Organic Versus Inorganic Supports for Metallocenes: The Influence of Rigidity on the Homogeneity of the Polyolefin Microstructure and Properties

A procedure to obtain very uniform polyolefin copolymers by supported metallocenes is presented. Conventional metallocene or Ziegler–Natta catalysts, both immobilized on inorganic supports, yield only copolymers with inhomogeneous comonomer incorporation and broad short-chain branching distribution. The main reasons are diffusional limitations of the monomers or the multisite character of the catalysts. By comparing inorganic and organic supports, we demonstrate that metallocenes immobilized on organic supports solve these problems. In this regard, organic and soft nanosized polystyrene particles (nPS) versus industrially used, hard, and inorganic SiO₂ were used to support [Me₂Si­(Ind)₂ZrCl₂/MAO (I) and Me₂Si­(Benz­[e]-Ind)₂ZrCl₂/MAO (BI)] catalysts for ethylene/1-hexene copolymerization. In the inorganic case, the catalyst systems show a substantial inconsistency in the copolymers’ branching distribution, resulting in phase separation. One phase is hexene-poor with high melting temperature (T_m) and high molecular weight (MW). The second, hexene-rich phase, however, shows lower T_m and MW. By using organic supports, comonomers are uniformly inserted into the polymer chain and homogeneous microstructured copolymers are obtained. These findings are mainly attributed to diffusion processes of the monomers into the soft organic material. To prove this conclusion and to elucidate the structure of the catalyst system, various characterization techniques such as time-of-flight secondary ion mass spectrometry and scanning electron microscopy–energy-dispersive X-ray were performed.