to give a single polymer.
  • In such a process the transition metal containing polymerization catalyst disclosed herein can be termed the first active polymerization catalyst. Monomers useful with these catalysts are those described (and also preferred) above. A second active polymerization catalyst (and optionally one or more others) is used in conjunction with the first active polymerization catalyst. The second active polymerization catalyst may be a late transition metal catalyst, for example as described herein, in previously incorporated U.S. Pat. No. 5,880,241, U.S. Pat. No. 6,060,569, U.S. Pat. No. 6,174,975 and U.S. Pat. No. 5,714,556, and/or in U.S. Pat. No. 5,955,555 (also incorporated by reference herein for all purposes as if fully set forth). Other useful types of catalysts may also be used for the second active polymerization catalyst. For instance so-called Ziegler-Natta and/or metallocene-type catalysts may also be used. These types of catalysts are well known in the polyolefin field, see for instance Angew. Chem., Int. Ed. Engl., vol. 34, p. 1143-1170 (1995), EP-A-0416815 and U.S. Pat. No. 5,198,401 for information about metallocene-type catalysts; and J. Boor Jr., Ziegler-Natta Catalysts and Polymerizations, Academic Press, New York, 1979 for information about Ziegler-Natta-type catalysts, all of which are hereby included by reference. Many of the useful polymerization conditions for all of these types of catalysts and the first active polymerization catalysts coincide, so conditions for the polymerizations with first and second active polymerization catalysts are easily accessible. Oftentimes the “co-catalyst” or “activator” is needed for metallocene or Ziegler-Natta-type polymerizations. In many instances the same compound, such as an alkylaluminum compound, may be used as an “activator” for some or all of these various polymerization catalysts.
  • In one preferred process described herein the first olefin(s) (the monomer(s) polymerized by the first active polymerization catalyst) and second olefin(s) (the monomer(s) polymerized by the second active polymerization catalyst) are identical, and preferred olefins in such a process are the same as described immediately above. The first and/or second olefins may also be a single olefin or a mixture of olefins to make a copolymer. Again it is preferred that they be identical particularly in a process in which polymerization by the first and second active polymerization catalysts make polymer simultaneously.
  • In some processes herein the first active polymerization catalyst may polymerize a monomer that may not be polymerized by said second active polymerization catalyst, and/or vice versa. In that instance two chemically distinct polymers may be produced. In another scenario two monomers would be present, with one polymerization catalyst producing a copolymer, and the other polymerization catalyst producing a homopolymer, or two copolymers may be produced which vary in the molar proportion or repeat units from the various monomers. Other analogous combinations will be evident to the artisan.
  • In another variation of this process one of the polymerization catalysts makes an oligomer of an olefin, preferably ethylene, which oligomer has the formula R70CH═CH2, wherein R70 is n-alkyl, preferably with an even number of carbon atoms. The other polymerization catalyst in the process then (co)polymerizes this olefin, either by itself or preferably with at least one other olefin, preferably ethylene, to form a branched polyolefin. Preparation of the oligomer (which is sometimes called an α-olefin) by a second active polymerization-type of catalyst can be found in previously incorporated U.S. Pat. No. 5,880,241, as well as in WO99/02472 (also incorporated by reference herein).
  • Likewise, conditions for such polymerizations, using catalysts of the second active polymerization type, will also be found in the appropriate above-mentioned references.
  • Two chemically different active polymerization catalysts are used in this polymerization process. The first active polymerization catalyst is described in detail above. The second active polymerization catalyst may also meet the limitations of the first active polymerization catalyst, but must be chemically distinct. For instance, it may have a different transition metal present, and/or utilize a different type of ligand and/or the same type of ligand that differs in structure between the first and second active polymerization catalysts. In one preferred process, the ligand type and the metal are the same, but the ligands differ in their substituents.
  • Included within the definition of two active polymerization catalysts are systems in which a single polymerization catalyst is added together with another ligand, preferably the same type of ligand, which can displace the original ligand coordinated to the metal of the original active polymerization catalyst, to produce in situ two different polymerization catalysts.
  • The molar ratio of the first active polymerization catalyst to the second active polymerization catalyst used will depend on the ratio of polymer from each catalyst desired, and the relative rate of polymerization of each catalyst under the process conditions. For instance, if one wanted to prepare a “toughened” thermoplastic polyethylene that contained 80% crystalline polyethylene and 20% rubbery polyethylene, and the rates of polymerization of the two catalysts were equal, then one would use a 4:1 molar ratio of the catalyst that gave crystalline polyethylene to the catalyst that gave rubbery polyethylene. More than two active polymerization catalysts may also be used if the desired product is to contain more than two different types of polymer.
  • The polymers made by the first active polymerization catalyst and the second active polymerization catalyst may be made in sequence, i.e., a polymerization with one (either first or second) of the catalysts followed by a polymerization with the other catalyst, as by using two polymerization vessels in series. However it is preferred to carry out the polymerization using the first and second active polymerization catalysts in the same vessel(s), i.e., simultaneously. This is possible because in most instances the first and second active polymerization catalysts are compatible with each other, and they produce their distinctive polymers in the other catalyst's presence. Any of the processes applicable to the individual catalysts may be used in this polymerization process with 2 or more catalysts, i.e., gas phase, liquid phase, continuous, etc.
  • Catalyst components which include transition metal complexes of (I), (II) or (XII), with or without other materials such as one or more cocatalysts and/or other polymerization catalysts are also disclosed herein. For example, such a catalyst component could include the transition metal complex supported on a support such as alumina, silica, a polymer, magnesium chloride, sodium chloride, etc., with or without other components being present. It may simply be a solution of the transition metal complex, or a slurry of the transition metal complex in a liquid, with or without a support being present.
  • The polymers produced by this process may vary in molecular weight and/or molecular weight distribution and/or melting point and/or level of crystallinity, and/or glass transition temperature and/or other factors. For copolymers the polymers may differ in ratios of comonomers if the different polymerization catalysts polymerize the monomers present at different relative rates. The polymers produced are useful as molding and extrusion resins and in films as for packaging. They may have advantages such as improved melt processing, toughness and improved low temperature properties.
  • Hydrogen or other chain transfer agents such as silanes (for example trimethylsilane or triethylsilane) may be used to lower the molecular weight of polyolefin produced in the polymerization process herein. It is preferred that the amount of hydrogen present be about 0.01 to about 50 mole percent of the olefin present, preferably about 1 to about 20 mole percent. When liquid monomers (olefins) are present, one may need to experiment briefly to find the relative amounts of liquid monomers and hydrogen (as a gas). If both the hydrogen and monomer(s) are gaseous, their relative concentrations may be regulated by their partial pressures.
  • Copolymers of ethylene and certain polar comonomers such as H2C═CHC(O)R32 are described herein (first and second polymers), and they contain first branches of the formula —(CH2)nCH3 and second branches of the formula —(CH2)mC(O)R33, wherein R32 is —OR34 or any group readily derivable from it, R33 is R32 or any group readily derivable from it, R34 is hydrocarbyl or substituted hydrocarbyl, and each R35 is hydrogen, hydrocarbyl or substituted hydrocarbyl. By “any group readily derivable from it” is meant any derivative of a carboxylic acid which is readily interconverted from the carboxylic acid itself or a derivative of a carboxylic acid. For example a carboxylic acid ester may be converted to a carboxylic acid by hydrolysis, an amide by reaction with a primary or secondary amine, a carboxylate salt (for example with an alkali or alkaline earth metal) by hydrolysis and neutralization, an acyl halide by hydrolysis and reaction with a compound such as thionyl chloride, nitriles, and others.
  • The first and/or second polymers, and/or third polymers in some instances, have the following characteristics in various combinations that separates them from other copolymers made from the same monomers. These characteristics are:
  • the ratio of first branches wherein n is 0 to first branches wherein n is 1 is about 3.0 or more, preferably about 4.0 or more;
  • the ratio of first branches wherein n is 0 to first branches wherein n is 3 is 1.0 or more, preferably 1.5 or more;
  • the ratio of second branches wherein m is 0 to second branches wherein m is one or more is at least about 3.0, more preferably at least about 5.0;
  • the total number of first branches where n is 0, 1, 2 and 3 in said polymer is about 10 or more per 1000 CH2 groups, preferably about 20 or more;
  • the incorporation of repeat units derived from H2C═CHC(O)R33 is 0.3 mole percent or more based on the total repeat units derived from ethylene and H2C═CHC(O)R33, preferably about 0.5 mole percent or more, especially preferably 1.1 mole percent or more, and very preferably about 1.5 mole percent or more (if there are repeat units in which R33 vanes, the total of such units shall be used);
  • the polymers have end groups of the formula ˜˜˜˜˜˜˜-HC═CH—C(O)—R32 and at least about 5 mole percent, preferably at least about 10 mole percent, of said monomer incorporated is present in said polymer as end groups of the formula ˜˜˜˜˜˜˜-HC═CH—C(O)—R33, wherein ˜˜˜˜˜˜˜ is the remainder of the polymer chain of said end group (the polymer chain the end group is attached to); and/or
  • the said unsaturated end groups are at least 0.001 mole percent, preferably at least about 0.01 mole percent, and more preferably at least 0.1 mole percent, of the total repeat units (ethylene and polar comonomer(s)) in said polymer.
  • In these polymers any number of these characteristics can be combined as features of these polymers, including the preferred characteristics.
  • The first, second and third polymers may also contain “saturated” end groups of the formula ˜˜˜˜˜˜C(O)R33, which with present analytical techniques may be indistinguishable from second branches where m is ≧5. In some instances end groups may have the formula ˜˜˜˜˜˜CH═CH2 (a vinyl end group). Such end groups may sometimes be polymerizable, and therefore polymers with such end groups may be useful as macromonomers.
  • It is difficult, and sometimes not possible, to distinguish between ester groups which are saturated polymer ends (no olefin bond associated with the end group), and ester groups at the ends of long branches by 13C NMR spectroscopy (created by chain walking event, a CWE). In both cases the carbonyl group is shifted from about 175.5 ppm for the in-chain comonomer to 170-174 ppm for the saturated end group or CWE. Usually the saturated ester end group or CWE peak in the region 170-174 ppm is very small and present in only trace quantities. Because of the very low levels of this peak, it is difficult to confirm by 2D NMR this hypothesis, and the assignment should be considered tentative. Review of many of the experimental results obtained show that in many examples no saturated end groups and/or CWE are present. However in some examples up to 50 mole percent, more commonly up to 20 mole percent, of the total amount of acrylate ester appears to be present as saturated end groups and/or CWE. These numbers are very approximate, since the contents of the saturated end groups and/or CWE are typically so small the error in the measurement is relatively large.
  • Some NMR and separations evidence exists that these copolymers may sometimes be capped by short runs of acrylate homopolymers, presumably by free radical polymerization of acrylate ester at the beginning and/or end of the coordination polymerization of a polymer chain.
  • The first, second and third polymers are useful in many ways, for instance,
  • 1. Tackifiers for low strength adhesives (U, vol. A1, p. 235-236) are a use for these polymers. Elastomeric and/or relatively low molecular weight polymers are preferred.
  • 2. The polymers are useful as base resins for hot melt adhesives (U, vol. A1, p. 233-234), pressure sensitive adhesives (U, vol. A1, p. 235-236) or solvent applied adhesives. Thermoplastics are preferred for hot melt adhesives. The polymers may also be used in a carpet installation adhesive.
  • 3. Base polymer for caulking of various kinds is another use. An elastomer is preferred. Lower molecular weight polymers are often used.
  • 4. The polymers, particularly elastomers, may be used for modifying asphalt, to improve the physical properties of the asphalt and/or extend the life of asphalt paving, see U.S. Pat. No. 3,980,598.
  • 5. Wire insulation and jacketing may be made from any of the polymers (see EPSE, vol. 17, p. 828-842). In the case of elastomers it may be preferable to crosslink the polymer after the insulation or jacketing is formed, for example by free radicals.
  • 6. The polymers, especially the branched polymers, are useful as base resins for carpet backing, especially for automobile carpeting.
  • 7. The polymers may be used for extrusion or coextrusion coatings onto plastics, metals, textiles or paper webs.
  • 8. The polymers may be used as a laminating adhesive for glass.
  • 9. The polymers are useful for blown or cast films or as sheet (see EPSE, vol. 7 p. 88-106; ECT4, vol. 11, p. 843-856; PM, p. 252 and p. 432ff). The films may be single layer or multilayer, the multilayer films may include other polymers, adhesives, etc. For packaging the films may be stretch-wrap, shrink-wrap or cling wrap. The films are useful for many applications such as packaging foods, geomembranes and pond liners. It is preferred that these polymers have some crystallinity.
  • 10. The polymers may be used to form flexible or rigid foamed objects, such as cores for various sports items such as surf boards and liners for protective headgear. Structural foams may also be made. It is preferred that the polymers have some crystallinity. The polymer of the foams may be crosslinked.
  • 11. In powdered form the polymers may be used to coat objects by using plasma, flame spray or fluidized bed techniques.
  • 12. Extruded films may be formed from these polymers, and these films may be treated, for example drawn. Such extruded films are useful for packaging of various sorts.
  • 13. The polymers, especially those that are elastomeric, may be used in various types of hoses, such as automotive heater hose.
  • 14. The polymers may be used as reactive diluents in automotive finishes, and for this purpose it is preferred that they have a relatively low molecular weight and/or have some crystallinity.
  • 15. The polymers can be converted to ionomers, which when they possess crystallinity can be used as molding resins. Exemplary uses for these ionomeric molding resins are golf ball covers, perfume caps, sporting goods, film packaging applications, as tougheners in other polymers, and usually extruded) detonator cords.
  • 16. The functional groups on the polymers can be used to initiate the polymerization of other types of monomers or to copolymerize with other types of monomers. If the polymers are elastomeric, they can act as toughening agents.
  • 17. The polymers can act as compatibilizing agents between various other polymers.
  • 18. The polymers can act as tougheners for various other polymers, such as thermoplastics and thermosets, particularly if the olefin/polar monomer polymers are elastomeric.
  • 19. The polymers may act as internal plasticizers for other polymers in blends. A polymer which may be plasticized is poly(vinyl chloride).
  • 20. The polymers can serve as adhesives between other polymers.
  • 21. With the appropriate functional groups, the polymers may serve as curing agents for other polymers with complimentary functional groups (i.e., the functional groups of the two polymers react with each other).
  • 22. The polymers, especially those that are branched, are useful as pour point depressants for fuels and oils.
  • 23. Lubricating oil additives as Viscosity Index Improvers for multigrade engine oil (ECT3, Vol 14, p. 495-496) are another use. Branched polymers are preferred. Ethylene copolymer with acrylates or other polar monomers will also function as Viscosity Index Improvers for multigrade engine oil with the additional advantage of providing some dispersancy.
  • 24. The polymers may be used for roofing membranes.
  • 25. The polymers may be used as additives to various molding resins such as the so-called thermoplastic olefins to improve paint adhesion, as in automotive uses.
  • 26. A flexible pouch made from a single layer or multilayer film (as described above) which may be used for packaging various liquid products such as milk, or powder such as hot chocolate mix. The pouch may be heat sealed. It may also have a barrier layer, such as a metal foil layer.
  • 27. A wrap packaging film having differential cling is provided by a film laminate, comprising at least two layers; an outer reverse which is a polymer (or a blend thereof) described herein, which contains a tackifier in sufficient amount to impart cling properties; and an outer obverse which has a density of at least about 0.916 g/mL which has little or no cling, provided that a density of the outer reverse layer is at least 0.008 g/mL less than that of the density of the outer obverse layer. It is preferred that the outer obverse layer is linear low density polyethylene, and the polymer of the outer obverse layer have a density of less than 0.90 g/mL. All densities are measured at 25° C.
  • 28. Fine denier fibers and/or multifilaments. These may be melt spun. They may be in the form of a filament bundle, a non-woven web, a woven fabric, a knitted fabric or staple fiber.
  • 29. A composition comprising a mixture of the polymers herein and an antifogging agent. This composition is especially useful in film or sheet form because of its antifogging properties.
  • 30. If the polymers are functionalized with monomers such as fluoroalkyl acrylate esters or other fluorine-containing monomers, they are useful for selectively imparting surface activity to polyolefins. This would be of use reducing fluid penetration in flash-spun polyolefin films for medical and other applications. The fluoro-functionalized polyolefins would also be useful for dispersing fluoropolymers in lubricant applications.
  • 31. Mixtures of ethylene homopolymers or oligomers together with copolymers of ethylene and acrylates and optionally other monomers are useful as adhesion promoters, surface active agents, tougheners, and compatibilizers for additives.
  • In the above use listings, sometimes a reference is given which discusses such uses for polymers in general. All of these references are hereby included by reference. For the references, “U” refers to W. Gerhartz, et al., Ed., Ullmann's Encyclopedia of Industrial Chemistry, 5th Ed. VCH Verlagsgesellschaft mBH, Weinheim, for which the volume and page number are given, “ECT3” refers to the H. F. Mark, et al., Ed., Kirk-Othmer Encyclopedia of Chemical Technology, 4th Ed., John Wiley & Sons, New York, “ECT4” refers to the J. I Kroschwitz, et al., Ed., Kirk-Othmer Encyclopedia of Chemical Technology, 4th Ed., John Wiley & Sons, New York, for which the volume and page number are given, “EPSE” refers to H. F. Mark, et al., Ed., Encyclopedia of Polymer Science and Engineering, 2nd Ed., John Wiley & Sons, New York, for which volume and page numbers are given, and “PM” refers to J. A. Brydson, ed., Plastics Materials, 5th Ed., Butterworth-Heinemann, Oxford, UK, 1989, and the page is given.
  • In the Examples, all pressures are gauge pressures. The following abbreviations are used:
  • ΔHf—heat of fusion (in J/g)
  • BAF—tetrakis(bis-3,5-(trifluoromethyl)phenyl)borate
  • DSC—differential scanning calorimetry
  • GPC—gel permeation chromatography
  • PMAO-IP—improved processing methylaluminoxane from Akzo-Nobel
  • RB—round-bottomed
  • RT—room temperature
  • TCB—1,2,4-trichlorobenzene
  • THF—tetrahydrofuran
  • Am—amyl
  • Ar—aryl
  • BAF—tetrakis(3,5-trifluoromethylphenyl)borate
  • BArF—tetrakis(pentafluorophenyl)borate
  • BHT—2,6-di-t-butyl-4-methylphenol
  • Bu—butyl
  • Bu2O—dibutyl ether
  • CB—chlorobenzene
  • Cmpd—compound
  • E—ethylene
  • EG—end-group, refers to the ester group of the acrylate being located in an unsaturated end group of the ethylene copolymer
  • EGPEA—2-phenoxyethyl acrylate
  • Eoc—end-of-chain
  • Equiv—equivalent
  • Et—ethyl
  • EtsBu—percent of ethyl branches occurring in sec-butyl ended branches
  • GPC—gel permeation chromatography
  • HA—hexyl acrylate
  • Hex—hexyl
  • IC—in-chain, refers to the ester group of the acrylate being bound to the main-chain of the ethylene copolymer
  • IDA—isodecyl acrylate
  • Incorp—incorporation
  • i-Pr—iso-propyl
  • M.W.—molecular weight
  • MA—methyl acrylate
  • Me—methyl
  • MeOH—methanol
  • MesBu—percent of methyl branches occurring in sec-butyl ended branches
  • MI—melt index
  • Mn—number average molecular weight
  • Mp—peak average molecular weight
  • Mw—weight average molecular weight
  • N:—not determined
  • PDI—polydispersity; Mw/Mn
  • PE—polyethylene
  • Ph—phenyl
  • Press—pressure
  • RI—refractive index
  • Rt or RT—room temperature
  • t-Bu—t-butyl
  • TCB—1,2,4-trichlorobenzene
  • Temp—temperature
  • THA—3,5,5-trimethylhexyl acrylate
  • THF—tetrahydrofuran
  • TO—number of turnovers per metal center=(moles monomer consumed, as determined by the weight of the isolated polymer or oligomers) divided by (moles catalyst)
  • tol—toluene
  • Total Me—Total number of methyl groups per 1000 methylene groups as determined by 1H or 13C NMR analysis
  • UV—ultraviolet
  • Examples 1-89 Ligand Precursor and Catalyst Synthesis
  • All operations related to the catalyst synthesis were performed in a nitrogen drybox or using a Schlenk line with nitrogen protection. Anhydrous solvents were used in all cases. Solvents were distilled from drying agents under nitrogen using standard procedures: chlorobenzene from P2O5; THF from sodium benzophenone ketyl. Ni[II] allyl chloride and NaBAF were prepared according to the literature.
  • (Tert-butyl)2PCH2Li was synthesized by reacting (tert-butyl)2PCH3 with tert-butyl lithium in heptane in a 109° C. bath for a few hours. The product was filtered and washed with pentane. (Tert-butyl)2PLi was synthesized by reacting (tert-butyl)2PH with n-butyl lithium in heptane at 90° C. for 6 h. Ph2PLi was made by reacting Ph2PH with n-butyl lithium at RT for 3 d at RT. The NMR spectra were recorded using a Bruker 500 MHz spectrometer or a Bruker 300 MHz spectrometer.
  • In the Examples 1-89 the following catalysts were used:
  • Figure US20100222531A1-20100902-C00014
    Figure US20100222531A1-20100902-C00015
    Figure US20100222531A1-20100902-C00016
    Figure US20100222531A1-20100902-C00017
  • Example 1 Synthesis of Catalyst 1
  • In a drybox, 0.50 g (tert-butyl)2PCH2Li was mixed with 20 mL THF in a Schlenk flask. It was brought out of the drybox and placed in an ice-water bath. One atmosphere of hexafluoroacetone was applied to the flask. The mixture was allowed to stir at 0° C. under 1 atm of hexafluoroacetone for 1 h. The hexafluoroacetone flow was stopped. The reaction mixture was allowed to warm up to RT, during which time gas evolution was seen. The mixture was then stirred at RT for 1 h and was transferred back to the drybox. The THF was evaporated. The product was dried under full vacuum overnight. A yellow solid was obtained. 31PNMR in THF-d8: singlet peak at 13.07 ppm. 1HNMR in THF-d8: 2.08 ppm (2H, d, JPH=4.6 Hz, P—CH2—); 1.22 ppm (18H, d, JPH=11.2 Hz, —C(CH3)3). A small amount of THF (˜0.2 eq) existed in the solid product. To this product was added 0.405 g ((allyl)NiCl)2 and 15 mL THF. The mixture was allowed to stir at RT over the weekend. The mixture was evaporated to dryness, extracted with 30 mL toluene, filtered through Celite®, followed by 3×5 mL toluene wash. Solvent was evaporated. The product was dried under full vacuum overnight. The product became powdery after triturating with pentane. Yellow brown solid (0.82 g) was obtained. 31PNMR in CD2Cl2: singlet peak at 78.81 ppm.
  • Example 2 Synthesis of Catalyst 2
  • A 100-mL round-bottomed flask was charged with 292 mg (1.60 mmol) of benzophenone dissolved in ca. 15 mL THF. Then the (t-Bu)2P—CH2Li (266 mg, 1.60 mmol) dissolved in ca. 15 mL THF was added. The solution turns from colorless to dark blue. It was stirred for one hour after which time, a solution of (Ni(C3H5)Cl)2 (217 mg, 0.80 mmol) in 15 mL THF was added. It was stirred for an additional 1 h and the solvent removed. The residue was extracted with hexane and toluene and the solvent removed. The residue was washed with small amounts of hexane and dried. The yield was 395 mg (71%). 1HNMR (CD2Cl2, 23° C., 300 MHz) d 8.2-7.9 (m, 4H, Ar); 7.4-6.9 (m, 6H, Ar); 5.10 (m, 1H); 4.26 (brs, 1H); 3.25 (dd, J=14 Hz, J=5 Hz, 1H), 2.80 (m, 2H), 2.24 (brs, 1H), 1.16 (d, J=13 Hz, 1H), 0.97 (d, JP—H=13 Hz, 9H); 0.80 (d, JP—H=13 Hz). 31PNMR (CD2Cl2, 23° C.): d 84.0. 13CNMR (CD2Cl2, 23° C., 75 MHz) d 156.1 (5); Ar C—H signals overlapping with C6D6 signal; 127.2 (s); 125.7 (d, JP—C=6 Hz); 109.3 (d, JC—H=157 Hz); 86.7 (d, JP—C=10 Hz); 69.1 (m, JP—C=22 Hz); 41.2 (dt, JP—C=25 Hz, JC—H=127 Hz); 37.6 (m, JP—C=6 Hz); 33.8 (m); 29.9 (q, JC—H=124 Hz).
  • A single red-orange crystal was grown from CH2Cl2/hexane at ambient temperature, and X-ray diffraction data confirmed the structure. No LiCl was present in the structure based X-ray single crystal diffraction analysis.
  • Example 3 Synthesis of Catalyst 3
  • In a drybox, 0.2273 g (tert-butyl)2PCH2Li was mixed with 20 mL THF in a 100 mL RB flask. The mixture was cooled at −30° C. for 30 min. Under stirring, 0.50 g monoimine-A was added to the solution while the solution was still cold. The reaction mixture turned yellow blue right away. The mixture was allowed to warm up to RT and to stir at this temperature overnight. THF was evaporated. The product was dried under vacuum for 7 h. A deep yellow green solid (0.912 g) was isolated. 31PNMR in THF-d8: singlet peak at 18.56 ppm. To the product was added 0.1847 g ((allyl)NiCl)2 and 20 mL THF in a RB flask. The mixture was allowed to stir for 6.5 h at RT. The mixture was evaporated to dryness. The residue was extracted with 25 mL toluene. It was filtered through Celite®, followed by 3×5 mL toluene wash. The solution was evaporated to dryness. The product was then dried under full vacuum overnight. Dark green solid (0.92 g) was isolated.
  • Figure US20100222531A1-20100902-C00018
  • Example 4 Synthesis of Catalyst 4
  • In a drybox, 0.35 g (tert-butyl)2PCH2Li was added to the −30° C. solution of 0.4409 g monoimine-B in 30 mL THF in a 100 mL RB flask. The reaction mixture turned yellow blue immediately. The mixture was allowed to warm up to RT and stirred at this temperature for 19 h. THF was evaporated. The product was dried under vacuum. 31PNMR in THF-d8: Two singlet peaks. One was a sharp and tall peak at 20.54 ppm and another was a wide and short peak at 18.74 ppm. To the product was added 0.2812 g ((allyl)NiCl)2 and 30 mL THF in a RB flask. The mixture was allowed to stir for 18 h at RT. The mixture was evaporated to dryness. The residue was extracted with 30 mL toluene. It was filtered through Celite®, followed by 3×5 mL toluene wash. The solution was evaporated to dryness. The solid product was then dried under vacuum for 8 h. 31PNMR in C6D6: two major singlet peak at 81.75 ppm and 79.92 ppm, as well as a minor singlet peak at 20.05 ppm. Electron spray mass spectroscopy showed major peaks at 468 and 470 (due to 58Ni and 60Ni isotopes); which indicated that the desired product picked up a proton in the spray process. X-ray single crystal diffraction analysis confirmed the structure. No LiCl was present in the structure.
  • Examples 5 Synthesis of Catalyst 5
  • A 100 mL RB flask was charged with 217 mg (0.82 mmol) of 2,2,2-trifluoro-2′,4′,6′-trimethoxyacetophenone dissolved in ca. 10-15 mL THF. Then (t-Bu)2P—CH2Li (136 mg, 0.82 mmol) dissolved in ca. 10-15 mL THF was added. The initially purple solution (color came from traces impurities in starting ketone) turned clear yellow. It was stirred for one h after which time, a solution of (Ni(C3H5)Cl)2 (111 mg, 0.41 mmol) in 10-15 mL THF was added. It was stirred for an additional one h and the solvent removed. The residue was washed with hexane and dried in vacuo to yield 362 mg (78%). Key NMR signals (incomplete): 1H-NMR (CD2Cl2, 23° C., 300 MHz) δ 6.5-6.2 (brm, 2H, Ar); 5.3 (brm, 1H), 4.8 (brs, 1H); 4.1 (brs, 2H); 3.8 (brs, 9H); 3.7-2.0 (brm); 2.0-0.8 (brm, t-Bu signals). Two isomers (50:50) by 31PNMR (CD2Cl2, 23° C., 300 MHz): δ 81.4; 80.2. 13CNMR (CD2Cl2, 23° C., 125 MHz): δ 161.3 (s); ca. 112 (brs); ca. 94.0 (brm, J=158 Hz); 93.2 (br); ca. 86; 68.1; 58.4; 56.3; 55.6. A single red-orange crystal was grown from CH2Cl2/hexane at ambient temperature, and the structure confirmed by X-ray diffraction. The complex contained one equivalent of LiCl, and existed as a dimer bridged by LiCl.
  • Example 6 Synthesis of Catalyst 6
  • A 200 mL RB flask was charged with 300 mg (1.10 mmol) of 2,4,6-trimethoxybenzophenone dissolved in ca. 20 mL THF. Then (t-Bu)2P—CH2Li (183 mg, 1.10 mmol) dissolved in ca. 20 mL THF was added. It was stirred for one h, after which time, a solution of (Ni(C3H5)Cl)2 (149 mg, 0.55 mmol) in THF (ca. 20 mL) was added. It was stirred for an additional one h and the solvent removed. The residue was washed with hexane and dried in vacuo to yield 664 mg product. Key NMR signals (incomplete): 1HNMR (CD2Cl2, 23° C., 300 MHz) δ 7.64 (brs, 1H, Ar); 7.51 (brs, 1H, Ar); 7.14 (brt, 2H, Ar); 7.00 (brt, 1H, Ar); 6.14 (s, 2H); 5.28 (m, 1H); 5.0-4.5 (brm, 2H); 3.67 (s, 3H, OCH3); 3.64 (s, 6H, OCH3); 3.26 (brs, 1H); 2.87 (dd, 1H, J=14 Hz, J=5 Hz); 2.8-2.4 (brm, 2H); 1.7-0.7 (brm, 18H, t-Bu). Two isomers (50:50) by 31PNMR (CD2Cl2, 23° C., 75 MHz): δ 79.0; 78.2. 13CNMR (CD2Cl2, 23° C., 125 MHz): δ 167.9 (d, JP-C=4.5 Hz); 159.9 (s); 158.5 (brs); 154.4 (brs); 127.6 (dd, JC-H=158 Hz, J=7.5 Hz); 126.1 (dt); 125.7 (dt, J=150 Hz); 111.0 (brd); 95.0 (dd, JC-H=159 Hz, J=4.7 Hz); 87.2 (brs); 67.0 (brdt, JP—C=22 Hz); 57.7 (q, JC-H=145 Hz); 55.6 (q, JC-H=144 Hz); ca. 40.0 (brs); 39.7 (dt, JP-C=25 Hz); 35.3 (d, JP-C=18 Hz); 33.7 (d, JP-C=16 Hz); 30.0 (brq, JC-H=127 Hz). A single red-orange crystal was grown from CH2Cl2/hexane at ambient temperature, and an X-ray diffraction confirmed the structure. The complex contained one equivalent of LiCl, and existed as a dimer bridged by LiCl.
  • Example 7 Synthesis of Catalyst 7
  • A 200 mL RB flask was charged with 300 mg (1.17 mmol) of 2,2-dimethoxy-2-phenylacetophenone dissolved in ca. 20 mL THF. Then (t-Bu)2P—CH2Li (195 mg, 1.17 mmol) dissolved in ca. 20 mL THF was added. It was stirred for one h, after which time a solution of (Ni(C3H5)Cl)2 (158 mg, 0.59 mmol) in THF (ca. 20 mL) was added. It was stirred for an additional h and the solvent removed. The residue was washed with hexane and dried in vacuo to yield 438 mg (67%). Two isomers (50:50) by 31PNMR (CD2Cl2, 23° C., 300 MHz): δ 82.1 (s) and δ 81.5 (s). A single red-orange crystal was grown from CH2Cl2/hexane at ambient temperature, and X-ray diffraction data confirmed the structure. The complex contained one equivalent of LiCl, and existed as a dimer bridged by LiCl.
  • Example 8 Synthesis of Catalyst 8
  • In a drybox, 0.3043 g (tert-butyl)2PLi was added to a −30° C. solution of 0.5284 g 2,2,2-trifluoro-2′,4′,6′-trimethoxyacetophenone (Aldrich) in 15 mL THF in a 100 mL RB flask. The reaction mixture turned yellow. The mixture was allowed to warm up to RT and stir at this temperature overnight. THF was evaporated. The product was dried under vacuum for 6 h. 31PNMR in THF-d8: a singlet peak at 41.28 ppm. The product was mixed with 0.1608 g. ((allyl)NiCl)2 and 15 mL THF in a RB flask. The mixture was allowed to stir for 2 h at RT. It was then evaporated to dryness. The residue was mixed with 10 mL toluene. Pentane (40 mL) was then added into the flask. The brown solid was filtered, followed by 3× pentane wash and dried in vacuo. Brown solid (0.445 g) was obtained. 31PNMR in THF-d8: two singlet peak at 50.31 ppm and 50.05 ppm.
  • Example 9 Synthesis of Catalyst 9
  • In a drybox, 0.30 g (tert-butyl)2PCH2Li was added to a −30° C. solution of 0.3072 g ethyl trifluoropyruvate (Lancaster) in 15 mL THF in a 100 mL RB flask. The reaction mixture turned golden yellow. The mixture was allowed to warm up to RT and stir at this temperature for 1 h. THF was evaporated. The product was dried under vacuum overnight. The product was mixed with 0.247 g ((allyl)NiCl)2 and 15 mL THF in a RB flask. The mixture was allowed to stir for 1 h at RT. The mixture was then evaporated to dryness. The residue was dissolved by adding 10 mL toluene. Pentane (40 mL) was then added into the flask. The yellow solid was filtered, followed by 3× pentane wash and dried in vacuo. Yellow solid (0.36 g) was obtained. 31PNMR in THF-d8: The major singlet peak at 78.24 ppm and two small singlet peaks at 96.72 ppm and 218.21 ppm. A single crystal was grown and the structure was confirmed synchrotron diffraction analysis. The complex contained one equivalent of LiCl, and existed as a dimer bridged by LiCl.
  • Example 10 Synthesis of Catalyst 10
  • In a drybox, 0.502 g (tert-butyl)2PLi was added to a −30° C. solution of 0.5613 g ethyl trifluoropyruvate (Lancaster) in 25 mL THF in a 100 mL RB flask. The reaction mixture turned yellow and then copper color. The mixture was allowed to warm up to RT and to stir at this temperature overnight. THF was evaporated. The product was dried under vacuum. 31PNMR in THF-d8: singlet peak at 41.22 ppm. The product was mixed with 0.453 g ((allyl)NiCl)2 and 25 mL THF in a RB flask. The mixture was allowed to stir for 1 h at RT. The mixture was evaporated to dryness. The residue was mixed with 5 mL toluene. Pentane (40 mL) was then added into the flask. The brown solid was filtered, followed by 3× pentane wash and dried in vacuo. Brown solid (0.745 g) was obtained. 31PNMR in THF-d8: Singlet peak at 46.04 ppm.
  • Example 11 Synthesis of Catalyst 11
  • In a drybox, 0.40 g Ph2PLi was added to a −30° C. solution of 0.4357 g monoimine-B in 25 mL THF in a 100 mL RB flask. The reaction mixture turned orange. The mixture was allowed to warm up to RT and stir at this temperature for 1 h. THF was evaporated. The product was dried under vacuum. 31PNMR in THF-d8: A major singlet peak at −22.60 and two small singlet peaks at −16.15 ppm and −82.25 ppm. The product was mixed with 0.2798 g ((allyl)NiCl)2 and 25 mL THF in a RB flask. The mixture was allowed to stir for 2 h at RT. The mixture was evaporated to dryness. The residue was extracted with toluene, filtered and washed with toluene. Solvent was evaporated. The product was dried in vacuo.
