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New High Melt Index (I2) Metallocene Polyethylene Blend for Tough Injection Molding Part Solutions

IP.com Disclosure Number: IPCOM000249729D
Publication Date: 2017-Mar-28
Document File: 4 page(s) / 652K

Publishing Venue

The IP.com Prior Art Database

Related People

Dan Xu: AUTHOR [+4]

Abstract

High Melt Index (MI) (I2) (e.g., 20~50 MI) Low Density (LD) Polyethylene (PE) or LDPE is widely used in injection molding processes for excellent processability (e.g., flowability), good softness and hand feel, and surface smoothness. The higher MI, the better processability and the easier to inject thin wall parts. But high MI LDPE inherently has poor mechanical properties, incurring a high breakage rate of the bottom parts when stacked in the storage and in long distance shipping to consumers. The breakage issue happens for all ranges of high MI LDPE. Typically, the higher the MI and the thinner the parts, the more serious the issue. The new high MI metallocene polyethylene (mPE) grade, Exceed™ 0019 Performance Polymer with an MI of 19 g/10m and a density 0.918 g/cm3 (available from ExxonMobil Chemical Company, Houston, TX) is superior to LDPE in a full range of mechanical properties, including both toughness and stiffness. The high MI enables the grade to be fit into the injection molding process. The density of 0.918 g/cm3 is slightly lower than that of the incumbent LD (0.919 g/cm3) which may contribute to give the same level of softness and hand feel. Additionally, a blend of this Exceed mPE with LDPE improves the toughness (e.g., stress crack resistance in this case) and maintains acceptable levels of processability and surface smoothness and softness. Formulations with 20~60% Exceed 0019IM blending with LDPE were designed to achieve different toughness. DoE was employed to generate a systematic run series, and different processing parameters, such as cabin pressure and die temperature were optimized as well. With this finding, there is a strong commercial potential to broaden the applications with these mPE blending solutions.

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New High Melt Index (I2) Metallocene Polyethylene Blend for Tough Injection Molding Part Solutions

Abstract: High Melt Index (MI) (I2) (e.g., 20~50 MI) Low Density (LD) Polyethylene (PE) or LDPE is widely used in injection molding processes for excellent processability (e.g., flowability), good softness and hand feel, and surface smoothness. The higher MI, the better processability and the easier to inject thin wall parts. But high MI LDPE inherently has poor mechanical properties, incurring a high breakage rate of the bottom parts when stacked in the storage and in long distance shipping to consumers. The breakage issue happens for all ranges of high MI LDPE. Typically, the higher the MI and the thinner the parts, the more serious the issue. The new high MI metallocene polyethylene (mPE) grade, Exceed™ 0019 Performance Polymer with an MI of 19 g/10m and a density 0.918 g/cm3 (available from ExxonMobil Chemical Company, Houston, TX) is superior to LDPE in a full range of mechanical propert...