CA1263793A - Small particle size hydrated alumina as an impact synergist for impact modified vinyl halide polymers - Google Patents

Abstract

ABSTRACT

The invention relates to a method for increasing the impact resistance of a polymeric vinyl halide material which comprises:
incorporating into a polymeric vinyl halide material a) an impact modifier; and b) alumina hydrate having an average particle size of less than about one micron;
in amount which forms a synergistic combination for increasing the impact resistance of said polyvinyl halide material.

Description

1263~9:3 SMALL PARTICLE SIZE HYDRATED ALUMINA
AS AN IMPACT SYNERGIST FOR IMPACT
MODIFIED VINYL HALIDE POLYMERS

BACKGROUND OF THE INVENTION

This divisional application is divided out of parent application serial No. 415,883 filed on November 18, 1982.
The invention of the divisional and parent applications is directed to polymeric vinyl halide formulations and more part-icularly to the use of very fine particle size (less than about 1~ avg.) hydrated alumina to form a synergistic combination with impact modifiers or fillers in polymeric vinyl halide formulat-ions, preferably rigid formulations.
This divisional application is directed to combinations with impact modifiers, while the parent application is directed to combinations with fillers.
Generally, the most commercially important polymeric vinyl halide material is polyvinyl chloride (PVC) and this inven-tion will be described herein in terms of PVC. However, it is to be understood that it is applicable to other polymeric vinyl halide materials, as hereinafter defined.
Fillers are added to polymeric vinyl halide materials primarily to reduce cost and, when used in low concentrations, to provide a scrubbing action and reduce plateout. Generally, when their concentration is high enough to affect physical proper-ties, they increase modulus, decrease tensile strength and elon-gation, and usually decrease impact strength. There are a few ~;2~3'-~93 -la- 24133-613D

fillers, such as fine particle size precipitated, hydrated silicas and ultra-fine, precipitated, coated calcium carbonates that maintain, and even enhance, irnpact strength in rigid PVC
formulations [J. Radosta, 37th ~PE Annual Technical Conference Preprints, pg. 593 (1979)]. These fillers have not gained wide use in -- 12~3~93 ~

exterior rigid PVC applications because of their adverse effect on weatherability.
Hydrated alumina has been gaining acceptance as an additive for use in plastic parts, its low cost along with 5 its flame-retardant and smoke-suppressing characteristics being most widely referred to in the literature (J. Z.
Keating, Plastics Compounding, pg. 23, July/August, 1980).
Most reported uses of hydrated alumina in PVC compounds have been generally limited to plasticized compositions where lO improved flame retardancy is obtained when used in concentrations greater than about 10 parts per hundred of polymer [A. W. Morgan, T. C. Mathis and J. D. Hirchen, 30th SPE Annual Technical Conference Preprints, Chicago, pg. 475 (1972); R. W. Sprague, "Systematic Study of Firebrake ZB as 15 a Fire Retardant in PVC - Part IV Alumina Trihydrate as a Synergist", April, 1973, January, 1975, U. S. Borax Research Corporation, Anaheim, California; C. E. Hoke, ~PE Journal, 29 pg. 36 (May, 19733], but I. Sobolev and E. A. Woychesin, SPE Annual Technical Conference Preprints, pg. 709 (1973) 20 report the use of a 40~ loading of hydrated alumina in a rigid PVC formula as a smoke suppressant and show that the filler did not reduce the impact strength. Further, it has recently been suggested, for example, in U. S. Patent 3,957,723 to Lawson et al U.S. Patent 3,985,706 to Kay, U.S.
25 Patent 4,143,030 to Hartitz, and U.S. Patent 4,147,690 to Rich, that improved flame retardancy and smo~e suppression can be achieved by a synergistic combination of alumina trihydrate with zinc oxide, zinc borate or bizmuth subcarbonate.
It has now been found that extremely fine particle size (less than l~u) hydrated alumina can not only be used as an ~2637'93 additive for PVC which does not reduce the impact strength of the material, but unexpectedly shows a high degree of synergism with conventional impact modifiers to give significant increases in impact strength accompanied by improved processibility and weather-ing, Hydrated alumina has often been called alumina hydrate or alumina trihydrate. The empirical formula is s ~ times written A1203.3H20 because at elevated temperature, it functions as a flame retardant by decomposing to aluminum oxide and water. But this formula is technically incorrect. The product is actually finely divided crystalline aluminum hydroxide with the composit-ion Al (OH)3.

