Ethylene-α-olefin-polyene copolymer processability
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Solution Overview
Problem
Conventional ethylene-α-olefin-nonconjugated polyene copolymers do not adequately satisfy both roll kneading processability and extrusion processability, which are essential for producing polymer compositions like rubber hoses.
Innovation Solution
An ethylene-α-olefin-nonconjugated polyene copolymer with specific molecular weight ratios, iodine values, and intrinsic viscosities is developed, incorporating ethylene, α-olefin, and nonconjugated polyene units, optimized for improved roll kneading and extrusion processability through precise polymerization conditions and catalyst composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional ethylene-α-olefin-nonconjugated polyene copolymer is used, then basic polymer properties are maintained, but roll kneading processability and extrusion processability are insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling multiple polymer properties including intrinsic viscosity (0.5-1.8 dl/g), molecular weight ratios (Mz/Mn: 15-25, Mw/Mn: 3-5), iodine value (1-50), and monomer composition ratios. These parameter optimizations resolve the contradiction by enabling both good roll kneading processability and extrusion processability simultaneously, which conventional polymers could not achieve.
2Ease of operation
If polymer composition is optimized for roll kneading processability, then mixing ease improves, but extrusion processability deteriorates
Solution Approach 1:
The patent resolves this contradiction through coordinated parameter changes: controlling intrinsic viscosity at 0.5-1.8 dl/g for kneading ease, while simultaneously optimizing Mz/Mn (15-25) and Mw/Mn (3-5) ratios for extrusion performance. The specific iodine value range (1-50) and monomer composition further balance these competing requirements.
Solution Approach 2:
The patent creates a composite polymer structure incorporating ethylene units, α-olefin units, and nonconjugated polyene units in specific ratios. This composite composition enables the material to exhibit both good roll kneading characteristics and extrusion processability, resolving the contradiction between these two manufacturing requirements.
3Strength
If molecular weight is increased to improve mechanical properties, then strength increases, but processability decreases
Solution Approach 1:
The patent resolves this contradiction by changing molecular weight parameters strategically: controlling Mz/Mn ratio (15-25) and Mw/Mn ratio (3-5) to achieve a balanced molecular weight distribution. This enables the polymer to have sufficient strength while maintaining good processability in both roll kneading and extrusion operations.
Data Source
AI summary
Provided is an ethylene-α-olefin-nonconjugated polyene copolymer having ethylene units, α-olefin units and nonconjugated polyene units, wherein the copolymer satisfies the following requirements: (A): the intrinsic viscosity [η] is 0.5 to 1.8 dl/g, (B): the content of ethylene units is 50 to 90 mol % and the content of α-olefin units is 50 to 10 mol % where the sum total of the contents of ethylene units and α-olefin units is taken as 100 mol %, (C): the iodine value is 1 to 50, (D): the ratio of tan δ taken at 100° C. and 2 cpm to tan δ taken at 100° C. and 1000 cpm is from 1.0 to 1.7, and (E): the ratio of the Z-average molecular weight to the number average molecular weight is from 15 to 25 and the weight average molecular weight to the number average molecular weight is from 3 to 5.