Long-Lived Layered Silicates-immobilized 2,6-Bis(Imino)pyridyl Iron (II) Catalysts for Hybrid Polyethylene Nanocomposites by In Situ Polymerization: Effect of Aryl Ligand and Silicate Modification

Heterogeneous-layered silicate-immobilized 2,6-bis(imino)pyridyl iron (H) dichloride/MDAO catalysts, in which the active polymerization species are intercalated within sodium- and organomodified-layered silicate galleries, were prepared for producing hybrid exfoliated polyethylene (PE) nanocomposites by means of in Situ polymerization. The inorganic filler was first treated with modified-methylaluminoxane (MMAO) to produce a supported cocatalyst: MMAO reacts with silicates replacing most of the organic surfactant, thus modifying the original crystallographic clay order. MMAO anchored to the nanoclay was able to activate polymerization iron complexes initiating the polymer growth directly from the filler lamellae interlayer. The polymerization mechanism taking place in between the montmorillonite lamellae separates the layers, thus promoting deagglomeration and effective clay dispersion. Transmission electron microscopy revealed that in situ polymerization by catalytically active iron complexes intercalated within the lower organomodified clay led to fine dispersion and high exfoliation extent. The intercalated clay catalysts displayed a longer polymerization life-time and brought about ethylene polymerization more efficiently than analogous homogeneous systems. PEs having higher molecular masses were obtained. These benefits resulted to be dependent more on the filler nature than on the ligand environment around the iron metal center and the experimental synthetic route.