SUMMARY OF THE INVENTION

Very fine particle size (less than about 1~ avg.) hydrated alumina is useful as a filler material in polymeric vinyl halide materials, and when used in combination with impact modifiers ~r fillers, act synergistically to enhance the impact strength of the PVC materials.
According to one aspect of the invention of the parent application there is provided a polymeric vinyl halide composit-ion having improved weatherability and processing characterist-ics which consist essentially of a polymeric vinyl halide material, a filler material and up to 24 phr of hydrated alumina having an average particle size less than 1~.

~a -In accordance with the invention of the present divisional application there is provided a method for increasing the impact resistance of a polymeric vinyl halide material which comprises incorporating in a polymeric vinyl halide material an amount of an impact modifier which is a synthetic high molecular weight polymeric rubbery material and of hydrated alumina having an average particle size less than about 1~ which forms a synergistic combination for increasing the impact resistance of said polyvinyl halide material.
In accordance with the invention of the parent applica-tion there is also provided polymeric vinyl halide compositions having improved weatherability and processing characteristics, comprising a polyvinyl chloride polymer or copolymer, a filler material ~, 12~3793 and hydrated alumina having an average particle size less than 1~.
Preferably, said compositions also contain an impact modifier in an amount sufficient to form a synergistic combination of impact modifier with said hydrated alumina which substantially enhances the impact strength thereof.
Also provided in accordance with the invention of the parent application is a method for improving the weatherability of filled polymeric vinyl halide material which comprises incorporating in a polymeric vinyl halide material containing a reinforcing filler, a hydrated alumina having an average particle size less than about 1~.
There is also provided a composition which is suitable for improving the impact resistance of polymeric vinyl halide material which comprises an impact modifier which is a synthetic high molecular weight polymeric rubbery material and hydrated alumina having an average particle size of less than about 1~ in the relative proportions of said impact modifier and hydrated alumina that is sufficient to form a synergistic combination.
DETAILED DESCRIPTION OF THE INVENTION
Very fine particle size (less than about 1~ avg) hydrated alumina compounded into impact modified rigid PVC formulations gives compositions that surprisingly and unexpectedly exhibit a significant synergistic increase in impact strength. The effect has been demonstrated with a wide variety of impact modifiers generally used in rigid PVC applications.
Torque rheometer and extrusion tests on rigid PVC formu-lations containing such very fine particle size i263793 hydrated alumina show that motor amperage and torques decrease as hydrated alumina concentration increases.
Concurrently, an increase in dynamic heat stability was observed.
Another benefit derived from the use of the very fine particle size hydrated alumina in exterior PVC formulations is improved weatherability with the potential for reducing the amount of titanium dioxide or other fillers that are conventionally used for particular applications.
10 Formulations compounded with various levels of the very fine particle size hydrated alumina in accordance with the invention outperformed those with titanium dioxide alone when exposed to both outdoor and accelerated weathering environments. In addition, formulations using reduced 15 levels of titanium dioxide in conjunction with said hydrated alumina weathered as well as compounds using higher levels of titanium dioxide alone.
As used herein, very fine particle size hydrated alumina means hydrated alumina having an average particle 20 size of less than about l,u and preferably about 0.5~ (0.4 to 0.6~) or less. Generally, if the average particle size of the hydrated alumina is greater than the above limit there will be a deleterious effect on the Izod impact strength of the material.
It is preferred that the particle size distribution of the hydrated alumina be such that there is no substantial percentage of particles which have a particle size greater than about 1~.
The term "Impact Strength" means the Izod Impact 30 Strength as determined in accordance with the procedures of ASTM D-256. Generally, this test is conducted by preparing 1263~93 samples measuring 2-1/2 x 1/2 x 1/~ or 1/4 inch in dimension, notching the speciments as specified, and impacting the specimens vertically supported in the cantilever beam impact test with a pendulum hammer. The 5 energy absorbed in the width of the sample is transmitted to a range scale which registers the force in pounds from which is calculated the impact strength in foot pounds/inch of notch.
The term "polymeric vinyl halide" means homopolymers lO and copolymers derived from a vinyl halide as well as polymer blends containing said homopolymer or copolymer as a component. The homopolymers, copolymers and polymer blends containing a vinyl halide useful in the practice of this invention include for example, (1) polyvinyl chloride, 15 polyvinylidene chloride, polyvinyl bromide, polyvinyl fluoride and polyvinylidene fluoride, (2) copolymers of vinyl chloride with one or more copolymerizable ethylenically unsaturated monomers such as vinylidene chloride, vinyl acetate, vinyl butyrate, vinyl benzoate, 20 diethyl fumarate, diethyl maleate, other alkyl fumarates and maleates, vinyl propionate, acrylic acid, methyl acrylate,

