Butene-1 Polymer Composition High Melt Flow Rate
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Solution Overview
Problem
Butene-1 polymers with high melt flow rates face challenges in achieving specific property profiles for various applications, such as adhesion force, temperature resistance, and melt viscosity, due to their crystallinity and molecular weight distribution, which are not adequately addressed by existing technologies.
Innovation Solution
A butene-1 polymer composition is developed by combining two butene-1 polymers with different comonomer contents, specifically up to 5% and 6-20% by mole, to achieve a unique profile of properties, including high melt flow rates, low crystallinity, and improved rheological and mechanical properties, without using free radical generating agents, thereby enhancing fluidity and adhesion characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If butene-1 polymers with high melt flow rate are used, then fluidity in molten state is improved, but crystallinity and mechanical properties deteriorate
Solution Approach 1:
The patent combines two different butene-1 polymers (first and second polymers) with distinct comonomer contents and molecular weight characteristics into a single composition. This merging allows the composition to exhibit both high fluidity (from the second polymer with higher comonomer content) and good mechanical properties (from the first polymer with lower comonomer content), resolving the contradiction between ease of operation and strength.
Solution Approach 2:
The invention creates a composite polymer composition by blending two butene-1 polymers with different compositional characteristics. The first polymer (with 1-10 mol% comonomer) provides structural integrity and mechanical strength, while the second polymer (with 11-20 mol% comonomer) contributes to fluidity and processability. This composite approach allows simultaneous achievement of contradictory properties.
2Productivity
If free radical generating agents are used to increase MFR, then melt flow rate is improved, but chemical contamination and odor worsen
Solution Approach 1:
The patent extracts and eliminates the need for free radical generating agents (such as peroxides) from the polymerization process. Instead of using chemical agents to increase MFR, the invention achieves high melt flow rates through physical blending of polymers with different comonomer contents and molecular weight distributions. This removal of harmful chemical agents resolves the contradiction between productivity improvement and reduction of harmful factors.
Solution Approach 2:
The invention converts the potential harm of chemical contamination into a benefit by using a purely physical blending approach. Rather than relying on chemical reactions that introduce contaminants, the patent utilizes the beneficial effects of combining polymers with different properties, transforming what would be a harmful chemical process into a beneficial physical mixing process that achieves the same MFR enhancement without side effects.
3Ease of operation
If comonomer content is increased to improve fluidity, then melt flow rate is improved, but crystallinity and tensile properties worsen
Solution Approach 1:
The patent applies local quality by assigning different comonomer content levels to different polymer components within the composition. The first polymer contains 1-10 mol% comonomer (optimized for mechanical properties), while the second polymer contains 11-20 mol% comonomer (optimized for fluidity). Each component has locally optimized quality for its specific function, and their combination achieves overall performance that neither component could achieve alone.
Data Source
AI summary
A butene-1 polymer composition having MFR values of from 400 to 2000 g/10 min, measured according to ISO 1133 at 190°C with a load of 2.16 kg, comprising: A) a butene-1 homopolymer or a copolymer of butene-1 with one or more comonomers selected from ethylene and higher alpha-olefins, having a copolymerized comonomer content of up to 5% by mole; B) a copolymer of butene-1 with one or more comonomers selected from ethylene and higher alpha-olefins, having a copolymerized comonomer content of from 6% to 20% by mole; said composition having a total copolymerized comonomer content from 4% to 15% by mole, referred to the sum of A) and B), and a content of fraction soluble in xylene at 0°C of 60% by weight or less, determined on the total weight of A) and B).