Butene-1 Polymer Composition for High Melt Flow Rate
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Solution Overview
Problem
Butene-1 polymers with high melt flow rates lack an optimal combination of properties for applications in films and fibers, requiring a balance of fluidity, mechanical strength, and crystallinity, which existing technologies fail to achieve without chemical contamination from free radical generating agents.
Innovation Solution
A butene-1 polymer composition with specific comonomer contents and molecular weight distributions, achieved using a metallocene catalyst system, which enhances melt flow rate, tensile properties, and crystallinity without the need for free radical generating agents, allowing for blending with other polyolefins and use in hot-melt compositions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If free radical generating agents like peroxides are used to increase MFR value, then melt flow rate is improved, but chemical contamination and unpleasant odor occur
Solution Approach 1:
The invention removes harmful free radical generating agents from the polymerization process while maintaining high MFR through controlled copolymer composition and molecular weight distribution, thereby eliminating chemical contamination and odor
Solution Approach 2:
The invention achieves high MFR by changing fundamental polymer parameters - specifically comonomer content (4-15% by mole) and molecular weight distribution (Mw/Mn ≤ 4) - rather than using chemical additives, thus improving productivity without contamination
2Productivity
If comonomer content is increased to improve fluidity, then melt flow rate is improved, but crystallinity may be reduced
Solution Approach 1:
The invention optimizes comonomer content to a specific range (4-15% by mole) that balances fluidity and crystallinity, achieving MFR ≥ 20 g/min while maintaining measurable crystallinity, unlike higher comonomer contents that would reduce crystallinity
Solution Approach 2:
The invention creates a composite polymer structure combining butene-1 homopolymer and copolymer components with different comonomer contents (CA ≤ 5% and CB = 6-20%), achieving both fluidity and crystallinity through compositional synergy
3Productivity
If molecular weight is reduced to increase melt flow rate, then fluidity is improved, but tensile properties may deteriorate
Solution Approach 1:
The invention changes molecular weight distribution parameters (Mw/Mn ≤ 4 and Mw ≤ 300,000) to achieve high MFR while maintaining adequate tensile properties through optimized chain length distribution rather than simply reducing molecular weight
Solution Approach 2:
The invention creates local quality variations in the polymer structure through specific comonomer distribution and molecular weight distribution, achieving high fluidity in the melt state while maintaining structural integrity for tensile properties in the solid state
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition achieves high fluidity, low hardness, and measurable crystallinity, making it suitable for films, fibers, and hot-melt adhesives, while avoiding chemical contamination and maintaining desirable mechanical properties.
Implementation Method 1
which is made possible by using a metallocene catalyst
Implementation Method 2
while still retaining a measurable crystallinity
Data Source
AI summary
A butene-1 polymer composition having MFR values of from 20 to less than 100 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 75% by weight or less, determined on the total weight of A) and B).