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.