  • Example 12 Synthesis of Catalyst 12
  • In a drybox, 0.40 g Ph2PLi was added to a −30° C. solution of 0.3794 g benzophenone in 25 mL THF in a 100 mL RB flask. The reaction mixture turned blue-green. The mixture was allowed to warm up to RT and to stir at this temperature for 1 h. THF was evaporated. The product was dried under vacuum. 31PNMR in THF-d8: A major singlet peak at −14.28 and a small singlet peaks at −26.30 ppm, as well as a tiny singlet peak at −39.62 ppm. The product was mixed with 0.2796 g ((allyl)NiCl)2 and 25 mL THF in a RB flask. The mixture was allowed to stir for 2 h at RT. The mixture was evaporated to dryness. The residue was extracted with toluene, filtered and washed with toluene. Solvent was evaporated. The product was dried in vacuo.
  • Example 13 Synthesis of Catalyst 13
  • In a drybox, 0.30 g (tert-butyl)2PCH2Li was added to a −30° C. solution of 0.5137 g 4,4′-bis(dimethylamino)thio-benzophenone in 20 mL THF in a 100 mL RB flask. The reaction mixture turned golden yellow. The mixture was allowed to warm up to RT and to stir at this temperature for a few h. THF was evaporated. The product was dried under vacuum overnight. 31PNMR in THF-d8: A major singlet peak at 21.53 ppm and some minor peaks at 26.05 ppm, 24.34 ppm, 16.58 ppm and 12.74 ppm. The product was mixed with 0.148 g ((allyl)NiCl)2 and 15 mL THF in a RB flask. The mixture was allowed to stir for 2 h at RT. The mixture was evaporated to dryness. The solid product was dried in vacuo overnight. 31PNMR in THF-d8: A singlet peak at 101.84 ppm.
  • Example 14 Synthesis of Catalyst 14
  • In a drybox, 0.40 g (tert-butyl)2PCH2Li was added to a −30° C. solution of 0.2485 g benzonitrile in 20 mL THF in a 100 mL RB flask. The reaction mixture turned red-orange. The mixture was allowed to warm up to RT and stir at this temperature for a few hours. THF was evaporated. The product was dried under vacuum overnight. 31PNMR in THF-d8: A broad singlet peak at 7.26 ppm. 1HNMR in THF-d8 indicated that it was (t-Bu)2PCH(Li)C(Ph)=NH: 1.14 ppm (18H, (CH3)3C—, d, 3JPH=10.8 Hz); 3.71 ppm (1H, broad singlet); 4.23 ppm (1H, broad singlet, —C(Ph)=NH); 7.11 ppm (1H, ArH, t); 7.18 ppm (2H, ArH, t); 7.64 ppm (2H, ArH, d). The product was mixed with 0.327 g ((allyl)NiCl)2 and 20 mL THF in a RB flask. The mixture was allowed to stir for 2.5 h at RT. The mixture was evaporated to dryness. The solid product was extracted with 10 mL toluene and was filtered through Celite®, followed by 3×10 mL toluene wash. Toluene was evaporated. The solid product was dried in vacuo overnight. Dark brown solid (0.379 g) was obtained. 31PNMR in THF-d8: A singlet peak at 73.06 ppm. 1HNMR in THF-d8 indicated that it is the expected ((t-Bu)2PCH2C(Ph)=NNi(allyl)) complex: 1.26 and 1.41 ppm (9H each, (CH3)3C—, d, 3JPH=12.9 Hz for both); 1.59 and 2.49 ppm (1H each, d, PCHH′); 3.11, 3.59, 3.68, 4.24 ppm (1H each, broad singlets, allyl-H); 5.02 ppm (1H, m, central allyl-H); 7.26 ppm (3H, s, ArH); 7.53 ppm (2H, s, ArH).
  • Example 15 Synthesis of Catalyst 15
  • In a drybox, 0.40 g (tert-butyl)2PLi was added to a −30° C. solution of 0.2186 g trimethylacetonitrile in 20 mL THF in a 100 mL RB flask. The reaction mixture turned yellow. The mixture was allowed to warm up to RT and to stir at this temperature for 3 d. THF was evaporated. The product was dried under vacuum overnight. 31PNMR in THF-d8: 45.93 ppm and a minor peak at 21.13 ppm. The product was mixed with 0.357 g ((allyl)NiCl)2 and 20 mL THF in a RB flask. The mixture was allowed to stir for 1 h at RT. The mixture was evaporated to dryness. The solid product was extracted with toluene and was filtered through Celite®, followed by 3× toluene wash. Toluene was evaporated. The solid product was dried in vacuo overnight. Red-brown solid (0.476 g) was obtained.
  • Example 16 Synthesis of Catalyst 16
  • In a drybox, 0.40 g (tert-butyl)2PCH2Li was added to a −30° C. solution of 0.2003 g trimethylacetonitrile in 20 mL THF in a 100 mL RB flask. The reaction mixture turned yellow. The mixture was allowed to warm up to RT and stir at this temperature for 3 d. THF was evaporated. The product was dried under vacuum overnight. 31PNMR in THF-d8: A major singlet peak at 17.67 ppm and a minor peak at 12.78. The product was mixed with 0.327 g ((allyl)NiCl)2 and 20 mL THF in a RB flask. The mixture was allowed to stir for 1 h at RT. The mixture was evaporated to dryness. The solid product was mixed with 10 mL toluene first and then 40 mL pentane. The solid was filtered, followed by 3× pentane wash and dried in vacuo overnight. 31PNMR in THF-d8: A singlet peak at 73.48 ppm. 1HNMR in THF-d8: 1.18 ppm (d, —P(CH3)3, 18H); 1.34 ppm (d, —C(CH3)3, 9H); 1.49 ppm, 2.38 ppm (1H each, d, PCHH′); 3.01 ppm, 3.23 ppm, 3.44 ppm, 3.97 ppm (1H each, brs, allyl-H); 4.92 ppm (1H, central allyl-H, m).
  • Example 17 Synthesis of Catalyst 17
  • In a drybox, 0.40 g (tert-butyl)2PLi was added to a −30° C. solution of 0.5529 g benzil in 20 mL THF in a 100 mL RB flask. The reaction mixture turned dark red-brown. The mixture was allowed to warm up to RT and stir at this temperature overnight. THF was evaporated. The product was dried under vacuum overnight. 31PNMR in THF-d8: A major singlet peak at 41.09 ppm and a minor peak at 2.45 ppm. The product was mixed with 0.359 g ((allyl)NiCl)2 and 20 mL THF in a RB flask. The mixture was allowed to stir for 1 h at RT. The mixture was evaporated to dryness. The solid product was mixed with 10 mL toluene first and then 90 mL pentane. The solid was filtered, followed by 3× pentane wash and dried in vacuo overnight. Light brown solid (0.59 g) was obtained.
  • Example 18 Synthesis of Catalyst 18
  • In a drybox, 0.40 g (tert-butyl)2CH2PLi was added to a −30° C. solution of 0.5066 g benzil in 20 mL THF in a 100 mL RB flask. The reaction mixture turned dark red-brown. The mixture was allowed to warm up to RT and to stir at this temperature overnight. THF was evaporated. The product was dried under vacuum overnight. 31PNMR in THF-d8: A major singlet peak at 14.28 ppm and several minor peaks were observed. The product was mixed with 0.329 g ((allyl)NiCl)2 and 20 mL THF in a RB flask. The mixture was allowed to stir for 1 h at RT. The mixture was evaporated to dryness. The solid product was mixed with 10 mL toluene first and then 90 mL pentane. The solid was filtered, followed by 3× pentane wash and dried in vacuo overnight. Yellow solid (0.285 g) was obtained. 31PNMR in THF-d8: A major singlet peak at 94.03 ppm and minor peaks at 67.51, 66.72 and 62.29 ppm were observed.
  • Example 19 Synthesis of Catalyst 19
  • A 100 mL RB flask was charged with 102 mg (0.86 mmol) of phenyl isocyanate dissolved in ca. 10 mL THF. Then (t-Bu)2P—CH2Li (143 mg, 0.86 mmol) dissolved in ca. 10 mL THF was added. The solution is clear yellow. It was stirred for one h, after which time a solution of (Ni(C3H5)Cl)2 (116 mg, 0.43 mmol) in 15 mL THF was added. The solution turned brown-yellow. It was stirred for an additional one h and the solvent removed. The residue was washed with hexane and dried in vacuo. The yield was 207 mg (57%). Key NMR signals (incomplete): 1HNMR (CD2Cl2, 23° C., 300 MHz) δ 7.7-6.5 (brm, Ar); 5.32 (brs), 5.09 (m); 3.64 (brm); 3.01 (brm); 3.0-2.3 (brm); 2.0-0.6 overlapping signals+two doublets (J=14 Hz) at 1.42 ppm and 1.27 ppm corresponding to t-Bu signals). 31PNMR (CD2Cl2, 23° C., 300 MHz): δ 50.6.
  • Example 20A Synthesis of (t-Bu)2POC(CH3)2C(CH3)2OH
  • In a drybox, 0.623 g pinacol and 2.0 g (t-Bu)2PCl were dissolved in 20 mL THF. To this mixture was added over 10 min 0.4438 g KH in portions. The mixture was allowed to stir at RT for 12 d. The mixture was filtered through Celite®, followed by 3×5 mL THF wash. Solvent was evaporated. The viscous liquid was dried overnight. Light tan viscous liquid was obtained. 31PNMR in CD2Cl2: A singlet peak at 135.29 ppm and a few minor peaks. Crystals grew out of the liquid in several days. X-ray single crystal analysis indicated that it was the desired product. It existed as tetramer in the solid state through hydrogen bonding.
  • Example 20B Synthesis of Catalyst 20
  • Catalyst 20 was generated in-situ by adding 13.9 mg of (t-Bu)2POC(CH3)2C(CH3)2OH to a chlorobenzene solution of (TMEDA)NiMe2 (10.2 mg in 5 mL chlorobenzene, TMEDA=tetramethylethylenediamine).
  • Example 20C Polymerization using Catalyst 20
  • The in-situ prepared Catalyst 20 (0.05 mmol, see Example 20B) was screened for ethylene polymerization at 6.9 MPa of ethylene at 50° C. for 18 h in a shaker tube. Polyethylene (0.067 g) was obtained. It had melting points of 131° C. (166.7 J/g) and 114° C. (33.5 J/g).
  • Example 21 Synthesis of Catalyst 21
  • In a drybox, 0.489 g (tert-butyl)2PCH2Li was mixed with 25 mL THF in a Schlenk flask. It was brought out of the drybox and placed in an ice-water bath. One atmosphere of carbon dioxide was applied to the flask. The mixture was allowed to stir at 0° C. under 1 atm of carbon dioxide for 15 min and then at RT for 45 min. The CO2 flow was stopped. THF was evaporated. The product was dried under full vacuum overnight. Tan yellow solid was obtained. Part of the product (0.4204 g) was mixed with 0.2704 g ((allyl)NiCl)2 in 20 mL THF. The mixture was allowed to stir at RT for 40 min. The mixture was evaporated to dryness and was added to 5 mL toluene to dissolve, followed by addition of about 70 mL pentane. The solid was filtered, followed by 3×5 mL pentane wash. The product was dried under full vacuum overnight. Orange solid (0.48 g) was obtained. 31PNMR in THF-d8: singlet peak at 51.70 ppm. 1HNMR in THF-d8: 5.34 ppm (bm, central allyl-H, 1H); 2.67-2.95 (bm, allyl-CH2 and PCH—, 6H); 1.34 ppm (d, JPH=12.4 Hz, C(CH3)3, 18H). Lithium NMR in C6D8 of 21 and a crystal structure of the Zwitterion tetrafluoroborate derivative indicate that one equivalent of Li+ present which can potentially complex to 21 does not in fact complex to 21.
  • Example 22 Synthesis of Catalyst 22
  • In a drybox, 0.1009 g (tert-butyl)2PCH2C(Ph)2OLi.THF (see Example 2) was dissolved in 5 mL THF in a 20 mL vial. To this was added 56 mg of ZrCl4. The solution turned a peach color. It was allowed to stir overnight. Solvent was evaporated and the resulting solid was dried in vacuo.
  • Example 23 Synthesis of Catalyst 23
  • In a drybox, 0.1009 g (tert-butyl)2PCH2C(Ph)2OLi.THF (see Example 2) was dissolved in 5 mL THF in a 20 mL vial. To this was added 45.5 mg of TiCl4. The solution turned dark amber. It was stirred overnight. Solvent was evaporated and the resulting tan solid was dried in vacuo.
  • Ethylene Polymerization Screening Using the Nickel Catalysts 1-21
  • In a drybox, a glass insert was loaded with the isolated Ni catalysts (except Catalyst 20 in Example 20, which was generated in-situ). Solvent (TCB or chlorobenzene), optionally comonomers were added to the glass insert. A Lewis acid cocatalyst (typically BPh3 or B(C6F5)3) was often added to the solution. The insert was then capped and sealed. Outside of the drybox, the tube was placed under ethylene and was shaken mechanically at desired temperature listed in Table 3 for about 18 h. Sometimes an aliquot of the solution was used to acquire a 1HNMR spectrum. The remaining portion was added to about 20 mL of methanol in order to precipitate the polymer. The polymer was isolated, washed with methanol several times and dried in vacuo.
  • Ethylene Polymerization Screening By the Catalysts 22 and 23, in the Presence of MAO
  • In a drybox, a glass insert was loaded with 0.02 mmol of the isolated Zr or Ti catalyst and 9 mL of 1,2,4-trichlorobenzene. It was then cooled to −30° C. PMAO-IP (1 mL 12.9 wt % (in Al) toluene solution) was added to the frozen solution. It was put in a −30° C. freezer. The insert was then capped and sealed. Outside of the drybox, the cold tube was placed under ethylene and was shaken mechanically at desired temperature listed in Table 3, condition V, for about 18 h. Methanol (about 15 mL) and 2 mL conc. hydrochloric acid was added to the mixture. The polymer was isolated, washed with methanol several times and dried in vacuo.
  • Polymer Characterization
  • The results of ethylene polymerization and copolymerization catalyzed by Catalysts 1-23 under different reaction conditions (See Table 3) are reported in Tables 4-13. The polymers were characterized by NMR, GPC and DSC analysis. A description of the methods used to analyze the amount and type of branching in polyethylene is given in previously incorporated U.S. Pat. No. 5,880,241. GPC's were run in trichlorobenzene at 135° C. and calibrated against polyethylene using universal calibration based on polystyrene narrow fraction standards. DSC was recorded between −100° C. to 150° C. at a heating rate of 10° C./min. Data reported here are all based on second heat. 1HNMR of the polymer samples was run in tetrachloroethane-d2 at 120° C. using a 500 MHz Bruker spectrometer.
  • TABLE 3
    Conditions for Ethylene Polymerization
    and Copolymerization Screening.
    I 0.02 mmol catalyst, 10 mL TCB, RT, 18 h, 6.9 MPa ethylene,
    10 eq B(C6F5)3
    II 0.02 mmol catalyst, 10 mL TCB, RT, 18 h, 1.0 MPa ethylene,
    10 eq B(C6F5)3
    III 0.02 mmol catalyst, 10 mL TCB, 60° C., 18 h, 1.0 MPa ethylene,
    10 eq B(C6F5)3
    IV 0.02 mmol catalyst, 3 mL TCB, 2 mL E-10-U*, 60° C., 18 h, 1.0
    MPa ethylene, 40 eq B(C6F5)3
    V 0.02 mmol catalyst, 9 mL TCB, 1 mL PMAO-IP (12.9 wt % (in Al)
    in toluene), RT, 18 h, 6.9 MPa ethylene
    VI 0.02 mmol catalyst, 4 mL TCB, 1 mL n-hexyl acrylate, 120° C.,
    18 h, 6.9 MPa ethylene, 40 eq B(C6F5)3
    VII 0.02 mmol catalyst, 10 mL TCB, 60° C., 18 h, 1.0 MPa ethylene,
    10 eq B(C6F5)3, 1 eq NaBAF
    *Ethyl-10-Undecylenate.
  • TABLE 4
    Ethylene Polymerization at 6.4 MPa Ethylene in Shaker Tubes (0.05 mmol
    catalyst, 5 mL chlorobenzene, 18 h)
    Cocatalyst/ Yield #Me/ m.p.
    Ex. Catalyst amt T(° C.) (g) 1000CH2 (° C.) Mw/PDI TON* *
    24 1 BPh3/5 eq 25 10.202 <1 136 (162*) 737,803/3.5  7,287
    25 1 B(C6F5)3/5 eq 25 4.764 9 128 134,256/60.2 3,403
    26 1 none 25 0
    27 1 BPh3/5 eq 80 4.990 6 133 47,301/3.3 3,564
    28 1 B(C6F5)3/5 eq 80 1.710 12 124  15,813/14.0 1,221
    29 2 B(C6F5)3/5 eq 80 2.280 31 125  4,759/3.0 1,629
    30 2 BPh3/5 eq 80 0
    31 4 B(C6F5)3/10 eq 50 4.862 86 114, 106  28,765/41.8 3,466
    32 11 B(C6F5)3/10 eq 50 0.117 25 119, 102 209
    33 12 B(C6F5)3/2 eq 50 0.046 19 119, 102 82
    *Heat of fusion (in J/g)
  • TABLE 5
    Ethylene (Co)polymerization at 2.1 MPa Ethylene in
    Shaker Tubes (0.05 mmol catalyst, 5 mL solvent/comonomer, 18 h)
    Cocatalyst/ Solvent/ T Yield Mole % #Me/ m.p. Mw/ TON
    Ex. Catalyst eq Comonomer (° C.) (g) Comonomer 1000 CH2 (° C.) PDI E/Comonomer
    34 1 BPh3/2 C6H5Cl 50 5.518  <1a) 136 173,568/3.1  3941
    35 1 BPh3/5 C6H5Cl 50 4.56  2 135 191,589/5.1 3,321
    36 1 BPh3/10 C6H5Cl 50 5.132  2 137 268,453/3.5 3,666
    37 1 BPh3/10 1-Hexene 50 1.295  12 111 121,450/2.4 /
    38 1 BPh3/10 E-4-P* 50 4.972 3.0  1b) 117  62,753/3.7 3,100/97 
    39 2 B(C6F5)3/2 C6H5Cl 50 1.816  8 127  20,100/9.2 1,297
    40 2 B(C6F5)3/10 C6H5Cl 50 12.314  12   125***  19,712/5.1 8,796
    41 2 B(C6F5)3/10 1-Hexene 50 3.662  48c)  99  14,611/5.2 /
    42 2 B(C6F5)3/30 E-10-U** 80 5.616 9.9  24 −10  7,298/6.0 2,189/240
    43 3 B(C6F5)3/10 C6H5Cl 50 1.799  28 113  189,503/16.6 1,285
    44 3 BPh3/10 C6H5Cl 50 0
    45 3 B(C6F5)3/10 1-Hexene 50 0.738  87  72 146,422/3.4 /
    46 3 B(C6F5)3/30 E-10-U 80 3.427 2.2 105 117, 106    264,357107.9 2,089/47 
    *Ethyl-4-pentenoate
    **Ethyl-10-Undecylenate
    ***Heat of fusion: 200 J/g.
    a)No alkyl branches based on 13CNMR.
    b)No alkyl branches, 2.6 mole % ethyl-4-pentenoate based on 13CNMR.
    c)Based on 13CNMR, total Me was 34.4 (1.7Me, 2.7Et, 0.7Pr, 25.9Bu, 0.5Am, 2.9Hex+). The enriched butyl branch is consistent with the significant 1-hexene incorporation in ethylene copolymerization.
  • TABLE 6
    Ethylene (Co)polymerization 1.0 MPa Ethylene at 50° C. in
    Shaker Tubes (0.05 mmol catalyst, 5 mL solvent/comonomer, 18 hr)
    Cocatalyst/ Yield Mole % #Me/ Mw/ TON
    Ex Catalyst eq Solvent/Comonomer (g) Comonomer 1000CH2 PDI E/Comonomer
    47 2 B(C6F5)3/30 MUE* 1.928 6.3 11 7,674/3.7 952/64
    48 4 B(C6F5)3/30 MUE 0.102 6.0 24 17,303/11.7 51/3
    *Methyl undecenyl ether (CH2═CH(CH2)9OCH3).
  • TABLE 7
    Condition I in Table 3
    Yield #Me/ m.p.
    Ex Catalyst (g) 1000CH2 (° C.) (ΔHf) Mw/PDI TON
    49 2 7.264 6 128 (234) 32,932/3.82 12,947
    50 5 15.560 10 125 (218) 13,921/4.91 27,734
    51 6 11.718 14 124 (206) 10,411/3.68 20,886
    52 7 10.619 20 117 (185) 2,792/2.57 18,927
    53 13 0.029 7 131 (161) 49,268/4.1 52
    54 8 8.970 22 125 (142) 187,705/4.9 15,988
    55 9 9.728 12 130 (194) 30,547/18.3 17,339
    56 10 0.112 22 127 (182) 190,093/ 200
    182.7
    trimodal
    57 14 6.401 121 120 (81)  67,779/251.5 11,409
    trimodal
    58 15 8.407 16 126 (102) 93,871/3.1 14,985
    59 16 0.088 73 123 (99)  25,262/24.7 157
    60 17 1.250 30 129 (141) 73,164/2.4 2228
    61 18 14.279 33 118 (148) 4,162/4.7 25,450
    62 19 11.233 21 121 (169) 14,451/7.0 20,022
    63 21 19.292 52 114 (169), 4,593/3.9 34,386
    108
  • TABLE 8
    Condition II in Table 3
    Yield #Me/ m.p.
    Ex Catalyst (g) 1000CH2 (° C.) (ΔHf) Mw/PDI TON
    64 2 2.492 19 120 (140) 46,024/4.5 4,442
    65 5 1.202 10 127 (181) 52,542/4.3 2,142
    66 6 2.631 30 120 (130) 11,521/3.2 4,689
    67 7 1.188 21 122 (207)  6,405/3.2 2,117
    68 9 2.057 22 125 (175)  32,505/37.8 3,666
  • TABLE 9
    Condition III in Table 3
    Yield #Me/ m.p.
    Ex Catalyst (g) 1000CH2 (° C.) (ΔHf) Mw/PDI TON
    69 2 1.934 11 125 (164) 13,263/3.1  3447
    70 5 6.624 13 124 (194) 10,468/3.2  11,807
    71 6 6.276 30 115 (198) 5,285/3.6 11,186
    72 7 4.196 32 115 (172) 2,688/2.6 7,479
    73 18 5.629 38 108 (88)  8,381/9.1 10,033
    74 19 9.868 50 100 (63)  7,784/9.8 17,589
    75 21 6.560 31 113 (112) 5,581/5.5 11,692
  • TABLE 10
    Condition IV in Table 3
    Yield #Me/ Mole % m.p. TON
    Ex Catalyst (g) 1000CH2 Comonomer (° C.) (ΔHf) Mw/PDI E/EU*
    76 2 0.648 6 2.8 112 (124) 5,737/2.6 947/28
    77 5 3.861 6 4.9 108 (92)  6,315/2.5 4,939/257 
    78 6 0.129 12 5.1 124, 108 (124) 7,435/4.0 164/9 
    79 7 0.268 16 4.8  88 (116) 1,665/2.9 347/17
    80 15 0.060 15 2.6 114 (132) 29,070/6.8  89/2
    81 18 2.360 11 15.0 3,017/2.5 1,798/318 
    82 19 1.165 21 10.6 7,057/4.0 1,095/130 
    *Ethylene/Ethyl-10-undecylenate
  • TABLE 11
    Condition V in Table 3
    Yield #Me/ m.p.
    Ex Catalyst (g) 1000CH2 (° C.) (ΔHf) TON
    83 22 5.50 21 132 (157) 9,803
    84 23 4.520 18 134 (136) 8,056
    85  23* 4.543 8 134 (125) 8,097
    *One equivalent of (tert-butyl)2PCH2CPh2OLi•THF was added to Catalyst 23.
  • TABLE 12
    Condition VI in Table 3
    Yield #Me/ Mole % m.p. TON
    Ex Catalyst (g) 1000CH2 Comonomer (° C.) (ΔHf) Mw/PDI E/HA
    86 21 14.07 27 0.74* 114 (184) 2,757/3.0 24,079, 179
    *0.42 mole % in chain acrylate branch and 0.32 mole % unsaturated chain end.
  • TABLE 13
    Condition VII in Table 3
    Yield #Me/ m.p.
    Ex. Catalyst (g) 1000CH2 (° C.) (ΔHf) Mw/PDI TON
    87 2 6.902 29 121 (145) 15,842/5.6  12,302
    88 5 13.547 18 122 (167) 8,675/4.6 24,146
    89 7 13.858 59 106 (110) 3,033/3.3 24,700
  • As noted above, one potential problem with the copolymerization of ethylene (and/or other olefins) and a polar comonomer such as an acrylate is the possibility of obtaining a homopolymer of the polar comonomer because of free radical polymerization of that polar comonomer. One method of determining whether such a homopolymer is present is to run an NMR spectrum of the polymer(s). Unfortunately, using 1H-NMR for some of the more common acrylate monomers such as methyl acrylate the 1H spectra of the homopolymer and ethylene copolymers overlap, so a quantitative analysis is difficult. Although this analysis can be done by 13C-NMR, it is more difficult, expensive and time consuming. However, when an acrylate of the formula H2C═CHC(O)OR36, wherein R36 is —CH2CH2OR37, and R37 is aryl or substituted aryl, preferably aryl, is used, the peaks do not overlap at all in the 1H-NMR spectra, and that is a great advantage in determining whether the copolymer is “contaminated” with homopolymer.
  • Total methyls per 1000 CH2 are measured using different NMR resonances in 1H and 13C NMR. Because of accidental overlaps of peaks and different methods of correcting the calculations, the values measured by 1H and 13C NMR will usually not be exactly the same, but they will be close, normally within 10-20% at low levels of acrylate comonomer. In 13C NMR the total methyls per 1000 CH2 are the sums of the 1B1, 1B2, 1B3, and 1B4+, EOC resonances per 1000 CH2, where the CH2's do not include the CH2's in the alcohol portions of the ester group. The total methyls measured by 13C NMR do not include the minor amounts of methyls from the methyl vinyl ends or the methyls in the alcohol portion of the ester group. By 1H NMR the total methyls are measured from the integration of the resonances from 0.6 to 1.08 and the CH2's are determined from the integral of the region from 1.08 to 2.49 ppm. It is assumed that there is 1 methine for every methyl group, and ⅓ of the methyl integral is subtracted from the methylene integral to remove the methine contribution. The methyl and methylene integrals are also usually corrected to exclude the values of the methyls and methylenes in the alcohol portion of the ester group, if this is practical. Because of the low levels of incorporation, this is usually a minor correction.
  • FIG. 1 shows the 1H-NMR spectrum of a mixture of an EGPEA (Z=1, R37 is phenyl) homopolymer in a mixture with an EGPEA compolymer with ethylene. The spectrum was obtained on a 500 MHz Bruker Avance spectrometer on a 5 mm QNP probe on samples diluted ˜10 mg/0.5 ml in tce-d2 at 120° C. using a 90 degree pulse of 14 μsec, a spectral width of 12.8 kHz, an acquisition time of 2.6 sec and a recycle delay of 30 sec. A total of 8 transients were acquired. Spectra were referenced to tce-d2 at 5.928 ppm. FIG. 1 also indicates the assignments of the various peaks. Using EGPEA (and other acrylates described above) separation of the homopolymer and copolymer peaks is clear and quantitative analysis of the mixture is possible.
  • Another NMR analysis used below is end group analysis of ethylene copolymers with acrylates. 100 MHz 13C NMR spectra were obtained on a Varian® Unity 400 MHz spectrometer on typically 10 wt % solutions of the polymers and 0.05 M CrAcAc in 1,2,4-trichlorobenzene (TCB) in a 10 mm probe unlocked at 120° C. using a 90 degree pulse of 19.2 μsec, a spectral width of 35 kHz, a relaxation delay of 5 s, an acquisition time of 0.64 s. and inverse gated decoupling (decoupling only during acquisition). A few samples were run under similar conditions on a Bruker Avance 500 MHz NMR. A typical sample contained 310 mg polymer and 60 mg CrAcAc in TCB with a total volume of 3.1 mL (Varian recommended volume) in a 10 mm NMR tube; care was taken that the sample was very well mixed and uniform in consistency. Samples were preheated for at least 15 min. in the NMR before acquiring data. Data acquisition time was typically 10.5 hr per sample. The T1 values of the carbons of an ethylene/methyl acrylate copolymer sample were measured under these conditions to be all less than 0.9 s. The longest T1 measured was for the Bu+, EOC resonance at 14 ppm, which was 0.84 s. Spectra are referenced to the solvent—the TCB high field resonance at 127.918 ppm.
  • Integrals of unique carbons in each branch were measured and were reported as number of branches per 1000 methylenes. Counted in these methylenes are those in the backbone (main chain) and branches, but not methylenes in the alcohol portions of esters, for example the —OCH2 CH3 methylene in an ethyl ester. These integrals are accurate to +/−5% relative for abundant branches and +/−10 or 20% relative for branches present at less than 10 per 1000 methylenes. FIG. 2 shows such a spectrum together with assignments of various carbon atoms.
  • Figure US20100222531A1-20100902-C00019
  • Details about NMR nomenclature (e.g., 2B5+) and other details of NMR polymer analysis, will be found in previously incorporated U.S. Pat. No. 5,880,241.
  • GPC molecular weights are reported versus polystyrene standards. Unless noted otherwise, GPC's were run with RI detection at a flow rate of 1 mL/min at 135° C. with a run time of 30 min. Two columns were used: AT-806MS and WA/P/N 34200. A Waters RI detector was used and the solvent was TCB with 5 grams of BHT per 3.79 L. Dual UV/RI detection GPC was run in THF at rt using a Waters 2690 separation module with a Waters 2410 RI detector and a Waters 2487 dual absorbance detector. Two Shodex columns, KF-806M, were used along with one guard column, KF-G. In addition to GPC, molecular weight information was at times determined by 1H NMR spectroscopy (olefin end group analysis) and by melt index measurements (g/10 min at 190° C.).
  • Figure US20100222531A1-20100902-C00020
    Figure US20100222531A1-20100902-C00021
    Figure US20100222531A1-20100902-C00022
  • Example 90 Synthesis of Catalyst 24
  • In a drybox, 0.100 g Catalyst 21 and 15 mL toluene were combined. To this orange solution was added 0.177 g tris(pentafluorophenyl)boron at RT. The cloudy orange solution was stirred at RT overnight. The reaction mixture was filtered through Celite®, followed by 3×5 mL toluene wash. The filtrate was evaporated to ca. 2 mL and was added 50 mL pentane. The yellow precipitate was filtered and washed with 3×5 mL pentane. The product was dried in vacuo. Final yield of the yellow solid was 0.088 g (33%). X-ray single crystal analysis confirmed the proposed structure (Zwitter-ionic complex). 31PNMR in CD2Cl2: δ 60.05 (s). 1HNMR in CD2Cl2: (obtained by 1D NOE, 2D 1H—13C correlation (HMQC) and NOESY experiments): δ 5.42 (sept, central allyl-H, 1H); 4.18 (vd, J=7.9 Hz, syn-terminal allyl-H, on the C═O side, 1H); 3.04-3.07 (m, overlapped peaks of syn-terminal-allyl proton that is close to (t-Bu)2P and anti-terminal-allyl proton that is close to C═O, 2H total); 2.82-2.98 (ABX pattern (X is phosphorus), JAB=18.4 Hz, 2JPH=8.3 Hz, PCHH′, 2H total); 1.77 (d, 2JPH=12.9 Hz, anti-terminal-allyl-H that is close to (t-Bu)2P, 1H); 1.35 (d, 3JPH=14.7 Hz, C(CH3)3, 9H); 1.18 (d, 3JPH=14.7 Hz, C(CH3)3, 9H). 19FNMR in CD2Cl2: δ −134.89 (d, J=20.2 Hz, ortho-F, 6F); −159.75 (t, para-F, 3F); −165.63 (t, meta-F, 6F).
  • Example 91 Synthesis of Catalyst 25
  • In a drybox, 0.3545 g (1.806 mmole) trans-stilbene oxide and 20 mL THF were combined. The clear solution was cooled at −30° C. for 0.5 h. Then 0.3 g (1.806 mmole) (t-Bu)2PCH2Li was added. The resulting pale yellow reaction was stirred at RT for 3 h. The reaction was evaporated under full vacuum overnight. 31PNMR of the ligand precursor in THF-d8: δ 12.00 (s, major); 26.73 (s, minor). Then 0.6443 g (1.778 mmole) ligand precursor and 20 mL THF were combined. To this solution was added 0.2404 g (0.889 mmole) nickel allyl chloride dimer. After stirring overnight, the reaction was evaporated under full vacuum. To the resulting residue was added 20 mL toluene. The solution was filtered through Celite®, followed by 3×10 mL toluene wash. The filtrate was evaporated under full vacuum. To the residue was added 30 mL pentane and the resulting solid was stirred for several minutes. The solid was filtered and was washed with 3×10 mL pentane. The sample was dried in vacuo for several hours. Final weight of the light brown solid was 51.4 mg (6%).
  • Example 92 Synthesis of Catalyst 26
  • In a drybox, 0.387 g (1.972 mmole) trans-stilbene oxide and 20 mL THF were combined. The clear solution was cooled to −30° C. for 0.5 h. Then 0.3 g (1.972 mmole) (t-Bu)2PLi was added. The amber reaction was stirred at RT for 2.5 h. The reaction was then evaporated under full vacuum. Then 0.6769 g (1.943 mmole) ligand precursor and 20 mL THF were combined. To the reaction was added 0.2627 g (0.9715 mmole) nickel allyl chloride dimer. After stirring overnight, the reaction was evaporated under full vacuum. To the resulting residue was added 20 mL toluene. The solution was filtered through Celite®, followed by 3×10 mL toluene wash. The filtrate was evaporated under full vacuum to dryness. Final weight of the dark brown solid was 0.5148 g (60%).
  • Example 93 Synthesis of Catalyst 27
  • In a drybox, 0.300 g (1.806 mmole) (t-Bu)2PCH2Li and 20 mL THF were combined in a 50 mL Schlenk flask. The flask was removed from the drybox, placed on the Schlenk line, and degassed. After cooling the pale yellow solution to 0° C. with an ice bath, SO2 was applied at 1 atm. The ice bath was removed after 20 min and the reaction was allowed to warm to RT. After 15 min, SO2 was discontinued. The reaction mixture was stirred for an additional 25 min. The reaction mixture was then evaporated to remove excess SO2. The reaction mixture was transferred into a drybox. The solution was evaporated under full vacuum overnight. Then 0.4058 g (1.763 mmole) ligand precursor and 20 mL THF were combined. To this yellow solution was added 0.2385 g (0.882 mmole) nickel allyl chloride dimer. The dark red reaction mixture was stirred at RT for 2 h. The reaction mixture was then evaporated under full vacuum. The resulting red residue was triturated with 25 mL pentane. The solid was filtered and washed with 3×10 mL pentane. The sample was dried in vacuo for 45 minutes.
