Butene-1 Terpolymer Catalyst and Composition for UFH Pipes
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Solution Overview
Problem
Butene-1 polymers used in pipes for Under Floor Heating applications lack sufficient pressure and temperature resistance combined with flexibility and elasticity, and existing production methods result in high catalyst residues and unsatisfactory mechanical properties.
Innovation Solution
Development of a butene-1 terpolymer with specific compositions of propylene and ethylene units, processed using a stereospecific catalyst system involving Ti compounds and alkylaluminum components, to achieve improved mechanical properties and reduced catalyst residues, including a bimodal molecular weight distribution and tailored melt flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If TiCl3 based catalysts are used for polymerization, then polymerization can be achieved, but the yield is low and catalyst residues are high (more than 300 ppm of Ti)
Solution Approach 1:
The patent changes the catalyst system parameters from TiCl3 based catalysts to stereospecific catalysts comprising Ti compounds supported on MgCl2 with specific electron-donor compounds. This parameter change increases polymerization yield and reduces catalyst residues below 300 ppm of Ti, eliminating the need for deashing step
Solution Approach 2:
The patent extracts and removes the harmful TiCl3 based catalyst system and replaces it with a stereospecific catalyst system supported on MgCl2. This extraction of the problematic catalyst component eliminates the high catalyst residue issue while maintaining high polymerization yield
2Strength
If conventional butene-1 (co) polymers are used, then pressure and creep resistance are achieved, but flexibility and elasticity are insufficient
Solution Approach 1:
The patent changes the compositional parameters by incorporating specific amounts of propylene (0.5-13 mol%) and ethylene (0.5-3 mol%) units into the butene-1 polymer structure. This compositional modification maintains pressure and creep resistance while significantly improving flexibility and elasticity for UFH applications
Solution Approach 2:
The patent creates a composite polymer structure by combining butene-1, propylene, and ethylene units in specific proportions. This composite terpolymer structure integrates the strength characteristics of butene-1 with the flexibility contributions from propylene and ethylene units, achieving balanced mechanical properties
3Stress or pressure
If rigid butene-1 (co) polymers are produced with narrow MWD, then pressure resistance is achieved, but flexural modulus is too high
Solution Approach 1:
The patent implements a dynamic and flexible molecular weight distribution (MWD) strategy, producing polymers with broader MWD (Mw/Mn of 4 or higher) compared to conventional narrow MWD polymers. This dynamic MWD control allows the material to exhibit appropriate flexural modulus while maintaining pressure resistance, overcoming the rigidity issue of conventional polymers
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 terpolymer exhibits enhanced pressure and temperature resistance, flexibility, and elasticity, meeting the demanding requirements of Under Floor Heating applications while minimizing catalyst residues and improving overall mechanical performance.
Implementation Method 1
polymerizing the monomers in the presence of a stereospecific catalyst comprising (A) a solid component comprising a Ti compound and an electron-donor compound supported on MgCl2; (B) an alkylaluminum compound
Data Source
AI summary
Butene-1 terpolymers havinga content of propylene derived units of 0.5-13% mol, anda content of ethylene derived units of 1-3% mol,a ratio C3/C2 of the content of propylene and ethylene derived units is of from 1 to 10, said butene-1 terpolymers having a melt flow rate MIE, measured at 190° C./2.16 Kg of from 0.3 to 3 g/10 min, and a molecular weight distribution curve determined by GPC with a ratio Mw/Mn of from 4 to 10, and the portion of molecular weights of 1×105 or lower, accounting for 22% or larger of the total area.