Butene-1 Polymer High Melt Flow Rate Metallocene Catalyst
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Solution Overview
Problem
Butene-1 polymers with high melt flow rates lack optimal molecular weight distribution and glass transition temperature, limiting their application in films and fibers, and require the use of free radical generating agents that introduce chemical contamination and unpleasant odors.
Innovation Solution
A butene-1 polymer with a specific melt flow rate, intrinsic viscosity, molecular weight distribution, and glass transition temperature, produced using a metallocene catalyst system without free radical generating agents, allowing for improved properties and reduced contamination.
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 are introduced
Solution Approach 1:
The invention extracts and eliminates the harmful free radical generating agents (peroxides) from the polymerization process while maintaining the desired high melt flow rate through alternative catalytic systems, thereby removing the source of chemical contamination and odor
Solution Approach 2:
The invention changes the fundamental parameters of the polymerization process by using metallocene catalysts with specific molecular structures and activation methods, achieving high MFR through catalyst design rather than post-polymerization treatment with harmful agents
2Ease of manufacture
If molecular weight distribution is not properly controlled, then polymerization is simpler, but final polymer properties are suboptimal
Solution Approach 1:
The invention changes the molecular weight distribution parameters through precise control of metallocene catalyst structure and activation conditions, achieving narrow MWD (Mw/Mn ≤ 3.5) that delivers optimal polymer properties while maintaining manufacturing simplicity
Solution Approach 2:
The invention implements feedback control through careful selection of catalyst ligand structures and activation methods that inherently produce the desired molecular weight distribution, allowing real-time adjustment of polymerization conditions to maintain optimal properties
3Ease of manufacture
If glass transition temperature is not optimized, then polymer synthesis is easier, but application performance in films and fibers is limited
Solution Approach 1:
The invention changes the glass transition temperature parameter to -18°C or lower through specific metallocene catalyst design and polymerization conditions, enabling the polymer to exhibit optimal flexibility and processability for film and fiber applications while maintaining ease of synthesis
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 polymer exhibits low hardness, high elongation at break, and low glass transition temperature, enhancing its suitability for films, fibers, and hot-melt adhesives while avoiding chemical contamination and odor issues.
Implementation Method 1
produced using a metallocene catalyst system
Data Source
AI summary
A butene-1 polymer having: a) a Melt Flow Rate value 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; • b) an intrinsic viscosity (IV) measured in tetrahydronaphthalene (THN) at 135°C equal to lower than 0.95 dl/g; • c) a Mw/Mn value equal to or lower than 3.5, the lower limit being of 1.5; • d) a Mz value of 180,000 g/mol or higher; • e) a comonomer content, when comonomer is present, of up to 5% by weight.