  • Example 94 Synthesis of Catalyst 28
  • In a drybox, 0.6214 g (3.01 mmole) bis(trimethylsilyl)sulfur diimide and 20 mL THF were combined. The yellow solution was cooled at −30° C. for 45 min. Then 0.5 g (3.01 mmole) (t-Bu)2PCH2Li was added. The orange-brown reaction mixture was stirred at RT for 1 h. To the reaction mixture was added 0.407 g (1.505 mmole) nickel allyl chloride dimer. The red solution was stirred at RT for 3 h. The reaction mixture was then evaporated under full vacuum overnight. To the residue was added 20 mL toluene. The solution was filtered through Celite®, followed by 3×10 mL toluene wash. The filtrate was evaporated under full vacuum. Final weight of the orange-brown solid was 1.0114 g (72%). 31PNMR in THF-d8: δ 93.78 (s).
  • Example 95 Synthesis of Catalyst 29
  • In a drybox, 0.4189 g (3.01 mmole) N-thionylaniline and 20 mL THF were combined. The clear solution was cooled at −30° C. for 0.5 h. Then 0.5 g (3.01 mmole) (t-Bu)2PCH2Li was added. The resulting orange-brown reaction was stirred at RT for 1 h. To the reaction mixture was added 0.407 g (1.505 mmole) nickel allyl chloride dimer. The red solution was stirred for 3 h at RT. The reaction mixture was then evaporated under full vacuum. To the residue was added 5 mL toluene, followed by 50 mL pentane. The resulting solid was stirred for several min, filtered, and washed with 3×10 mL pentane. Final weight of the dull orange-yellow solid was 0.884 g (67%). 31PNMR in THF-d8: 77.18 (s).
  • Example 96 Synthesis of Catalyst 30
  • In a drybox, 0.485 g (3.01 mmole) 1-methylisatin and 20 mL THF were combined. The orange solution was cooled at −30° C. for 45 min. Then 0.500 g (3.01 mmole) (t-Bu)2PCH2Li was added. The reaction mixture turned purple and it was stirred at RT for 1 h. To the reaction mixture was added 0.407 g (1.505 mmole) nickel allyl chloride dimer. The red solution was stirred at RT for 3 h. The reaction mixture was then evaporated under full vacuum overnight. To the residue was added 20 mL toluene. The solution was filtered through Celite®, followed by 3×10 mL toluene wash. The filtrate was evaporated under full vacuum. Final weight of the dark brown solid was 1.463 g.
  • Example 97 Synthesis of Catalyst 31
  • In a drybox, 0.6646 g (1.765 mmole) ArN═C(H)—C(H)═NAr (Ar=2,6-diisopropylphenyl) and 20 mL THF were combined. The yellow solution was cooled at —30° C. for 0.5 h. Then 0.2932 g (1.765 mmole) (t-Bu)2PCH2Li was added. The resulting orange-red reaction was stirred at RT for 1 h. To the reaction was added 0.2386 g (0.8825 mmole) nickel allyl chloride dimer. The red solution was stirred at RT for 3 h. The reaction was then evaporated under full vacuum. To the residue mixture was added 20 mL toluene. The solution was filtered through Celite®, followed by 3×10 mL toluene wash. The filtrate was evaporated under full vacuum. Final weight of the dark brown solid was 0.6937 g (62%).
  • Example 98 Synthesis Catalyst 32
  • In a drybox, 0.250 g (1.64 mmole) sodium chioromethylsulfonate and 20 mL THF were combined. The mixture was cooled to −30° C. for 0.5 h. Then 0.25 g (1.64 mmole) (t-Bu)2PLi was added and the mixture was stirred and allowed to slowly warm up to RT. As it warmed, the reaction mixture became cloudy orange. The reaction mixture was stirred at RT for two days. The resulting cloudy brown solution was evaporated under full vacuum. Then 0.425 g (1.62 mmole) ligand precursor and 20 mL THF were combined. To this brown suspension was added 0.219 g (0.81 mmole) nickel allyl chloride dimer. The resulting red-brown reaction mixture was stirred at RT for 3 h. The reaction mixture was then evaporated under full vacuum to dryness. The sample was triturated with 25 mL pentane. The solid was filtered and washed with 3×10 mL pentane. It was dried in vacuo for 1.5 h. Final weight of the light brown solid was 0.369 g (67%).
  • Example 99 Synthesis of Catalyst 33
  • In a dry box, to a 100 mL flask containing 10 mL of THF solution of 1,3-diisopropylcarbodiimide (0.0816 g, 0.64 mmole), was slowly added the THF solution of (t-Bu)2PCH2Li (0.107 g, 0.64 mmole). The solution changed from yellow to colorless upon stirring overnight. Solvent was removed. The residue was rinsed with pentane. White powder (0.136 g, 0.467 mmole) was obtained in 72% yield. 1H NMR of the ligand precursor (in C6D6): δ 0.98 (d, 18H, t-Bu-H); 1.3 (dd, 12H, —CH(CH3)2); 1.96 (s, d, 2H, PCH2); 3.80 (m, 2H, —CH(CH3)2). It contained one equivalent of hydrolyzed product that might be resulted of hydrolysis of the lithium salt during the period outside of the drybox. 31PNMR (C6D6): δ 21.837 (s); 13.177 (s). In the dry box, 0.0542 g (0.185 mmole) of the ligand precursor and 0.0441 g (0.092 mmole) allyl-Ni-bromide dimer {((2-MeO2C—C3H4)NiBr)2} were mixed in 10 mL THF in a 50 mL flask. The mixture was stirred for 1 h. THF was removed in vacuo and the residue was extracted with ether. After removal of ether, the product was washed with pentane. Light brown solid (0.0434 g, 0.098 mmole) was obtained in 53% yield. 31PNMR (C6D6): δ 61.89 (s).
  • Example 100 Synthesis of Catalyst 34
  • In a dry box, to a 100 mL RB flask containing 10 mL THF solution of 1,3-bis-(2,6-diisopropylphenyl) carbodiimide (0.245 g, 0.675 mmole), was slowly added THF solution of (t-Bu)2PCH2Li (0.112 g, 0.675 mmole). Upon stirring overnight, the solution turned from yellow to colorless. Solvent was removed and the product was washed with pentane. White powder (0.272 g, 0.514 mmole) was obtained in 76% yield. 1HNMR (C6D6): δ 0.98 (d, 24H, —CH(CH3)2); 1.37 (d, 18H, t-Bu-H); 2.41 (d, 2H, PCH2); 3.26 (m, 2H, —CH(CH3)2); 3.56 (m, 2H, —CH(CH3)2); 6.92-7.60 (m, 6H, Ar—H). 31PNMR (C6D6): δ 19.12 (s): In the dry box, 0.0814 g (0.154 mmole) of the ligand precursor and 0.0366 g (0.077 mmole) of the allyl-Ni-bromide dimer (((2-MeO2C—C3H4)NiBr)2) were mixed in 10 mL THF in a 50 ml RB flask and the mixture was stirred for 1 h. THF was removed in vacuo and the residue was extracted with ether. Upon removal of the ether, the product was washed with pentane. Yellow powder (0.0906 g, 0.133 mmole) was obtained in 87% yield. 31PNMR (C6D6): δ 59.68 (s).
  • Example 101 Synthesis of Catalyst 35
  • In a dry box, to the 100 mL RB flask containing 10 mL of THF solution of 1,3-bis(trimethylsilyl)carbodiimide (0.0813 g, 0.436 mmole), was added slowly a THF solution of (t-Bu)2PCH2Li (0.0725 g, 0.436 mmole). The solution turned from yellow to colorless after stirring overnight. Solvent was removed. The white solid residue, which is soluble in pentane, was mixed with 0.1036 g (0.218 mmole) of allyl-Ni-bromide complex (((2-MeO2C—C3H4)NiBr)2) in 30 mL THF. The mixture was stirred for an hour. Solvent was then removed under vacuum. The residue was extracted with ether. Solvent was removed. The solid was rinsed with pentane. Orange powder (0.0515 g, 0.102 mmole) was obtained in 23% yield. 1HNMR (C6D6): δ 0.21 (s, 1H, allyl-H); 0.25 (s, 18H, —Si(CH3)3); 0.94 (d, 19H, t-Bu-H and allyl-H); 1.28 (s, 2H, PCH2); 3.0 (s, 1H, allyl-H); 3.3 (s, 3H, —OCH3); 3.62 (s, 1H, allyl-H). 31PNMR (C6D6): δ 57.65.
  • Example 102 Synthesis of Catalyst 36
  • In a dry box, to a 100 mL RB flask containing 10 mL of THF solution of 1,3-dicyclohexylcarbodiimide (0.143 g, 0.694 mmole), was added slowly a THF solution of (t-Bu)2PCH2Li (0.115 g, 0.694 mmole) at RT. The color of the solution turned yellow and the mixture was stirred overnight. Solvent was removed under vacuum and the white solid residue was mixed with 0.1649 g (0.348 mmole) of allyl-Ni-bromide complex (((2-MeO2C—C3H4)NiBr)2) in 30 mL of THF. The mixture was stirred for 1 h. Solvent was then removed under vacuum. The residue was extracted with ether. Ether was then removed. The solid was rinsed with pentane. Orange powder (0.150 g, 0.287 mmole) was obtained in 41% yield. 31PNMR (C6D6): δ 62.55 (s).
  • Example 103 Synthesis of Catalyst 37
  • In a dry box, to a 100 mL RB flask containing 10 mL THF solution of 1-naphthylisothiocyanate (0.079 g, 0.426 mmole), was slowly added a THF solution of (t-Bu)2PCH2Li (0.0709 g, 0.426 mmole) at −30° C. The solution turned yellow orange and it was stirred for one h while the solution warmed up to RT. Solvent was removed. The solid residue was mixed with 0.101 g (0.312 mmole) of allyl-Ni-bromide complex (((2-MeO2C—C3H4)NiBr)2) in 30 mL THF. The mixture was stirred for 1 h. Solvent was removed under vacuum. The residue was extracted with ether. Solvent was evaporated and the product was rinsed with pentane. Brown powder (0.176 g, 0.351 mmole) was obtained in 82% yield. 31PNMR (C6D6): δ 73.43 (s, major).
  • Example 104 Synthesis of Catalyst 38
  • In a dry box, to a 100 mL RB flask containing 10 mL THF solution of cyclohexylisothiocyanate (0.0439 g, 0.311 mmole), was added slowly a THF solution of (t-Bu)2PCH2Li (0.0568 g, 0.311 mmole) at −30° C. The solution turned yellow orange it was stirred for 1 h, during which time the solution warmed up to RT. Solvent was removed. The solid residue was mixed with 0.0739 g (0.156 mmole) of allyl-Ni-bromide complex (((2-MeO2C—C3H4)NiBr)2) in 30 mL THF. The mixture was stirred for 1 h. Solvent was removed under vacuum. The residue was extracted with ether. The solvent was removed. The product was rinsed with pentane. Brown powder (0.0773 g, 0.169 mmole) was obtained in 54% yield. 31PNMR (C6D6): δ 66.69 (s, major).
  • Example 105 Synthesis of Catalyst 39
  • In a dry box, benzoylisocyanate (0.1966 g, 1.336 mmole) was dissolved in 20 mL THF in a 100 mL RB flask. The solution was cooled to ca. −30° C. in a freezer. (t-Bu)2PCH2Li (0.2220 g, 1.336 mmole) was added to the above cold solution under stirring. The mixture turned dark red. It was allowed to stir at RT for 4 h. The solution was then evaporated to dryness. To the ligand precursor (ca. 1.300 mmole) was added 20 mL THF. Under stirring, nickel allyl chloride dimer (0.1760 g, 0.6500 mmole) was added to the mixture. The solution became dark red. It was allowed to stir at RT for 2 h. Solvent was evaporated. Toluene (ca. 8 mL) was added to the brick red residue. Upon brief stirring, large excess of pentane was added. The resulting solid was filtered, followed by 3× pentane wash, and dried in vacuo. Pale orange solid (0.4223 g, 72%) was obtained.
  • Examples 106-120
  • Polymerizations with catalysts 24 through 38 are shown in Tables 14 and 15.
  • TABLE 14
    Condition I in Table 3
    Cata- Yield #Me/ m.p.
    Ex lyst (g) 1000CH2 (° C.) (ΔHf) Mw/PDI TON
    106  24* 7.81 26 118 (52.2)  4,495/4.9 13,900
    107 25 2.89 15 123 (0.6)  17,614/8.9  5,150
    108 26 8.26 21 122 (173.1) 19,394/11.2 14,700
    109 27 4.66 33 129 (147.6) 226,688/8.8  8,300
    110 28 1.07 20 127 (182.2) 34,420/33.5 1,900
    111 29 6.14 17 123 (159.3) 12,964/5.2  10,900
    112 30 9.71 32 123 (172.2) 4,898/8.1 17,300
    113 31 7.82 13 121 (126.8) 563,495/5.1  13,900
    114 32 11.75 12 131 (225.5) 254,365/106.4 20,940
    *No B(C6F5)3 was used. The catalyst self-initiated ethylene polymerization.
  • TABLE 15
    Ethylene Polymerization Using 0.02 mmole Catalyst,
    5 mL TCB and 10 eq B(C6F5)3, at RT
    under 6.9 MPa Ethylene for 18 h
    Yield #Me/ m.p. (° C.)
    Ex Catalyst (g) 1000CH2 (ΔHf) Mw TON
    115 33 4.427 27 129 (173.8) Trimodal 7604
    116 34 0.181 25 117 (116.9) Trimodal 343
    117 35 0.698 15 126 (190.1) 67,352 1160
    118 36 3.388 27 128 (165.6) Insoluble 4452
    in TCB
    119 37 0.083 35 130 (137.2) Trimodal 140
    120 38 0.321 21 129 (168.5) 70,329 535
  • Figure US20100222531A1-20100902-C00023
  • Examples 121-150
  • Examples 121-150 are listed in Tables 16-20 below. The structures for these compounds illustrate just one of the possible products and binding modes that may have formed during the synthesis of the ligand and the subsequent synthesis of the nickel compound and are not meant to be restrictive. The polymerizations were carried out according to General Polymerization Procedure A. Varying amounts of acrylate homopolymer are present in some of the samples. In Tables 16-20, the yield of the polymer is reported in grams and includes the yield of the dominant ethylene/acrylate copolymer as well as the yield of any acrylate homopolymer that was formed. Molecular weights were determined by GPC, unless indicated otherwise. All copolymerizations were run for 18 h, unless otherwise noted.
  • General Polymerization Procedure A: In a drybox, a glass insert was loaded with the nickel compound and, optionally, a Lewis acid (e.g., BPh3 or B(C6F5)3) and borate (e.g., NaBAF or LiBArF) and any other specified cocatalysts. Next, the solvent was added to the glass insert followed by the addition of any co-solvents and then comonomers. The insert was greased and capped. The glass insert was then loaded in a pressure tube inside the drybox. The pressure tube was then sealed, brought outside of the drybox, connected to the pressure reactor, placed under the desired ethylene pressure and shaken mechanically. After the stated reaction time, the ethylene pressure was released and the glass insert was removed from the pressure tube. The polymer was precipitated by the addition of MeOH (˜20 mL). The polymer was then collected on a frit and rinsed with MeOH and, optionally, acetone. The polymer was transferred to a pre-weighed vial and dried under vacuum overnight. The polymer yield and characterization were then obtained.
  • TABLE 16
    Ethylene Homopolymerizations, (0.02 mmol Cmpd, 25° C.,
    1.0 MPa, 10 mL TCB, 10 equiv B(C6F5)3)
    NaBAF PE Total
    Ex. Cmpd equiv PE g TO M.W. Me
    121 40 10 1.08a 1,920 Mw = 37,044; Mn = 4,989; Mw/Mn = 7.43 22.4
    122 40 1 2.49a 4,440 Mw = 34,072; Mn = 4,693; Mw/Mn = 7.26 44.6
    123 42 0 1.01 1,800 Mw = 25,754; Mn = 905 Mw/Mn = 28.46 79.2
    124 43 0 1.79 3,190 Mw = 12,361; Mn = 519; Mw/Mn = 23.80 59.4
    aFormation of a surface polymer film on the reaction mixture appeared to limit the productivity of these polymerizations.
  • TABLE 17
    Ethylene/Acrylate Copolymerizations (6.9 MPa, 100° C.)(0.02 mmol Cmpd, 10 mL
    total of TCB + Acrylate, 20 equiv B(C6F5)3)
    Acrylate
    Acrylate NaBAF Incorp. Total
    Ex. Cmpd mL equiv Yield g mol % M.W. Me
    125 42 EGPEA 1 0 0.38 0.5 Mn(1H) = 3,531 19.7
    126 41 EGPEA 1 0 0.077 0.3 Mn(1H) = 16,192 17.7
    127 43 EGPEA 1 0 0
    128 44 EGPEA 1 0 0.094 0.4 Mw = 3,259; Mp = 1,067; nd
    Mn = 988; Mw/Mn = 3.30
    129 40 EGPEA 1 0 0.10 1.3a Mw = 11,396; Mp = 7,282; 6.9
    Mn = 4,581; Mw/Mn = 2.49
    130 40 EGPEA 1 1 2.40 0.66 13C Mw = 6,649; Mp = 6,271; nd
    0.33 IC Mn = 3,104; Mw/Mn = 2.14
    0.33 EG
    131 40 EGPEA 1 20 8.61 0.38 13C Mw = 6,674; Mp = 5,860; nd
    0.19 IC Mn = 3,209; Mw/Mn = 2.08
    0.19 EG
    132 40 EGPEA 2 20 5.50 0.77 13C Mw = 5,238; Mp = 4,484; nd
    0.39 IC Mn = 2,423; Mw/Mn = 2.16
    0.38 EG
    133 41 EGPEA 2 20 0.61 A Mw = 5,032, Mp = 4,711; nd
    Mn = 2,330; Mw/Mn = 2.16
    134 42 EGPEA 2 20 1.06 1.0 Mw = 4,237; Mp = 3,286; 14.2
    Mn = 1,548; Mw/Mn = 2.74
    135 43 EGPEA 2 20 0.70 A nd nd
    136 40 EGPEA 4 20 2.02 0.70 Mw = 3,201; Mp = 2,755; 11.0
    Mn = 1,688; Mw/Mn = 1.90
    137 40 MA 0.5 10 13.21 0.41 13C Mw = 5,008; Mp = 4,932; 8.6
    0.21 IC Mn = 1,582; Mw/Mn = 3.16
    0.20 EG
    138 40 MA 0.5 20 11.45 0.57 13C Mw = 4,461; Mp = 3,994; 10.2
    0.33 IC Mn = 1,755; Mw/Mn = 2.54
    0.24 EG
    139 40 HA 2 20 1.48 0.60 13C Mw = 4,034; Mp = 3,699; 7.4
    0.21 IC Mn = 1,849; Mw/Mn = 2.18
    0.39 EG
    140 40 HA 1 20 9.88 0.36 13C Mw = 5,834; Mp = 5,525; 8.2
    0.15 IC Mn = 2,251; Mw/Mn = 2.59
    0.21 EG
    141 40 EGPEA 1 10 0.40 0.5 Mw = 7,123; Mn = 3,183; 8.5
    .005 mmol Mp = 6,843; Mw/Mn = 2.24
    aLarge amount of homopolymer was formed: overlaps with any copolymer resonances in the 1H NMR spectrum.
  • TABLE 18
    Ethylene/Acrylate Copolymerizations (6.9 MPa) (0.02 mmol Cmpd, 18 h,
    10 mL total of TCB + EGPEA, 20 equiv B(C6F5)3, 10 equiv NaBAF)
    Acrylate
    EGPEA Temp. Incorp. Total
    Ex. Cmpd mL ° C. Yield g mol % M.W. Me
    142 40 2 120 12.40 0.69 13C Mw = 3,813; Mn = 1,577; nd
    0.37 IC Mp = 3,234; Mw/Mn = 2.42
    0.32 EG
    143 40 4 120 5.16 Tracea Mw = 2,660; Mp = 2,528; nd
    Mn = 1,305; Mw/Mn = 2.04
    144 41 2 120 5.30 1.1 Mw = 3,331; Mp = 3,047; 13.8
    Mn = 1,386; Mw/Mn = 2.40
    145 40 4 120 3.30 1.5 Mw = 3,125; Mp = 3,139; 16.8
    Mn = 1,476; Mw/Mn = 2.12
    146 40 4 120 4.10 2.2
    147 40 2 130 8.99 2.8 Mw = 3,479; Mp = 3,202; 25.7
    Mn = 1,510; Mw/Mn = 2.30
    148 40 2 120 4.57 2.2 Mw = 3,914; Mp = 3,592; 32
    0.001 mmol Mn = 1,761; Mw/Mn = 2.22
    aLarge amount of acrylate homopolymer was formed, preventing quantitative determination of percent acrylate incorporation in the copolymer. Ester groups incorporated both in branches and in unsaturated end groups.
  • TABLE 19
    Ethylene/Acrylate Copolymerizations (3.5 MPa, 120° C.)(18 h, 10 mL total
    of TCB + EGPEA, 20 equiv B(C6F5)3, 10 equiv NaBAF)
    Acrylate
    EGPEA Temp. Incorp. Total
    Ex. Cmpd mL ° C. Yield G mol % M.W. Me
    149 40 1 120 2.48 0.69 13C Mw = 3,675; Mp = 3,403; nd
     0.01 mmol 0.37 IC Mn = 1,701; Mw/Mn = 2.16
    0.32 EG
    150 40 1 120 0.21 Tracea Mw = 3,272; Mp = 3,403; nd
    0.005 mmol Mn = 1,701; Mw/Mn = 2.01
    aLarge amount of acrylate homopolymer was formed, preventing quantitative determination of percent acrylate incorporation in the copolymer.
  • TABLE 20
    Branching Analysis for Some MA and HA Copolymers of Table 17a
    Total Me
    Ex. Me Me Et Hex+ & eoc Am+ & eoc Bu+ & eoc ester
    137 8.6 2.4 1.0 6.4 5.8 5.2 2.5
    138 10.2 2.5 2.1 7.5 6.1 5.6 3.9
    139 7.4 2.4 0.6 5.3 5.0
    140 8.2 3.1 5.1 5.1
    aPr and Bu branches were not detected in these copolymers.
  • Figure US20100222531A1-20100902-C00024
    Figure US20100222531A1-20100902-C00025
    Figure US20100222531A1-20100902-C00026
    Figure US20100222531A1-20100902-C00027
    Figure US20100222531A1-20100902-C00028
    Figure US20100222531A1-20100902-C00029
    Figure US20100222531A1-20100902-C00030
    Figure US20100222531A1-20100902-C00031
    Figure US20100222531A1-20100902-C00032
    Figure US20100222531A1-20100902-C00033
  • Examples 151-439
  • Examples 151-439 are listed in Tables 21-57 below. They were carried out with nickel complexes 45-97 shown above. For each of 45-97 the counterion is BAF. The polymerizations were carried out according to General Polymerization Procedure A. Varying amounts of acrylate homopolymer are present in some of the isolated polymers. In Tables 21-58, the yield of the polymer is reported in grams and includes the yield of the dominant ethylene/acrylate copolymer as well as the yield of any acrylate homopolymer that was formed. Molecular weights were determined by GPC, unless indicated otherwise. Mole percent acrylate incorporation and total Me were determined by 1H NMR spectroscopy, unless indicated otherwise. Mole percent acrylate incorporation is typically predominantly IC, unless indicated otherwise. The LiB(C6F5)4 used (LiBArF) included 2.5 equiv of Et2O. All copolymerizations were run for 18 h, unless otherwise noted.
  • TABLE 21
    Reproducibility of Ethylene/Acrylate Copolymerizations Using 45 (0.02 mmol
    Cmpd, 6.9 MPa., 120° C., 18 h, 10 mL Total of TCB + Acrylate,
    40 equiv B(C6F5)3)
    Acrylate
    Acrylate Incorp. Total
    Ex. mL Yield g mol % M.W. Me
    151 EGPEA 2 9.77 1.20 (13C) Mp = 8,651; Mw = 8,930; Mn = 3,983; PDI = 2.24 54.6
    152 EGPEA 2 12.47 1.4 Mp = 12,036; Mw = 12,662; Mn = 4,449; PDI = 2.85 51.8
    153 EGPEA 2 10.73 2.0 Mp = 13,657; Mw = 14,740; Mn = 5,348; PDI = 2.76 54.5
    154 HA 2 2.08 1.28 (13C) Mp = 6,838; Mw = 6,534; Mn = 1,331; PDI = 4.91 53.2
    155 HA 2 2.42 1.16 (13C) Mp = 6,625; Mw = 7,524; Mn = 3,305; PDI = 2.28 54.9
  • TABLE 22
    Variation of Acrylate Concentration, Acrylate Structure, Solvent and Temperature
    in Ethylene/Acrylate Copolymerizations Using 45 (0.02 mmol Cmpd, 6.9 MPa E,
    18 h, 10 mL Total of TCB + Acrylate, 40 epuiv B(C6F5)3)
    Acrylate Temp Acryl. Incorp. Total
    Ex. mL ° C. Yield g (mol %) M.W. Me
    156 EGPEA 1 120 16.72 0.7 Mp = 12,452; Mw = 13,952; 69.8
    Mn = 4,319; PDI = 3.23
    157 EGPEA 2 120 12.47 1.4 Mp = 12,036; Mw = 12,662; 51.8
    Mn = 4,449; PDI = 2.85
    158 EGPEA 4 120 5.37 2.70 (13C) Mp = 6,623; Mw = 9,878; Mn = 3,388; 42.6 (13C)
    PDI = 2.92
    159 EGPEA 2 100 4.21 1.60 (13C) Mp = 20,949; Mw = 21,275; 26.1 (13C)
    Mn = 9,605; PDI = 2.21
    160 EGPEA 4 100 3.13 3.60 (13C) Mp = 12,760; Mw = 14,733; 20.6 (13C)
    Mn = 6,092; PDI = 2.42
    161 IDAa 2 80 0.89 1.6 (13C) nd nd
    162 IDAb 1 80 1.75 nd Mp = 30,258; Mw = 32,201; nd
    Mn = 13,047; PDI = 2.47
    163 HA 1 120 2.70 0.66 (13C) Mp = 8,851; Mw = 9,678; Mn = 2,252; 54.7
    PDI = 4.30
    164 HA 2 120 2.08 1.28 (13C) Mp = 6,838; Mw = 6,534; Mn = 1,331; 53.2
    PDI = 4.91
    165 MA 120 13.08 0.10 (13C)c Mp = 10,797; Mw = 12,929; 76.0
    0.25 Mn = 4,798; PDI = 2.69
    166 MA 120 13.17 0.17 (13C)d Mp = 12,267; Mw = 13,485; 72.0
    0.5 Mn = 4,587; PDI = 2.94
    167 MA 1 120 15.45 0.19 (13C)d Mp = 13,376; Mw = 13,971; 78.6
    Mn = 4,694; PDI = 2.98
    aTotal Volume = 5 mL: 2 mL IDA + 3 mL Bu2O; No TCB used.
    bTotal Volume = 5 mL: 4 mL TCB and 1 mL IDA;
    cAcrylate homopolymer not detected by 13C NMR spectroscopy.
    dAcrylate homopolymer detected by 13C NMR spectroscopy.
  • TABLE 23
    Variation of Acrylate Concentration and Temperature in Ethylene/EGPEA
    Copolymerizations with Cmpd. 46 (0.02 mmol Cmpd, 6.9 MPa E, 18 h, 10 mL
    Total of TCB + EGPEA, 40 equiv B(C6F5)3)
    Acrylate
    EGPEA Temp Incorp. Total
    Ex. mL ° C. Yield g mol % M.W. Me
    168 2 120 2.17 0.03 (13C) Mp = 12,550; Mw = 13,744; Mn = 5,936;
    PDI = 2.32
    169 2 100 1.88 0.44 (13C) Mp = 17,362; Mw = 17,905; Mn = 8,075; 28.6
    PDI = 2.16
    170 4 120 1.22 Nda Mp = 8,651; Mw = 8,930; Mn = 3,983;
    PDI = 2.24
    171 4 100 0.032 1.1 Mp = 13,111; Mw = 13,076; Mn = 6,062; 24.3
    PDI = 2.16
    aDue to significant homopolymer formation, percent acrylate incorporation in the copolymer was not determined by 1H NMR spectroscopy.
  • TABLE 24
    Effect of Counterion on Ethylene/EGPEA Copolymerizations Using
    Cmpd 45 (0.02 mmol Cmpd, 6.9 MPa E, 120° C., 18 h, 8 mL TCB,
    2 mL EGPEA, 40 equiv B(C6F5)3)
    Acrylate
    Incorp. Total
    Ex. Counterion Yield g mol % M.W. Me
    172 [B[3,5-C6H3—(CF3)2]4] 12.47 1.4 Mp = 12,036; Mw = 12,662; 51.8
    Mn = 4,449; PDI = 2.85
    173 [B(C6F5)4] 16.72 1.5 Mp = 15,316; Mw = 17,100; 57.1
    Mn = 6,108; PDI = 2.80
    174 [N(SO2CF3)2] 5.38 1.9 Mp = 12,551; Mw = 13,097; 52.6
    Mn = 4,949; PDI = 1.78
  • TABLE 25
    Effect of Bu2O Addition on Ethylene/Acrylate Copolymerizations
    Using Cmpd 45 (0.02 mmol Cmpd, 6.9 MPa E, 120° C., 18 h, 8 mL
    Total of TCB + Bu2O, 2 mL EGPEA, 40 equiv B(C6F5)3)
    Bu2Oa Acrylate Total
    Ex. mL Yield g Incorp. mol % M.W. Me
    175 0 12.47 1.4 Mp = 12,036; Mw = 12,662; Mn = 4,449; PDI = 2.85 51.8
    176 2 5.10 1.72 (13C) Mp = 6,952; Mw = 8,846; Mn = 3,044; PDI = 2.91 65.0
    177 4 8.73 1.08 (13C) Mp = 7,135; Mw = 8,894; Mn = 3,313; PDI = 2.68 66.5
    178 8 11.94 b Dual UV/RI. Nd
    UV: Mp = 7,616; Mw = 50,244; Mn = 1,819;
    PDI = 27.62;
    RI: Mp = 12,075; Mw = 14,395; Mn = 5,150;
    PDI = 2.80
    aAmount of acrylate homopolymer formation increases as the amount of Bu2O increases.
    b According to 13C NMR spectroscopy, the polymer was a mixture of polyethylene and poly(EGPEA); no copolymer resonances were observed.
  • TABLE 26
    Variation of the Lewis Acid (LA) Cocatalyst in Ethylene/Acrylate
    Copolymerizations, Including Copolymerization in the Absence of a Lewis Acid
    Cocatalyst (0.02 mmol Cmpd, 6.9 MPa E; 120° C., 18 h, 10 mL Total of TCB +
    Acrylate)
    Acrylate
    Acrylate Incorp. Total
    Ex. Cmpd mL LA/equiv Yield g Mol % M.W. Me
    179 45 EGPEA 2 B(C6F5)3 12.47 1.4 Mp = 12,036; Mw = 12,662; 51.8
    40 Mn = 4,449; PDI = 2.85
    180 45 EGPEA 2 BPh3 2.73 2.2 Mp = 11,442; Mw = 13,348; 49.5
    40 Mn = 4,897; PDI = 2.73
    181 45 EGPEA 2 AlPh3 1.15 a Mp = 3,207; Mw = 4,233; Nd
    40 Mn = 1,723; PDI = 2.46
    182 45 EGPEA 1 B(C6F5)3 16.72 0.7 Mp = 12,452; Mw = 13,952; 69.8
    40 Mn = 4,319; PDI = 3.23
    183 45 EGPEA 1 B(C6F5)3 5 2.62 0.23 (13C) Mp = 12,529; Mw = 12,302; 55.8
    Mn = 5,147; PDI = 2.39
    184 46 THA 2 B(C6F5)3 2.37 0.23 Mp = 12,775; Mw = 13,777;
    40 Mn = 7,165; PDI = 1.92
    185 46 THA 2 None 0.63 0.64 (13C) Dual UV/RI. 34.0
    UV: Mp = 8,098;
    Mw = 687,552, Mn = 6,306;
    PDI = 109.04;
    RI: Mp = 9,383; Mw = 12,732;
    Mn = 5,694; PDI = 2.24
    a Due to significant homopolymer formation, percent acrylate incorporation in the copolymer was not determined by 1H NMR spectroscopy.
  • TABLE 27
    Effect of alpha-Diimine Structure on Ethylene/Acrylate Copolymerizations (0.02 mmol
    Cmpd, 6.9 MPa E, 120° C., 18 h, 9 mL TCB, 1 mL EGPEA, 40 equiv
    B(C6F5)3)
    Acrylate Incorp.
    Ex. Cmpd Yield g mol % M.W. Total Me
    186 45 16.72 0.7 Mp = 12,452; Mw = 13,952; Mn = 4,319; 69.8
    PDI = 3.23
    187 47 14.02 0.8 Mp = 9,915; Mw = 13,027; Mn = 3,660; 69.5
    PDI = 3.56
    188 48 0
    189 50 3.96 0.55 (13C) Mp = 14,350; Mw = 15,584; Mn = 7,421 72.0
    (13C)
    190 51 2.28 1.8 Mp = 15,543; Mw = 17,651; Mn = 7.561; 64.8
    PDI = 2.33
    191 55 7.64 1.6 Mp = 14,350; Mw = 15,584; Mn = 7,421 68.6
    192 56 8.81 Ndc Mp = 946; Mw = 7,044; Mn = 911; Nd
    PDI = 7.73
    193 57 12.28 1.1 Mp = 14,408; Mw = 16,770; Mn = 6,740; 71.7
    PDI = 2.49
    194 58 18.19 1.0 Mp = 14,315; Mw = 15,940; Mn = 5,887; 85.6
    PDI = 2.71
    195 59 15.30 0.8 Mp = 12,221; Mw = 16,421; Mn = 5,647; 78.6
    PDI = 2.91
    196 60 0
    197 61 16.78 0.8 Mp = 13,852; Mw = 16,074; Mn = 4,701; 77.0
    PDI = 3.42
    198 62 2.28 0.9 Mp = 1,162; Mw = 1,609; Mn = 642; 75.2
    PDI = 2.51
    199 63 1.08 1.6 Mp = 10,915; Mw = 12,370; Mn = 5,370; 74.2
    PDI = 2.30
    200 64 5.32 1.6 Mp = 42,905; Mw = 43,993; Mn = 16,290; 105.0 
    PDI = 2.70
    201a 64 5.55 0.3 RI (THF, rt): Mp = 101,394; 101.5 
    Mw = 1,154,459; Mn = 5,516;
    PDI = 209.31
    202a 64 1.66b 0.3 RI (THF, rt): Mp = 94,326; 99.5
    Mw = 5,952,749; Mn = 8,304;
    PDI = 716.88
    aEx 201 and 202 include 20 equiv B(C6F5)3; Ex. 201 also includes 20 equiv LiB(C6F5)4 and Ex. 202 includes 20 equiv NaBAF;
    bSome polymer was lost in isolation;
    cNot determined due to broad 1H NMR spectrum.
  • TABLE 28
    Effect of alpha-Diimine Structure on Ethylene/Acrylate Copolymerizations (0.02 mmol
    Cmpd, 6.9 MPa E; 120° C., 18 h, 8 mL TCB, 2 mL of EGPEA, 40 equiv
    B(C6F5)3)
    Acrylate Incorp.
