Olefin Polymer Fiber High Tenacity Processability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current high density polyethylene (HDPE) technologies face challenges in balancing mechanical properties like high tenacity and processibility for high strength fiber applications, as catalysts such as Zeigler-Natta and metallocene catalysts either prioritize tenacity at the expense of processibility or vice versa, resulting in inferior performance for fiber products.
Innovation Solution
Development of an olefin-based polymer using a supported metallocene catalyst with a density of 0.94-0.96 g/cm³, melt index of 0.1-1.5 g/10min, and polydisperse index of 2-7, which allows for high drawing ratios and tenacity while maintaining superior processibility, achieved through optimized molecular weight distribution and catalyst support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallocene catalyst is used to prepare high density polyethylene, then tenacity is improved, but processibility deteriorates
Solution Approach 1:
The patent modifies the catalyst system parameters by introducing a specific support material (silica or alumina) with controlled surface area (100-1000 m²/g) and chemical composition to the metallocene catalyst. This parameter change allows the catalyst to produce polyethylene with optimized molecular weight distribution (polydisperse index of 2-7) that simultaneously achieves high tenacity (9-12 gf/denier) and good processibility, resolving the contradiction between these two properties
Solution Approach 2:
The patent creates a composite catalyst system by combining metallocene catalyst with support materials (silica or alumina). This composite approach allows the catalyst to exhibit both the high tenacity production capability of metallocene and the processibility enhancement provided by the support material's physical and chemical properties, thereby achieving both improved tenacity and maintained processibility
2Ease of manufacture
If Zeigler-Natta catalyst or chromium catalyst is used to prepare high density polyethylene, then processibility is improved, but tenacity deteriorates
Solution Approach 1:
The patent changes the catalyst type parameter from conventional Zeigler-Natta or chromium catalysts to supported metallocene catalyst with specific support characteristics. This parameter change results in polyethylene with controlled molecular weight distribution (polydisperse index of 2-7) that achieves both good processibility and high tenacity (9-12 gf/denier), eliminating the need to choose between these two properties
3Strength
If molecular weight distribution is made narrower to improve drawing ratio, then tenacity is improved, but processibility deteriorates
Solution Approach 1:
The patent optimizes the molecular weight distribution parameter by controlling the polydisperse index to be within 2-7 through the supported metallocene catalyst system. This optimized parameter range allows the polymer to achieve high drawing ratio (7-14 times) and high tenacity (9-12 gf/denier) while maintaining adequate processibility, resolving the contradiction between narrow distribution benefits and processing capability
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 olefin-based polymer achieves a tenacity of 9-12 gf/denier and drawing ratio of 7-14 times, enhancing both mechanical properties and processibility, making it suitable for high strength fiber production without the limitations of existing catalysts.
Implementation Method 1
polymerizing an olefin-based monomer in the presence of a supported metallocene catalyst
Data Source
AI summary
The present invention is related to an olefin-based polymer and a fiber including the same. Specifically, the olefin-based polymer according to the present invention is characterized in that 1) the density is 0.94 ∼ 0.96 g/cm3, 2) the melt index (MI; 190°C. 2.16kg) is 0.1 - 1.5 g/10min, and 3) the polydisperse index (PDI; Mw/Mn) is 2 - 7, and the olefin-based polymer may be prepared by using a supported metallocene catalyst. The olefin-based polymer according to the present invention can prepare a fiber showing the characteristics of high drawing and high tenacity.