2-ethylhexyl acrylate, butyl acrylate, ethyl acrylate and other alkyl acrylates, methacrylic acid, methyl methacrylate, ethyl methacrylate, butyl methacrylate, 25 hydroxyethyl methacrylate and other alkyl methacrylates, methyl alpha chloroacrylate, styrene, vinyl ethers such as vinyl ethyl ether, vinyl chloroethyl ether and vinyl phenyl ether, vinyl ketones such as vinyl methyl ketone and vinyl phenyl ketone, l-fluoro, -l-chloroethylene, acrylonitrile, 30 chloroacrylonitrile, allylidene diacetate, chloroallylidene diacetate, olefins such as ethylene and propylene, and t3) - ~63793 polymer blends such as blends of polyvinyl chloride and polyethy]ene, polyvinyl chloride and polymethyl methacrylate, polyviny] chloride and polybutvl chloride and acrylonitrile-butadiene-styrene terpolymers and ternary 5 mixtures such as those containing polyvinyl chloride, polyethylene methacrylate.
Typical vinyl halide copolymers useable in this invention include vinyl chloride-vinyl acetate, vinyl chloride-vinylidene chloride, vinyl chloride-diethyl-10 fumarate, vinyl chloride-trichloroethylene and vinyl chloride-2-ethylhexyl acrylate~ The polymer blends useable in the practice of this invention comprise physical blends of at least two or more distinct polymeric species and typically contain from 25 to 9S weight percent of vinyl 15 halide homopolymer or vinyl halide copolymer. The vinyl halide copolymexs useable in the practice of this invention typically contain from about 25 to about 95 mole percent vinyl halide units.
In preferred embodiments of the present composition, 20 the polymer is a homopolymer or copolymer of vinyl chloride.
This preference is based on the lower cost and commercial availability of vinyl chloride relative to other vinyl halides.
While the very fine particle size hydrated alumina 25 herein described may be used as a filler material in both rigid and flexible polymeric vinyl halide formulations, the surprisingly superior impact strength that can be achieved is of particular commercial significance in rigid formulations (those having less than 10~ plasticizer).
The parameters surroundins and the effect of the use of a very fine particle size hydrated alumina in accordance 1~3793 with the practice of the invention will now be discussed seriatum, with reference to the accompanying drawings, in which:
Figure 1 is a graphical illustration of the effect of hydrated alumina concentration on the Izod impact strength of a polymeric vinyl halide formulation;
Figure 2 is a graphical illustration of the effect of hydrated alumina on extrusion, measured as head pressure, and torque, m~asured as motor amperage, for a second polymeric vinyl halide formulation; and Figure 3 is a graphical illustration of the effect of hydrated alumina and calcium carbonate on weathering of a rigid PVC formulation.
A Impact Synergism When calcium carbonate fillers with an average particle size over 1.0~ are used in rigid PVC formulations, they generally have an adverse effect on impact strength. When the average particle size is less than 1.0~, there is no loss in impact strength and, occasionally a slight improvement in impact strength will occur. In formulations containing bGth impact modifiers and calcium carbonate fillers, there are only slight improvements in impact strength over that obtained with the impact modifier itself.
In non-impact modifier containing PVC formulations the very fine-particle size hydrated alumina used in accordance with this invention also gives small increases in impact strength.
However, in PVC formulations containing impact modifiers, hydrated alumina having a very fine particle size (less than about 1~) as herein described behaves dramatically different than calcium ~2637~3 carbonate and acts synergistically with the impact modifier to give a significant and unexpected increase in impact strength.
These results are shown in Table 1.
The surprising and unexpected increase in impact strength that is achieved is independent of the type of impact modifier used in the formulation. Impact modifiers generally are rubbery materials which are either partially or completely incompatible with the polymeric vinyl halide and are present as a separate discrete phase. This is in contra5t to plasticizers which are completely compatible with the polymeric vinyl halide. Further, impact modifiers - 8a -~1263793 improve impact strength without significantly reducing the heat distortion temperature or impairing other desirable mechanical and physical properties. Representative impact modifiers included but are not limited to chlorinated polyethylene, modified acrylic, all-acrylic, ABS and MBS modifiers. It is believed that any conventional impact modifier can be used in the formulations and that the very fine particle size hydrated alumina will continue to show these synergistic effects. For example, the addition of 6 parts per hundred parts resin of very fine particle size hydrated alumina to rigid PVC formulations containing 5 phr of a conventional impact modifier gave increases in Izod impact strength from almost twice to over ten times the impact strength obtained without the addition of hydrated alumina.
The data in Table 2 demonstrated that increases in Izod impact from 5-20 ft.-lbs./in. notch can be obtained.