    Ex. Cmpd Yield g mol % M.W. Total Me
    203 45 12.47 1.4 Mp = 12,036; Mw = 12,662; Mn = 4,449; 51.8
    PDI = 2.85
    204 46 2.17 0.03 (13C) Mp = 12,550; Mw = 13,744; Mn = 5,936;
    PDI = 2.32
    205 47 4.10 2.0 Mp = 8,181; Mw = 9,903; Mn = 3,243; 59.9
    PDI = 3.05
    206 48 0
    207 49 0
    208 50 1.10 1.7 Dual UV/RI. 60.5
    UV: Mp = 19,292; Mw = 374,248;
    Mn = 7,268; PDI = 51.49;
    RI: Mp = 22,404; Mw = 26,916;
    Mn = 11,257; PDI = 2.39
    209 51 2.32 3.1 Mp = 14,689; Mw = 17,651; Mn = 4,327; 77.8
    PDI = 2.29
    210 52 0.087 a Dual UV/RI. a
    UV: Mp = 21,556; Mw = 47,428;
    Mn = 6,142; PDI = 7.72;
    RI: Mp = 40,121; Mw = 40,676;
    Mn = 18,309; PDI = 2.22
    211 53 9.41 2.9 (13C) Mp = 485; Mw = 1,035; Mn = 317; 84.2
    PDI = 3.27 (13C)
    212 56 0.49 Dual UV/RI.
    UV: Mp = 2,195 and 75;
    Mw = 1,301,735; Mn = 3,351;
    PDI = 388.41;
    RI: Mp = 2,652; Mw = 84,063;
    Mn = 3,608; PDI = 23.30
    213 57 2.94 Mp = 9,779; Mw = 12,435; Mn = 4,519;
    PDI = 2.75
    214 58 7.77 1.7 Dual UV/RI. 60.3
    UV: Mp = 21,192; Mw = 201,274;
    Mn = 10,087; PDI = 19.95;
    RI: Mp = 22,402; Mw = 95,991;
    Mn = 11,047; PDI = 8.69
    215 61 5.77 2.4 Mp = 9,535; Mw = 11,659; 56.1
    Mn = 4,357; PDI = 2.68
    Examples 216-221 below include 20 equiv of B(C6F5)3
    216 71 3.45 0.6 Mp = 20,054; Mw = 19,855; 63.4
    Mn = 9,070; PDI = 2.19
    217 72 1.32 1.6 Mp = 14,328; Mw = 16,242; 66.2
    Mn = 6,327; PDI = 2.57
    218 73 0.27
    219 69 1.79 1.5 Dual UV/RI. 62.1
    UV: Mp = 15,033;
    Mw = 21,410; Mn = 6,666;
    PDI = 3.21;
    RI: Mp = 8,520;
    Mw = 16,322; Mn = 2,159;
    PDI = 7.56
    220b 45 7.50 1.0 Mp = 13,125; Mw = 14,026; 51.0
    Mn = 6,211; PDI = 2.26
    221c 55 3.07 1.3 Mp = 7,458; Mw = 10,026; 58.2
    Mn = 3,566; PDI = 2.81
    a1H NMR spectrum is broad;
    b20 equiv NaBAF present;
    c20 equiv LiBArF present.
  • TABLE 29
    Effect of Pressure on Ethylene/EGPEA Copolymerizations (0.02 mmol Cmpd,
    120° C., 18 h, 8 mL TCB, 2 mL EGPEA, 40 equiv B(C6F5)3)
    Acrylate
    Press. Incorp. Total
    Ex. Cmpd MPa Yield g mol % M.W. Me
    222 45 6.9 12.47 1.4 Mp = 12,036; Mw = 12,662; Mn = 4,449; 51.8
    PDI = 2.85
    223 45 4.1 4.30 2.9 Mp = 7,492; Mw = 11,174; Mn = 3,738; 57.7
    PDI = 2.99
    224 47 6.9 4.10 2.0 Mp = 8,181; Mw = 9,903; Mn = 3,243; 59.9
    PDI = 3.05
    225 47 4.1 0.70 3.3 Dual UV/RI. 59.8
    UV: Mp = 8,392; Mn = 4,579;
    Mw = 174,212; PDI = 38.05;
    RI: Mp = 9,874; Mn = 5,504; Mw = 18,139;
    PDI = 3.30
  • TABLE 30
    13C NMR Branching Analysis for EGPEA Copolymers
    Total Hex+ & Am+ & Bu+ & MesBu MesBu
    Ex. Me Me Et Pr Bu eoc eoc eoc (%) (%)
    151 51.4 32.2 6.5 2.8 2.1 5.5 7.3 9.9 3.68 19.86
    158 42.6 23.7 6.9 3.8 2.1 4.6 8.1 8.3 Nd Nd
    169 27.3 19.0 1.7 1.7 1.0 3.2 3.4 4.8 Nd Nd
    159 26.1 17.7 2.9 1.2 1.0 1.9 2.5 4.2 Nd Nd
    160 20.6 14.2 2.0 1.6 0.9 2.0 3.8 2.8 Nd Nd
    211 84.2 36.9 10.2 3.1 4.1 21.8 31.0 34.0 9   54.8 
    199 72.0 45.1 6.2 3.3 4.3 7.8 13.4 17.4 Nd Nd
  • TABLE 31
    13C NMR Branching Analysis for MA Copolymers
    Hex+ & Am+ & Bu+ & MesBu MesBu
    Ex. Total Me Me Et Pr Bu eoc eoc eoc (%) (%)
    167 78.2 45.2 9.9 4.1 4.7 9.8 14.5 19.0 4.4 19.9
    166 72.0 41.7 10.0 3.9 8.5 11.9 16.3 4.2 18.9
    165 76.0 42.7 11.0 4.0 8.7 12.8 18.3 5.8 23.1
    250 52.2 30.1 8.0 2.4 2.8 6.2 8.4 11.7 Nd Nd
    251 62.4 35.1 8.7 3.6 4.6 7.4 11.3 15.0 Nd Nd
    252 65.5 39.1 8.5 2.6 3.8 7.7 12.7 15.3 Nd Nd
    253 79.6 44.9 11.1 3.4 4.1 10.0 14.7 20.1 Nd Nd
    254 61.9 47.5 9.0 3.6 5.0 8.9 14.0 1.8 Nd Nd
    255 35.7 23.1 4.2 1.9 1.4 3.0 5.8 6.9 Nd Nd
    256 43.9 27.1 5.5 2.6 1.9 4.4 6.4 8.7 Nd Nd
  • TABLE 32
    13C NMR Branching Analysis for HA Copolymers
    MesBu MesBu
    Ex. Total Me Me Et Pr Bu Am+ & eoc Bu+ & eoc (%) (%)
    154 53.2 27.5 5.3 3.1 2.8 16.4 17.3 trace trace
    163 54.7 29.4 6.4 3.5 3.3 13.4 15.4 3.8 14.2
    155 54.9 32.2 6.4 3.0 2.2 13.6 13.3 Nd Nd
    253 32.8 22.1 3.2 1.5 1.1 6.2 6.0 Nd Nd
    257 23.9 16.7 1.7 1.5 1.8 5.9 4.0 Nd Nd
    258 28.3 19.7 3.2 1.4 1.4 3.7 4.0 Nd Nd
  • TABLE 33
    13C NMR Branching Analysis for THA Copolymers
    Hex+ & Am+ & Bu+ & MesBu MesBu
    Ex. Total Me Me Et Pr Bu eoc eoc eoc (%) (%)
    184 34.0 22.7 3.2 2.3 1.8 3.7 4.1 5.8 3.3 15.7
  • TABLE 34
    Effect of Counterion on Ethylene/EGPEA Copolymerizations Using Cmpd
    45 (0.02 mmol Cmpd, 6.9 MPa E, 100° C., 18 h, 9 mL TCB, 1 mL EGPEA, 20 equiv
    B(C6F5)3)
    Acrylate
    Incorp. Total
    Ex. Counterion Yield g mol % M.W. Me
    226 [B[3,5-C6H3—(CF3)2]4] 7.55 0.7 Mp = 24,874; Mw = 27,982; 46.4
    Mn = 11,277; PDI = 2.48
    227 [B(C6F5)4] 5.41 0.9 Mp = 18,648; Mw = 20,469; 44.3
    Mn = 8,130; PDI = 2.52
  • TABLE 35
    Effect of Solvent on Ethylene/EGPEA Copolymerizations Using Cmpd 45
    (0.02 mmol Cmpd, 6.9 MPa E, 100° C., 18 h, 9 mL Solvent, 1 mL
    EGPEA, 20 equiv B(C6F5)3)
    Acrylate
    Incorp.
    Ex. Solvent Yield g mol % M.W. Total Me
    228 TCB 7.55 0.7 Mp = 24,874; Mw = 27,982; 46.4
    Mn = 11,277; PDI = 2.48
    229 p-Xylene 11.32 0.6 Mp = 21,849; Mw = 21,579; 52.7
    Mn = 9,271; PDI = 2.33
    230 2,2,4-Trimethyl- 2.04 1.6 Mp = 12,625; Mw = 13,906; 44.3
    pentane Mn = 5,591; PDI = 2.74
    231 FC-75 1.04 5.4 Mp = 1,837; Mw = 3,468; 18.7
    Mn = 1,265; PDI = 2.74
  • TABLE 36
    Effect of B(C6F5)3 and NaBAF Concentrations
    on Ethylene/EGPEA Copolymerizations Using Cmpd 45 (0.02 mmol
    Cmpd, 6.9 MPa E, 100° C., 18 h, 8 mL TCB, 2 mL of EGPEA)
    Acrylate
    B(C6F5)3 NaBAF Incorp.
    Ex. equiv equiv Yield g mol % M.W. Total Me
    232 40 20 7.53 1.2 Mp = 16,054; Mw = 19,338; 38.6
    Mn = 8,066; PDI = 2.40
    233 40 10 5.38 1.3 Mp = 17,925; Mw = 18,882; 27.5
    Mn = 8,495; PDI = 2.22
    234 20 10 7.01 1.5 Mp = 17,546; Mw = 18,485; 29.6
    Mn = 7,769; PDI = 2.38
    235 20 10 6.29 1.2 Mp = 14,365; Mw = 16,722; 29.5
    Mn = 6,646; PDI = 2.52
    236a 20 10 4.69 1.3 Mp = 16,912; Mw = 18,207; 33.6
    Mn = 7,126; PDI = 2.57
    a250 ppm phenothiazine was added to the acrylate; For entries 1-4, the acrylate contained 250 ppm 1,4-benzoquinone.
  • TABLE 37
    Effect of Solvent on Ethylene/Acrylate Copolymerizations Using Cmpd 45 (0.02 mmol
    Cmpd, 6.9 MPa, 100° C., 18 h, 8 mL Solvent, 2 mL of EGPEA)
    Acrylate
    B(C6F5)3 NaBAF Incorp. Total
    Ex. Solvent equiv equiv Yield g mol % M.W. Me
    237 TCB 40 20 7.53 1.2 Mp = 16,054; Mw = 19,338; 38.6
    Mn = 8,066; PDI = 2.40
    238 TCB 20 10 7.01 1.5 Mp = 17,546; Mw = 18,485; 29.6
    Mn = 7,769; PDI = 2.38
    239 Toluene 40 20 6.05 1.0 Mp = 14,852; Mw = 16,995; 48.2
    Mn = 7,853; PDI = 2.16
    240 2,2,4- 40 20 1.51 1.7 Mp = 6,633; Mw = 7,942; 41.8
    Trimethyl- Mn = 4,157; PDI = 1.91
    pentane
    241 2,2,4- 40 20 2.09 1.3 Mp = 12,923; Mw = 16,462; 42.7
    Trimethyl- Mn = 6,313; PDI = 2.61
    pentane
    242 Chloro- 20 10 9.16 1.0 Mp = 16,417; Mw = 18,316; 33.3
    benzene Mn = 7,496; PDI = 2.44
    243 p-Xylene 20 10 7.46 1.0 Mp = 16,975; Mw = 18,211; 33.1
    Mn = 7,246; PDI = 1.84
  • TABLE 38
    Effect of Acrylate Concentration, Acrylate Structure and Temperature on
    Ethylene/Acrylate Copolymerizations (0.02 mmol Cmpd, 6.9 MPa E, 18 h, 10 mL
    Total of TCB + Acrylate, 20 equiv B(C6F5)3)
    Acrylate
    Acrylate Temp Incorp. Total
    Ex. Cmpd mL ° C. Yield g mol % M.W. Me
    244 45 EGPEA 1 100 7.55 0.7 Mp = 24,874; Mw = 27,982; 46.4
    Mn = 11,277; PDI = 2.48
    245 45 EGPEA 1  80 2.20 0.6 Mp = 38,136; Mw = 39,514; 49.6
    Mn = 20,849; PDI = 1.90
    246 45 EGPEA  80 5.41 0.4 Mp = 45,864; Mw = 45,281; 81.7
    0.5 Mn = 23,339; PDI = 1.94
    247 45 HA 1 100 5.68 0.66 (13C) Mp = 22,173; Mw = 21,451; 32.8
    Mn = 9,298; PDI = 2.31 (13C)
    248 45 HA 1  80 1.65 1.0 Mp = 27,677; Mw = 29,086; 26.3
    Mn = 12,715; PDI = 2.29
    249 47 EGPEA 1  80 0.08 0.8 Mp = 17,915; Mw = 17,005; 51.4
    Mn = 6,567; PDI =
    250 45 MA 100-135 10.58 0.31 (13C) Mp = 28,080; Mw = 21,336; 52.1
    0.25 Mn = 4,233; PDI = 5.04
    251 45 MA 100-135 8.36 0.51 (13C) Mp = 20,078; Mw = 17,262; 62.1
    0.5 Mn = 3,831; PDI = 4.51
    252 47 MA 100-135 3.61 0.57 (13C) Mp = 4,716; Mw = 6,741; 65.1
    0.25 Mn = 1,796; PDI = 3.75
    253 47 MA 100-135 1.90 0.61 (13C) Dual UV/RI 78.8
    0.5 UV: Mp = 3,803;
    Mw = 5,095; Mn = 1,350;
    PDI = 3.77;
    RI: Mp = 5,237;
    Mw = 6,717; Mn = 3,805;
    PDI = 2.39
    254 57 MA 100-135 4.22 0.37 (13C) Mp = 8,697; Mw = 14,347; 61.5
    0.25 Mn = 3,656; PDI = 3.92
    10 equiv of NaBAF was added to Ex. 255 below and 20 equiv of NaBAF were
    added to entries 256-261 below.
    255 45 MA 100 4.28 1.09 (13C) Mp = 13,677; Mw = 15,046; 35.7
    0.5 Mn = 7,270; PDI = 2.07
    256 45 MA 100 9.36 0.53 (13C) Mp = 16,828; Mw = 17,679; 43.7
    0.5 Mn = 7,546; PDI = 2.34
    257 45 HA 2 100 1.07 1.20 (13C) Mp = 8,501; Mw = 9,737; 23.9
    Mn = 4,703; PDI = 2.07
    258 45 HA 1 100 4.76 0.53 (13C) Mp = 16,421; Mw = 17,244; 28.3
    Mn = 7,900; PDI = 2.18
    259 45 EGPEA 2 135 1.20 1.1 Mp = 7,174; Mw = 8,652; 74.9
    Mn = 3,719; PDI = 2.33
    260 45 EGPEA 2 130 5.59 1.2 Mp = 9,545; Mw = 10,772; 58.2
    Mn = 4,927; PDI = 2.19
    261 45 EGPEA 2 120 7.01 1.5 Mp = 17,546; Mw = 18,485; 29.6
    Mn = 7,769; PDI = 2.38
  • TABLE 39
    Effect of alpha-Diimine Structure on Ethylene/EGPEA Copolymerizations
    (0.02 mmol Cmpd, 6.9 MPa E, 100° C. 18 h, 9 mL TCB, 1 mL EGPEA,
    20 equiv B(C6F5)3)
    Acrylate Incorp.
    Ex. Cmpd Yield g mol % M.W. Total Me
    262 55 7.55 0.7 Mp = 24,874; Mw = 27,982; Mn = 11,277; 46.4
    PDI = 2.48
    263 68 0.32 0.5 Mp = 13,743; Mw = 18,058; Mn = 5,435; 60.3
    PDI = 3.32
    264 69 1.48 0.3 Mp = 838; Mw = 1,731; Mn = 796; 57.5
    PDI = 2.17
  • TABLE 40
    Effect of alpha-Diimine Structure on Ethylene/Acrylate Copolymerizations (0.02 mmol
    Cmpd, 6.9 MPa E, 18 h, 8 mL TCB, 2 mL of EGPEA)
    Acrylate
    Temp B(C6F5)3 NaBAF Yield Incorp. Total
    Ex. Cmpd (° C.) (equiv) (equiv) (g) (mol %) M.W. Me
    265 45 100 40 20 7.53 1.2 Mp = 16,054; 38.6
    Mw = 19,338; Mn = 8,066;
    PDI = 2.40
    266 76 100 40 20 4.22 1.0 Mp = 24,124; 31.4
    Mw = 27,307;
    Mn = 14,435; PDI = 1.89
    267 75 100 40 20 5.68 1.2 Mp = 14,987; 79.2
    Mw = 16,393; Mn = 6,919;
    PDI = 2.37
    268 74 100 40 20 3.42 0.6 Mp = 31,607; 41.2
    Mw = 34,104;
    Mn = 17,087; PDI = 2.00
    269 77 100 40 20 0.025 1.9 Mn(1H): No olefins 33.5
    detected
    270 45 135 20 10 1.20 1.1 Mp = 7,174; Mw = 8,652; 74.9
    Mn = 3,719; PDI = 2.33
    271 64 135 20 10 1.05 0.5 Mp = 25,027; 111.4
    Mw = 30,553;
    Mn = 12,666; PDI = 2.41
    272 45 135 20 10 2.55 1.0 Mp = 6,743; Mw = 8,241; 85.8
    Mn = 887; PDI = 9.29
  • TABLE 41
    Effect of Borane Concentration and Inhibitor on Ethylene/EGPEA
    Copolymerizations (0.02 mmol Cmpd 45, 6.9 MPa E, 120° C., 18 h, 6 mL TCB, 4 mL
    EGPEA)
    Acrylate
    B(C6F5)3 Incorp. % Ester in Total
    Ex. equiv Inhibitor Yield g mol % Copolymera M.W. Me
    273 40 None 5.37 2.70 (13C) 12% Mp = 6,623; 42.6
    Mw = 9,878; (13C)
    Mn = 3,388;
    PDI = 2.92
    274 20 NaBAF 3.02 2.2 20% Mp = 12,928; 28.4
    20 equiv Mw = 13,956;
    Mn = 5,371;
    PDI = 2.60
    275 20 BQ 250 ppm 2.59 2.6 16% Mp = 8,739; 27.5
    Mw = 10,424;
    Mn = 3,480;
    PDI = 3.00
    276 20 NaBAF 3.07 2.4 23% Mp = 11,454; 29.9
    20 equiv Mw = 12,303;
    BQ 250 ppm Mn = 4,114; PDI =
    aThe percent of the ester groups in the 1H NMR spectrum of the isolated polymer sample that belong to copolymer. Due to the high acrylate concentration, the isolated polymers all contained some homopolymer. The EGPEA used contained 100 ppm hydroquinone in addition to the NaBAF and 1,4-benzoquinone (BQ) inhibitors that were added to the individual runs.
  • TABLE 42
    Steric Effects on Ethylene/MA Copolymerizations Utilizing Long Reaction Times
    (90 h) and Low Catalyst Concentrations (0.019 mmol Cmpd), (211 equiv B(C6F5)3
    and 105 equiv NaBAF were used. Mole % incorp. and total Me determined by 13C
    NMR spectroscopy.)
    MA mL Acrylate
    (p-Xylene Press Temp Incorp Total
    Ex Cmpd mL) MPa ° C. Yield g mol % M.W. Me
    277 45 0.5 3.5 120 0.892 1.33 Mp = 6,812; Mw = 7,201; 72.5
    (9.5) Mn = 3,410; PDI = 2.05
    278 76 0.5 3.5 120 0.937 1.02 Mp = 7,911; Mw = 8,993; 82.7
    (9.5) Mn = 4,499; PDI = 2.00
    279 74 0.5 3.5 120 0.840 0.93 Mp = 8,726; Mw = 9,799; 94.9
    (9.5) Mn = 4,511; PDI = 2.00
    280 64 0.5 3.5 120 0.106 nd Mp = 13,521; Mw = 14,744; nd
    (9.5) Mn = 6,125; PDI = 2.41
    281 45 1.0 3.5 120 0.007 nd nd nd
    (14.0)
    282 45 0.5 6.9 120 3.340 0.82 Mp = 12,403; Mw = 13,853; 50.4
    (9.5) Mn = 5,681; PDI = 2.44
    283 76 0.5 6.9 120 4.221 0.48 Mp = 20,376; Mw = 20,960; 58.1
    (9.5) Mn = 9,659; PDI = 2.17
    284 74 0.5 6.9 120 5.424 0.43 Mp = 28,364; Mw = 30,997; 68.5
    (9.5) Mn = 12,568; PDI = 2.47
    285 64 0.5 6.9 120 0.95 0.30 Mp = 47,858; Mw = 47,408; 97.2
    (9.5) Mn = 20,796; PDI = 2.28
    286 45 1.0 6.9 120 2.518 0.97 Mp = 13,043; Mw = 14,076; 46.3
    (14.0) Mn = 5,931; PDI = 2.37
    287 45 0.5 6.9 100 3.865 0.62 Mp = 23,142; Mw = 24,270; 30.9
    (9.5) Mn = 10,544; PDI = 2.30
    288 76 0.5 6.9 100 3.720 0.45 Mp = 34,987; Mw = 36,412; 37.4
    (9.5) Mn = 16,929; PDI = 2.15
    289 74 0.5 6.9 100 4.041 0.51 Mp = 53,630; Mw = 50,877; 48.0
    (9.5) Mn = 24,819; PDI = 2.05
    290 64 0.5 6.9 100 0.860 0.50 Mp = 64,690; Mw = 60,660; 78.1
    (9.5) Mn = 31,328; PDI = 1.94
    291 45 1.0 6.9 100 1.631 0.83 Mp = 17,935; Mw = 17,277; 35.7
    (14.0) Mn = 7,070; PDI = 2.44
  • TABLE 43
    13C NMR Branching Analysis for MA Copolymers of Table 42
    Hex+ &
    Ex. Total Me Me Et Pr Bu eoc Am+ & eoc Bu+ & eoc
    277 72.5 42.6 10.0 3.8 3.9 7.1 13.1 16.2
    58.7% 13.8% 5.2% 5.4% 9.8% 18.1% 22.4%
    278 82.7 48.9 10.3 4.4 4.2 10.3 15.0 19.2
    59.1% 12.5% 5.3% 5.0% 12.5% 18.2% 23.2%
    279 94.9 54.5 13.4 5.2 5.3 12.7 17.0 21.8
    57.5% 14.1% 5.5% 5.6% 13.4% 18.0% 22.9%
    282 50.4 32.0 5.7 2.6 2.5 6.7 8.3 10.0
    63.6% 11.4% 5.2% 5.0% 13.3% 16.5% 19.8%
    283 58.1 37.5 6.6 3.0 2.7 6.3 8.8 11.1
    64.5% 11.3% 5.1% 4.7% 10.8% 15.1% 19.1%
    284 68.5 44.4 6.9 3.5 3.3 7.1 10.1 13.6
    64.8% 10.1% 5.1% 4.8% 10.4% 14.7% 19.9%
    285 97.2 65.4 10.0 4.1 4.1 9.4 13.3 17.8
    67.3% 10.3% 4.2% 4.2% 4.6% 13.7% 18.3%
    286 46.3 29.6 5.1 2.4 1.9 5.2 6.7 9.2
    64.0% 11.0% 5.1% 4.0% 11.3% 14.5% 19.9%
    287 30.9 20.4 4.1 1.4 1.0 2.7 3.7 5.0
    66.0% 13.3% 4.6% 3.1% 8.7% 12.0% 16.1%
    288 37.4 24.0 4.8 1.9 1.1 3.8 4.6 6.8
    64.2% 12.8% 5.0% 3.1% 10.1% 12.2% 18.1%
    289 48.0 32.6 4.7 2.5 1.7 4.5 5.9 8.3
    67.9% 9.7% 5.1% 3.6% 9.5% 12.3% 17.3%
    290 78.1 53.9 7.3 3.3 3.1 7.7 10.6 13.7
    69.0% 9.3% 4.2% 3.9% 9.9% 13.5% 17.5%
    291 35.7 23.2 4.0 1.7 1.8 4.4 5.4 6.8
    35.7% 11.1% 4.7% 5.2% 12.4% 15.0% 19.1%
  • TABLE 44
    Ethylene/EGPEA Copolymerizations in Chlorobenzene(18 h, 10 mL Total Volume of Chlorobenzene + EGPEA)
    Na- Acrylate
    Cmpd EGPEA B(C6F5)3 BAF Press Temp Incorp Total
    Ex. mmol mL equiv equiv MPa ° C. Yield g mol % M.W. Me
    292 45 0.01 1 40 20 6.9 100 10.28 0.4 Mp = 22,374; Mw = 23,126; Mn = 10,630; PDI = 2.18 49.5
    293 45 0.005 1 80 40 6.9 100 7.84 0.5 Mp = 26,320; Mw = 26,956; Mn = 12,371; PDI = 2.18 82.7
    294 64 0.005 1 80 40 6.9 100 1.85 0.4 Mp = 83,096; Mw = 81,919; Mn = 39,427; PDI = 2.08 71.5
    295 55 0.005 1 80 40 6.9 100 1.87 0.7 Mp = 22,984; Mw = 24,347; Mn = 12,365; PDI = 1.97 41.3
    296 45 0.01 1 40 20 3.5 120 5.59 0.6 Mp = 9,544; Mw = 10,892; Mn = 4,896; PDI = 1.97 73.5
    297 64 0.01 1 40 20 3.5 120 0.78 0.4 Mp = 26,286; Mw = 26,534; Mn = 13,114; PDI = 2.02 134.2
    298 55 0.01 1 40 20 3.5 120 1.97 Mp = 7,250; Mw = 8,005; Mn = 3,348; PDI = 2.39
    299 45 0.01 1 40 20 6.9 120 12.49 0.6 Mp = 14,470; Mw = 15,044; Mn = 6,519; PDI = 2.31 70.6
    300 45 0.01 2 40 20 6.9 120 6.01 1.5 Mp = 11,778; Mw = 12,804; Mn = 5,707; PDI = 2.24 61.2
    301 45 0.01 3 40 20 6.9 120 4.14 2.4 Mp = 7,806; Mw = 10,643; Mn = 4,312; PDI = 2.47 48.6
    302 45 0.005 1 80 40 6.9 120 7.29 0.6 Mp = 11,733; Mw = 13,519; Mn = 5,644; PDI = 2.40 67.2
    303 45 0.005 2 80 40 6.9 120 5.07 1.4 Mp = 9,852; Mw = 11,599; Mn = 4,755; PDI = 2.44 67.1
    304 78 0.02 2 20 10 6.9 120 0.96 1.4a Mp = 30,063; Mw = 25,126; Mn = 7,262; PDI = 3.46 28.0
    305 78 0.02 4 20 10 6.9 120 1.06 1.1a Mp = 4,852; Mw = 6,734; Mn = 2,384; PDI = 2.82 12.5
    306 45 0.005 1 80 40 3.5 120 2.64 0.8 Mp = 10,797; Mw = 11,715; Mn = 5,047; PDI = 2.32 66.8
    307 45 0.005 2 80 40 3.5 120 2.95 1.9 Mp = 8,636; Mw = 9,312; Mn = 4,496; PDI = 2.07 67.6
    308 45 0.01 2 40 20 3.5 120 2.96 1.2 Mp = 7,616; Mw = 8,630; Mn = 3,709; PDI = 2.33 66.3
    309 45 0.01 3 40 20 3.5 120 2.70 1.9 Mp = 5,039; Mw = 7,443; Mn = 2,709; PDI = 2.75 59.0
    310 45 0.0025 1 160 80 3.5 120 1.59 0.9 Mp = 7,737; Mw = 8,732; Mn = 4,051; PDI = 2.16 73.0
    311 45 0.0025 1 160 80 6.9 100 2.52 0.8 Mp = 25,609; Mw = 25,456; Mn = 11,960; PDI = 2.13 27.5
    312 45 0.0025 2 160 80 6.9 100 2.02 2.1 Mp = 20,773; Mw = 21,386; Mn = 10,385; PDI = 2.06 22.1
    313 45 0.0025 0.5 160 80 6.9 100 5.85 trace Mp = 23,609; Mw = 25,970; Mn = 12,143; PDI = 2.14 nd
    314 45 0.00125 1 160 80 6.9 100 1.67 1.0 Mp = 22,495; Mw = 23,371; Mn = 11,316; PDI = 2.07 27.4
    315 45 0.00125 1 160 80 6.9 120 2.96 0.9 Mp = 12,729; Mw = 13,757; Mn = 6,189; PDI = 2.22 68.2
    316 45 0.0025 0.5 160 80 6.9 120 7.27 0.4 Mp = 13,244; Mw = 15,491; Mn = 6,318; PDI = 2.45 70.8
    317 45 0.0025 2 160 80 6.9 120 3.22 1.5 Mp = 12,047; Mw = 13,044; Mn = 6,043; PDI = 2.16 55.6
    318 45 0.0025 1 160 80 6.9 120 5.02 0.7 Mp = 12,942; Mw = 13,493; Mn = 6,073; PDI = 2.22 58.7
    aDue to the high homopolymer content of the polymer sample, the reported percent acrylate incorporation in the copolymer is an approximation.
  • TABLE 45
    Ethylene/EGPEA Copolymerizations in TCB: Variation of Catalyst Concentration
    and Structure, and Temperature(6.9 MPa E, 18 h, 10 mL Total Volume of TCB +
    EGPEA)
    Na- Acrylate
    Cmpd EGPEA B(C6F5)3 BAF Temp Incorp Total
    Ex. mmol mL equiv Equiv ° C. Yield g mol % M.W. Me
    319 45 1 40 20 140 3.01 0.5 Mp = 7,507; 87.5
    0.01 Mw = 8,668;
    Mn = 3,753;
    PDI = 2.31
    320 45 2 40 20 140 2.43 1.6 Mp = 6,568; 80.8
    0.01 Mw = 7,865;
    Mn = 3,535;
    PDI = 2.22
    321 45 1 80 40 140 2.41 0.7 Mp = 7,192; 88.7
    0.005 Mw = 8,650;
    Mn = 3,909;
    PDI = 2.21
    322 45 2 80 40 140 1.66 1.6 Mp = 6,197; 82.0
    0.005 Mw = 7,988;
    Mn = 3,234;
    PDI = 2.47
    323 45 1 160 80 140 4.54 0.7 Mp = 7,443; 91.6
    0.0025 Mw = 8,725;
    Mn = 3,328;
    PDI = 2.62
    324 96 1 20 10 120 2.14 1.2 Mp = 9,128; 120.9
    0.02 Mw = 12,153;
    Mn = 5,089;
    PDI = 2.39
    325 97 1 20 10 120 1.79 0.6 Mp = 56,495; 18.0
    0.02 Mw = 56,319;
    Mn = 25,240;
    PDI = 2.23
  • TABLE 46
    Ethylene/MA Copolymerizations: Variation of Temperature
    (0.0025 mmol Cmpd, 160 equiv B(C6F5)3, 80 equiv NaBAF, 6.9 MPa E, 18 h, 0.5 mL
    MA, 9.5 mL Chlorobenzene)
    Acrylate
    Temp Incorp Total
    Ex Cmpd ° C. Yield g Mol % M.W. Me
    326 45 100 2.90 0.53 (13C) Mp = 17,308; Mw = 18,706; Mn = 9,144; 31.8
    PDI = 2.05
    327 45 120 2.59 0.45 (13C) Mp = 9,967; Mw = 10,394; Mn = 4,713; 51.8
    PDI = 2.21
  • TABLE 47
    13C NMR Branching Analysis for MA and HA
    Copolymers of Tables 46, 49 and 50
    Ex. Total Me Me Et Pr Bu Hex+ & eoc Am+ & eoc Bu+ & eoc
    326 31.8 21.3 3.6 1.6 1.6 2.9 4.7 5.3
    327 51.8 31.6 5.8 13.1 2.6 4.8 8.9 11.2
    346 71.7 45.2 7.6 3.7 3.4 6.2 11.0 15.2
    347 71.8 45.9 7.8 3.8 3.8 6.5 11.1 14.4
    354 48.6 29.7 6.1 2.9 2.6 3.7 6.9 9.9
    364 58.5 36.5 7.8 2.7 2.8 9.6 11.6
    366 60.2 36.0 7.9 3.4 2.6 5.7 9.5 12.8
    383 31.1 22.0 3.5 1.2 1.6 2.8 4.0 4.5
    384 28.5 19.1 2.6 1.6 1.4 2.0 4.4 5.3
    388 98.6 68.1 12.2 2.5 2.8 11.2 12.1 15.8
  • TABLE 48
    Ethylene/EGPEA Copolymerizations: Variation of Catalyst Structure and
    Cocatalyst Concentration (18 h, 6.9 MPa E, 120° C., 0.5 mL EGPEA)
    Na- Acrylate
    Cmpd Solvent B(C6F5)3 BAF Incorp Total
    Ex. mmol mL equiv Equiv Yield g mol % M.W. Me
    328 45 CB 320 160 1.80 0.4 Mp = 13,525; 59.8
    0.00125 9.5 Mw = 13,741; Mn = 6,126;
    PDI = 2.24
    329 45 CB 640 160 3.72 0.3 Mp = 11,892; 61.6
    0.00125 9.5 Mw = 13,222; Mn = 6,184;
    PDI = 2.14
    330 45 CB 1600 160 2.90 0.4 Mp = 11,920; 65.3
    0.00125 9.5 Mw = 12,850; Mn = 6,419;
    PDI = 2.00
    331 45 CB 320 320 3.05 0.3 Mp = 12,013; 66.8
    0.00125 9.5 Mw = 12,568; Mn = 5,783;
    PDI = 2.17
    332 45 Toluene 320 160 3.52 0.3 Mp = 10,810; 65.4
    0.00125 9.5 Mw = 12,116; Mn = 5,518;
    PDI = 2.20
    333 45 CB 320 160 1.47 0.7 Mp = 13,399; 53.4
    0.00125 4.5 Mw = 14,553; Mn = 7,141;
    PDI = 2.04
    334 61 CB 320 160 1.70 0.4 Mp = 6,206; Mw = 7,385; 65.7
    0.0025 9.5 Mn = 3,287; PDI = 2.25
    335 57 CB 320 160 0.76 0.3 Mp = 15,079; 68.5
    0.0025 9.5 Mw = 15,975; Mn = 8,241;
    PDI = 1.94
    336 74 CB 320 160 3.58 0.2 Mp = 29,889; 72.6
    0.0025 9.5 Mw = 34,141;
    Mn = 17,674; PDI = 1.93
    337 71 CB 320 160 0.055 0.2 Mp = 13,750; 91.2
    0.0025 9.5 Mw = 15,066; Mn = 7,535;
    PDI = 2.00
  • TABLE 49
    Ethylene/Acrylate Copolymerizations: Variation of Catalyst Structure, Catalyst and Cocatalyst Concentration (18 h, 6.9 MPa E,
    120° C.)
