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Spatially resolved catalysis for controlling the morphology of polymer particles.

Morphology control is essential to optimize the properties of polymer blends and inorganic / organic hybrid materials. Properties such as mechanical stability, impact strength or scratch resistance can be adjusted by the homogeneous incorporation of a second polymer in a blend or hybrid material. However, simple blending of two distinct materials can lead to ill-defined mixtures with an irregular distribution of the components. It is already known that supported catalysts can adjust the morphology of polyolefin particles, such as size and bulk density. The control is transferred from the shape of the supporting particles to the product, and also the support can fragment into smaller particles during polymerization. Numerous catalysts have already been investigated on such supports. Mixtures of metallocenes have also been used, but the catalysts were statistically distributed either on inorganic or organic supports. As a result, only amorphous polymer blends have been observed. Using the replication effect, we not only control the shape of the particles, but also generate an inner morphology (core-shell structure) during the polymerization and avoid the use of emulsion polymerization. The loading of different catalysts on different areas of the support results in the spatially resolved formation of different polymers. A well-structured catalyst system acts as a template for the formation of the final morphology in the product particle. As both immobilized catalysts and the polymers are migrationally stable, the final product represents the core-shell structure of the initial catalytic system.