Polymer Composition Compatibilization for Melt Flow and Impact Balance
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Solution Overview
Problem
Existing methods to increase the melt flow rate of polymer resins often compromise impact resistance, making it difficult to achieve desired processing temperatures and throughputs while maintaining suitable polymer properties for various applications.
Innovation Solution
A method involving the use of a compatibilizing agent, such as an ester compound derived from a polyol with three or more hydroxy groups and an aliphatic carboxylic acid with carbon-carbon double bonds, combined with a peroxide compound, to enhance the melt flow rate of thermoplastic polymers while preserving or improving impact resistance, by processing these components in a melt mixing apparatus above the melting point of the polymer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the molecular weight of the polyolefin polymer is decreased to increase the melt flow rate, then the melt flow rate is improved, but the impact resistance of the polymer is significantly lowered
Solution Approach 1:
The patent introduces a compatibilizing agent as an intermediary substance that mediates between the polymer chains and the peroxide compound. This compatibilizing agent contains functional groups that can react with both the polymer and the peroxide, facilitating controlled degradation while maintaining impact resistance. The compatibilizing agent acts as a bridge that enables the desired chemical modification without the harmful side effects of direct peroxide-polymer interaction.
Solution Approach 2:
The patent changes the chemical parameters of the system by introducing specific functional groups (carboxylic acid groups) that can interact with the peroxide compound. By modifying the chemical composition and introducing reactive functional groups, the patent achieves controlled molecular weight reduction while preserving the structural integrity needed for impact resistance. The parameter change involves transitioning from direct peroxide-polymer reaction to a mediated reaction through compatibilizing agents with specific chemical properties.
2Productivity
If higher processing temperatures are used to compensate for low melt flow rate, then the desired throughput can be achieved, but the polymer may undergo excessive degradation and lose its mechanical properties
Solution Approach 1:
The patent changes the chemical reactivity parameters of the system by introducing peroxide compounds and compatibilizing agents. This chemical modification enables melt flow rate enhancement at lower processing temperatures, thereby avoiding thermal degradation. The parameter change involves shifting from thermal control to chemical control of the degradation process, allowing precise management of molecular weight reduction without excessive heat exposure.
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
This approach effectively increases the melt flow rate of polymer compositions while maintaining or enhancing impact resistance, allowing for more efficient processing and broader application suitability without the typical trade-offs seen in prior technologies.
Implementation Method 1
melt-blending the resin in an extruder with a compound capable of generating free radicals, such as a peroxide
Implementation Method 2
The weight average molecular weight of the polymer is reduced and the MFR is increased
Implementation Method 3
providing a compatibilizing agent, the compatibilizing agent comprising an ester compound formally derived from a polyol comprising three or more hydroxy groups and an aliphatic carboxylic acid comprising one or more carbon-carbon double bonds
Implementation Method 4
processing the thermoplastic polymer, the compatibilizing agent, and the peroxide compound in the melt mixing apparatus at a temperature that exceeds the melting point of the thermoplastic polymer
Data Source
AI summary
A method for making a polymer composition comprises the steps of providing a thermoplastic polymer, providing a compatibilizing agent, providing a peroxide compound, and melt mixing the thermoplastic polymer, compatibilizing agent, and peroxide compound. The compatibilizing agent comprises an ester compound formally derived from a polyol comprising three or more hydroxy groups and an aliphatic carboxylic acid comprising one or more carbon-carbon double bonds. A masterbatch composition comprises a thermoplastic binder, a peroxide compound, and an ester compound. A concentrate composition comprises an antioxidant and an ester compound.