    Na- Acrylate
    Cmpd Solvent/mL B(C6F5)3 BAF Incorp Total
    Ex. mmol Acrylate/mL Equiv equiv Yield g mol % M.W. Me
    338 45, 0.00125 CB/9, EGPEA/1 640 160 1.79 0.6 Mp = 11,857; Mw = 12,974; Mn = 5,887; PDI = 2.20 59.4
    339 45, 0.0025 CB/14, EGPEA/1 640 160 3.47 0.4 Mp = 11.853; Mw = 12,966; Mn = 5,513; PDI = 2.35 64.2
    340 45, 0.00125 CB/14, EGPEA/1 640 160 2.02 0.5 Mp = 12,305; Mw = 12,062; Mn = 5,229; PDI = 2.31 67.1
    341 45, 0.00125 CB/14, EGPEA/1 960 320 2.26 0.4 Mp = 11,788; Mw = 12,131; Mn = 5,524; PDI = 2.20 60.9
    342 45, 0.0025 CB/13, EGPEA/2 960 160 2.54 0.7 Mp = 10,220; Mw = 11,156; Mn = 5,349; PDI = 2.09 62.1
    343 74, 0.00125 CB/14, EGPEA/1 960 160 0.77 0.2 Mp = 29,720; Mw = 32,471; Mn = 17,281; PDI = 1.88 66.1
    344 74, 0.0025 CB/13, EGPEA/2 960 160 1.35 0.5 Mp = 26,232; Mw = 27,641; Mn = 14,194; PDI = 1.95 69.6
    345 74, 0.00125 Toluene/14, EGPEA/1 960 160 1.55 0.2 Mp = 30,222; Mw = 32,909; Mn = 18,006; PDI = 1.83 69.6
    346 74, 0.00125 CB/14.5, MA/0.5 960 160 0.82 0.3 Mp = 23,118; Mw = 23,916; Mn = 10,009; PDI = 2.39 71.7
    (13C) (13C)
    347 74, 0.0025 CB/14, MA/1 960 160 1.32 0.4 Mp = 11,962; Mw = 13,390; Mn = 6,417; PDI = 2.09 71.8
    (13C) (13C)
    348 45, 0.00125 TCB/9.5, EGPEA/0.5 640 320 2.33 trace Mp = 14,132; Mw = 15,668; Mn = 6,596; PDI = 2.38 nd
    349 45, 0.00125 TCB/9, EGPEA/1 640 320 2.03 0.9 Mp = 11,996; Mw = 13,748; Mn = 6,235; PDI = 2.21 51.9
    350 45, 0.0019 TCB/9.5, EGPEA/0.5 421 210 4.71 0.4 Mp = 13,326; Mw = 15,974; Mn = 6,186; PDI = 2.58 57.4
    351 45, 0.0019 TCB/9, EGPEA/1 421 210 3.29 0.8 Mp = 11,534; Mw = 13,641; Mn = 5,635; PDI = 2.42 60.2
    352 45, 0.0019 TCB/9.5, EGPEA/0.5 210 210 4.43 0.4 Mp = 12,953; Mw = 13,730; Mn = 5,116; PDI = 2.68 nd
    353 45, 0.0019 p-Xylene/9.5, EGPEA/ 421 210 5.62 0   Mp = 14,910; Mw = 32,190; Mn = 8,859; PDI = 3.63 71.8
    0.5
    354 45, 0.0019 TCB/9.75, MA/0.25 421 210 0.81 0.3 Mp = 11,398; Mw = 13,504; Mn = 5,827; PDI = 2.32 48.6
    (13C) (13C)
    355 78, 0.01 TCB/9, EGPEA/1 80 40 0.59 Nda Mp = 64,840; Mw = 57,576; Mn = 24,348; PDI = 2.36 nd
    356 78, 0.01 TCB/9, EGPEA/1 80 40 0.56 Nda Mp = 64,496; Mw = 59,869; Mn = 30,765; PDI = 1.95 nd
    357 76, 0.0019 TCB/9.5, EGPEA/0.5 421 210 3.95 0.5 Mp = 21,762; Mw = 23,924; Mn = 12,118; PDI = 1.97 67.5
    358 45, 0.0019 TCB/9, EGPEA/1 421 210 3.74 0.6 Mp = 12,616; Mw = 15,891; Mn = 6,055; PDI = 2.62 57.1
    359 45, 0.0019 p-Xylene/8, Butyl 421 210 1.24 0.7 Mp = 8,918; Mw = 9,634; Mn = 4,250; PDI = 2.27 62.8
    Ether/1 EGPEA/1
    360 45, 0.0019 p-Xylene/4.5, Butyl 421 210 0.91 0.8 Mp = 6,913; Mw = 8,108; Mn = 4,024; PDI = 2.02 67.6
    Ether/4.5, EGPEA/1
    361 45, 0.0019 Butyl Ether/9, EGPEA/1 421 210 0.97 1.0 Mp = 6,100; Mw = 6,969; Mn = 3,626; PDI = 1.92 66.8
    362 45, 0.00125 p-Xylene/9, EGPEA/1 640 320 0.98 0.5 Mp = 21,762; Mw = 23,924; Mn = 12,118; PDI = 1.97 67.5
    363 45, 0.0019 TCB/9, HA/1 421 210 0.025 Nd Nd Nd
    364 45, 0.00125 p-Xylene/9, HA/1 640 320 2.53 0.6 Mp = 11,816; Mw = 11,804; Mn = 5,225; PDI = 2.26 58.5
    (13C) (13C)
    365 45, 0.0019 TCB/9.5, MA/0.5 421 210 0.083 Nd Nd Nd
    366 45, 0.00125 p-Xylene/9.5, MA/0.5 640 320 2.58 0.75 Mp = 10,362; Mw = 10,505; Mn = 5,123; PDI = 2.05 67.5
    (13C) (13C)
    367 79, 0.0019 TCB/9, EGPEA/1 421 105 0.018 Nd Nd Nd
    368 59, 0.0019 TCB/9, EGPEA/1 421 105 0.51 1.1 Mp = 6,858; Mw = 7,745; Mn = 3,968; PDI = 1.95 47.2
    369 80, 0.0019 TCB/9, EGPEA/1 421 105 0.59 0.6 Mp = 11,196; Mw = 14,898; Mn = 6,228; PDI = 2.39 60.0
    370 81, 0.0019 TCB/9, EGPEA/1 421 105 0.004 Nd Nd Nd
    371 45, 0.0019 p-Xylene/9, EGPEA/1 421 105 3.20 0.6 Mp = 14,259; Mw = 14,764; Mn = 6,250; PDI = 2.36 55.6
    372 45, 0.0019c TCB/9, EGPEA/1 421 105 2.64 0.6 Mp = 13,840; Mw = 15,593; Mn = 7,075; PDI = 2.20 57.1
    373 82, 0.0019 TCB/9, EGPEA/1 421 105 0.32 Nd Mp = 35,840; Mw = 37,957; Mn = 20,356; PDI = 1.86 Nd
    374 45, 0.0019 TCB/9, EGPEA/1 421 105 0.18 2.0 Mp = 13,679; Mw = 15,497; Mn = 7,382; PDI = 2.10 60.4
    375 45, 0.0019 p-Xylene/9, EGPEA/1 421 105 0.86 1.2 Mp = 6,984; Mw = 8,147; Mn = 3,927; PDI = 2.07 55.6
    376 64, 0.002 p-Xylene/3, EGPEA/2 200 100 0.25 4.2b Mp = 13,668; Mw = 14,464; Mn = 6,967; PDI = 2.08 59.4
    377 64, 0.002 p-Xylene/8, EGPEA/2 200 100 0.76 3.1 Mp = 25,728; Mw = 26,593; Mn = 13,836; PDI = 1.92 87.2
    378 64, 0.002 p-Xylene/4.5, MA/0.5 200 100 0.52 2.3 Mp = 30,000; Mw = 31,999; Mn = 14,434; PDI = 2.22 98.6
    (13C) (13C)
    379 64, 0.002 p-Xylene/4.5, MA/0.5 800 100 0.68 Nd Mp = 28,722; Mw = 31,214; Mn = 13,352; PDI = 2.34 Nd
    aAny copolymer resonances are obscured by the homopolymer resonances.
    bPercent acrylate incorporation in the copolymer is an estimate due to the high homopolymer content of the sample.
    c+100 equiv MeAl(BHT)2
  • TABLE 50
    Ethylene/Acrylate Copolymerizations: Variation of Solvent and Acrylate
    Substituent (18 h, 6.9 MPa E, 100° C.)
    Na- Acrylate
    Cmpd Solvent/mL B(C6F5)3 BAF Incorp Total
    Ex. mmol Acrylate/mL Equiv equiv Yield g mol % M.W. Me
    380 45 Toluene/9 421 105 1.28 1.1 Mp = 20,773; 38.0
    0.0019 EGPEA/1 Mw = 21,618;
    Mn = 10,131;
    PDI = 2.13
    381 45 Toluene/9 421 105 1.40 0.4 Mp = 20,340; 49.2
    0.0019 HA/1 Mw = 20,560;
    Mn = 9,573;
    PDI = 2.15
    382 45 CB/9 421 105 0.57 0.5 Mp = 18,173; 43.4
    0.0019 HA/1 Mw = 18,605;
    Mn = 8,670;
    PDI = 2.15
    383 45 Toluene/9.5 421 105 1.99 0.6 Mp = 20,997; 31.1
    0.0019 MA/0.5 (13C) Mw = 21,705; (13C)
    Mn = 10,684;
    PDI = 2.03
    384 45 CB/9.5 421 105 1.33 0.4 Mp = 13,279; 28.5
    0.0019 MA/0.5 Mw = 15,028;
    Mn = 7,635;
    PDI = 1.97
  • TABLE 51
    Ethylene/Hexyl Acrylate Copolymerizations: Variation of Catalyst Structure (18 h,
    6.9 MPa E, 120° C., 1 mL Hexyl Acrylate, 9 mL p-Xylene)
    Acrylate
    Cmpd B(C6F5)3 LiB(C6F5)4 Incorp Total
    Ex. 0.005 mmol equiv equiv Yield g mol % M.W. Me
    385 79 80 40 1.92 1.3 Mp = 20,773; 78.4
    Mw = 21,618;
    Mn = 10,131; PDI = 2.13
    386 81 80 40 0.011 Nd Nd Nd
    387 53 80 40 0.41 2.3 Mp = 782; Mw = 1,183; 98.4
    Mn = 409; PDI = 2.89
  • TABLE 52
    Ethylene/EGPEA Copolymerizations: Variation of p-Substituent on the N-Aryl
    Ring (0.0019 mmol Cmpd, 18 h, 6.9 MPa E, 120° C., 1 mL EGPEA, 9 mL TCB)
    Acrylate
    B(C6F5)3 LiB(C6F5)4 Incorp Total
    Ex. Cmpd equiv equiv Yield g mol % M.W. Me
    388 45 211 105 3.98 0.8 Mp = 14.113; Mw = 16,389; 53.2
    Mn = 6,722; PDI = 2.44
    389 83 211 105 3.78 0.8 Mp = 15,156; Mw = 16,926; 54.4
    Mn = 7,557; PDI = 2.24
    390 84 211 105 2.80 1.1 Mp = 14,422; Mw = 15,390; 48.7
    Mn = 6.960; PDI = 2.21
  • TABLE 53
    Ethylene/2,2,3,3,3-Pentafluoropropyl acrylate (PPA) Copolymerizations (0.0019 mmol
    Cmpd, 18 h, 10 mL Total Volume of p-Xylene + PPA, 100° C., 6.9 MPa E)
    Acrylate
    PPA B(C6F5)3 NaBAF Incorp Total
    Ex. Cmpd mL equiv equiv Yield g mol % M.W. Me
    391 45 1 211 105 5.93 0.2 Mp = 25,838; 31.3
    Mw = 26,041;
    Mn = 10,736; PDI = 2.43
    392 74 1 211 105 4.09 0.3 Mp = 67,066; 45.5
    Mw = 64,176;
    Mn = 32,073; PDI = 2.00
    393 45 2 211 105 3.76 0.3 Mp = 22,227; 28.6
    Mw = 22,623;
    Mn = 10,036; PDI = 2.25
    394 74 2 211 105 3.36 0.3 Bimodal: 48.4
    Mp = 56,152;
    Mw = 49,560;
    Mn = 18,664; PDI = 2.66
  • TABLE 54
    Ethylene/EGPEA Copolymerizations: Variation of Catalyst Structure, Pressure
    and Temperature (18 h, 1 mL EGPEA, 9 mL p-Xylene, 0.0019 mmol Cmpd, 211
    equiv B(C6F5)3, 105 equiv NaBAF)
    Acrylate
    Press Temp Incorp Total
    Ex. Cmpd MPa ° C. Yield g mol % M.W. Me
    395 85 3.5 80 0.016 trace Nd
    396 86 3.5 80 0.437 0.8 Mp = 916; Mw = 1,670; Mn = 739; 39.9
    0.6 IC PDI = 2.26
    0.2 EG
    397 87 3.5 80 0.429 2.1 Mp = 26,655; Mw = 28,284; 31.1
    Mn = 13,707; PDI = 2.06
    398 88 3.5 80 0.203 2.2 Mp = 2,832; Mw = 3,358; 44.4
    Mn = 1,754; PDI = 1.92
    399 89 3.5 80 0
    400 85 6.9 120 0.318 0.7 Mp = 327; Mw = 1,150; Mn = 305; 57.7
    PDI = 3.77
    401 86 6.9 120 1.49 0.6, 0.4 Mp = 488; Mw = 864; Mn = 364; 82.1
    IC, 0.2 EG PDI = 2.37
    402 87 6.9 120 3.14 0.5 Mp = 15,311; Mw = 15,880; 65.7
    Mn = 7,213; PDI = 2.20
    403 88 6.9 120 0.565 1.1 Mp = 1,702; Mw = 2,418; 95.7
    Mn = 1,148; PDI = 2.11
    404 89 6.9 120 0
    405 90 6.9 120 1.86 1.3 Mp = 4,834; Mw = 5,311; 52.5
    Mn = 2,530; PDI = 2.10
    406 91 6.9 120 0.50 1.6, 1.3 Mp = 1,382; Mw = 2,217; 78.4
    IC, 0.3 EG Mn = 982; PDI = 2.26
    407 92 6.9 120 1.32 0.8 Mp = 22,852; Mw = 24,968; 69.9
    Mn = 12,472; PDI = 2.00
    408 93 6.9 120 0
    409 94 6.9 120 1.24 1.4 Mp = 4,172; Mw = 4,579; 60.8
    Mn = 2,254; PDI = 2.03
    410 95 6.9 120 0
    411 78 6.9 130 0.047 Ndb Mp = 20,248; Mw = 20,678; Nd
    Mn = 7,869; PDI = 2.63
    412 64 6.9 130 0.336 0.7 Mp = 31.486; Mw = 32,872; 108.5 
    Mn = 14,840; PDI = 2.22
    413 74 6.9 130 2.87 1.0, 0.7 Mp = 19,881; Mw = 20,567; 97.0
    IC, 0.3 EG Mn = 8,185; PDI = 2.51
    aPredominant alpha olefin end groups; some internal olefin end groups also present.
    bDiagnostic 1H NMR copolymer resonances, if present, are obscured by homopolymer resonances.
  • TABLE 55
    Ethylene/EGPEA Copolymerizations: Variation of Catalyst Structure, Cocatalyst
    Concentration, and Borate Counterion and Structure (0.0019 mmol Cmpd, 18 h, 2 mL
    EGPEA, 8 mL p-Xylene, 100° C., 6.9 MPa E)
    Acrylate
    B(C6F5)3 Borate Incorp Total
    Ex. Cmpd equiv 105 equiv Yield G mol % M.W. Me
    414 74 211 NaBAF 0.746 3.4a Mp = 28,528; Mw = 29,829; 32.1
    Mn = 11,409; PDI = 2.61
    415 74 211 LiBArF 0.647 1.9 Mp = 39,148; Mw = 36,313; 41.3
    Mn = 14,745; PDI = 2.46
    416 74 421 NaBAF 0.217 1.3 Mp = 26,280; Mw = 27,880; 36.9
    Mn = 13,106; PDI = 2.13
    417 74 421 LiBArF 0.358 1.2 Mp = 33,089; Mw = 33,479; 44.6
    Mn = 15,943; PDI = 1.57
    418 76 421 LiBArF 0.738 1.2 Mp = 29,924; Mw = 29,685; 36.1
    Mn = 12,971; PDI = 2.29
    419 92 421 LiBArF 0.385 1.1 Mp = 34,623; Mw = 35,775; 33.4
    Mn = 18,240; PDI = 196
    420 64 421 LiBArF 0.009 0.7 Mn(1H): No olefins 58.8
    421 93 421 LiBArF 0.021 1.5 Mn(1H): No olefins 33.2
    422 96 421 LiBArF 0.109 Nd Nd Nd
    423 90 421 LiBArF 0.982 2.5 Mp = 7,599; Mw = 8,271; 26.3
    Mn = 3,746; PDI = 2.21
    424 74 211 LiBArF 0.86 1.6 Mp = 26,306; Mw = 28,886; 37.6
    Mn = 10,439; PDI = 2.77
    425 74 105 LiBArF 1.23 2.2 Mp = 16,233; Mw = 21,189; 38.5
    Mn = 8,573; PDI = 2.47
    426 74 53 LiBArF 4.75 0 Mp = 76,091; Mw = 76,631; Nd
    Mn = 24,522; PDI = 3.13
    aThere is overlap of copolymer and homopolymer resonances in the 1H NMR spectrum due to the relatively large amount of homopolymer formed. Therefore, the percent acrylate incorporation in the copolymer is an approximation.
  • TABLE 56
    Ethylene/EGPEA Copolymerizations: Variation of Catalyst Structure and
    Concentration (18 h, 1 mL EGPEA, 9 mL p-Xylene, 80° C., 6.9 MPa E)
    Acrylate
    Cmpd B(C6F5)3 LiB(C6F5)4 MeAl(BHT)2 Incorp Total
    Ex. mmol equiv equiv equiv Yield g mol % M.W. Me
    427 59 40 20 0 6.73 1.6 Mp = 21,259; 15.3
    0.01 0.9 IC Mw = 21,724;
    0.7 EG Mn = 10,233;
    PDI = 2.12
    428 59 211 105 20 0.739 1.1 Mp = 19,634; 10.9
    0.0019 Mw = 20,285;
    Mn = 8,383;
    PDI = 2.42
    429 94 40 20 0 3.87 1.3 Mp = 11,047; 24.5
    0.01 0.9 IC Mw = 11,998;
    0.4 EG Mn = 4,529;
    PDI = 2.65
    430 94 211 105 20 1.22 0.7 Mp = 9,998; 17.1
    0.0019 Mw = 12,341;
    Mn = 4,993;
    PDI = 2.47
    431 53 40 20 0 2.26 1.0 Mp = 1,562; 31.8
    0.01 0.9 IC Mw = 2,097;
    0.1 EG Mn = 818;
    PDI = 2.56
  • TABLE 57
    Ethylene/Acrylate Copolymerizations: Variation of Catalyst Structure, Acrylate
    Structure and Temperature (0.004 mmol Cmpd, 18 h, 100 equiv B(C6F5)3, 50
    equiv LiB(C6F5)4, 9 mL p-Xylene, 6.9 MPa E)
    Acrylate
    Temp. Acrylate Incorp Total
    Ex. Cmpd ° C. 1 mL Yield G mol % M.W. Me
    432 45 80 EGPEA 0.070 0.6 Mp = 24,391; Mw = 28,348; 8.5
    0.5 IC Mn = 11,007; PDI = 2.58
    0.1 EG
    433 45 80 HA 0.294 1.0 Mp = 45,116; Mw = 71,337; 14.2
    Mn = 14,837; PDI = 4.81
    434 94 80 EGPEA 0.074 0.5 Mp = 9,723; Mw = 13,173; 8.0
    Mn = 6,276; PDI = 2.10
    435 94 80 HA 0.362 0.8 Mp = 14,965; Mw = 15,692; 12.4
    Mn = 6,605; PDI = 2.38
    436 90 80 HA 0.286 0.8 Mp = 17,982; Mw = 17,990; 9.7
    Mn = 6,559; PDI = 2.74
    437 45 40 EGPEA 0
    438 91 40 EGPEA 0
    439 94 40 EGPEA 0
  • Examples 440-555
  • In these Examples sometimes alkylaluminum compounds are used as cocatalysts. These alkylaluminums were purchased from commercial sources, PMAO-IP (97) (polymethylaluminoxane from Akzo-Nobel, Inc., 12.7 wt % aluminum in toluene, (0.88 g/ml at 30° C.)) or synthesized by literature methods, (AlMe2(Et2O)2)(MeB(C6F5)3) (98) (WO0011006), AlMe(2,6-t-Bu-4-Me(OC6H2))2 (99) (A. P. Shreve, et al., Organometallics, vol. 7, p. 409 (1988)). and (Al-i-Bu2(OC6F5))2 (100) (D. G. Hendershot, et al., Organometallics, vol. 10 p. 1917 (1991)).
  • Figure US20100222531A1-20100902-C00034
  • The transition metal complexes (101-117) are either isolated compounds or in situ generated from a combination of compounds. Such combinations are shown under the compound designation (number). Syntheses of compounds other than α-diimines or their complexes are described in the following references:
  • 45-97, 101, 102, 103, 104, 105, 109, 110, 116 and 117, are α-diimines and/or Ni complexes the same as or similar to those described in U.S. Pat. No. 6,034,259 and references therein, and U.S. Pat. No. 6,103,658, and these α-diimines and/or Ni complexes are made by methods similar to those described therein. The synthesis of the ligand for 79 is reported in Y. Yamamoto et al., J. Organometal. Chem., vol. 489, p. 21-29 (1995), and K. Sugano, et al., Chem. Lett., vol. 1991 p. 921-924.
  • The synthesis of the α-diimine for 110 is described in U.S. Pat. No. 6,103,658.
  • Methods for making 115 are found in U.S. Pat. No. 6,174,975.
  • Synthesis of 108 is found in previously incorporated U.S. patent application Ser. No. ______ (filed concurrently on 31 May 2001, Applicant's reference CL1655 US NA).
  • Syntheses of 106 and 107 are found herein.
  • All of the immediately documents are hereby included by reference.
  • Metal complexes or ingredients for in situ preparations are shown below:
  • Figure US20100222531A1-20100902-C00035
    Figure US20100222531A1-20100902-C00036
    Figure US20100222531A1-20100902-C00037
  • General Polymerization Procedure for Examples 440-555. In a drybox, a glass insert was loaded with a combination of ligand and metal precursor or an isolated metal precatalyst and 2 mL of solvent. The solution was cooled to −30° C. and a solid portion of aluminum cocatalyst (such as 98, 99 or 100) or solution of PMAO-IP (97) was added followed by 4 mL of solvent and the solution was cooled to −30° C. This cooling was done to prevent any polymerization catalyst decomposition prior to contact with the monomers, in case the catalyst was thermally unstable. A solution was made with salt (see below), comonomer and 3 mL of solvent. The solution was added to the glass insert and then cooled to −30° C. The insert was capped and placed into double ziplock bags. Outside the drybox the rack was transferred to a pressure tube and flushed with ethylene. The pressure tube was pressurized with ethylene and heated to the desired temperature and mechanically shaken for the duration of time listed in the table. The reaction solution was quenched with 30 mL of methanol or acidic methanol (10:90 HCl methanol solution) and the polymer was isolated by filtration, rinsed with additional methanol and dried under vacuum.
  • Polymerization results are presented in Tables 58-64. A short description/explanation for each table is given below. “Salt” in these tables indicates the addition of NaBAF or LiB(C6F5)4 to the polymerization solution and it appeared to inhibit or prevent acrylate homopolymerization, and will be shown as simply Na or Li in the table.
  • Table 58: Table 58 contains examples with Ni catalysts, diimine with Ni(acac)2, and alkylaluminum cocatalysts for EGPEA and ethylene copolymerization. At these high ratios of Ni to salt and Al cocatalysts we had some significant acrylate homopolymerization. The acrylate homopolymer was found in two forms, a powder which was a mixture of copolymer with some acrylate homopolymer as identified by 1H NMR, and a gelatin consisting of acrylate homopolymer which was physically separated and not included in the polymer weight in the tables. The solution volume was approximately 10 mL in each case, therefore, the solvent added was 10 mL minus the volume added for the liquid comonomer.
  • Table 59: Table 59 shows examples of some of the better catalysts under conditions with low concentration of Ni and high concentration of salt and Al cocatalysts. In these examples consistently good yields of EGPEA/ethylene copolymer were obtained. Further characterization of these polymers is indicated by Mw from GPC as well as incorporation of acrylate (mole %) in the copolymer that was calculated from 1H NMR spectra of the polymer.
  • Table 60: This table has very low Ni concentrations and more acrylate homopolymer and low yields of polymer are obtained overall.
  • Table 61: Different combinations of Ni compounds and cocatalysts are used.
  • Table 62: Examples for E-10-U copolymerizations with ethylene.
  • Table 63: Hexyl acrylate copolymerization with Ni catalyst.
  • Table 64: Other catalysts for EGPEA copolymerization.
  • TABLE 58
    Ethylene and EGPA copolymerization (18 h, 6.9 MPa E, 0.02 mmol Ni)
    Catalyst
    Ex. mmol Salt (eq) Al (eq) EGPEA solvent Temp Yield (g)
    440 104 Li (5) 100 (50) 1 mL 1,2,4-TCB 120° C. 1.439
    441 104 Li (5) 100 (50) 2 mL 1,2,4-TCB 120° C. 1.033
    442 104 Na (5)  97 (200) 2 mL 1,2,4-TCB 120° C. 6.011
    443 104 Li (5) 100 (50) 2 mL p-xylene 120° C. 2.982
    444 104 Li (5)  99 (50) 1 mL 1,2,4-TCB 120° C. 6.522
    445 103 Li (5) 100 (50) 1 mL p-xylene 100° C. 1.287
    446 103 Na (5)  97 (200) 1 mL p-xylene 100° C. 5.077
    447 104 Li (5) 100 (50) 1 mL p-xylene 100° C. 9.073
    448 104 Na (5)  97 (200) 1 mL p-xylene 100° C. 3.96
    449 104 Na (5) 100 (50) 1 mL 1,2,4-TCB 100° C. 2.179
    450 103 Li (5) 100 (50) 1 mL 1,2,4-TCB 100° C. 3.053
    451 103 Li (5)  97 (200) 1 mL 1,2,4-TCB 100° C. 5.977
    452 104 Li (5)  97 (200) 1 mL 1,2,4-TCB 100° C. 6.114
    453 105 Li (5)  97 (200) 1 mL 1,2,4-TCB 100° C. 1.109
    454 105 Li (5) 100 (50) 1 mL 1,2,4-TCB 100° C. 3.392
    455 116 Na (5) 100 (50) 1 mL 1,2,4-TCB 100° C. 1.931
    456 103 Na (5) 100 (50) 1 mL 1,2,4-TCB 100° C. 1.269
    457 103 Na (5)  97 (200) 1 mL 1,2,4-TCB 100° C. 5.066
    458 105 Na (5) 100 (50) 1 mL 1,2,4-TCB 100° C. 4.628
    459 104 Na (10) 100 (50) 1 mL 1,2,4-TCB 100° C. 0.387
    460 104 Na (5)  97 (200) 1 mL 1,2,4-TCB 100° C. 6.538
    461 104 Li (5) 100 (50) 1 mL 1,2,4-TCB 100° C. 1.131
    462 104 Li (5) 100 (50) 1 mL 1,2,4-TCB 100° C. 4.477
    463 104 no salt 100 (50) 1 mL 1,2,4-TCB 100° C. 1.198
    464 104 Na (1) 100 (50) 1 mL 1,2,4-TCB 120° C. 0.50
    465 104 Na (1) 100 (50) 1 mL 1,2,4-TCB 120° C. 0.260
    466 104 Na (1)  97 (200) 1 mL 1,2,4-TCB 120° C. 5.411
    467 104 Na (5) 100 (50) 1 mL 1,2,4-TCB 120° C. 0.176
    468 104 Na (1) 100 (50) 1 mL 1,2,4-TCB 100° C. 0.254
    469 104 Na (1)  97 (200) 1 mL 1,2,4-TCB 100° C. 4.231
    470 104 Na (5) 100 (50) 1 mL 1,2,4-TCB 100° C. 1.460
  • TABLE 59
    Ethylene and EGPEA Copolymerization (6.9 MPa E, p-xylene solvent)
    Ex. Catalyst mmol Ni Salt eq Al eq mL acrylate Hrs Temp Yield Kg/g Ni Mw Mol % Ac
    471 101 0.002 Li (250) 98 (250) 1.0 18 120 4.766 41 19051 0.36
    472 101 0.002 Li (250) 98 (250) 1.5 18 120 3.170 27 16830 0.64
    473 106 0.002 Li (250) 98 (250) 1.0 18 120 8.332 71 5539 0.17l/0.19e
    474 101 0.001 Li (750) 98 (500) 1.0 18 120 2.576 44 16000 0.57
    475 101 0.004 Li (125) 98 (125) 1.0 18 100 7.24 31 27476 0.70
    476 101 0.002 Li (250) 98 (250) 1.0 18 100 4.749 40 25432 0.42
    477 101 0.002 Li (250) 98 (250) 1.5 18 100 3.213 27 22992 0.61
    478 106 0.002 Li (250) 98 (250) 1.0 18 100 4.398 37 7262 0.19l/0.16e
    479 101 0.001 Li (750) 98 (500) 1.0 18 100 3.374 57 24042 0.30
    480 101 0.004 Li (125) 98 (125) 1.0 64 120 15.08 64 17153 0.29
    481 101 0.002 Li (250) 98 (250) 1.0 64 120 10.521 90 16817 0.47
    482 101 0.002 Li (250) 98 (250) 1.5 64 120 9.455 80 17930 0.8 
    483 106 0.002 Li (250) 98 (250) 1.0 64 120 7.833 67 5469 0.20l/0.18e
    484 107 0.002 Li (250) 98 (500) 1.0 64 120 1.191 10 2045 ND
    485 101 0.004 Li (125) 98 (125) 1.0 64 100 13.073 56 26512 0.41
    486 101 0.002 Li (250) 98 (250) 1.0 64 100 8.807 75 25472 1.2 
    487 101 0.002 Li (250) 98 (250) 1.5 64 100 6.183 53 23585 0.84
    488 106 0.002 Li (250) 98 (250) 1.0 64 100 7.100 60 6803 0.15l/0.13e
    489 107 0.002 Li (250) 98 (500) 1.0 64 100 0.834 7 3135 ND
    490 102 0.004 Li (125) 100 (250)  1.0 18 120 7.259 31 13945 0.25
    491 102 0.004 Li (125) 98 (125) 1.0 18 120 9.147 39 14056 0.35
    492 102 0.004 Li (125) 98 (125) 2.0 18 120 3.23 14 11652 0.94
    493 101 0.004 Li (125) 100 (250)  1.0 18 120 6.165 26 13988 0.33
    494 101 0.004 Li (125) 98 (125) 1.0 18 120 9.355 40 15724 0.49
    495 102 0.02 Li (10) 100 (25)  1.0 18 120 6.58 6 N/A 0.55
    496 102 0.02 Li (10) 98 (25)  1.0 18 120 18.921 16 N/A 0.34
    497 106 0.004 Li (25) 98 (50)  1.0 18 100 4.190 18 N/A 0.22l/0.29e
    498 108 0.004 Li (25) 98 (50)  1.0 18 100 0.123 0.5 N/A ND
    499 107 0.004 Li (25) 98 (50)  1.0 18 100 2.114 9 N/A 0.38l/0.37e
    500 101 0.004 Li (25) 98 (50)  1.0 18 100 2.750 12 N/A 0.42
    501 102 0.004 Li (25) 98 (50)  1.0 18 100 1.547 7 10621 0.48
    Footnotes for Table 59:
    N/A indicates that a sample was not submitted for 1H NMR or GPC.
    ND (not determined) indicates that the formation of excess acrylate homopolymer overlaps the region for determining copolymer content. For the incorporation of acrylate in the ethylene copolymer (Mol % Ac) the in chain (i) and end of chain (e) position is indicated.
  • TABLE 60
    Ethylene and acrylate Copolymerization (18 h, 120° C., 6.9 MPa E, p-xylene solvent, Al compound 98)
    Ex. Catalyst mmol Ni Salt eq Al eq mL acrylate Yield Kg/g Ni Mw Mol % Ac
    502 101 0.001 Li (500)  (500) 1.0 EGPEA 3.443 59 17680 copoly
    503 101 0.0005 Li (1000) (1000) 1.0 EGPEA 1.998 34 16178 copoly
    504 106 0.001 Li (500)  (500) 1.0 EGPEA 1.560 27 5500 copoly
    505 106 0.0005 Li (1000) (1000) 1.0 EGPEA 1.08 37 5550 ND
    506 109 0.001 Li (500)  (500) 1.0 EGPEA 0.576 10 17704 ND
    507 101 0.001 Li (500)  (500) 0.5 MA 3.024 52 15041 copoly
    508 101 0.0005 Li (1000) (1000) 0.5 MA 1.507 51 N/A N/A
    509 106 0.001 Li (500)  (500) 0.5 MA 0.225 4 N/A N/A
    510 106 0.0005 Li (1000) (1000) 0.5 MA 0.390 13 N/A N/A
    511 109 0.001 Li (500)  (500) 0.5 MA 0.553 9 N/A N/A
    512 101 0.001 Li (500)  (500) 0.5 HA 1.08 18 N/A N/A
    513 101 0.0005 Li (1000) (1000) 0.5 HA 0.982 33 N/A N/A
    514 106 0.001 Li (500)  (500) 0.5 HA 0.314 5 N/A N/A
    515 106 0.0005 Li (1000) (1000) 0.5 HA 0.303 10 N/A N/A
    516 109 0.001 Li (1000) (1000) 0.5 HA 0.672 11 N/A N/A
    N/A indicates that a sample was not submitted for 1H NMR or GPC.
    ND (not determined) indicates that the formation of excess acrylate homopolymer overlaps the region for determining copolymer content.
    copoly = acrylate-ethylene copolymer detected by 1H NMR.
  • TABLE 61
    Ethylene and EGPEA Copolymerization (18 h, 120° C., 6.9 MPa E, p-xylene
    solvent, 1.0 ml EGPEA)
    Ex. Catalyst Mmol Ni Salt eq Al eq Yield Mw
    517 104 0.004 Li (125)  98 (125) 8.451 17004
    518 117 0.004 Li (125)  98 (125) 0.543 17988, 26687
    519 106 0.002 Li (250)  98 (250) 2.644  4787
    520 115 0.01 Li (30) 99 (20)/B(C6F5)3 (10) 0.307 N/A
    521 110 0.01 Li (30) 99 (20)/B(C6F5)3 (10) 1.417 26934
    522 102 0.01 Li (30) 99 (20)/B(C6F5)3 (10) 8.456 14038
    523 101 0.01 Li (30) 99 (20)/B(C6F5)3 (10) 8.283 13607
    524 111 0.01 Li (30) 100 (50)  0.897 N/A
    525 101 0.01 Li (30) 98 (25) 11.741 11838
    526 101 0.01 Li (30) 99 (25) 2.647 11370
    527 102 0.01 Li (30) 99 (25) 2.412 11766
    528 106 0.002 Li (150)  98 (250) 1.612  4235
    529 106 0.002 Li (150) 100 (500) 1.559 3812, 6321
    530 106 0.002 Li (150)  99 (500) 0.450 N/A
    531 107 0.002 Li (150)  98 (250) 0.929 N/A
    532 107 0.002 Li (150) 100 (500) 1.595  1785
    533 107 0.002 Li (150)  99 (500) 0.782 N/A
    534 108 0.002 Li (150)  98 (250) 0.263 N/A
    535 108 0.002 Li (150) 100 (500) 0.839 N/A
    536 108 0.002 Li (150)  99 (500) 0.387 N/A
    copoly = acrylate-ethylene copolymer detected by 1H NMR,
    ND (not determined) indicates that the polyacrylate region swamped out the region of interest for the copolymer therefore it is not determined.
