Solid Organic Peroxide Composition for Non-Inert Polypropylene Extrusion
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Solution Overview
Problem
Existing processes for producing high melt strength polypropylene (HMS-PP) using organic peroxides face challenges such as degradation, discoloration, and safety hazards when extruded under non-inert conditions, and require complex and costly inert atmospheres, which are not practical for recycling applications.
Innovation Solution
An organic peroxide composition in solid form comprising specific organic peroxides, a water retaining agent, and water, which allows for extrusion under non-inert conditions without degradation or discoloration, and is safer and easier to handle, maintaining high melt strength properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If organic peroxides are used to produce high melt strength polypropylene under non-inert extrusion conditions, then the process complexity and cost are reduced, but the polypropylene product becomes discoloured, shows signs of degradation, and has inferior melt strength properties
Solution Approach 1:
A nitrogen atmosphere is introduced as an intermediary medium in the extrusion process. This inert gas environment protects the polypropylene from oxidative degradation while maintaining process simplicity, achieving both reduced complexity and reliable melt strength properties
Solution Approach 2:
The extrusion parameters are optimized including temperature profile control and nitrogen flow rate adjustment. By carefully controlling these parameters, the process achieves high melt strength properties without requiring complex equipment modifications
2Object-affected harmful factors
If water-containing organic peroxide formulations are used, then safety is improved by reducing friction and impact sensitivity, but the risk of explosion increases if water evaporates and peroxide concentration increases
Solution Approach 1:
Nitrogen gas serves as an intermediary protective atmosphere during extrusion. It prevents unintended oxidation and decomposition of the peroxide while allowing the water-containing formulation to maintain its safety benefits without explosion risk
Solution Approach 2:
The formulation is designed with water as a cushioning agent that prevents friction and impact sensitivity. The nitrogen atmosphere provides beforehand protection against any potential peroxide concentration increase, cushioning against explosion risk before it can occur
3Strength
If dialkyl peroxydicarbonates are used to improve melt strength, then long chain branches are created and melt strength increases, but the decomposition products evaporate and condense on other surfaces causing fogging
Solution Approach 1:
Nitrogen atmosphere acts as an intermediary that captures and contains the alcoholic decomposition products. These products dissolve in the nitrogen environment without evaporating and condensing on external surfaces, thus preventing fogging while maintaining melt strength enhancement
Solution Approach 2:
The decomposition products that would normally cause harmful fogging are converted into a beneficial dissolved state in the nitrogen atmosphere. This transforms a harmful evaporation- condensation process into a controlled dissolution process that maintains both melt strength and clarity
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 composition enables the production of polypropylene with maintained melt strength and safety under non-inert extrusion conditions, reducing the risk of explosion and improving handling, making it suitable for polypropylene recycling.
Implementation Method 1
b) at least one water retaining agent that is a solid at room temperature
Implementation Method 2
The treatment with peroxide creates long chain branches. The more long chain branches, the higher the melt strength.
Implementation Method 3
At higher temperatures, the decomposition product of the dialkyl peroxydicarbonate—i.e. alcohols such as cetyl alcohol, myristyl alcohol, and 4-tert-butylcyclohexanol—tend to evaporate from the HMS-PP and condense on other surfaces
Implementation Method 4
the alcoholic decomposition product may evaporate and condense on the package's lid or the microwave window
Data Source
AI summary
An organic peroxide composition in solid form comprisesa) at least one organic peroxide of the formulawherein each R is individually chosen from Cis alkyl groups;b) at least one water retaining agent that is a solid at room temperature; andc) water.