Hydrated Alumina ParticlP Size While the use of small particle size hydrated alumina (average size of 1~) is not detrimental to the impact strength of PVC formulations and the use of larger particle size hydrated alumina will reduce the impact strength of the PVC composition, the very substantial increase in impact strength that is achieved with a synergistic combination of a conventional impact modifier and the very fine particle size (less than 1~) hydrated alumina as herein described is totally unexpected and surprising.
Table 3 shows that impact synergism is specific to hydrated alumina with an average particle size below about lZ63~93 1~. Tests with an average particle size of 1~ show no effect on impact while larger particle size materials are detrimental to impact strength.

C. Hydrated Alumina Concentration We have determined that maximum increase in impact strength appears to occur at a ratio of very fine particle size hydrated alumina to impact modifier of about 2-4:1, but significant increases in impact strength are obtained even at a 1:1 ratio and some useful effect is noticed as low as a 1:2 ratio. Even lower ratios may be used with some effect but generally commercially significant results necessitate at least the 1:2 ratio.
For example, with a formulation containing 3 phr modified acrylic modifier, maximum impact was obtained at at a ratio of 2:1 hydrated alumina to impact modifier. When the concentration of hydrated alumina was increased to an 8:1 ratio of hydrated alumina to impact modifier, impact strength equivalent to 3 phr impact modifier without hydrated alumina was obtained (Figure 1).
Impact modifiers are generally utliized in the range of about 1 phr to about 15 phr, and preferably in the range of about 2 phr to about lC phr. The particular level will depend on the end use of the material. For example, injection molded PVC generally has an impact modifier level of about 2-3 phr while rigid PVC used for building siding has a usual level of about 4-8 phr. The use of verv small particle size hydrated alumina in accordance with this invention will allow the use of somewhat lower levels of impact modifier. Inasmuch as high levels of impact modifier tend to reduce tensile strength and heat distortion i263~9~

temperature, the reduced level of impact modifier can provide polymeric vinyl halide materials which exhibit somewhat superior physical properties.
Optimum concentration of impact modifier and hvdrated alumina will depend upon the formulation and desired performance characteristics of the compound. For example, if an Izod impact of 2.0 is sufficient for an outdoor weathering compound, then the data shown in Figure 1 illustrates that a formulation with 3 phr impact modifier can contain as much as 24 phr hydrated alumina and still maintain the same impact strength while taking ad~antage of the surprising improvement in weathering and processing characteristics also described herein and shown in Tables 6 and 7 and Figure 2. If improved impact is also desired, the lS hydrated alumina concentration can be reduced somewhat to obtain the desired impact properties while still obtaining advantageous weathering.
While as described above, the ratio of hydrated alumina to impact modifier can be as high as 8:1, it is preferred that the concentration of hydrated alumina be no higher than about 50 phr. If the level is greater than 50 phr, the processing characteristics may deteriorate and it may be difficult to distribute the hydrated alumina uniformly throughout the polymeric material.

D. Processibility The addition of very fine particle size hydrated alumina to rigid PVC formulations as herein described results in improved processing characteristics as evidenced by reduced torques, stock temperatures and pressures, as well as increased dynamic processing stability.