    N/A indicates that a sample for 1H NMR or GPC was not submitted.
  • TABLE 62
    Ethylene and E-10-U Copolymerization (18 h, p-xylene solvent)
    mmol T Pres.
    Ex. Catalyst Ni Salt eq Al eq mL E-10-U ° C. MPa Yield Mw
    537 102 0.01 0 98 (50) 2.0 60 1.0 2.50  N/A
    538 106 0.002 Li (150)  98 (250) 1.0 120 6.9 8.525 6043
    539 106 0.004 Li (75)  98 (125) 1.7 120 6.9 0.531 4820
    540 115 0.01 Li (30) 99 (50) 1.7 120 6.9 0.101 N/A
    541 106 0.004 Li (75)  98 (125) 1.7 60 3.5 0.018 N/A
    542 115 0.01 Li (30) 99 (50) 1.7 60 3.5 0.091 N/A
    543 111 0.02 Na (1) 100 (50)  1.1 80 5.2 9.770 N/A
    544 112 0.02 Na (1) 100 (50)  1.1 80 5.2 0.160 N/A
    N/A indicates that a sample for 1H NMR or GPC was not submitted.
  • TABLE 63
    Copolymerization of ethylene and HA (18 h, 100° C., 6.9 MPa E)
    mmol mL
    Ex. Catalyst Ni Salt eq Al eq acrylate solvent Yield Mw
    545 104 0.02 Na (5) 97 (200) 1.0 HA 1,2,4TCB 4.881  4177
    546 104 0.02 Na (5) 97 (200) 2.0 HA 1,2,4TCB 3.392 21281
    547 104 0.02 Li (5) 99 (50)  1.0 HA 1,2,4TCB 6.443 21943
    548 104 0.02 Li (5) 99 (50)  1.0 HA p-xylene 7.655 29495
  • TABLE 64
    Copolymerization of Ethylene and EGPEA(18 h, 120° C., 6.9 MPa E, 0.01 mmol Ni)
    Ex. Catalyst Salt eq Al eq mL acrylate solvent Yield Mw
    549 103 Li (50) 98 (50) 1.0 p-xylene 19.010 13399
    550 116 Li (50) 98 (50) 1.0 p-xylene 16.671 15559
    551 102 Li (50) 98 (50) 1.0 p-xylene 11.724 12804
    552 102 Na (50)  97 (100) 1.0 1,2,4-TCB 5.848 26061
    553 102 Na (50) 97 (50) 1.0 1,2,4-TCB 5.550 11620
    554 103 Na (50)  97 (100) 1.0 1,2,4-TCB 10.108 12359
    555 103 Na (50) 97 (50) 1.0 1,2,4-TCB 9.116 14836
  • Examples 556-651
  • Various isocyanates were used with a single precursor, di-t-butylphosphinomethyl lithium to prepare variously substituted ligands (see below). Nickel complexes were then prepared in situ, and polymerizations carried out.
  • All reactions were performed under an atmosphere of nitrogen. The isocyanates for the catalyst preparation were obtained from commercial sources, and were purified by distillation, sublimation, or recrystallization; the compounds were stored under nitrogen before use. TCB was purchased anhydrous and used is as is. Additional solvents were distilled from drying agents under nitrogen using standard procedures: chlorobenzene from P2O5; and THF, from sodium benzophenone ketyl, Ni(II) allyl chloride and NaBAF were prepared according to the literature.
  • Ninety-five isocyanates were prepared as THF solutions (0.0500 M) and are listed in Table 65. These solutions were prepared in glass vials capped with Teflon® lined silicone septa to maintain an inert atmosphere and prevent evaporation.
  • Preparation of catalyst solutions was performed according to equation 1.
  • Figure US20100222531A1-20100902-C00038
  • In a typical procedure, each sample was prepared by adding sequentially 150(±3) μL of an isocyanate solution (0.0500 M in THF) followed by 150(±3) μL of a solution of (t-Bu)2PCH2Li (0.0500 M in THF), followed by 150(±3) μL of a solution of (NiCl(η3-C3H5))2 (0.0250 M in THF) to a septa sealed 2 mL glass vial. The solvent was then removed from each vial by purging with a nitrogen gas stream and each vial was then dried for 2 h in a vacuum chamber. A solution of cocatalyst (B(C6F5)3, B(C6H5)3 or NaBAF) 300 μL (0.1250 M in chlorobenzene or TCB) was added into each vial. Each vial was placed in a high-pressure reactor. The reactor was pressurized to the desired pressure (typically 6.9 MPa or 1.0 MPa) with ethylene and kept at that pressure for 18 h. At the end of the run, the solvent was removed from each vial under vacuum. After this operation each vial was weighed to obtain a polymer yield. To rapidly determine the presence of copolymer, a sample was taken out of each vial and placed in an NMR tube, CDCl3was added and the solution was analyzed submitted by 1H NMR spectroscopy. In some (usually promising) cases, samples were dissolved in TCE and submitted for high temperature 13C NMR spectroscopy.
  • Condition 1
  • Run at room temperature and 6.9 MPa of ethylene. Five equivalents of tris(pentafluorophenyl)borane were present as a cocatalyst. Eighteen hours was chosen as the run time to allow for comparison of the lowest and highest yielding catalysts. Results are presented in Table 65. The experimental procedure was repeated several times and despite some changes in yields, activity trends remained the same.
  • Condition 2
  • This was the same as Condition 1, except the ethylene pressure was 1.0 MPa. Results are shown in Table 65.
  • Condition 3
  • This was the same as Condition 1, except 5 equivalents of triphenylborane was used as a cocatalyst and the polymerization was run at 1.0 MPa ethylene pressure. This condition was repeated several times with similar results each time. Results are shown in Table 65.
  • Condition 4
  • This was run under the same conditions as Condition 1 except, one equivalent of NaBAF was added (150 μl of a 0.05M solution in THF) after the addition of nickel allyl chloride.
  • Condition 5
  • Run at room temperature and under 6.9 MPa of ethylene. Five equivalents of tri(pentafluorophenyl)borane were used. The cocatalyst, instead of being dissolved in pure TCB was dissolved in a 1:5 (v:v) mixture of EGPEA and TCB. Because EGPEA has a high boiling point, vials were weighed out immediately after the polymerization reaction without drying. Relative yields were obtained by difference of the weights of the “wet” vials and the pre-tared vials. Results are presented in Table 65. This condition was repeated several times and despite some changes in yields, activity trends remain the same.
  • Condition 6
  • This was the same as Condition 5 except the polymerization was run at 100° C. Results are presented in Table 65. This condition was repeated several times and despite some changes in yields, activity trends remain the same.
  • Condition 7
  • This was run in the same manner as Condition 6 except 1 equivalent of NaBAF added (150 μl of a 0.05M solution in THF) was also added after the nickel allyl chloride was added. Results are given in Table 65. 13C NMR analysis indicates that the polymer in Example 582 gives a copolymer with 1.04 mol % incorporation under this condition.
  • Condition 8
  • This condition was the same as Condition 7, except the EGPEA contained 250 ppm of benzoquinone as a free radical polymerization inhibitor. Results are given in Table 65. 13C NMR analysis indicates that the polymers produced in Examples 583 and 591 gave copolymers with trace incorporation of EGPEA, the polymer of Example 585 had 0.17 mol % incorporation of EGPEA, the polymer of Example 632 had 0.51 mol % incorporation of EGPEA, and the polymer of Example 640 had 0.90 mol % incorporation of EGPEA, all under this condition.
  • TABLE 65
    CONDITION
    Ex. NAME 1 2 3 4 5 6 7 8
    556 TRANS-2-PHENYLCYCLOPROPYL ISOCYANATE 1.2262 0.3589 0.0875 0.1950 0.4978 0.4518 0.249 0.3437
    557 PHENYL ISOCYANATE 0.6409 0.1067 0.046 0.0982 0.4686 0.6287 0.3906 0.3762
    558 2-BROMOPHENYL ISOCYANATE 0.5133 0.1321 0.0485 0.0994 0.4733 0.7043 0.3068 0.3811
    559 2-FLUOROPHENYL ISOCYANATE 0.3426 0.1074 0.0703 0.1568 0.437 0.5479 0.4299 0.4407
    560 2,4-DIFLUOROPHENYL ISOCYANATE 0.5988 0.1008 0.0615 0.1875 0.4797 0.7257 0.448 0.4373
    561 2,6-DIFLUOROPHENYL ISOCYANATE 0.3429 0.1111 0.0392 0.0974 0.4859 0.6638 0.4485 0.4626
    562 2-CHLOROPHENYL ISOCYANATE 0.4882 0.1215 0.0462 0.1257 0.5097 0.6995 0.4705 0.4645
    563 2,3-DICHLOROPHENYL ISOCYANATE 0.4516 0.1075 0.0434 0.1196 0.413 0.7917 0.4686 0.4702
    564 2,6-DICHLOROPHENYL ISOCYANATE 0.4058 0.1061 0.0506 0.1088 0.4688 0.7486 0.4394 0.3883
    565 2-METHOXYPHENYL ISOCYANATE 1.0975 0.113 0.0584 0.1183 0.4762 0.5993 0.5925 0.4257
    566 2,4-DIMETHOXYPHENYL ISOCYANATE 1.0943 0.1198 0.0415 0.1243 0.5168 0.6874 0.561 0.3869
    567 2-ETHOXYPHENYL ISOCYANATE 1.1473 0.1133 0.044 0.1469 0.4535 0.7136 0.4882 0.4019
    568 2-(TRIFLUOROMETHYL)PHENYL ISOCYANATE 0.4246 0.1013 0.0424 0.2715 0.5181 0.7255 0.4381 0.4564
    569 O-TOLYL ISOCYANATE 0.6267 0.1229 0.0862 0.1757 0.4151 0.7253 0.5005 0.4611
    570 2,6-DIMETHYLPHENYL ISOCYANATE 0.5454 0.1198 0.0603 0.1429 0.4016 0.6963 0.4101 0.3991
    571 2-ETHYLPHENYL ISOCYANATE 0.6052 0.1166 0.0781 0.1382 0.4254 0.6031 0.4255 0.4705
    572 3-BROMOPHENYL ISOCYANATE 0.587 0.1001 0.0761 0.1376 0.4664 0.6937 0.3257 0.4718
    573 3,4-DICHLOROPHENYL ISOCYANATE 0.813 0.0945 0.0536 0.1796 0.4698 0.7749 0.5005 0.5852
    574 4-BROMOPHENYL ISOCYANATE 0.6361 0.1074 0.0577 0.1428 0.4594 0.7041 0.5411 0.4898
    575 4-FLUOROPHENYL ISOCYANATE 0.8563 0.1152 0.0986 0.1222 0.4424 0.6754 0.5557 0.3903
    576 4-CHLOROPHENYL ISOCYANATE 0.7498 0.1242 0.0641 0.1239 0.4887 0.3319 0.4404 0.4185
    577 4-METHOXYPHENYL ISOCYANATE 0.5989 0.1302 0.0778 0.1245 0.4746 0.7178 0.6034 0.5034
    578 4-(TRIFLUOROMETHYL)PHENYL ISOCYANATE 0.651 0.0773 0.0539 0.1410 0.469 0.7685 0.4609 0.4037
    579 P-TOLYL ISOCYANATE 0.7736 0.1045 0.0744 0.1335 0.4849 0.6127 0.2255 0.5482
    580 TERT-BUTYL ISOCYANATE 1.0498 0.0808 0.1742 0.3829 0.422 1.3345 0.6914 0.6516
    581 (S)-(−)-1-PHENYLETHYL ISOCYANATE 0.873 0.1171 0.0923 0.1276 0.4037 0.8667 0.6858 0.6728
    582 ISOPROPYL ISOCYANATE 0.2012 0.0777 0.0107 0.1421 0.2749 0.6658 0.394 0.5266
    583 ETHYL ISOCYANATE 1.3347 0.1538 0.0805 0.1814 0.4434 1.2218 0.5436 0.6256
    584 ALLYL ISOCYANATE 0.9033 0.1644 0.0976 0.1347 0.6952 1.0612 0.4884 0.6627
    585 N-BUTYL ISOCYANATE 1.1664 0.1843 0.0637 0.1220 0.4643 1.8471 0.4761 0.6228
    586 CYCLOHEXYL ISOCYANATE 0.8991 0.0932 0.1353 0.2726 0.488 1.791 0.6514 0.6029
    587 1-NAPHTHYL ISOCYANATE 0.7214 0.0943 0.1161 0.1352 0.4344 0.7355 0.3902 0.4148
    588 2,6-DIISOPROPYLPHENYL ISOCYANATE 0.4853 0.1204 0.0914 0.1423 0.3988 0.6511 0.329 0.077
    589 BENZYL ISOCYANATE 1.1479 0.1492 0.1403 0.2398 0.5289 0.7776 0.5322 0.62
    590 3,5-BIS(TRIFLUOROMETHYL)PHENYL ISOCYANATE 0.7095 0.1125 0.1214 0.1271 0.4763 0.8135 0.4492 0.4084
    591 2,5-DIFLUOROPHENYL ISOCYANATE 0.4158 0.1146 0.0131 0.1836 0.4606 0.4177 0.3512 0.4228
    592 2,4,5-TRICHLOROPHENYL ISOCYANATE 0.3766 0.1572 0.0236 0.2077 0.4821 0.8006 0.4808 0.5625
    593 2,4,6-TRICHLOROPHENYL ISOCYANATE 0.5539 0.1011 0.0304 0.1775 0.4748 0.7127 0.4425 0.4596
    594 2-ISOPROPYLPHENYL ISOCYANATE 0.6127 0.1362 0.0693 0.1165 0.4707 0.6892 0.4572 0.4482
    595 2,3-DIMETHYLPHENYL ISOCYANATE 0.8057 0.1345 0.0872 0.1027 0.4844 0.7251 0.4875 0.4715
    596 4-METHOXY-2-METHYLPHENYL ISOCYANATE 0.6799 0.1668 0.0762 0.1207 0.4756 0.7112 0.3862 0.6706
    597 5-CHLORO-2,4-DIMETHOXYPHENYL ISOCYANATE 0.7214 0.1385 0.0716 0.1091 0.4337 0.7176 0.4579 0.6935
    598 3,5-DICHLOROPHENYL ISOCYANATE 0.6604 0.106 0.0931 0.1802 0.4473 0.7304 0.4414 0.6873
    599 5-CHLORO-2-METHOXYPHENYL ISOCYANATE 0.5286 0.113 0.057 0.1062 0.4621 0.7468 0.4694 0.4146
    600 3,4,5-TRIMETHOXYPHENYL ISOCYANATE 0.636 0.1275 0.0592 0.1148 0.4942 0.7509 0.523 0.7049
    601 3,5-DIMETHOXYPHENYL ISOCYANATE 0.6032 0.1015 0.0839 0.1171 0.4479 0.7324 0.5068 0.6608
    602 3-(METHYLTHIO)PHENYL ISOCYANATE 0.7208 0.0708 0.0715 0.0954 0.4626 0.7488 0.4867 0.3239
    603 3,5-DIMETHYLPHENYL ISOCYANATE 0.7576 0.1096 0.088 0.1073 0.4382 0.6381 0.4942 0.5342
    604 2-METHOXY-5-METHYLPHENYL ISOCYANATE 0.721 0.0987 0.0217 0.1216 0.4154 0.6463 0.4118 0.3875
    605 4-IODOPHENYL ISOCYANATE 0.5297 0.0883 0.0413 0.0881 0.4478 0.6757 0.1696 0.4612
    606 4-PHENOXYPHENYL ISOCYANATE 0.5906 0.1005 0.0936 0.0609 0.4485 0.6619 0.4136 0.4024
    607 4-(METHYLTHIO)PHENYL ISOCYANATE 0.4779 0.0937 0.1195 0.1086 0.4006 0.737 0.4584 0.5003
    608 4-ISOPROPYLPHENYL ISOCYANATE 0.5101 0.0769 0.0509 0.2092 0.4664 0.6183 0.407 0.4313
    609 OCTYL ISOCYANATE 0.9398 0.2845 0.1001 0.1300 0.486 1.4104 0.4526 0.4872
    610 2,4,6-TRIMETHYLPHENYL ISOCYANATE 0.7957 0.1156 0.067 0.1761 0.3983 0.6478 0.2829 0.2392
    611 2-ISOPROPYL-6-METHYLPHENYL ISOCYANATE 0.6618 0.1211 0.0738 0.0693 0.3989 0.577 0.3896 0.186
    612 2,6-DIETHYLPHENYL ISOCYANATE 0.5731 0.1098 0.0834 0.1372 0.4013 0.5009 0.4077 0.3754
    613 4-(TRIFLUOROMETHOXY)PHENYL ISOCYANATE 0.3959 0.0939 0.094 0.1096 0.4692 0.7275 0.454 0.4577
    614 4-(TRIFLUOROMETHYLTHIO)PHENYL ISOCYANATE 0.5944 0.1932 0.0353 0.0783 0.4089 0.7622 0.4608 0.4214
    615 2-CHLORO-5-(TRIFLUOROMETHYL)PHENYL ISOCYANATE 0.7326 0.105 0.0647 0.0876 0.4005 0.7298 0.2464 0.4005
    616 2-CHLORO-6-METHYLPHENYL ISOCYANATE 0.5883 0.1192 0.0613 0.1059 0.486 0.7034 0.3467 0.0977
    617 2,4,5-TRIMETHYLPHENYL ISOCYANATE 0.5944 0.1185 0.0966 0.1776 0.4417 0.6765 0.6212 0.4493
    618 2-TERT-BUTYL-6-METHYLPHENYL ISOCYANATE 0.8171 0.1604 0.0643 0.0848 0.4026 0.4572 0.1104 0.1466
    619 3-CHLORO-2-METHOXYPHENYL ISOCYANATE 0.5302 0.1404 0.0814 0.1427 0.459 0.782 0.4478 0.4052
    620 3-CHLORO-4-FLUOROPHENYL ISOCYANATE 0.4591 0.0945 0.1072 0.1099 0.4595 0.7624 0.4699 0.4507
    621 4-BROMO-2,6-DIMETHYLPHENYL ISOCYANATE 0.5464 0.13 0.1132 0.1166 0.4638 0.6462 0.4518 0.4093
    622 2,6-DIBROMO-4-FLUOROPHENYL ISOCYANATE 0.391 0.1774 0.0342 0.1319 0.401 0.7821 0.4095 0.4055
    623 PHENETHYL ISOCYANATE 0.8483 0.2427 0.1198 0.1491 0.4586 1.256 0.4523 0.4349
    624 2,4-DICHLOROBENZYL ISOCYANATE 0.8151 0.1546 0.1385 0.1366 0.5296 0.7782 0.5995 0.7227
    625 2-(METHYLTHIO)PHENYL ISOCYANATE 0.5143 0.0504 0.0428 0.2408 0.4157 0.7048 0.4431 0.2206
    626 2-BIPHENYLYL ISOCYANATE 0.5349 0.0985 0.0553 0.0910 0.4516 0.6602 0.2644 0.3317
    627 3-IODOPHENYL ISOCYANATE 0.6515 0.1149 0.0254 0.1153 0.4593 0.6019 0.4004 0.4163
    628 4-BIPHENYLYL ISOCYANATE 0.6505 0.1266 0.0859 0.1763 0.4478 0.6759 0.5337 0.6352
    629 1-(4-BROMOPHENYL)ETHYL ISOCYANATE 0.6759 0.1045 0.1104 0.1413 0.3993 0.8374 0.5492 0.639
    630 3-ISOCYANATOPROPYLTRIETHOXYSILANE 0.781 0.1447 0.0601 0.1449 0.4447 0.7711 0.68 0.63
    631 2,6-DICHLOROPYRID-4-YLISOCYANATE 0.3357 0.0929 0.0374 0.2234 0.464 0.4699 0.4956 0.4817
    632 2-BROMO-4,6-DIFLUOROPHENYL ISOCYANATE 0.3853 0.3034 0.0332 0.1377 0.4981 0.7634 0.3552 0.4703
    633 (R)-(+)-1-PHENYLETHYL ISOCYANATE 1.1374 0.0968 0.1314 0.1229 0.3998 0.7987 0.6867 0.6773
    634 1-(1-NAPHTHYL)ETHYL ISOCYANATE 0.6728 0.096 0.1357 0.0961 0.3994 0.776 0.6416 0.6752
    635 3,4-DIFLUOROPHENYL ISOCYANATE 0.5316 0.0918 0.1369 0.1027 0.3697 0.6019 0.3812 0.3829
    636 3-ISOPROPENYL-ALPHA,ALPHA-DIMETHYLBENZYL 0.8534 0.0668 0.1206 0.1723 0.3914 0.807 0.5119 0.5786
    ISOCYANATE
    637 2-(TRIFLUOROMETHOXY)PHENYL ISOCYANATE 0.4523 0.1001 0.1084 0.1736 0.4919 0.7178 0.3949 0.3472
    638 1-ADAMANTYL ISOCYANATE 1.1437 0.1182 0.1838 0.3750 0.5557 1.0394 0.6603 0.6336
    639 1,1,3,3-TETRAMETHYLBUTYL ISOCYANATE 1.109 0.1097 0.0803 0.1382 0.387 1.0645 0.6671 0.6077
    640 4-BROMO-2-FLUOROPHENYL ISOCYANATE 0.3947 0.1083 0.0481 0.1094 0.4643 0.763 0.4426 0.5667
    641 2-FLUORO-5-METHYLPHENYL ISOCYANATE 0.4424 0.1073 0.0694 0.1698 0.4776 0.7708 0.4446 0.5312
    642 2,3,4-TRIFLUOROPHENYL ISOCYANATE 0.9257 0.163 0.0954 0.1493 0.4571 0.7804 0.4449 0.5111
    643 4-(DIMETHYLAMINO)PHENYL ISOCYANATE 0.5244 0.1365 0.0726 0.1531 0.4774 0.7787 0.6345 0.6669
    644 2-(DIFLUOROMETHOXY)PHENYL ISOCYANATE 0.6934 0.1497 0.0594 0.2253 0.4678 0.7701 0.532 0.3925
    645 4-(DIFLUOROMETHOXY)PHENYL ISOCYANATE 0.7621 0.1233 0.0703 0.1651 0.4521 0.7201 0.558 0.6245
    646 2-CHLOROBENZYL ISOCYANATE 0.8213 0.2136 0.1897 0.1704 0.6774 1.0548 0.5373 0.7148
    647 4-FLUOROBENZYL ISOCYANATE 0.9973 0.2161 0.1757 0.1925 0.5137 0.7897 0.4974 0.6074
    648 4-METHOXYBENZYL ISOCYANATE 0.7301 0.2021 0.1636 0.2216 0.4744 0.8084 0.5537 0.719
    649 4-FLUORO-2-(TRIFLUOROMETHYL)PHENYL ISOCYANATE 0.4066 0.0944 0.0717 0.1451 0.5543 0.7581 0.1094 0.5099
    650 2,6-DIBROMO-4-ISOPROPYLPHENYL ISOCYANATE 0.3894 0.125 0.0461 0.1033 0.4346 0.7307 0.1975 0.4574
    651 3-PYRIDYL ISOCYANATE 0.3692 0.1585 0.066 0.3655 0.491 0.6084 0.2017 0.069
  • Example 652 Synthesis of Catalyst Derived From t-Butyl Isocyanate
  • A 500-mL round-bottomed flask was charged with 536 mg (5.40 mmol) of t-butylisocyanate dissolved in ca. 30 mL THF. Then (t-Bu)2P—CH2Li (898 mg, 5.40 mmol) dissolved in ca. 30 mL THF was added. The reaction was stirred for one h after which time, a solution of (Ni(C3H5)Cl)2 (730 mg, 2.70 mmol) in THF (ca. 30 mL) was added and stirred for an additional one h and the solvent removed. The residue was washed with hexane and dried in vacuo to yield 1.80 g (83%) of a purple powder. 1H-NMR (CD2Cl2, 23° C., 300 MHz): d 6.0-4.0 (broad signals), 4.0-2.0 (broad signals), 1.0-0.0 (broad signals, t-Bu), 31P-NMR (CD2Cl2, 23° C., 300 MHz): δ 46.7 (s).
  • Examples 653-673
  • Toluene was purified according to R. H. Grubbs et. al., Organometallics, 1996, 15, p. 1518-1520. Methyl acrylate was sparged with nitrogen and passed through a column of activated neutral alumina in the drybox before use. In a drybox 1.77 g NaBAF, B(C6F5)3 (see Table 66), methyl acrylate (see Table 66) and all but 20 mL of the toluene were combined. The total volume of the reaction mixture was 100 mL and the amount of methyl acrylate and toluene were calculated on this basis. This solution was transferred to a metal addition cylinder in the drybox, and the solution was then charged to a nitrogen-purged 450 mL jacketed autoclave. In the drybox 45 (0.0286 g) was dissolved in the remaining 20 mL of toluene and mixed for 30 minutes on a lab Vibramixer®. This solution was transferred via cannula under positive nitrogen pressure to a small metal addition cylinder attached to the autoclave. While stirring, the autoclave was charged with ethylene to 350 kPa and vented three times. The reactor and its contents were heated to the reaction temperature (Table 66) using a steam/water mixture in the autoclave jacket. After achieving the desired operating temperature, the autoclave was pressurized with ethylene to 350 to 690 kPa below the desired operating pressure (Table 66). The catalyst addition cylinder was charged with ethylene to the desired operating pressure, and the catalyst solution was then pressure injected to begin the polymerization. Ethylene was fed to maintain a constant pressure. After 6 h, the reaction was cooled to RT. All volatiles were removed from the reaction solution using a rotary evaporator. The evaporated residue was washed with three 50-100 mL portions of methanol with decanting of the methanol into a fritted glass filter after each wash. The methanol insoluble solids were then transferred to the filter with methanol and washed on the filter with additional methanol. The solids were dried for 18 hours at 60° C. in a vacuum oven. Molecular weights of the isolated polymer samples were determined by GPC. 13C NMR of the dried polymers was used to calculate the weight % of homopoly(methyl acrylate), the mole % MA content of the ethylene/methyl acrylate copolymer, and the amount of branching in the polymer. (See FIG. 3 for 13C peak assignments and formulas for the mole % calculations.) Weight % calculations were done using the mole % values and the molecular weights of the components.
  • TABLE 66
    B(C6F5)3 Wt %
    Temp E Press. Methyl (mole Isolated Homopoly Mole % MA in Branching
    Ex. (° C.) (MPa) Acrylate(vol %) equiv/Ni) Yield (g) MA copolymer CH3/1000 CH2 Mw Mw/Mn
    653 100 4.1 20.0 200 0.7 65.65 1.60 32.3 2353 1.96
    654 140 6.9 5.0 100 13.5 3.26 0.68 88.1 6273 2.11
    655 100 6.9 5.0 200 3.67 0.01 0.57 33.0 17478 2.02
    656 140 6.9 5.0 300 24.96 2.22 0.31 86.7 6031 2.00
    657 100 6.9 20.0 300 0.72 14.46 1.17 59.2 4427 1.98
    658 100 6.9 20.0 100 1.94 69.63 1.89 52.9 6494 2.33
    659 140 6.9 20.0 200 7.3 48.59 1.41 86.9 3896 2.53
    660 140 6.9 5.0 100 13.67 5.60 0.58 94.6 5850 2.15
    661 100 6.9 20.0 100 1.85 74.44 1.96 37.1 5678 2.42
    662 100 4.1 5.0 100 1.16 2.14 0.92 47.3 13332 1.97
    663 100 4.1 5.0 300 1.59 2.13 1.04 46.2 11085 2.07
    664 120 5.5 12.5 100 6.05 22.72 1.69 56.0 5888 1.95
    665 120 4.1 5.0 200 7.59 2.71 0.88 68.8 7429 2.03
    666 100 5.5 5.0 200 2.74 1.53 0.76 37.3 13347 2.02
    667 140 4.1 5.0 200 14.44 6.91 1.00 99.2 4192 2.36
    668 140 4.1 20.0 300 4.86 54.01 3.20 97.4 2298 1.99
    669 140 4.1 20.0 100 4.0 74.77 1.15 121.5 2144 2.17
    670 100 4.1 5.0 100 1.47 7.61 1.24 45.2 11389 2.57
    671 100 4.1 5.0 300 2.58 1.82 0.64 42.1 8923 2.25
    672 100 4.1 12.5 200 0.71 13.88 1.93 43.2 4858 1.82
    673 140 4.1 20.0 100 4.6 75.97 2.60 110.5 2200 3.07
  • Examples 674-769
  • All reactions were performed under a nitrogen atmosphere. The additives were obtained from commercial sources and used as received. Solvents were purchased anhydrous and distilled from P2O5 (chlorobenzene), sodium benzophenone ketyl (THF), CaH2 (acetonitrile) or used as received (TCB, methanol).
  • The additives were prepared as solutions (0.0375 M) in THF (Ex. 674-722), acetonitrile (Ex. 723-739), methanol (Ex. 740-754) and water (Ex. 755-758). These solutions were prepared in glass vials capped with Teflon® lined silicone to septa to maintain inert atmosphere and prevent evaporation.
  • The nickel compounds used are shown below.
  • Figure US20100222531A1-20100902-C00039
  • General Polymerization Procedure: In a nitrogen flushed box, a 150 μL or 750 μL of additive solution (0.0375 M) was added to a septum sealed 2 mL glass vial. The septum cap was removed and the solvent was removed under a nitrogen gas stream and the sample was dried for 20 min in a vacuum chamber. Additives for Ex. 763-773 were added to separate 2 mL glass vials by weighing solid (0.0056 mmol or 0.028 mmol) directly into the vial. The vial was recapped and a solution (3 mL of THF) of catalyst A, B or C was added to the vial. Catalysts B and C may contain 0-2 equiv of LiCl and we have assumed 1 equiv for the purposes of calculating a molecular weight. The septum cap was removed and the solvent was removed under a nitrogen gas stream and the sample was dried for 20 min in a vacuum chamber. The vial was recapped with a septum cap. A 0.300 mL polymerization solution containing solvent, cocatalyst(s) and acrylate monomer, if any, was added into each vial. Each vial was placed into a high-pressure reactor and pressurized with ethylene to the desired pressure and temperature for a total of 18 h. For ethylene polymerization experiments the volatiles were removed from each vial in a heated (approx. 50° C.) vacuum chamber. The weight of the vial was measured and the tare weight of the vial was subtracted to calculate the weight of polymer generated (catalyst residue is not taken into consideration). For ethylene copolymerization experiments the vial is weighed directly and the tare weight of the vial was subtracted to calculate the relative weight of polymer generated (the solvent, monomer and catalyst residue are not subtracted from this weight). The amounts of polymers produced (in g) are given in Table 67. Polymerization conditions are given below.
  • Condition 1: Catalyst B with 5 equiv of additive and 0.300 mL of chlorobenzene. The polymerization was conducted at 6.9 MPa of ethylene at RT for 18 h.
  • Condition 2: Catalyst B with 1 equiv of additive, 5 equiv of B(C6F5)3 and 0.300 mL of chlorobenzene. The polymerization was conducted at 1.0 MPa of ethylene at RT for 18 h.
  • Condition 3: Catalyst B with 5 equiv of additive, 1 equiv of NaBAF and 0.300 mL of chlorobenzene solution (the chlorobenzene solution contained 2.5 volume % of diethyl ether). The polymerization was conducted at 6.9 MPa ethylene at RT for 18 h.
  • Condition 4: Catalyst A with 1 equiv of additive, 5 equiv of B(C6F5)3, 5 equiv of LiB(C6F5)4 and 0.300 mL of TCB solution (the TCB solution contained 20 volume % of EGPEA). The polymerization was conducted at 6.9 MPa of ethylene at 100° C. for 18 h.
  • Condition 5: Catalyst B with 1 equiv of additive, 5 equiv of B(C6F5)3, 5 equiv of LiB(C6F5)4 and 0.300 mL of 1,2,4-TCB solution (the 1,2,4-TCB solution contained 20 volume % of EGPEA). The polymerization was conducted at 6.9 MPa of ethylene at 100° C. for 18 h.
  • Condition 6: Catalyst A with 5 equiv of additive, 5 equiv of LiB(C6F5)4 and 0.300 mL of TCB solution (the TCB solution contained 20 volume % of EGPEA). The polymerization was conducted at 6.9 MPa of ethylene at 100° C. for 18 h.
  • Condition 7: Catalyst C with 1 equiv of additive, 5 equiv of B(C6F5)3 and 0.300 mL of chlorobenzene. The polymerization was conducted at 3.5 MPa of ethylene at RT for 18 h.
