Morphology Control in Metallocene Polymerization; Organic Supports vs. Non-aqueous Emulsion Polymerization

Nano-sized latex support in metallocene polymerization is known to be able to avoid fuming or leaching and leads to a powder-like and well-processable polymer. Focus has been put on the fragmentation behaviour of the particles, a key parameter to morphology control. To study the different behaviour of the new systems as classical inorganic supported metallocenes, e.g. SiO₂, a wide range of analytical methods were applied. Fluorescence microscopy, polymerization videomicroscopy, as well as kinetic studies led to a better understanding of the process. The performance of the supports was approved by several phenoxy-imine type catalysts ("FI-Catalyst"), which were combined with a tailored latex support. Ultra high molecular weight polyethylene (UHMWPE) was synthesized without any reactor fouling thereby. A different approach towards the metallocene catalyzed olefin polymerization is also presented. Based on emulsion polymerization, it enables very good control over product morphology. The completely hydrophobic system consists of perfluorinated solvent as a continuous phase and a hydrocarbon solvent as a dispersed phase. In contrast to the already existing water based emulsion polymerization of olefins, very high molecular weights are achieved.