A standard siding formulation containing, for example, 10 phr of said very fine particle size hydrated alumina, maintained an equilibrium torque of 1525 meter-grams and a stock temperature of 206C compared to 1650 meter-grams and 208C for the same formulation without hydrated alumina. In the same torque rheometer study, the compound with 10 phr hydrated alumina showed a 13~ increase in heat stability with a stability time of 22.2 minutes compared to 19.6 minutes for the control. The saMe compound with 6 phr of said hydrated alumina gave a 9% increase in heat stability over the control (Table 4).
In addition to the torque rheometer studies, the same compounds were processed under controlled conditions on a Kraus-Maffei 25 mm conical twin screw laboratory extruder equipped with a 2-1/2", 40 mil strip die. The use of very fine particle size hydrated alumina resulted in reduced tor~ues tlower motor amperage) and pressures. The data is shown in Figure 2.
A common problem among weatherable rigid PVC processors is screw and barrel wear caused by the abrasiveness of titanium dioxide (Moh hardness about 6.5). Unlike alumina, which is very hard (Moh hardness about 9), hydrated alumina is relatively soft and similar to calcium carbonate with a Moh hardness of about 3. The potential for reduced ti,tanium 25 dioxide levels when formulating with the very fine particle size hydrated alumina could lead to reduced barrel and screw wear.

E. Weatherability Another surprising and unexpected benefit derived from the use of the very fine particle size hydrated alumina as .

lZ63793 herein described in rigid PVC formulations is improved weatherability with the potential for reducing Tio2 levels. For example, a standard siding formulation was compounded with various levels of very fine particle size hydrated alumina and extruded on the KM-25 laboratory extruder. Accelerated light stability testing of extruded samples in a Fluorescent Sunlamp/Black Light (FSBL) light source showed that the addition of hydrated alumina improved light stability (Table 5).
Another series was similarly extruded and ~ested in a QUV machine. It also showed that addition of very small particle size hydrated alumina improved light stability. In this series, a formulation containing 10 phr TiO2 and 6 phr of such hydrated alumina appeared to be at least equivalent in light stability to the control formulation containing 12 phr Tio2 and no hydrated alumina (Table 6~.
Long term outdoor weathering tests have been conducted with hydrated alumina formulations for 12 months. White compound extruded strips were weathered 45 south in Arizona and green compound extruded strips were weathered 45 south in Florida. The results as shown in Tables 7 and 8 show this improvement.
Arizona weathering tests conducted on rigid PVC
formulations containing very small particle size hydrated alumina and calcium carbonate show that the compound containing calcium carbonate was more susceptible to yellowing and subsequent chalking than either the control or the formulation containing hydrated alumina. This characteristic of calcium carbonate is the reason this filler is not widely used in exterior compounds, especially iZ~;3~3 colored formulations where chalking is especially detrimental (Figure 3).
Variable height impact tests (VHIT) were run on the green extruded strips prepared for Florida weathering tests.
Impact results on the extruded samples containing hydrated alumina in accordance with the invention were equivalent to the control (Table 8).
In addition to the very fine particle size hydrated alumina and impact modifiers herein described, the polymeric vinyl halide compositions may contain the usual compounding ingredients such as stabilizers and fillers and optional additives such as pigments, lubricants, dyes, ultraviolet light absorbing agents, plasticizers and the like.
Generally, the very fine particle size hydrated alum-~
ina may be introduced into the polymeric vinyl halide formulat-ion in any conventional manner, such as by preblending the selected hydrated alumina and impact modifier before blending with the polymeric resin, or alternatively, the components are blended individually in the resin. It is of course necessary that it be dispersed substantially uniformly throughout the mixture. In extruded formulations incorporation of hydrated alumina tends to reduce back pressure, so one should be careful that sufficient shear exists for thorough dispersion.
Conventional processing temperatures and conditions may be utilized so long as the processing temperature remains below about 230 C. If the processing temperature is higher than that value, there may be some decomposition of the hydrated alumina due to loss of water.

