Integrated Ziegler–Natta/Brookhart‐Ni Catalysts for the Synthesis of Sutured Polar High‐Impact Polypropylenes

Abstract The direct synthesis of polar high‐impact polypropylenes using industrially‐preferred heterogeneous catalysts is challenging due to the poisoning of polar functional groups towards metal center and the high stereo‐selectivity requirement. In this work, dual‐site catalysts combining Ziegler–Natta and Brookhart‐Ni catalysts were used to produce polar polyolefin ionomers, followed by polar high‐impact polypropylenes containing isotactic polypropylene and branched polyethylene as toughening agents. Three combination modes between these catalysts were investigated, including mixed, core–shell, and integrated types. The integrated dual‐site catalyst achieved the optimal material properties because the polyolefin ionomer acted as a suture molecule that stitched different components into a whole network. This produced sutured polar high‐impact polypropylenes with excellent mechanical properties and compatibility with polar substances. The restraining effect of the suture molecules greatly reduced the release of microplastic particles after aging. Moreover, the obtained polar high‐impact polypropylene can serve as an efficient compatibilizer to recycle polyethylene/polypropylene mixed‐waste plastics. This work provides an appealing and potentially practical strategy to upgrade the widely used polypropylenes and to alleviate the ever‐growing plastic pollution issue.