Precipitation polymerization (PP) is a powerful tool to prepare various types of uniform polymer particles owing to its outstanding advantages of easy operation and the absence of any surfactant. Several PP approaches have been developed up to now, including traditional thermo-induced precipitation polymerization (TRPP), distillation precipitation polymerization (DPP), reflux precipitation polymerization (RPP), photoinduced precipitation polymerization (PPP), solvothermal precipitation polymerization (SPP), controlled/‘‘living’’ radical precipitation polymerization (CRPP) and self-stabilized precipitation polymerization (2SPP). In this review, a general introduction to the categories, mechanisms, and applications of precipitation polymerization and the recent developments are presented, proving that PP has great potential to become one of the most attractive polymerization techniques in materials science and bio-medical areas.

The less-expensive and earth-abundant nickel catalyst is highly promising in the copolymerization of ethylene with polar monomers and has thus attracted increasing attention in both industry and academia. Herein, we have summarized the recent advancements made in the state-of-the-art nickel catalysts with different types of ligands for ethylene copolymerization and how these modifications influence the catalyst performance, as well as new polymerization modulation strategies. With regard to α-diimine, salicylaldimine/ketoiminato, phosphino-phenolate, phosphine-sulfonate, bisphospnine monoxide, N-heterocyclic carbene and other unclassified chelates, the properties of each catalyst and fine modulation of key copolymerization parameters (activity, molecular weight, comonomer incorporation rate, etc.) are revealed in detail. Despite significant achievements, many opportunities and possibilities are yet to be fully addressed, and a brief outlook on the future development and long-standing challenges is provided.

The introduction of polar functional groups into polyolefin chain structures creates opportunities to enhance specific properties, such as adhesion, dyeability, printability, compatibility, thermal stability, and electrical conductivity, which widen the range of potential applications for these modified materials. Transition metal catalysts, especially late transition metals, have proven to be highly effective in copolymerization processes due to their reduced Lewis acidity and electrophilicity. However, when compared to the significant progress and summary of synthetic methods, there is a distinct lack of a comprehensive summary of mechanistic studies pertaining to the catalytic systems involved in ethylene copolymerization catalyzed by palladium and nickel catalysts. In this review, we have provided a comprehensive summary of the latest developments in mechanistic studies of ethylene copolymerization with polar monomers catalyzed by late-transition-metal complexes. Experimental and computational methods were employed to conduct a detailed investigation of these organic and organometallic systems. It is mainly focused on ligand substitution, changes in binding modes, ethylene/polar monomer insertion, chelate opening, and β-H elimination. Factors that control the catalytic activity, molecular weight, comonomer incorporation ratios, and branch content are analyzed, these include steric repulsions between ligands and monomers, electronic effects arising from both ligands and monomers, and so on.

The direct copolymerization of ethylene with polar monomers to produce functional polyolefins continues to be highly appealing due to its simple operation process and controllable product microstructure. Low-cost nickel catalysts have been extensively utilized in academia for the synthesis of polar polyethylenes. However, the development of high-temperature copolymerization catalysts suitable for industrial production conditions remains a significant challenge. Classified by the resultant copolymers, this review provides a comprehensive summary of the research progress in nickel complex catalyzed ethylene-polar monomer copolymerization at elevated temperatures in the past five years. The polymerization results of ethylene–methyl acrylate copolymers, ethylene-tert–butyl acrylate copolymers, ethylene–other fundamental polar monomer copolymers, and ethylene–special polar monomer copolymers are thoroughly summarized. The involved nickel catalysts include the phosphine-phenolate type, bisphosphine-monoxide type, phosphine-carbonyl type, phosphine-benzenamine type, and the phosphine-enolate type. The effective modulation of catalytic activity, molecular weight, molecular weight distribution, melting point, and polar monomer incorporation ratio by these catalysts is concluded and discussed. It reveals that the optimization of the catalyst system is mainly achieved through the methods of catalyst structure rational design, extra additive introduction, and single-site catalyst heterogenization. As a result, some outstanding catalysts are capable of producing polar polyethylenes that closely resemble commercial products. To achieve industrialization, it is essential to further emphasize the fundamental science of high-temperature copolymerization systems and the application performance of resultant polar polyethylenes.

Ultrahigh molecular weight polyethylene (UHMWPE) is a class of high-performance engineering plastics, exhibiting a unique set of properties and applications. Although many advances have been achieved in recent years, the synthesis of UHMWPE is still a great challenge. In this contribution, a series of zirconium and hafnium complexes, [2,6-(R¹)₂-4-R²-C₆H₂-N-C(camphyl)=C(camphyl)-N-2,6-(R¹)₂-4-R²-C₆H₂]MMe₂(THF) (1-Zr: R¹ = Me, R² = H, M = Zr; 2-Zr: R¹ = Me, R² = Me, M = Zr; 1-Hf: R¹ = Me, R² = H, M = Hf; 2-Hf: R¹ = Me, R² = Me, M = Hf), bearing bidentate NN ligands with the bulky camphyl backbone were synthesized by the stoichiometric reactions of α-diimine ligands with MMe₄ (M = Hf or Zr). All Zr and Hf metal complexes were analyzed using ¹H and ¹³C NMR spectroscopy, and the molecular structures of complexes 1-Zr and 1-Hf were determined by single-crystal X-ray diffraction, revealing that the original α-diimine ligand was selectively reduced into the ene-diamido form and generated an 1,3-diaza-2-metallocyclopentene ring in the metal complexes. Zr complexes 1-Zr and 2-Zr showed moderate activity (up to 388 kg(PE)·mol⁻¹(M)·h⁻¹), poor copolymerization ability, but unprecedented molecular weight capability toward ethylene/1-octene copolymerization. Therefore, copolymers with ultrahigh molecular weights (>600 or 337 × 10⁴ g∙mol⁻¹) were successfully synthesized by 1-Zr or 2-Zr, respectively, with the borate cocatalyst [Ph₃C][B(C₆F₅)₄]. Surprisingly, Hf complexes 1-Hf and 2-Hf showed negligible activity under otherwise identical conditions, revealing the great influence of metal centers on catalytic performances.