~;~93 --Izod impact specimens were prepared using 35-40 mil sheet, milled at 325F for five minutes after banding. The milled sheet was then cut into four 6" x 6" sheets and plied, alternating the oriented sheets. The samples were compression molded into 1/8" plaques at 375F for ten minutes at 3000 PSI. Izod impact strength was determined according to ASTM D-256. Physical properties were determined according to the procedures described in ASTM
D-1784.
Torque rheometer dynamic processing stability was obtained using a Brabender*lasti-Corder (C. W. Brabender, Hackensack, N. J.) electrically heated torque rheometer equipped with a No. 6 bowl according to the conditions 1~ identified in the tables.
Accelerated and outdoor weathering and variable height impact test (VHIT) were all determined on e~truded strips obtained from compounds blended in a high intensity mixer and extruded under the same conditions on a KM-25 la~oratory extruder equipped with a 2-1/2", 40 mil strip die.
Extrusion conditions were Zones ~ 2 and #3, 320F, 295F, 325F, respectively, and 380F on the die at 20 rpm screw speed.
Variable height impact tests were carried out according to procedures described in ASTM D-3679.
Outdoor and accelerated weathering tests were carried out as follows:

Outdoor Weathering - All samples were exposed 45 south with backing.

* Trade Mark ~2~793 Fluorescent Sunlamp/Black Light (FSBL) - Samples were exposed with a repeating cycle of 100 hours U.V.
exposure followed by 68 hours dark time.
Q W - Accelerated Weathering Test - Samples were exposed with a repeating cycle of 2 hours U.V. at 50C
followed by 4 hours condensate at 50C using equipment conforming to ASTM G-53 manufactured by the Q-Panel Co., Cleveland, Ohio.

10 The following formulation materials were produced.

Formulation ''A'' PVC (K-65~ 100.0 TiO2 (rutile) 2.0 Calcium Stearate 0.8 Paraffin Wax, 165F 1.2 Processing Aid 1.0 Butyltin Mercaptide Stabilizer 1.5 Formulation "B"

PVC (K~65~ 100~0 TiO2 (rutile) 12.0 Modified Acrylic Modifier 5.0 Processing Aid 0.3 Calcium Stearate 2.0 Paraffin Wax, 165F 1.0 Butyltin Mercaptide Stabilizer 1.5 ~Z~3~93 Formulat_on "C"

PVC (K=65) 100.0 TiO2 (rutile) 6.0 Modified Acrylic Modifier 5.0 Processing Aid 1~0 Calcium Stearate 2.0 Paraffin Wax, 165F 1.0 Butyltin Mercaptide Stabilizer 1.5 Formulation "A: was used for the Izod impact studies, the results of which are summarized in Tables 1, 2 and 3;
and Formulation "B" was used for torque rheometer stability studies, extxusion, variable height impact testing and weathering studies, the results of which are summarized in Tables 4, 5, 6, 7 and 8. Formulation "C" was used for a weathering study in which hydrated alumina was compared to calcium carbonate, the results of which are shown in Figure

3. For green siding compound, a non-chalking grade of titanium dioxide was substituted for the chalking grade of titanium dioxide used in the white siding compound. Unless otherwise noted, hydrated alumina referred to in the tables was prepared by a precipitation process and had an average particle size of 0.5,u.

~Z~;3793 The following tables illustrate the effects ofhydrated alumina on various properties of rigid PVC
materials.

SYNERGISM OF HYDRATED ALUMINA & I~MPACT MODIFIER
Formulation '_"

Variable ~ 1 2 3 4 5 6 7 8 9 Modified Acrylic - 5 - 5 3 - 3 - 3 Hydrated Alumina - - 12 12 - 6 6 - -Calcium Carbonate(l) - - - - - - - B 6 Izod Impact 0.8 14.3 1.8 18.3 2.1 1.6 8.1 1.0 2.2 (ft.-lbs./in.-notch) (1) Coated, average particle size 0.8u.

