Ethylene Polymer Particle Composition for Flowable Stretch Molding
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Solution Overview
Problem
Current methods for producing ultrahigh molecular weight ethylenic polymer particles face challenges with poor flowability, leading to issues like fouling, coarse particle formation, and increased production costs, which affect the industrial productivity and physical properties of the final product.
Innovation Solution
The development of ethylenic polymer particles with specific surface areas, intrinsic viscosities, and bulk densities, along with the use of a compound with a molecular backbone and magnesium content, enhances flowability and inhibits fouling, allowing for improved stretch moldability and bindability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultrahigh molecular weight ethylenic polymer is used, then impact resistance and strength are improved, but flowability deteriorates
Solution Approach 1:
The patent changes the molecular weight parameter of the ethylenic polymer to a specific range (intrinsic viscosity 6-30 dl/g) to optimize both strength and flowability. This parameter optimization allows the polymer to maintain high impact resistance while achieving sufficient flowability for molding operations.
2Ease of manufacture
If solid phase stretch molding is used, then molding capability is improved, but coarse particle formation occurs
Solution Approach 1:
The patent optimizes the particle size parameters (median diameter 20-700 μm, specific surface area 0.5-5.0 m²/g) of the ethylenic polymer particles to prevent coarse particle formation during solid phase stretch molding. This ensures uniform feeding and molding while maintaining the molding capability.
3Productivity
If polymerization is conducted without fouling inhibition, then productivity is improved, but coarse particles and fouling increase
Solution Approach 1:
The patent introduces a specific polymerization catalyst system (Ziegler-Natta catalyst with specific components and ratios) as an intermediary to control the polymerization process. This catalyst system enables high productivity while preventing fouling and coarse particle formation by controlling the polymerization kinetics and particle morphology.
4Ease of operation
If powder transfer is performed with coarse particles, then material handling is simplified, but feed uniformity deteriorates
Solution Approach 1:
The patent optimizes the particle size distribution parameters (median diameter 20-700 μm, specific surface area 0.5-5.0 m²/g) to achieve a balance between material handling ease and feed uniformity. The controlled particle size distribution prevents coarse particle aggregation while maintaining free-flowing characteristics for uniform powder transfer and feeding.
Data Source
AI summary
One embodiment of the present invention is an ethylenic polymer particle, having a specific surface area of larger than 2.00 m2/g and 30.0 m2/g or smaller, as determined by a BET method from the adsorption/desorption isotherms measured by a nitrogen gas adsorption method, and a median diameter (D50) of 20 µm or larger and 700 pm or smaller as determined by laser diffraction/scattering.