  • TABLE 67
    CONDITION
    Ex. ADDITIVE 1 2 3 4 5 6 7
    674 4-CHLOROPHENYLBORONIC ACID 0.090 0.568 0.123 0.635 0.707 0.428 0.125
    675 ALUMINUM CHLORIDE 0.296 0.076 0.138 0.472 0.405 0.100 0.261
    676 ALUMINUM ISOPROPOXIDE 0.009 0.188 1.000 0.668 0.597 0.430 0.177
    677 ALUMINUM PHENOXIDE 0.020 0.706 0.482 0.614 0.694 0.412 0.175
    678 ALUMINUM TRIS(2,2,6,6-TETRAMENTYL-3,5-HEPTANEDIONATE) 0.105 0.067 0.059 0.572 0.612 0.422 0.133
    679 ALUMINUM TRI-SEC-BUTOXIDE 0.028 0.169 0.348 0.691 0.691 0.439 0.162
    680 BORON TRIFLUORIDE TERT-BUTYL METHYL ETHERATE 0.187 0.814 0.256 0.684 0.736 0.414 0.312
    681 COPPER(I) ACETATE 0.004 0.402 0.011 0.680 0.749 0.409 0.150
    682 COPPER(I) BROMIDE 0.005 0.426 0.032 0.671 0.667 0.423 0.134
    683 COPPER(II) ACETATE 0.009 0.296 0.013 0.685 0.681 0.429 0.073
    684 COPPER(II) BROMIDE 0.005 0.174 0.012 0.602 0.456 0.390 0.123
    685 COPPER(II) CHLORIDE 0.004 0.218 0.072 0.603 0.137 0.449 0.146
    686 COPPER(II) TRIFLUOROMETHANESULFONATE 0.057 0.052 0.042 0.618 0.789 0.460 0.073
    687 DIBUTYLTIN DICHLORIDE 0.011 0.414 0.209 0.623 0.559 0.431 0.126
    688 DIBUTYLTIN DIACETATE 0.012 0.525 0.324 0.501 0.775 0.424 0.107
    689 DIETHYL(3-PYRIDYL)BORANE 0.008 0.392 0.018 0.654 0.752 0.433 0.249
    690 DIMESITYLBORON FLUORIDE 0.330 0.237 0.471 0.685 0.759 0.478 0.249
    691 DIPHENYLZINC 0.011 0.431 0.242 0.499 0.571 0.432 0.635
    692 INDIUM(III) TRIFLUOROMETHANESULFONATE 0.494 0.094 0.598 0.532 0.767 0.445 0.257
    693 LITHIUM TRIFLUOROMETHANESULFONATE 0.018 0.532 0.019 0.694 0.765 0.451 0.152
    694 SODIUM TETRAPHENYLBORATE 0.237 0.081 0.046 0.610 0.775 0.494 0.183
    695 TIN(II) ACETATE 0.015 0.233 0.385 0.453 0.454 0.416 0.089
    696 TIN(II) BROMIDE 0.104 0.461 0.410 0.548 0.430 0.423 0.112
    697 TIN(II) FLUORIDE 0.001 0.568 0.028 0.648 0.734 0.439 0.179
    698 TRIMESITYLBORANE 0.014 0.536 0.032 0.645 0.725 0.456 0.258
    699 TRIS(4-ETHOXYPHENYL)BISMUTH 0.019 0.095 0.035 0.620 0.742 0.438 0.145
    700 TRIS(DIMETHYLAMINO)BORANE 0.002 0.109 0.022 0.639 0.735 0.421 0.116
    701 ZINC(II) BROMIDE 0.381 0.104 0.291 0.588 0.519 0.436 0.211
    702 ZINC(II) CHLORIDE 0.207 0.106 0.196 0.538 0.483 0.434 0.121
    703 1-NAPHTHALENEBORONIC ACID 0.010 0.090 0.044 0.706 0.795 0.517 0.092
    704 PHENYLBORONIC ACID 0.011 0.082 0.204 0.622 0.688 0.522 0.147
    705 TRIPHENYLBISMUTH 0.015 0.054 0.025 0.560 0.719 0.429 0.248
    706 SAMARIUM(II) IODIDE 0.030 0.100 0.028 0.504 0.411 0.438 0.156
    707 SODIUM TETRAKIS(P-TOLYL)BORATE 0.064 0.327 0.024 0.703 0.839 0.470 0.142
    708 AMMONIUM CERIUM(IV) NITRATE 0.019 0.094 0.026 0.609 0.425 0.440 0.123
    709 2-METHOXY PHENYLBORONIC ACID 0.009 0.121 0.392 0.690 0.762 0.490 0.120
    710 4-FLUOROPHENYL BORONIC ACID 0.049 0.825 0.144 0.705 0.757 0.528 0.109
    711 4-METHOXYPHENYL BORONIC ACID 0.016 0.574 0.121 0.732 0.786 0.494 0.104
    712 ALUMINUM ACETYLACETONATE 0.017 0.088 0.019 0.644 0.664 0.432 0.115
    713 ALUMINUM HEXAFLUOROACETYLACETONATE 0.153 0.479 0.562 0.654 0.716 0.445 0.071
    714 ALUMINUM TRIFLUOROMETHANESULFONATE 0.021 0.078 0.027 0.633 0.594 0.422 0.105
    715 DIMETHYLANILINIUMTETRAKIS(PENTAFLUORO PHENYL)BORATE 0.210 0.852 0.548 0.638 0.713 0.403 0.308
    716 LITHIUMTETRAKIS(PENTAFLUOROPHENYL) BORATE•DIETHERATE 0.064 0.967 0.037 0.667 0.736 0.461 0.138
    717 YTTERBIUM (III) TRIFLUOROMETHANESULFONATE HYDRATE 0.672 0.094 0.242 0.660 0.484 0.453 0.087
    718 TIN(II) ACETYLACETONATE 0.079 0.253 0.424 0.358 0.450 0.423 0.233
    719 TIN (II) HEXAFLUOROACETYLACETONATE 0.231 0.260 0.608 0.429 0.417 0.431 0.372
    720 P-TOLYLBORONIC ACID 0.010 0.632 0.221 0.669 0.749 0.509 0.128
    721 TRIS(4-TOLYL)BISMUTH 0.016 0.191 0.028 0.689 0.736 0.428 0.143
    722 TRIPHENYL ALUMINUM 0.670 0.370 0.418 0.664 0.513 0.430 1.036
    723 ALUMINUM (III) PHENOXIDE 0.003 0.552 0.039 0.664 0.774 0.452 0.420
    724 CERIUM(III) FLUORIDE 0.002 0.597 0.038 0.603 0.714 0.435 0.177
    725 COPPER(I) BROMIDE 0.047 0.279 0.133 0.625 0.463 0.449 0.217
    726 COPPER(I) CHLORIDE 0.009 0.193 0.147 0.683 0.517 0.464 0.158
    727 COPPER(I) IODIDE 0.118 0.642 0.030 0.655 0.684 0.453 0.136
    728 COPPER(II) ACETATE 0.007 0.201 0.010 0.663 0.686 0.418 0.055
    729 COPPER(II) BROMIDE 0.009 0.091 0.015 0.661 0.419 0.429 0.088
    730 COPPER(II) CHLORIDE 0.005 0.185 0.012 0.741 0.435 0.419 0.111
    731 COPPER(II) TRIFLUOROMETHANESULFONATE 0.018 0.061 0.022 0.739 0.833 0.459 0.065
    732 SAMARIUM(III) CHLORIDE 0.003 0.437 0.140 0.699 0.727 0.432 0.143
    733 TIN(II)TRIFLUOROMETHANESULFONATE 0.849 0.084 0.661 0.421 0.530 0.442 0.106
    734 YTTRIUM(III) CHLORIDE 0.151 0.101 0.060 0.442 0.351 0.377 0.212
    735 ZINC(II) TRIFLUOROMETHANESULFONATE 0.651 0.364 0.529 0.652 0.599 0.444 0.172
    736 YTTRIUM(III) TRIFLUOROMETHANESULFONATE 0.561 0.105 0.234 0.723 0.564 0.463 0.169
    737 TIN(II) OXIDE 0.002 0.656 0.028 0.699 0.766 0.450 0.145
    738 TRIFLUOROMETHANESULFONIMIDE 0.014 0.299 0.019 0.714 0.760 0.438 0.107
    739 CALCIUM(II) TRIFLUOROMETHANESULFONATE 0.335 0.101 0.057 0.728 0.783 0.454 0.125
    740 CERIUM(III) CHLORIDE 1.028 0.091 0.491 0.635 0.418 0.167 0.202
    741 COPPER(II) CHLORIDE 0.008 0.072 0.014 0.780 0.428 0.444 0.085
    742 COPPER(II) TRIFLUOROMETHANESULFONATE 0.018 0.065 0.017 0.709 0.844 0.449 0.086
    743 LANTHANUM(III) CHLORIDE 1.143 0.085 0.634 0.643 0.469 0.448 0.133
    744 LANTHANUM(III) TRIFLUOROMETHANESULFONATE 0.420 0.124 0.332 0.613 0.726 0.417 0.116
    745 MAGNESIUM(II) TRIFLUOROMETHANESULFONATE 0.342 0.125 0.499 0.644 0.744 0.458 0.129
    746 SCANDIUM(III) TRIFLUOROMETHANESULFONATE 0.469 0.082 0.401 0.637 0.270 0.444 0.118
    747 TIN(II) TRIFLUOROMETHANESULFONATE 0.681 0.094 0.933 0.464 0.507 0.440 0.090
    748 TRIETHANOLAMINE BORATE 0.010 0.128 0.013 0.494 0.583 0.426 0.081
    749 SAMARIUM(III)TRIFLUOROMETHANESUFFONATE 0.717 0.095 0.599 0.727 0.685 0.455 0.124
    750 SODIUM TETRAKIS(1-IMIDAZOYL)BORATE 0.012 0.746 0.019 0.476 0.432 0.437 0.120
    751 YTTRIUM(III) TRIFLUOROMETHANESULFONATE 0.506 0.091 0.313 0.751 0.563 0.468 0.111
    752 TRIFLUOROMETHANESULONIMIDE 0.012 0.363 0.017 0.738 0.779 0.446 0.077
    753 TIN(II) ACETYLACETONATE 0.006 0.079 0.011 0.451 0.361 0.430 0.104
    754 LANTHANIUM(III) TRISTRIFLUOROACETATE 0.882 0.130 0.428 0.489 0.720 0.427 0.200
    755 SAMARIUM(III) CHLORIDE 0.015 0.267 0.270 0.421 0.418 0.438 0.138
    756 TIN(II) FLUORIDE 0.018 0.581 0.350 0.616 0.755 0.440 0.169
    757 YTTRIUM(III) TRIFLUOROMETHANESULFONATE 0.277 0.107 0.248 0.699 0.536 0.465 0.105
    758 CALCIUM(II) TRIFLUOROMETHANESULFONATE 0.020 0.300 0.085 0.712 0.745 0.457 0.140
    759 LITHIUM TETRAKIS(PENTAFLUOROPHENYL) BORATE•DIETHERATE 0.074 0.233 0.028 0.700 0.709 0.469 0.199
    760 SODIUM TETRAKIS(3,5-BIS(TRIFLUOROMETHYL)PHENYL)BORATE 0.094 0.135 0.068 0.664 0.753 0.442 0.191
    761 DIMETHYLANILINIUM TETRAKIS(PENTAFLUOROPHENYL)BORATE 0.220 0.167 0.431 0.662 0.758 0.433 0.114
    762 [AliBu2(Et2O)]+ [B(C6F5)3R]−a 1.689 0.232 1.640 0.783 0.798 0.785 1.356
    763 Li[Al(OC6F5)4]b 0.747 0.049 0.121 0.646 0.617 0.429 0.238
    764 AlMes3•THFc 0.395 0.090 0.316 0.297 0.383 0.424 0.301
    765 AlMe(2,6-t-Bu-4-Me(OC6H2))2d,g,h 0.450 0.462 0.846 0.654 0.608 0.421 0.303
    766 Al-i-Bu2(OC6F5)e 1.132 0.247 1.385 0.720 0.799 0.299 0.630
    767 NO ADDITIVE 0.011 0.502 0.032 0.686 0.755 0.412 0.249
    768 TRITYL TETRAKIS(3,5-BIS(TRIFLUOROMETHYL)PHENYL)BORATEf,l 0.174 0.447 0.049 0.680 0.829 0.571 0.208
    769 TRIPHENYLBORON 0.610 0.648 0.685 0.625 0.429 0.268
    Footnotes for Table 67:
    Additives for 762-766 and 768 were synthesized by literature methods:
    amodification of preparation from WO0011006;
    bY. Sun, et al., Organometallics, vol. 19, p. 1625 (2000);
    cV. Srini, et al., Organometallics. vol. 8, p. 827 (1989);
    dM. Skowronska-Ptasinska, et al., Journal of Organometallic Chemistry, vol. 160, p. 403 (1978);
    eD. G. Hendershot, et al., Organometallics vol. 10, p. 1917 (1991);
    fS. R. Bahr and P. Boudjouk, Journal of Organic Chemistry, vol. 57, p. 5545 (1992).
    Substitutions for additives were made in the following experiments:
    gConditions 4-7 additive is Li[Al(OCPh(CF3)2)4] synthesized by a literature method, T. J. Barbarich, Thesis, 1998, Colorado State University;
    hConditions 5-7.
  • TABLE 68
    Copolymerization Using 0.02 mmole Catalyst, 40eq B(C6F5)3, 8 mL TCB, 2 mL HA,
    at 120° C. under 6.9 MPa E for 18 h
    Yield #Me/ Mole % m.p.
    Ex. Catalyst Sm(OTf)3 (g) 1000CH2 Comonomer (° C.) (ΔHf) Mw/PDI
    770  5 1eq 1.429 28 0.6 118 (96.0)  9,859/8.8
    771 21 1eq 8.184 31 1.28 (13C) 112 (182.7) 1,628/2.4
    0.40 IC
    0.88 EG
    772 39 0eq 0.216 28 0.8 111 (158.3) Bimodal
    97 First
    497,946/2.3
    Second
    MP = 887
  • TABLE 69
    Copolymerization Using 0.02 mmole Catalyst, 40eq B(C6F5)3,
    20eq LiB(C6F5)4, 8 mL TCB, 2 mL HA, at 120° C. under 6.9 MPa
    E for 18 h
    Mole %
    Cata- Yield #Me/ Co- m.p.
    Ex lyst (g) 1000CH2 monomer (° C.) (ΔHf) Mw/PDI
    773 5 3.998 10 0.54 (13C) 124 (209.5) 3,567/2.2
    0.25 IC
    0.29 EG
    774 7 1.075 19 0.38 (13C) 112 (191.2) 1,405/1.8
    0.19 IC
    0.19 EG
    775 6 1.253 13 0.53 (13C) 122 (190.6) 11,123/10.8
    0.25 IC
    0.28 EG
    776 2 0.461 9 0.41 (13C) 125 (186.6) 22,311/10.8
    0.20 IC
    0.21 EG
    777 26 0.897 11 0.61 (13C) 118 (172.3) 3,595/2.1
    0.39 IC
    0.22 EG
  • TABLE 70
    13C NMR Branching Analysis for EGPEA Copolymers
    Total Hex+ Am+ Bu+
    Ex Me Me Et Pr Bu & EOC & EOC & EOC
    773 10.0 1.8 1.3 0.1 1.5 8.4 6.7 6.8
    774 18.7 3.8 1.8 0.4 0.7 11.6 11.7 12.8
    775 12.7 2.0 1.6 0.4 0.7 7.9 8.2 8.6
    776 9.2 1.8 2.0 0.5 1.4 7.8 4.3 4.9
    777 11 1.5 2.5 0.4 1.1 8.2 6.9 6.8
  • Figure US20100222531A1-20100902-C00040
  • Example 778 Synthesis of 118
  • In a drybox, 0.300 g 40 and 0.487 g tris(3,5-bis(trifluoromethyl))borane were dissolved in 25 mL toluene. This mixture was allowed to stir at RT for 1 h. The mixture was filtered through Celite® and the solvent was evaporated. Brown solid (0.160 g) was obtained. A single crystal was obtained by slowly evaporate the methylene chloride/heptane solution of 40. X-Ray single crystal analysis confirmed the Zwitterionic structure of this catalyst.
  • TABLE 71
    Copolymerization Using 0.02 mmole Catalyst, with a Total Volume
    of 10 mL of TCB and Polar Monomer, at 80° C. under 3.4 MPa of Ethylene
    Polar Polar Monomer Yield
    Ex. Catalyst B(C6F5)3 Monomer Volume (mL) (g)
    779 2 40eq
    Figure US20100222531A1-20100902-C00041
    2 0.010
    780 118 0eq
    Figure US20100222531A1-20100902-C00042
    3 0.345
    781 2 40eq CH2═CH(CH2)2C(O)CH 3 3 0.020
    782 2 40eq
    Figure US20100222531A1-20100902-C00043
    3 0.556
    783 2 40eq CH2═CH(CH2)7C(CH2O)3 CCH 3 3 10.269
  • TABLE 72
    Ethylene Polymerization Using 0.01 mmole Catalyst, 20eq LiB(C6F5)4,
    10 mL TCB, at 60° C. under 3.4 MPa Ethylene for 18 h
    Yield #Me/ m.p.
    Ex Catalyst (g) 1000CH2 (° C.) (ΔHf) Mw/PDI
    784 2 1.842 8 126 (166.2) 35,425/2.8
    785 6 1.698 5 128 (172.7) 43,111/2.2
    786 5 4.377 16 123 (173.9) 17,351/3.0
    787 7 9.143 70 105 (157.2)  1,636/4.3
    788 30 0.281 17 123 (195.5) 12,383/9.6
  • TABLE 73
    Ethylene/CO Copolymerization Using 0.02 mmole Catalyst,
    40 eq B(C6F5)3, 10 mL TCB, at 100° C. under
    2.8 MPa Ethylene/CO (9:1 molar ratio) for 16 h
    Ex Catalyst Yield (g)
    789 21 0.345
    790 2 0.108
    791 5 0.201
    792 4 0.024
    793 40 0.480
  • Figure US20100222531A1-20100902-C00044
  • Syntheses of these compounds will be found in previously incorporated U.S. patent application Ser. No. ______ (filed concurrently 31 May 2001, Applicant's reference CL1655 US NA) and U.S. Provisional Patent Application ______ (filed concurrently 31 May 2001, Applicant's reference CL1744 US PRV1)(incorporated by reference herein for all purposes as if fully set forth).
  • TABLE 74
    Copolymerization Using 0.02 mmole Catalyst, 40 eq B(C6F5)3, 6 mL TCB, 4 mL HA,
    at 100° C. under 6.9 MPa E for 18 h
    Yield #Me/ Mole % HA m.p., (° C.) TON
    Ex. Catalyst (g) 1000CH2 in Polymer [ΔHf] Mw/PDI E/HA
    794 120 2.067* 24 3.9 106 [120] 7,664/2.3 3,009/121
    *In addition to 2.067 g copolymer, HA homopolymer (0.567 g) was also produced.
  • TABLE 75
    Copolymerization Using 0.02 mmole Catalyst, 40eq B(C6F5)3, 6 mL TCB, 4 mL HA,
    or EGPEA at 120° C. under 6.9 MPa E for 18 h
    Co-
    Monomer Yield #Me/ m.p. TON
    Ex. Catalyst (Mole %) (g) 1000CH2 (° C.) [ΔHf] Mw/PDI E/Comonomer
    795 120 HA 2.543* 29  97 [86.3] 6,688/2.7 3,587/170
    (4.4)
    796 120 EGPEA 3.182** 22 100 [88.8] 9,821/3.3 4,989/100
    (2.0)
    *Contained 2.543 g copolymer and 0.772 g homopolymer of HA
    **Contained 3.182 g copolymer and 1.963 g homopolymer of EGPEA
  • Figure US20100222531A1-20100902-C00045
  • TABLE 76
    E/HA Copolymerization Using 0.02 mmole Catalyst, 40 eq B(C6F5)3,, 20eq Li
    B(C6F5)4, 6 mL TCB, 4 mL HA, at 100° C. under 6.9 MPa E for 18 h
    Mole % HA Yield #Me/ TON
    Ex. Catalyst in Polymer (g) 1000CH2 m.p. (° C.) (ΔHf) Mw/PDI E/Comonomer
    797 121 2.3 0.356a 13 122 (138.6) 4,864/2.6 477/11
    798 126 0.2b 0.403c 3 126 (181.4) 19,918/8.0  659/6 
    aContained 0.302 g copolymer and 0.054 g homopolymer of HA
    b1 mL HA was used rather than 4 mL
    cContained 0.380 g copolymer and 0.023 g homopolymer of HA
  • TABLE 77
    Copolymerization Using 0.02 mmole Catalyst, 40 eq B(C6F5)3, 20eq Li B(C6F5)4,
    8 mL TCB, 2 mL HA, at 100° C. under 6.9 MPa E for 18 h
    Mole % HA
    Ex. Catalyst Yield (g)a #Me/1000CH2 in Polymer m.p. (° C.) (ΔHf) Mw/PDI
    799 121 1.750 27 0.8 124 (160.1) 10,049/3.47 
    800 122 1.710 26 1.2 118 (176.1) 3,422/2.42
    801 123 0.834 34 1.8 120 (147.9)  3,605/1,521
    802 124 0.478 52 2.2  95 (132.9) 2,392/2.37
    803 125 0.804 36 1.8 119 (153.5) 3,275/2.40
    804 127b 4.257 8 1.1 123 (158.1) 7,725/1.97
    aAll of the copolymer products contained a small amount of homopolymer of HA
    b20 eq of NaBArF was used here rather than 20eq of LiB(C6F5)4; toluene was used as solvent here rather than TCB
  • Examples 805-833
  • The reaction mixture including catalyst, solvent, acrylate and cocatalysts was assembled inside a nitrogen filled drybox and placed in a 50 mL stainless steel pressure vessel. A stir bar was added and the vessel sealed and removed from the drybox where it was pressurized with ethylene to the desired pressure. The vessel was heated and stirred with a constant pressure of ethylene for the duration of the reaction.
  • Figure US20100222531A1-20100902-C00046
  • TABLE 78
    NaBArf Mol %
    Ex. Catalyst mmol Ni eq B(C6F5)3 eq C6H5Cl mL EGPEA mL Time h Temp Yield Kg/g Ni Mw EGPEA
    805 45 0.001659 166 767 15 1.5 66 ~127° C. 15.74 161 13761 0.36/0.40
    806 45 0.001875 150 680 15.5 MA 1.0 18 ~ 124° C. 4.65 42 0.43
    807 45 0.0015 188 850 15 2.1 63 125° C. 10.9 124 0.45/0.47
    808 45 0.0015 188 850 15 1.5 63 117° C. 3.3 38 9948 0.7
    809 76 0.0015 188 850 15 1.5 17 125° C. 2.3 26 19213 0.6
    810 76 0.0015 188 850 15 1.5 17 120° C. 1.9 22 30124 low
    811 128 0.0015 188 850 15 1.5 17 80° C. 4.5 51 39600 low (0.2-0.3)
    812 128 0.00075 380 1700  17 2.1 18 82° C. 1.34 31 low
    813 74 0.00125 225 1017  15 tol. MA 1.0 66 120° C. 2.82 38
    814 45 0.0015 188 850 15 1.5 18 120° C. 4.65 51 12758 0.5
    815 45 0.0015 188 850 15 MA 1.0 72 123° C. 7.3 83 32036 0.24 (13C)
    816 128 0.0015 188 850 15 MA 1.0 72 100° C. 4.2 48 13082 0.29 (13C)
    817 51 0.0015 188 850 15 1.5 18 120° C. 0.7 8 20294 0.3
    818 45 0.0015 188 850 (Al+B−)a 15 1.5 18 120° C. 4.1 47 12133 0.3
    819 45 0.0015 188 430 (Al+B−)a 16 1.5 18 120° C. 2.8 32 14634 0.6
    820 45 0.0015 188 850 15 1.5 18 122° C. 3.5 40
    821 45 0.0015 188 850 15 MA 2 66 122° C. 8.5 97 13162 0.41 (13C)
    822 45 0.0015 188 850 15 MA 3 17 123° C. 4.9 56 8305 0.88 (13C)
    823 74 0.0015 188 850 15 MA 2 125 125° C. 4.1 47 23003
    824 45 0.0015 188 MAO 1 ml 15 1   18 125° C. 4.4 50 10011 Low
    825 45 0.0015 188 MAO 0.3 ml 15 1.5 18 100° C. 4.2 48 0.29
    826 45 0.0015 188 LiBb 850 15 1.5 18 122° C. 2.9 33 0.53
    827 45 0.0015 188 LiB MAO 0.2 ml 15 1.5 18 100° C. 1 11 12507 0.52
    828 45 0.0015 188 LiB MAO 0.3 ml 15 1.5 18 100° C. 1.3 15 11851 0.63
    829 45 0.0015 188 MAO 0.3 ml 15 1.5 18 100° C. 6.6 75 20849 0.27
    830 74 0.0015 188 1300  15 MA 3 115 120° C. 3.4 39 15103 0.56
    831 40 0.00166 170 766 15 1.5 18 ~118° C. 5.94 61 0.5*
    832 21 0.00166 170 766 16 1.5 18 ~125° C. 3.74 38 ~0.5
    833 40 0.0015 188 850 15 1.5 66 123° C. 5.2 59 1.2*
    aAl(OEt)2(Me2)BMe(C6F5)3.
    bLiB = Li(B(C6F5)42Et2O used in place of NaBArf.
    cIn chain and end-of-chain acrylate.
    MA = methyl acrylate;
    MAO = MMAO-12 (12.9 wt % Al in toluene, Akzo-Nobel);
    EGPEA added before borane
  • Examples 829-846
  • Figure US20100222531A1-20100902-C00047
  • Preparation of Supports
  • Support A: Inside a nitrogen filled drybox, dehydrated, spray-dried spherical silica (2 g, Grace XPO-2402, dehydrated to ˜1 mmol OH/g silica) was placed in 6 mL dry toluene and AlMe3 (3 mL, 2M in hexane, Aldrich) added. The slurry was agitated by shaking for 30 min after which the solids were filtered, washed with pentane and dried under vacuum.
  • Support B: Inside a nitrogen filled drybox, spray-dried spherical silica-alumina (1 g, Grace MS 13-1.10, dehydrated at 500° C.) was placed in 6 mL dry toluene and AlMe3 (1.8 mL, 2M in hexane, Aldrich) added. The slurry was agitated by shaking for 30 min after which the solids were filtered, washed with pentane and dried under vacuum.
  • Preparation of Catalysts
  • Catalyst I: Support A (0.5 g) was added to a solution of 45 (76 mg, 0.05 mmol) in anhydrous toluene. The slurry was agitated by shaking for 30 min after which the solids were filtered away from the brown filtrate and dried under vacuum.
  • Catalyst II: Silica supported MAO (Albemarle Corp, 18 wt % Al on spherical silica) was added to a solution of 45 (76 mg, 0.05 mmol) and B(C6F5)3 (0.133 g, 5 eq) in anhydrous toluene. The slurry was agitated by shaking for 30 min after which the solids were filtered away from the black/brown filtrate and dried under vacuum. ICP: % Ni=0.43%.
  • Catalyst III: Support A (0.5 g) was added to a solution of 45 (76 mg, 0.05 mmol) and B(C6F5)3 (0.133 g, 5 eq) in anhydrous toluene. The slurry was agitated by shaking for 30 min after which the solids were filtered away from the green/brown filtrate and dried under vacuum. ICP: % Ni=0.42%.
  • Catalyst IV: Inside a nitrogen filled drybox, spray-dried spherical silica alumina (0.5 g, Grace MS 13-1.10, dehydrated at 500° C. under flowing N2), was placed in anhydrous toluene (8 mL) and 45 (38 mg, 0.025mmol) added. The slurry was agitated by shaking for 30 minutes after which the orange brown solids were filtered, washed with toluene and finally pentane and dried under vacuum. ICP: % Ni=0.28%.
  • Catalyst V: Inside a nitrogen filled drybox, spray-dried spherical silica alumina (0.5 g, Grace MS 13-1.10, dehydrated at 500° C. under flowing N2), was placed in anhydrous methylene chloride (8 mL) and 129 (16 mg, 0.022 mmol) added. The slurry was agitated by shaking for 45 min after which the orange solids were filtered, washed with toluene and finally pentane and dried under vacuum. ICP: % Ni=0.24%.
  • Catalyst VI: Support B (0.25 g) was added to a solution of 45 (19 mg, 0.013 mmol) in anhydrous toluene. The slurry was agitated by shaking for 45 min after which the solids were filtered away from the dark green filtrate, washed with toluene and dried under vacuum.
  • Catalyst VII: Support A (0.25 g) was added to a solution of 45 (19 mg, 0.013 mmol in anhydrous toluene. The slurry was agitated by shaking for 45 min after which the solids were filtered away from the light brown filtrate, washed with toluene and dried under vacuum.
  • Catalyst VIII: Silica supported MAO (0.25 g, Albemarle, 18 wt % Al) was added to a toluene solution of 45 (19 mg, 0.013 mmol in 10 mL). The slurry was agitated by shaking for 30 min after which the solids were filtered away from the blue filtrate, washed with toluene and dried under vacuum. ICP; % Ni=0.36%.
  • Catalyst IX: Support B (0.25 g) was added to a solution of 45 (19 mg, 0.013 mmol) in anhydrous toluene. B(C6F5)3 (56 mg, Boulder Scientific) was added and the slurry was agitated by shaking for 30 min after which the solids were filtered away from the brown filtrate, washed with toluene and dried under vacuum. ICP % Ni=0.28%.
  • Catalyst X: Support A (0.25 g) was added to a solution of 45 (19 mg, 0.013 mmol) in anhydrous toluene. The slurry was agitated by shaking for 60 min after which the brown solids were filtered away from the green filtrate, washed with toluene and dried under vacuum.
  • Catalyst XI: Support A was added to a solution of 45 (19 mg, 0.013 mmol) in anhydrous toluene. The slurry was agitated by shaking for 60 min after which the orange solids were filtered away from the orange filtrate, washed with toluene and dried under vacuum.
  • Catalyst XII: Support A (0.25 g) was added to a solution of 129 (9.6 mg, 0.013 mmol) in anhydrous toluene. The slurry was agitated by shaking for 60 min after which the gray solids were filtered away from the purple filtrate, washed with toluene and dried under vacuum.
  • Catalyst XIII: Support A (0.25 g) was added to a solution of 40 (5.6 mg, 0.013 mmol) in anhydrous toluene. The slurry was agitated by shaking for 60 min after which the orange solids were filtered away from the orange filtrate, washed with toluene and dried under vacuum.
  • Catalyst XIV: Support A (0.25 g) was added to a solution of 21 (4.5 mg, 0.013 mmol) in anhydrous toluene. The slurry was agitated by shaking for 60 min after which the beige solids were filtered away from the filtrate, washed with toluene and dried under vacuum.
  • Copolymerization of Ethylene with EGPEA
  • The solid catalyst and cocatalyst components (catalyst ˜0.004 mmol, 0.177 g NaBAF, and optionally B(C6F5)3) were added to a glass insert. Solvent (anhydrous chlorobenzene, 9 mL) and EGPEA, (1 mL, filtered through basic alumina, Aldrich) were added last and the insert placed in a metal pressure vessel. Some ethylene was admitted and the vessel was heated to 120° C. and then pressurized to 6.9 MPa with ethylene and agitated for 18 h. After this time the reactor was cooled, the pressure released and the contents of the insert placed in stirring methanol to precipitate polymer product. The polymeric product was then filtered, washed well and dried. Results are given in Table 79.
  • TABLE 79
    B(C6F5)3 AlMe(BHT)2 % EGPEA3
    Ex Catalyst (mg) 98 eq 20 eq Yield (g) incorporated kg PE/g Ni1
    829 45 (5.8 mg)4 0.2 g 6.6 0.5 28
    830 45 (5.8 mg)4 0.2 g 40 mg 5.4 0.5 23
    831 45 (5.8 mg)4 40 mg 2.7 0.72 11
    832 VIII (77 mg) 0.6 0.4 3
    833 I (40 mg) 0.2 g 3.4 0.5 14
    834 IV (77 mg) 0.2 g 5.3 0.4 22
    835 V (77 mg) 0.2 g 2.1 0.5 9
    836 X (80 mg) 0.2 g 3.6 0.7 15
    837 XI (80 mg) 40 mg 3.0 0.82 13
    838 XII (80 mg) 40 mg 2.1 0.92 9
    839 XIII (80 mg) 40 mg 6.9 0.5 29
    840 XIV (80 mg) 40 mg 0.1 0.3 0.5
    1This is calculated based on the amount of nickel added when the catalyst was prepared. As substantial amounts of color washed away from the support this value represents a minimum activity,
    2Incorporation may be high due to presence of homopolymer which makes calculation of % incorporation less accurate,
    3Determined by H-NMR at 120° C. in TCE-d2.
    4No support.
  • Inside a nitrogen filled drybox the solid catalyst and cocatalyst components (2.5 mg NaBAF, and optionally B(C6F5)3) were added to glass inserts. Solvent (anhydrous chlorobenzene, 0.25 mL) and EGPEA, (0.05 mL, filtered through basic alumina, Aldrich) were added last and the inserts placed in a metal pressure vessel. The vessel was sealed, removed from the drybox and placed under an atmosphere of ethylene at 6.9 MPa and heated to 110-120° C. for 16 h. After cooling the vessel was opened and the reactions quenched with methanol, and the polymeric product filtered, washed with methanol and dried. Results are given in Table 80.
  • TABLE 80
    Yield % EGPEA3 End Groups
    Ex. Catalyst (mmol) (mg) incorporated Int:Term.
    841 451 (0.002) 0.36 1.5 9:1
    842 II (0.002) 0.13 1.3 1:1.1
    843 III (0.002) 0.13 1.9 1:1.1
    844 451 (0.001) 0.22 1.5 2:1
    845 VI (0.001) 0.08 1.92 1:1.3
    846 VII (0.001) 0.07 1.2 1:1.3
    120 mg B(C6F5)3 added as activator. No support
    2Incorporation may be high due to presence of homopolymer which makes calculation of % incorporation less accurate
  • Examples 847-850 General Procedure for Polymerizations in Tables 81-86
  • The polymerizations were carried out according to General Polymerization Procedure A. Varying amounts of acrylate homopolymer are s present in some of the isolated polymers. For acrylate copolymers, the yield of the polymer is reported in grams and includes the yield of the dominant ethylene/acrylate copolymer as well as the yield of any acrylate homopolymer that was formed. Molecular weights were determined by GPC, unless indicated otherwise. Mole percent acrylate incorporation and total Me were determined by 1H NMR spectroscopy, unless indicated otherwise. Mole percent acrylate incorporation is typically predominantly IC, unless indicated otherwise. The LiB(C6F5)4 used (LiBArF) included 2.5 equiv of Et2O.
  • Figure US20100222531A1-20100902-C00048
  • 2,6-Bis-dimethoxyphenyllithium was prepared from 14.18 g (0.103 mole) of 1,3-dimethoxybenzene, 77 mL of a 1.6 M solution of BuLi in hexanes and 0.23 mL of N,N,N′,N′-tetramethylethylenediamine in dry diethyl ether (72 mL). Dichloromethylphosphine (5.0 g, 0.04276 mole) was added at 0° C., and the reaction mixture was stirred at room temperature overnight. Methanol (20 mL) was added, and the mixture was concentrated to about half its original volume under reduced pressure. The resulting white precipitates were filtered and were recrystallized from methanol to give white crystals of bis-(2,6-dimethoxyphenyl)(methyl)-phosphine with 48% yield (6.6 g) and melting point at 112.33° C. 1H NMR (CDCl3) δ 1.75 (s (broad), 3H, Me-P), 3.55 (s, 12H, Me-O), 6.4-7.2 (m, 6H, aromatic protons); 31P NMR (CDCl3) δ-51. 5 ppm. LS/MS: found m/w is 321, calculated m/w is 321. Anal. found: C 64.30%; H 6.45%; calculated for C17H22O4P: C 63.49%; H 6.85%.
  • Synthesis of A-3. Bis-(2,6-dimethoxyphenyl)phosphino]-methyllithium (2,6-MeO-Ph)2P—CH2-Li) (0.33 g, 0.001 mole) was prepared from a 7 mL THF solution of equi-molar amounts of bis-(2,6-dimethoxyphenyl)-(methyl)phosphine and a 1.6 M solution of butyllithium in hexanes with a catalytic amount of TMEDA added. tert-Butylisocyanate (0.125 g, 0.001 mole) in 3 mL of THF was added to the reaction mixture, which was then stirred for 12 hours. Next, 0.24 g (0.0005 mole) of 2-methoxycarbonyl-allyl nickel bromide dimer [CH2═C(CO2Me)CH2)Ni(μ-Br)]2 and 0.89 g (0.001 mole) of NaBAF in 4 mL of THF was added to the reaction mixture, which was stirred overnight. The next day, the solvent was pumped off and the residue was redissolved in diethyl ether. The solution was filtered through Celite®, and solvent was removed under vacuum. Viscous brown product (0.92 g) was obtained. 31P NMR (CD2Cl2): one major peak at 26.49 ppm.
  • Synthesis of A-1 and A-4. Synthesis was in a fashion analogous to that reported for A-3 in above, except that (t-Bu)2PCH2Li was employed as the base for the synthesis of A-1 and different electrophiles were employed. The electrophiles employed and compound characterization follow:
  • 31P NMRa (CD2Cl2)
    Cmpd Electrophile δ
    A-1 2,4-Dimethoxy- 60.6 ppm (major);
    phenylisocyanate 62.1 ppm (minor)
    A-4 2,4,6-Trimethoxy- 22.5 (major)
    benzophenone
    aIn some cases, additional minor resonances were present in the 31P NMR spectrum.
