Liquid Ethylene Copolymer Polymerization Process

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Solution Overview

Problem

Existing polymerization processes for ethylene copolymers are not continuous, stable, or scalable, and they often require solvents, resulting in low acrylate content and high viscosity, which limits their application in coating materials.

Innovation Solution

A continuous high-pressure polymerization process that uses a monomer feed of ethylene and reactive acrylates in the presence of at least 2 wt% chain transfer agents, conducted in stirred high-pressure autoclaves or tube reactors, to produce a liquid ethylene copolymer with high acrylate content and low viscosity, suitable for solvent-free coating materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If existing polymerization processes are used, then ethylene copolymers can be produced, but the processes are not continuous, stable, or scalable and require solvents resulting in low acrylate content and high viscosity

Engineering Contradiction:

Improvecontinuous production capacityVSAvoidprocess stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements a continuous high-pressure polymerization process where monomer feed is continuously introduced into the reactor system, allowing uninterrupted production of ethylene copolymer. This eliminates batch-to-batch variations and enables scalable operation while maintaining consistent acrylate content and viscosity characteristics.

Inventive Principle:

Principle #20Continuity of useful action

2Ease of manufacture

If solvents are used in polymerization, then the process can proceed, but the acrylate content decreases and viscosity increases

Engineering Contradiction:

ImproveprocessabilityVSAvoidacrylate content

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent extracts and eliminates solvents from the polymerization system by conducting the reaction in neat monomers under high pressure. This removal of solvent phase allows for higher acrylate content in the copolymer while maintaining processability through controlled high-pressure conditions and chain transfer agent optimization.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If solvents are used in polymerization, then the process can proceed, but the viscosity of the copolymer increases

Engineering Contradiction:

ImproveprocessabilityVSAvoidviscosity

Core Design Contradiction:

Ease of manufactureVSStress or pressure

Solution Approach 1:

The patent changes the pressure parameter to high pressure conditions, enabling solvent-free polymerization that produces copolymers with lower viscosity. The high pressure facilitates monomer reactivity and polymer chain formation without solvent, while chain transfer agents control molecular weight and viscosity characteristics.

Inventive Principle:

Principle #35Parameter changes

4Quantity of substance

If high acrylate content is achieved, then coating material performance improves, but viscosity increases limiting application

Engineering Contradiction:

Improveacrylate contentVSAvoidviscosity

Core Design Contradiction:

Quantity of substanceVSStress or pressure

Solution Approach 1:

The patent utilizes high pressure parameters during polymerization to produce copolymers with high acrylate content while maintaining low viscosity. The pressure conditions control the polymerization kinetics and chain structure, enabling simultaneous achievement of high functionality and low viscosity suitable for coating applications.

Inventive Principle:

Principle #35Parameter changes

5Productivity

If continuous polymerization is implemented, then productivity increases, but process control complexity increases

Engineering Contradiction:

Improveoutput rateVSAvoidprocess control system

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent employs a high-pressure reactor system that serves multiple functions: it provides continuous mixing, heat control, and pressure maintenance in a single integrated apparatus. This multi-functionality enables continuous operation with enhanced productivity while managing control complexity through consolidated process equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 process achieves a high space-time yield, high acrylate content, and low viscosity ethylene copolymers, enabling the production of coating materials with high solid content and improved applicability, particularly in automotive and commercial vehicle coatings.

Implementation Method 1

where a monomer feed comprising the ethylene and the reactive acrylate is polymerized in the presence of at least 2 wt % of a chain transfer agent

Methodology Applied

Scientific EffectChain transfer:

Data Source

PatentUS11608393B2Polymerization process for liquid copolymers of ethylene and hydroxyalkyl(meth)acrylate

Publication Date: 2023.03.21 BASF SE

AI summary

The present invention relates to a continuous high-pressure polymerization process for the preparation of a liquid ethylene copolymer which comprises in polymerized for methylene; and a reactive acrylate which is selected from hydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylate, and hydroxybutyl (meth)acrylate, where a monomer feed comprising the ethylene and the reactive acrylate is polymerized in the presence of at least 2 wt % of a chain transfer agent. The present invention also relates to the liquid ethylene copolymer, to a coating material comprising the liquid ethylene copolymer and to a use of the liquid ethylene copolymer to produce a coating material.