Filled Polymer Compositions with Low Viscosity and Adhesion
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Solution Overview
Problem
Highly filled ethylene-based polymer compositions face challenges in balancing flow, mechanical, and adhesion properties, particularly when used as substrates for paint or coatings, as high filler loadings increase viscosity and reduce flow properties, while plasticizers improve flow but compromise mechanical and adhesion properties.
Innovation Solution
A composition comprising anhydride functionalized ethylene-based polymer with specific density, melt viscosity, and melt index, combined with fillers, which enhances mechanical properties and adhesion, allowing for improved balance of flow and mechanical properties, and suitable for use as substrates with paint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high filler loadings are used to improve mechanical properties and abrasion resistance, then mechanical properties are improved, but viscosity increases and flow properties are reduced
Solution Approach 1:
The patent applies parameter changes by carefully controlling the melt index of the ethylene-based polymer within a specific range (50-500 g/10min) and optimizing the filler loading level (10-60 wt%). By adjusting these parameters, the composition achieves a balance where high filler content improves mechanical properties while the controlled polymer flow characteristics prevent excessive viscosity increase, maintaining processability.
2Object-generated harmful factors
If plasticizers such as oils are added to reduce viscosity and improve flow characteristics, then flow properties are improved, but mechanical properties and adhesion properties deteriorate
Solution Approach 1:
The patent applies the extraction principle by completely eliminating plasticizers such as oils from the composition. Instead of using plasticizers to reduce viscosity, the invention relies on selecting an ethylene-based polymer with appropriate melt index characteristics (50-500 g/10min) that inherently provides the desired flow properties without compromising mechanical strength or adhesion when combined with fillers.
3Object-generated harmful factors
If plasticizers are added to improve flow characteristics, then flow properties are improved, but adhesion properties are reduced
Solution Approach 1:
The patent removes plasticizers from the composition entirely, using instead an ethylene-based polymer with controlled melt index (50-500 g/10min) that provides adequate flow characteristics without the adhesion penalties associated with plasticizer addition. This extraction of harmful substances maintains adhesion properties while achieving processability.
4Strength
If high filler loadings are used to improve abrasion and scratch resistance, then surface durability is improved, but viscosity increases reducing processability
Solution Approach 1:
The patent applies parameter changes by optimizing the melt index of the ethylene-based polymer to fall within 50-500 g/10min and controlling filler loading to 10-60 wt%. This parameter optimization ensures that high filler loadings can be used to achieve improved abrasion and scratch resistance while the controlled polymer flow characteristics maintain adequate processability and ease of manufacture.
Data Source
AI summary
The invention provides a composition comprising the following: A) a first polymer composition comprising an anhydride functionalized ethylene-based polymer, and optionally, an ethylene-based polymer; B) a filler; and wherein the anhydride functionalized ethylene-based polymer has a density from 0.855 g/cc to 0.900 g/cc and a melt viscosity, at 177°C, from 1000 to 50,000 cP.