Olefin-Based Copolymer Branch Gradient Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing olefin-based polymers prepared using conventional catalysts face challenges such as poor processability, difficulty in achieving homogeneous mixing of catalyst components, and limited control over physical properties like tensile strength and elongation, especially when producing bimodal copolymers with high molecular weight and specific density ranges.
Innovation Solution
An olefin-based copolymer with specific elution temperatures (Te1 and Te2) and branch gradient number (BGN) ranges is developed using a transition metal compound with a cyclopentadienyl ligand connected via a phenylene bridge and an amido group, allowing for high molecular weight and narrow molecular weight distribution, enhancing mechanical properties and processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a copolymer is prepared using CGC catalyst, then high molecular weight and improved physical properties are achieved, but processability deteriorates
Solution Approach 1:
The patent divides the polymer into two distinct components with different molecular weights and comonomer contents. The first component has high molecular weight and high comonomer content, while the second component has low molecular weight and low comonomer content. This segmentation allows each component to contribute different properties, resolving the contradiction between strength and processability.
Solution Approach 2:
The patent creates local quality differences within the copolymer by having different comonomer insertion ratios and molecular weights in different portions of the polymer. The high comonomer content regions provide flexibility and impact strength, while low comonomer content regions provide processability and structural integrity.
2Productivity
If a bimodal copolymer is prepared in a single reactor, then production efficiency is improved, but homogeneous mixing of catalyst components becomes difficult
Solution Approach 1:
The patent uses a dynamic catalyst system where the metallocene catalyst's activity and selectivity change over time during the polymerization reaction. This dynamic behavior allows the catalyst to produce different polymer components at different stages, achieving bimodal distribution in a single reactor without requiring complex mixing of multiple catalysts.
Solution Approach 2:
The patent achieves different polymer components by changing reaction parameters such as comonomer concentration, temperature, and catalyst activity during the polymerization process. These parameter changes allow the formation of high molecular weight and low molecular weight components in sequence within the same reactor.
3Reliability
If a supported hybrid catalyst is used, then catalyst activity is reduced, but preparation of olefin-based polymer with appropriate properties becomes difficult
Solution Approach 1:
The patent extracts the metallocene catalyst from the supported hybrid catalyst system and uses it as a homogeneous catalyst instead. This eliminates the activity reduction associated with supported catalysts while maintaining the ability to produce polymers with appropriate properties through controlled reaction conditions.
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 resulting polymer exhibits improved tensile strength, elongation, and mechanical properties, suitable for diverse applications including automotive, construction, and daily supplies, with controlled physical properties and reduced molecular weight distribution.
Implementation Method 1
polymerizing an olefin-based monomer using a catalyst composition comprising a transition metal compound
Implementation Method 2
an elution temperature 1 (Te1) and an elution temperature 2 (Te2), which are elution temperatures of the olefin-based polymer in a temperature range from -20°C to 130°C when measuring temperature rising elution fractionation (TREF)
Implementation Method 3
a branch gradient number (BGN) in the range from -1.0 to -0.001 when measured by chromatography Fourier transform infrared spectroscopy (GPC FT-IR)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to an olefin-based polymer which comprises an elution temperature 1 (Te1) and an elution temperature 2 (Te2) constituting olefin-based polymer elution temperatures in a temperature range of between -20 and 130 DEG C during temperature rising elution fractionation (TREF) measurement, and of which the branch gradient number (BGN) during GPC FT-IR measurement is in a range of between -1.0 and -0.001.