  • TABLE 81
    Ethylene Homopolymerizations and Ethylene/Acrylate Copolymerizations (18 h)
    Acrylate mL Acrylate
    Cmpd (Solvent B(C6F5)3 Press Temp Incorp. Total
    Ex (mmol) mL) (Borate) MPa ° C. Yield g mol % M.W. Me
    847 A-1 EGPEA 1 100  3.4 60 0.64 0.5 Mp = 13,148; 7.1
    (0.004) (p-Xylene 9) equiv 0.3 IC Mw = 14,087;
    (NaBAF 0.2 EG Mn = 6,487;
    50 PDI = 2.17
    equiv)
    848 A-1 EGPEA 1 20 equiv 1 60 0.09 1.4 Mp = 5,447; 13.3
    (0.02) (p-Xylene 9) (NaBAF 0.7 IC Mw = 8,088;
    10 0.7 EG Mn = 3,454;
    equiv) PDI = 2.17
    849 A-3 None 10 equiv 3.4 60 0.80 Mp = 801; 119
    (0.02) (p-Xylene (None) Mw = 37,894;
    10) Mn = 500;
    PDI = 75.77
    850 A-4 None 10 equiv 3.4 60 0.33 Mp = 956; 76.4
    (0.02) (p-Xylene (None) Mw = 52,382;
    10) Mn = 817;
    PDI = 64.09
  • TABLE 82
    Ethylene/Acrylate Copolymerizations (0.004 mmol Cmpd, 18 h, 100 equiv
    B(C6F5)3, 50 equiv LiB(C6F5)4, 1 mL EGPEA, 9 mL p-Xylene)
    Acrylate
    Press Temp. Incorp Total
    Ex Cmpd MPa ° C. Yield g Mol % M.W. Me
    851 45 2.1 60 0.008 0.7 Mn(1H): No Olefins 11.9
    852 91 2.1 60 0.008 1.5 Mn(1H): No Olefins 13.6
    853 94 2.1 60 0.011 1.2 Mn(1H): No Olefins 9.4
    854a 53 2.1 60 0.041 2.4 Mn(1H) = 3,528.3 24.7
    2.0 IC
    0.4 EG
    aPredominant alpha olefin end groups; some internal olefin end groups also present.
  • TABLE 83
    Ethylene/E-10-U Copolymerizations: Variation of Temperature
    and Pressure (0.02 mmol Cmpd; 2 mL E-10-U; 8 mL TCB;
    40 equiv B(C6F5)3; 18 h)
    Comonomer
    Press Temp Incorp
    Ex Cmpd MPa ° C. Yield g mol % M.W.
    855 46 1 25 3.24 3.3 Mp = 67,355;
    Mw = 74,377;
    Mn = 39,452;
    PDI = 1.89
    856 46 3.4 60 11.14 2.8 Mp = 67,243;
    Mw = 69,152;
    Mn = 34,553;
    PDI = 2.00
    857 46 6.9 120 6.09 1.1 Mp = 13.731;
    Mw = 20,516;
    Mn = 5,477;
    PDI = 3.75
  • TABLE 84
    Ethylene/Zonyl TAN (ZTAN) Copolymerization (0.002 mmol Cmpd; 200 equiv
    B(C6F5)3; 100 equiv NaBAF; 18 h)
    ZTAN g
    (p- Comonomer
    Xylene Press Temp Incorp Total
    Ex Cmpd mL) MPa ° C. Yield g Mol % M.W. Me
    858 45 2 6.9 120 17.90 Trace Mp = 11,579; Nd
    (8) Mw = 12,467;
    Mn = 4,226;
    PDI = 2.95
    859 45 3 4.1 80 0.613 0.52 Mp = 24,805; 20.3a
    (7) (13C Mw = 23,507; (13C
    NMR) Mn = 10,500; NMR)
    PDI = 2.24
    860 45 3 6.9 100 1.75 0.30 Mp = 20,490; 27.4b
    (0.002) (7) (13C Mw = 21,489; (13C
    NMR) Mn = 10,466; NMR)
    PDI = 2.05
    aBranches as determined by 13C NMR spectroscopy: 20.3 Total Me; 14.8 Me; 1.9 Et; 0.8 Pr, 1.2 Bu; 1.6 Hex+ and eoc; 2.7 Am+ and eoc; 2.8 Bu+ and eoc.
    bBranches as determined by 13C NMR spectroscopy: 27.4 Total Me; 18.9 Me; 2.9 Et; 1.3 Pr, 1.5 Bu; 3.5 Hex+ and eoc; 3.8 Am+ and eoc; 4.2 Bu+ and eoc.
  • TABLE 85
    Ethylene/Acrylate/alpha-Olefin Terpolymerizations (0.002 mmol
    Cmpd; 18 h; 6.9 MPa E; 120° C.; 8 mL p-Xylene; 200 equiv
    B(C6F5)3; 100 equiv NaBAF;
    alpha-Olefins: 1-Hexene, 1-H; Ethyl-10-Undecylenate, E-10-U)
    α- Acrylate E-10-U
    Acrylate Olefin Yield Incorpa Incorpa Total
    Ex Cmpd mL mL g mol % mol % Mea
    861 45 EGPEA 1 1-H 1 1.64 0.57 b 57.2c
    862 45 EGPEA 1 E-10- 2.24 0.86 0.80 45.0d
    U 1
    863 40 EGPEA 1 1-H 1 6.33 0.51 b 11.7e
    0.23 IC
    0.28 EG
    864 40 EGPEA 1 E-10- 3.48 0.42 0.33 8.7f
    U 1 0.21 IC
    0.21 EG
    aAcrylate incorporation, E-10-U incorporation, and Total Me were determined by 13C NMR spectroscopy. For 1-H terpolymers, acrylate incorporation was determined by assuming that the copolymer was derived from just ethylene and acrylate.
    b The larger number of butyl branches relative to ethyl branches is consistent with 1-hexene incorporation.
    c57.2 Total Me; 31.6 Me; 7.2 Et; 2.9 Pr, 7.4 Bu; 4.5 Hex+ and eoc; 8.7 Am+ and eoc; 15.4 Bu+ and eoc; MesBu = 1.8%; EtsBu = 16.4%.
    d45.0 Total Me; 23.8 Me; 5.6 Et; 6.6 Pr, 2.3 Bu; 4.1 Hex+ and eoc; 0.7 Am+ and eoc; 9.0 Bu+ and eoc; MesBu = 2.7%; EtsBu = 18.4%.
    e11.7 Total Me; 2.0 Me; 0.8 Et; 0.3 Pr, 1.5 Bu; 5.9 Hex+ and eoc; 5.5 Am+ and eoc; 8.6 Bu+ and eoc.
    f8.7 Total Me; ~0 Me; 0.6 Et; 1.4 Pr, 0.3 Bu; 6.7 Hex+ and eoc; 1.5 Am+ and eoc; 6.7 Bu+ and eoc.
  • Figure US20100222531A1-20100902-C00049
  • TABLE 86
    Ethylene/Acrylate Copolymerizations (0.02 mmol Cmpd; 6.9 MPa E; 1 mL
    EGPEA; 9 mL TCB; 18 h)
    Comonomer
    Borane Borate Temp Incorp Total
    Ex Cmpd equiv equiv ° C. Yield G mol % M.W. Me
    865 H-1 B(C6F5)3 NaBAF 120 1.28 0.2 Mp = 5,017; Mw = 6,796; 54.3
    20 10 IC & EG Mn = 1,840; PDI = 3.69
    866 H-2 BPh3 none 80 0.14 5.3 Bimodal 22.0
    20 UV: Mp = 21,679;
    RI Mp = 20,271;
  • Example 867 Synthesis of (t-Bu)2PCH2N(2,6-C6F2H3)OLi
  • Figure US20100222531A1-20100902-C00050
  • In a dry box, to a 50 mL flask containing 10 mL of THF solution of 1,3-difluoro-2-nitrosobenzene (0.0276 g, 0.193 mmol), was added slowly to a THF solution of (t-Bu)2PCH2Li (0.0321 g, 0.193 mmol) at −30° C. The solution was stirred 2 hours and it turned brown. After removal of the solvent, the purple residue was rinsed with pentane and dried under vacuum. A brown powder was obtained.
  • Example 868 Synthesis of (t-Bu)2PCH2N(3-OLi)C10H6)OLi
  • Figure US20100222531A1-20100902-C00051
  • In a dry box, to a 100 mL flask containing 20 mL of THF solution of 2-nitroso-1-naphthol (0.1044 g, 0.603 mmol), NaH (0.016 g, 1.1 equiv.) powder was added slowly at room temperature. When no more H2 was released, a THF solution of (t-Bu)2PCH2Li (0.1002 g, 0.603 mmol) at −30° C. was added slowly. The solution was stirred 2 hours and turned brown from yellow. After removing the solvent, a brown powder (0.1402 g, 0.388 mmol) was obtained in to 64% yield. 1H NMR (C6D6): complicated. 31P NMR (C6D6): major peak 29.5636 ppm.
  • Example 869 Synthesis of (t-Bu)2PCH2N(C6H5)OLi
  • Figure US20100222531A1-20100902-C00052
  • In a dry box, to a 100 mL flask containing 20 mL of THF solution of nitrosobenzene (0.0682 g, 0.64 mmol), was added slowly a THF solution of (t-Bu)2PCH2Li (0.1058 g, 0.64 mmol) at −30° C. The solution was stirred overnight and turned purple from yellow. After removing the solvent, a purple powder (0.1321 g, 0.483 mmol) was obtained in 76% yield. 1H NMR (C6D6): complicated; 31P NMR (C6D6): major peak 38.1167 ppm.
  • Example 870 Synthesis of (t-Bu)2PCH2N(2-CH3-C6H4)OLi
  • Figure US20100222531A1-20100902-C00053
  • In dry box, to a 100 mL flask containing 20 mL of THF solution of o-nitrosotoluene (0.0763 g, 0.63 mmol) was added slowly a THF solution of (t-Bu)2PCH2Li (0.1046 g, 0.63 mmol) at −30° C. The solution was stirred overnight and turned purple from yellow. After removing the solvent and rinsing with pentane, a purple powder (0.1538 g, 0.54 mmol) was obtained in 85% yield. 1H NMR (C6D6): complicated; 31P NMR (C6D6): complicated, indicating the desired product, but also additional products.
  • Examples 871-874 Polymerizations of Ethylene at 1000 psi of C2H4 in Shaker Tube
  • TO (molPE/
    Ex Ligand PE (g) mol cat)
    871 1001 3.0595 5110.9
    872 1002 7.9434 13827.2
    873 1003 6.8919 13165.7
    874 1004 3.9511 7226.8
  • Conditions: 0.02 mmol ligand, 1 equiv. Allyl-Ni complex, 10 equiv. B(C6F5)3, 5 ml TCB, RT, 18 h.
  • Figure US20100222531A1-20100902-C00054
    Figure US20100222531A1-20100902-C00055
  • The syntheses of aminopyrrole ligands is published in WO00/50470.
  • Example 875 Synthesis of Ligand 1005
  • A 50 mL round bottom flask was charged with 0.3988 g (2.745 mmol) of 40 wt. % glyoxal solution in water, 0.6045 g (5.49 mmol) of 1-amino-2,5-dimethylpyrrole, 15 ml methanol and 1 drop of formic acid. The mixture was stirred overnight and light brown precipitate formed. The solid was collected by filtration, rinsed with hexane and dried under vacuum. 0.46 g (1.9 mmol) of product was obtained in 69% yield. 1H NMR (CDCl3) δ 8.18 (s, 2, C—H), 5.8 (s, 4, Hpy), 2.3 (s, 12, CH3).
  • Example 876 Synthesis of Ligand 1006
  • A 50 mL round bottom flask was charged with 0.25 g (2.9 mmol) of 2,3-butadione, 0.696 g (6.318 mmol) of 1-amino-2,5-dimethylpyrrole, 20 ml methanol and 1 drop of formic acid. The reaction was monitored by TLC with elute of 10% ethyl acetate in hexane. Two major spots were showed on the TLC even after overnight stirring. The clear yellow mixture was stirred 2 days and the solvent was removed. The yellow residue was recrystallized with hexane. 0.26 g (0.96 mmol) of bis-substituted product and 0.3652 g (2.0 mmol) of mono-substituted product were obtained. 1H NMR (CDCl3) for bis-: δ 5.83 (s, 4, Hpy), 2.12 (s, 6, CH3), 2.0 (s, 12, CH3-Py). 1H NMR (CDCl3) for mono-: δ5.83 (s, 4, H-py), 2.52 (s, 3, CH3), 1.96 (s, 12, CH3-py), 1.92 (s, 3, CH3).
  • Example 877 Synthesis of Ligand 1007
  • A 150 mL round bottom flask was charged with 0.6 g (2.9 mmol) of acenaphthenequinone, 0.6488 g (5.89 mmol) of 1-amino-2,5-dimethylpyrrole, 50 ml methanol and 1 drop of formic acid. The reaction was monitored by TLC with elute of 30% ethyl acetate in hexane and stirred 3 days. The solvent was removed under vacuum and the red residue was separated on a silica gel column with 30% ethyl acetate in hexane. 0.07 g (0.19 mmol) of dark red crystals bis-substituted product and 0.06 g (0.2 mmol) of orange powder mono-substituted product were obtained. 1H NMR (CDCl3) for bis-: δ 7.96 (d, 2, H-acen), 7.5 (t, 2, H-acen), 6.74 (d, 2, H-acen), 5.99 (s, 4, H-py), 2.08 (s, 12, CH3-Py). 1H NMR (CDCl3) for mono-: δ 8.17 (d-d, 2, H-acen), 8.08 (d, 1, H-acen), 7.8 (t, 1, H-acen), 7.54 (t, 1, H-acen), 6.91 (d, 1, H-acen), 5.97 (s, 2, H-py), 2.02 (s, 6, CH3-Py).
  • If the reaction was carried out in toluene with p-toluenesulfonic acid as catalyst under reflux, the exclusive product was bis-substituted but it was isolated in very low yield.
  • Example 878 Synthesis of Ligand 1008
  • A 50 mL round bottom flask was charged with 0.1418 g (1.65 mmol) of 2,3-butadione, 0.5478 g (3.29 mmol) of 1-amino-2,5-diisopropylpyrrole, 20 ml methanol and 1 drop of formic acid. The reaction was monitored by TLC with elute of 10% ethyl acetate in hexane and stirred 2 days at 50° C. The solvent was removed under vacuum and the yellow oily residue was separated on a silica gel column with 5% ethyl acetate in hexane. 0.226 g (0.59 mmol) of yellow crystalline product was obtained in 36% yield. 1H NMR (CDCl3): □5.86 (s, 4, H-py), 2.53 (m, 4, H-Pr-i), 2.11 (s, 6, CH3)2, 1.10 (d, 24, CH3-Pr-i).
  • Example 879 Synthesis of Ligand 1009
  • A 100 mL round bottom flask was charged with 0.4418 g (2.43 mmol) of acenaphthenequinone, 0.907 g (4.85 mmol) of 1-amino-2-methyl-5-phenylpyrrole, 50 ml methanol and 1 drop of formic acid. The reaction was monitored by TLC with elute of 30% ethyl acetate in hexane and stirred 7 days at RT. The solvent was removed under vacuum and the red solid residue was separated on a silica gel column with 10% ethyl acetate in hexane. 0.15 g (0.30 mmol) of dark red crystals were obtained in 13% yield. 1H NMR (CD2Cl2): δ 8.06 (m, 2H), 7.72-7.6 (m, 6H), 7.32 (m, 4H), 7.18 (m, 2H), 6.92 (d, 1H), 6.86 (d, 1H), 6.66 (d-d, 2H), 6.38 (d, 2H), 2.32 (d, 6, CH3).
  • Example 880 Synthesis of Ligand 1010
  • A 100 mL round bottom flask was charged with 0.1881 g (2.18 mmol) of 2,3-butadione, 0.817 g (4.37 mmol) of 1-amino-2-methyl-5-phenylpyrrole, 50 ml methanol and 1 drop of formic acid. The reaction was stirred 7 days at RT and yellow precipitate formed. The reaction mixture was filtered through a frit to collect the yellow solid that then was dissolved in ether and dried over Na2SO4. The ether was removed and the yellow solid was dried under high vacuum. 0.46 g (1.17 mmol) yellow powder was obtained in 53% yield. 1H NMR (CD2Cl2): δ 7.20 (m, 8, Ph-H), 7.10 (t, 2, Ph-H), 6.20 (d, 2, Py-H), 5.95 (m, 2, Py-H), 2.05 (s, 6, CH3), 1.80 (s, 6, CH3).
  • Example 881 Synthesis of Ligand 1011
  • A 100 mL round bottom flask was charged with 0.129 g (1.5 mmol) of 2,3-butanedione, 0.7021 g (3.0 mmol) of 1-amino-2,5-diphenylpyrrole, 50 ml methanol and 1 drop of formic acid. The reaction was monitored by TLC with elute of 30% ethyl acetate in hexane and stirred 7 days at RT. The solvent was removed under vacuum and the red solid residue was separated on a silica gel column with 10% ethyl acetate in hexane. 0.4963 g (0.97 mmol) of yellow powder was obtained in 64% yield. 1H NMR (CD2Cl2): δ 7.37(m, 4, ph-H), 7.28 (m, 6, ph-H), 6.49 (s, 2, py-H), 1.76 (s, 6, CH3).
  • Example 882 Synthesis of Catalyst 1012
  • The ligand 7 (0.1102 g, 0.212 mmol), allyl-Ni dimer ([(2-MeO2C—C3H4)NiBr]2) (0.0505 g, 0.106 mmol) and Na(tetra[3,5-bis(trifluoromethyl)]-phenylborane) (0.1879 g, 0.212 mmol) were mixed in 20 mL of ether in a 50 mL of round bottom flask. The reaction mixture was stirred at room temperature for one hour and filtered through a Celite plug on a frit. Removal of the solvent yields a brown powder that was then rinsed with pentane and dried under high vacuum. 0.3069 g (0.199 mmol) product was collected in 94% yield. 1H NMR (CD2Cl2): δ 7.58-7.06 (m, 6, Ar—H), 6.46 (d, 2, Py-H), 6.40 (d, 2, Py-H), 3.65 (s, 2, allyl-H), 3.42 (s, 3, MeO), 1.90 (s, 6, CH3), 1.85 (s, 2, allyl-H).
  • Examples 883-898 Copolymerization of Ethylene and Polar-Comonomers
  • Into a glass vial used for shaker reaction, were weighed 0.02 mmol of the ligand, 1 equivalent of allyl-Ni dimer ([(2-MeO2C—C3H4)NiBr]2) and 10 equivalent of NaBaf. 2 ml of ether was added into the vial and shaken well. After two hours during which time the most of the ether was evaporated off, 20 equivalent of tri(pentafluorophenyl)-borane cocatalyst, 9 ml of 1,2,4-trichlorobenzene and 1 ml of ethylene glycol phenyl ether acrylate was added into the vial. The vials were placed into a shaker tube, sealed, and taken out from the dry box. The shaker tube was connected to a high pressure, ethylene shaker reaction unit.
  • Reaction conditions for polymerization were: 1000 psi ethylene, 120° C., 18 hours.
  • TABLE 87
    Results of shaker tube copolymerizations
    Polymer Catalyst Comon.
    yield Productivity Me/1000 Incorp. Peak MP (° C.)
    Ex Ligand (g) (Kg/g) Mw Mn Mn/Mw CH2 (Mol %) ΔH (J/g)
    883 1007 1.4967 1.37 2482 992 2.5 29.2 0.35  89
    broad
    884 1006 1.0752 0.88 3586 1306 2.75 28.5 0.27 114
    shoulder
    885 1008 2.3451 2.07 38156 20004 1.91 Trace  86
    shoulder
    886 1008 2.6151 2.75 22933 1106 20.74b Trace  93
    109
    887 1011 1.5141 1.09 5371 1209 4.44b trace 127
    shoulder
    888 1009 2.674 2.24 2754 1082 2.55b trace  66
    □158 
    889 1010 1.6429 1.33 3860 1166 3.31b trace 117
    shoulder
    890 1007 0.6397 0.78 20928 2232 9.37b trace 120
    shoulder
    891 1009 0.6282 0.53 208622 1615 129.15b  85
    bimodal broad
    892 1010 0.7601 0.61 4855 1644 2.95b 110
    broad
    893 1012 1.4557 1.22 16467 1116 14.76b 125
    160
    894 1012 1.2511 1.06 17343 844 20.55b Trace 124
      154.0
    895 1007 1.1725 1.38 2832 1207 2.35b 120
    shoulder
    896 1006 1.5382 0.97 29780 1160 25.68 0.15 122
    185
    897 1008 2.0138 2.08 14466 1293 11.19 trace
    898 1012 1.8074 1.56 54346 1881 28.9 0   125
    shoulder
    Notes:
    a. 20 equivalent of NaBarf,
    bRI data for GPC in THF, dual detector RI-UV,
    c. [AlMe2(Et2O)]+[MeB(C6F5)3]cocatalyst and p-xylene solvent,
    d. No allyl-Ni dimer needed,
    e. Hexyl acrylate comonomer.

Claims (18)

1. A process for the polymerization of olefins, comprising the step of contacting, at a temperature of about −100° C. to about +200° C., at least one polymerizable olefin with an active polymerization catalyst comprising a Group 3 through 11 (IUPAC) transition metal or a lanthanide metal complex of a ligand of the formula (I), (II) or (XII)
Figure US20100222531A1-20100902-C00056
wherein:
R1 and R2 are each independently hydrocarbyl, substituted hydrocarbyl or a functional group;
Y is CR11R12, S(T), S(T)2, P(T)Q, NR36 or NR36NR36;
X is O, CR5R6 or NR5;
A is O, S, Se, N, P or As;
Z is O, Se, N, P or As;
each Q is independently hydrocarbyl or substituted hydrocarbyl;
R3, R4, R5, R6, R11 and R12 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
R7 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group, provided that when Z is O or Se, R7 is not present;
R8 and R9 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
R10 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
each T is independently ═O or ═NR30;
R30 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
R31 and R32 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
R33 and R34 are each independently hydrocarbyl or substituted hydrocarbyl, provided that each is independently an aryl substituted in at least one position vicinal to the free bond of the aryl group, or each independently has an Es of −1.0 or less;
R35 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group, provided that when A is O, S or Se, R35 is not present;
each R36 is independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
m is 0 or 1;
s is 0 or 1;
is n is 0 or 1; and
q is 0 or 1;
and provided that:
any two of R3, R4, R5, R6, R8, R9, R11 and R12 bonded to the same carbon atom taken together may form a functional group;
any two of R1, R2, R3, R4, R5, R6, R7, R8, R9, R11, R12, R31, R32, R33, R34, R35 and R36 bonded to the same atom or vicinal to one another taken together may form a ring; and
when said ligand is (I), Y is C(O), Z is O, and R1 and R2 are each independently hydrocarbyl, then R1 and R2 are each independently an aryl substituted in one position vicinal to the free bond of the aryl group, or R1 and R2 each independently have an Es of −1.0 or less.
2. The process of claim 1, wherein said transition metal is Ni, Pd, Pt, Fe, Co, Ti, Zr, V, Hf, Cr or Cu.
3. The process of claim 2, wherein said transition metal is Ni, Pd, Ti or Zr.
4. The process of claim 1, wherein the ligand is (I) and:
the transition metal is Ni, m is O, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 is hydrocarbyl or substituted hydrocarbyl, R12 is hydrocarbyl, substituted hydrocarbyl or a functional group, and Z is O; or
the transition metal is Ti, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 is hydrocarbyl or substituted hydrocarbyl, R12 is hydrocarbyl, substituted hydrocarbyl or a functional group, and Z is O; or
the transition metal is Zr, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 is hydrocarbyl or substituted hydrocarbyl, R12 is hydrocarbyl, substituted hydrocarbyl or a functional group, and Z is O; or
the transition metal is Ni, m is O, n is 1, R3 and R4 are hydrogen, R7 is hydrocarbyl or substituted hydrocarbyl, Y is CR11R12, is hydrogen, R12 is hydrocarbyl or substituted hydrocarbyl, and Z is N; or
the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 and R12 taken together are oxo, and Z is O; or
the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, R7 is hydrocarbyl or substituted hydrocarbyl, Y is CR11R12, R11 and R12 taken together are oxo, and Z is N; or
the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is S(T), T is ═O and Z is O; or
the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is S(T), T is ═N-silyl, Z is N and R7 is silyl; or
the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is S(T), T is ═O, Z is N, and R7 is hydrocarbyl or substituted hydrocarbyl; or
the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 and R12 taken together are a ring and Z is 0; or
the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 and R12 taken together are N-hydrocarbyl- or N-substituted hydrocarbylimino, Z is N and R7 is hydrocarbyl or substituted hydrocarbyl; or
the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is S(T), T is ═O and Z is O; or
the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 and R12 taken together are sulfo, Z is N and R7 is hydrocarbyl or substituted hydrocarbyl.
5. A process for the polymerization of olefins, comprising the step of contacting, at a temperature of about −100° C. to about +200° C., at least one polymerizable olefin with a compound of the formula (IV), (V) or (XIII)
Figure US20100222531A1-20100902-C00057
wherein:
R1 and R2 are each independently hydrocarbyl, substituted hydrocarbyl or a functional group;
Y is CR11R12, S(T), S(T)2, P(T)Q, NR36 or NR36NR36;
X is O, CR5R6 or NR5;
A is O, S, Se, N, P or As;
Z is O, Se, N, P or As;
each Q is independently hydrocarbyl or substituted hydrocarbyl;
R3, R4, R5, R6, R11 and R12 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
R7 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group, provided that when Z is O or Se, R7 is not present;
R8 and R9 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
R10 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
each T is independently ═O or ═NR30;
R30 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
R31 and R32 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
R33 and R34 are each independently hydrocarbyl or substituted hydrocarbyl, provided that each is independently an aryl substituted in at least one position vicinal to the free bond of the aryl group, or each independently has an Es of −1.0 or less;
R35 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group, provided that when A is O, S or Se, R35 is not present;
each R36 is independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
m is 0 or 1;
s is 0 or 1;
n is 0 or 1; and
q is 0 or 1;
M is a Group 3 through Group 11 transition metal or a lanthanide metal;
and
L1 is a monodentate monoanionic ligand into which an ethylene molecule may insert between L1 and M, and L2 is a monodentate neutral ligand which may be displaced by ethylene or an empty coordination site, or L1 and L2 taken together are a monoanionic bidentate ligand into which ethylene may insert between said monoanionic bidentate ligand and said nickel atom, and each L3 is independently a monoanionic ligand and z is the oxidation state of M minus 2; and provided that;
any two of R3, R4, R5, R6, R6, R9, R11 and R12 bonded to the same carbon atom taken together may form a functional group;
any two of R1, R2, R3, R4, R5, R6, R7, R8, R9, R11, R12, R31, R32, R33, R34, R35 and R36 bonded to the same atom or vicinal to one another taken together may form a ring; and
when said compound is (IV), Y is C(O), Z is O, and R1 and R2 are each independently hydrocarbyl, then R1 and R2 are each independently an aryl substituted in one position vicinal to the free bond of the aryl group, or R1 and R2 each independently have an Es of -1.0 or less.
6. The process of claim 5, wherein M is Ni, Pd, Pt, Fe, Co, Ti, Zr, V, Hf, Cr or Cu.
7. The process of claim 6, wherein M is Ni, Pd, Ti or Zr.
8. The process of claim 5, wherein the compound is (IV) and:
M is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 is hydrocarbyl or substituted hydrocarbyl, R12 is hydrocarbyl, substituted hydrocarbyl or a functional group, and Z is O; or
M is Ti, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 is hydrocarbyl or substituted hydrocarbyl, R12 is hydrocarbyl, substituted hydrocarbyl or a functional group, and Z is O; or
M is Zr, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 is hydrocarbyl or substituted hydrocarbyl, R12 is hydrocarbyl, substituted hydrocarbyl or a functional group, and Z is O; or
M is Ni, m is 0, n is 1, R3 and R4 are hydrogen, R7 is hydrocarbyl or substituted hydrocarbyl, Y is CR11R12, R11 is hydrogen, R12 is hydrocarbyl or substituted hydrocarbyl, and Z is N; or
M is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 and R13 taken together are oxo, and Z is O; or
M is Ni, m is O, n is 1, R3 and R4 are hydrogen, R7 is hydrocarbyl or substituted hydrocarbyl, Y is CR11R12, R11 and R12 taken together are oxo, and Z is N; or
M is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is S(T), T is ═O and Z is O; or
M is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is S(T), T is ═N-silyl, Z is N and R7 is silyl; or
M is Ni, m is O, n is 1, R3 and R4 are hydrogen, Y is S(T), T is ═O, Z is N, and R7 is hydrocarbyl or substituted hydrocarbyl; or
M is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 and R12 taken together are a ring and Z is O; or
M is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 and R12 taken together are N-hydrocarbyl- or N-substituted hydrocarbylimino, Z is N and R7 is hydrocarbyl or substituted hydrocarbyl; or
M is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is S(T), T is ═O and Z is O; or
the transition metal is Ni, m is 0, n is 1, R3 and R4 are hydrogen, Y is CR11R12, R11 and R12 taken together are sulfo, Z is N and R7 is hydrocarbyl or substituted hydrocarbyl.
9. A polymerization catalyst component comprising a Group 3 through 11 transition metal or lanthanide metal complex of a ligand of the formula
Figure US20100222531A1-20100902-C00058
wherein:
R1 and R2 are each independently hydrocarbyl, substituted hydrocarbyl or a functional group;
Y is CR11R12, S(T), S(T)2, P(T)Q, NR36 or NR36NR36;
X is O, CR5R6 or NR5;
A is O, S, Se, N, P or As;
Z is O, Se, N, P or As;
each Q is independently hydrocarbyl or substituted hydrocarbyl;
R3, R4, R5, R6, R11 and R12 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
R7 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group, provided that when Z is O or Se, R7 is not present;
R8 and R9 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
R10 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
each T is independently ═O or ═NR30;
R30 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
R31 and R32 are each independently hydrogen, hydrocarbyl; substituted hydrocarbyl or a functional group;
R33 and R34 are each independently hydrocarbyl or substituted hydrocarbyl, provided that each is independently an aryl substituted in at least one position vicinal to the free bond of the aryl group, or each independently has an Es of −1.0 or less;
R35 is hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group, provided that when A is O, S or Se, R35 is not present;
each R36 is independently hydrogen, hydrocarbyl, substituted hydrocarbyl or a functional group;
m is 0 or 1;
s is 0 or 1;
n is 0 or 1; and
q is 0 or 1;
and provided that:
any two of R3, R4, R5, R6, R8, R9, R11 and R12 bonded to the same carbon atom taken together may form a functional group;
any two of R1, R2, R3, R4, R5, R6, R7, R8, R9, R11, R12, R31, R32, R34, R35 and R36 bonded to the same atom or vicinal to one another taken together may form a ring; and
when said ligand is (I), Y is C(O), Z is O, and R1 and R2 are each independently hydrocarbyl, then R1 and R2 are each independently an aryl substituted in one position vicinal to the free bond of the aryl group, or R1 and R2 each independently have an Es of −1.0 or less.
10. The component of claim 9, which is on a solid support.
11. The component of claim 9, wherein a cocatalyst which is an alkylaluminum compound or a borane or both is also present.
12. A process for forming an ethylene/polar monomer copolymer, comprising the step of contacting, under polymerizing conditions, a nickel complex of a bidentate neutral ligand or a bidentate monoanionic ligand, with a monomer component comprising one or more hydrocarbon olefins and one or more polar comonomers (and other optional components such as, for example, one or more cocatalysts and/or other additives), at a temperature of about 60° C. to about 170° C., provided that when CO is present, at least one other polar monomer is present.
13. The process of claim 12, wherein ethylene is present and an ethylene partial pressure of at least about 0.67 MPa is used.
14. The process of claim 12, wherein said one or more polar comonomers comprises H2C═CHR20C(O)Y, or H2C═CR25C(O)Y, wherein R20 is alkylene or substituted alkylene, R25 is hydrogen, and Y is —OH, —NR21R22, —OR23, or —SR24, wherein R21 and R22 are each independently hydrogen, hydrocarbyl or substituted hydrocarbyl, R23 and R24 are each hydrocarbyl or substituted hydrocarbyl.
15. The process of claim 12, wherein said bidentate ligand is
Figure US20100222531A1-20100902-C00059
wherein:
R26 and R27 are each independently hydrocarbyl or substituted hydrocarbyl, provided that the carbon atom bound to the imino nitrogen atom has at least two carbon atoms bound to it;
R28 and R29 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl, or R28 and R29 taken together are hydrocarbylene or substituted hydrocarbylene to form a carbocyclic ring;
R60 and R61 are each independently functional groups bound to the rest of (XV) through heteroatoms (for example O, S or N), or R60 and R61 (still containing their heteroatoms) taken together form a ring.
each R50 is independently hydrocarbyl or substituted hydrocarbyl;
each R51 is independently hydrogen, hydrocarbyl or substituted hydrocarbyl; and
each R52 is hydrocarbyl, substituted hydrocarbyl, hydrocarbyloxy, or substituted hydrocarbyloxy.
16. A polymer, consisting essentially of repeat units derived from ethylene, and one or more polar olefins of the formula H2C═CHC(O)R32, wherein R32 is —OR34 or any group readily derivable from it, and R34 is hydrocarbyl or substituted hydrocarbyl, wherein:
said polymer contains “first branches” of the formula —(CH2)nCH3 and “second branches” of the formula —(CH2)mC(O)R32, wherein m and n are independently zero or an integer of 1 or more; and
said polymer has the following structural characteristics:
(a) one or both of:
(1) the ratio of first branches wherein n is 0 to first branches wherein n is 1 is about 3.0 or more; and
(2) the ratio of first branches wherein n is 0 to first branches wherein n is 3 is 1.0 or more; and
(b) one or both of:
(1) the total number of first branches in which n is 0, 1, 2 and 3 in said polymer is about 10 or more per 1000 CH2 groups; and
(2) the incorporation of repeat units derived from H2C═CHC(O)R32 is 0.3 mole percent or more based on the total repeat units derived from the hydrocarbonolefin and H2C═CHC(O)R32.
17. A polymer, consisting essentially of repeat units derived from:
one or more hydrocarbon olefins, such as ethylene, and
one or more polar olefins of the formula H2C═CHC(O)R32, wherein R32 is —OR34, or any group readily derivable from it, and R34 is hydrocarbyl or substituted hydrocarbyl;
wherein in said polymer incorporation of repeat units derived from H2C═CHC(O)R32 is 0.3 mole percent or more based on the total repeat units; and
wherein said polymer has one or both of the following structural characteristics:
at least 5 mole percent of said repeat units derived from H2C═CHC(O)R32 are present in said polymer as end groups; and
said end groups are at least 0.001 mole percent of the total repeat units in said polymer;
and provided that said end groups have the formula
˜˜˜˜˜˜˜—HC═CH—C(O)—R32
wherein ˜˜˜˜˜˜˜ is the remainder of the polymer chain of said end group.
18. A polymer, consisting essentially of:
repeat units derived from ethylene;
repeat units derived from one or more monomers of the formula H2C═CHC(O)R32, wherein each R32 is independently —OR34 or any group readily derivable from it, and each R34 is independently hydrocarbyl or substituted hydrocarbyl, and
repeat units derived from one or more alpha-olefins of formulas H2C═CH—(CH2)t—H and/or H2C═CH-R75-G, wherein t is an integer of 1 to 20, R75 is alkylene or substituted alkylene, and G is an inert functional group.
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WO2001092347A3 (en) 2003-01-16
AU7507001A (en) 2001-12-11
WO2001092354A2 (en) 2001-12-06
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US7439314B2 (en) 2008-10-21
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US7998895B2 (en) 2011-08-16
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JP2003535190A (en) 2003-11-25
US20020037982A1 (en) 2002-03-28
BR0111657A (en) 2003-10-07
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US20100029469A1 (en) 2010-02-04
CA2408937A1 (en) 2001-12-06

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