Several homogeneous postmetallocene complexes are known
to produce
weakly entangled ultrahigh-molecular-weight polyethylene (disentangled UHMWPE) under controlled polymerization conditions
leading to ultimate mechanical properties. Major challenges in using
a homogeneous catalyst system exist such as reactor fouling and uncontrolled
polymer morphology, which could be addressed by heterogenization of
the single-site complex. In such a scenario, a heterogeneous catalytic
system that can synthesize ultrahigh-molecular-weight polyethylene
with a reduced number of entanglements, to an extent that the mechanical
properties are equivalent to those obtained using a postmetallocene
catalyst in a homogeneous condition, remains a challenge. Herein,
a magnesium chloride based in situ formed activator/support,
MgCl
x
/Et
n
Al
y
(2-ethyl-1-hexoxide)
z
, is employed with a highly active bis[N-(3-tert-butylsalicylidene)pentafluoroanilinato] titanium(IV)
dichloride (Cat. 1) for the synthesis of ultrahigh-molecular-weight
polyethylene with a reduced number of entanglements. A novel route
is adopted to make a nano-support that allows tailoring of the entangled
state and control over the resultant morphology without reactor fouling
and wall sheeting, thus providing the feasibility of pursuing the
polymerization via a continuous process. The synthesized nascent polymer
shows the formation of single crystals of linear UHMWPE, identifying
the fold surface and crystal thickness and suggesting a low entangled
state. The topological differences with the commercial entangled sample
are identified by chain diffusion from the noncrystalline to crystalline
region via solid-state NMR, following melting kinetics via DSC, and
transformation of the nonequilibrium melt into the equilibrium state
via rheology. Thus, the obtained disentangled crystals can be compressed
in the solid state, without melting, to an extent that the macroscopic
forces can be transferred to the molecular level. This allows the
desired chain orientation for securing the ultimate tensile modulus
(>200 N/tex) and tensile strength (>4.0 N/tex) in the synthesized
low entangled linear polyethylene having a weight average molar mass
exceeding a million grams per mole. These mechanical properties are
equivalent to those perceived using a homogeneous catalytic system
and are the first of their kind reported in a polymer synthesized
using a heterogeneous catalytic system.