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~37~33 EFFECT OF PARTICLE SIZE AND FILLER TYPE
(Formulation "A") phr Variable 1 2 3 4 5 6 Modified Acrylic 3.0 3.0 3.0 3.0 3.0 3.0 Hydrated Alumina - 6.0 6.0 6,0 - -Alumina - - - - 6.0- -Hydrated Silica ~ - 6.0 Average Particle Size, u. - 0.5 1.0 8.0 1.0 0.12 Izod Impact2.1 8.1 2.1 1.0 0.7 2.0 (ft.-lbs~/
in.-notch) ~2~;3793 EFFECT OF HYûRATED ALU~IINA
ON DYNA.UIC PROCESSING STABILITY(l) Variable Formulation A A B B B
TiO2 2.0 2.0 12.012.012.0 Modi~ied Acrylic 3.0 3.05.0 5.0 5.0 Hydrated Alumina - 6.0 - 6.0 10.0 Stability, ~in. 25.3 ?7.519.621.3 22.2 Equil.Torque, m-g. 2250 2200 165018001525 (1) Torque Rheometer Formulation "A: - 200C, 60g. charge 60 RPM
Formulation "B: - 200C, 65g, charge 75 RPM

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~26~793 -22~

THE EFFECT OF HYDRATED ALUMI~A ON
FSBL. (1) ACCELERATED WEATHERING
Variables 1 2 3 4 5 6 Modified Acrylic 3 3 3 4 4 4 Hydrated Alumina - 4.0 6.0 - 4.0 6.0 Hours Yellowness Index Initial 4.6 4.9 4.9 4.4 4.6 4.7 500 9.6 9.2 8.5 8.4 7.8 8.1 lOOO 16.1 14.5 13.7 14.0 12.8 12.6 1500 18.6 16.3 16.1 16.4 15.6 14.5 (1) Fluorescent Sunlamp/Black Light THE EFFECT OF HYDRATED ALUMINA ON
QUV ACCELERATED WEATHERIMG
(Formulation "B") Hydrated Yellowness Inde~
TiO2,phr Alumina, phr Initial 2 Wks. 4 Wks. 10 Wks.
12 - 4.4 6.310.5 13.2 12 6 3.2 5.3 8.3 11.2 12 10 3.2 5.7 8.5 10.7 6 3.2 5.6 8.8 11.8 ,. . . . . . .. .. .. . . . . . . . . . .. ... . . . . . . .

~2637~3 THE EFFECT OF HYDRATED ALUMINA
ON WEATHERI~G ~1) (Formulation "B") Variables 1 _ 2 3 _ TiO2 12 12 12 Modi~ied Acrylic 5 5 5 Hydrated Alumina - 3.0 6.0 Months _ Yellowness Inde~
0 3.0 3.0 3.1 3 9.4 804 6~4 6 10.0 9.1 6.3 9 11.6 9.9 6.7 12 14.2 13.6 9.7 (1) Arizona , . , . . . . . , . , , . _ .. . . . ~ . . .... . . . .

~63~7g3 THE EFFECT OF HYDRATED ALUMINA ON
WEATHEP.ING (1)(2~

Variables 1 2 _ 3 4 TiO2 12 12 12 12 ~odi~ied Acrylic 5 5 3 3 Hydrated Alumina - 6 - 6 VHIT, In.-Lbs/
Mil, 23C 3.4 3~4 3.6 3.5 Months _ E(3) 3 .3 .3 .4 .5 6 .6 .2 .5 .2 9 .7 .2 .6 .3 12 1.0 .7 .9 .5 (1) Florida (2) Formulation "B", non-chalking TiO2, 1.5 phr chrome o~ide (3) ASTM D-2244 . . .... . . ... .... .. . . . . . .. . . .. . . .

~263793 A series of polyvinyl chloride formulations were prepared using the proportion of ingredients listed in Table 9 to evaluate the effect of hydrated alumina on weatherability of formulations prepared with or without impact modifiers and/or plasticizers. Accelerated weathering tests (FSBL and QUV) described in Example l were used to evaluate each of the formulations and the results are also summarized in Table 9.
Each of the formulations of this example were milled for 5 minutes at 350F after bonding and test samples were compression molded at 350F for 5 minutes into 125 mil plaques. Yellowness index was obtained on a ~CBETH 1500 colormeter.
It can be seen from the results reported in Table 9 that each of the formulations containing very fine particle size hydrated alumina (0.5u avg) exhibited improved weatherability over those formulations which did not contain said hydrated alumina. This improvement in weatherabili~y can be seen for formulations which were prepared with or without an impact modifier or plasticizer, and with formulations containing both an impact modifier and plasticizer. While the results show that the impact modifier and plasticizer used in the formulations of this example result in improved weatherability, the use of hydrated alumina having an average particle size of 0.5u further enhanced the weatherability of the formulation.

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. ~ al A series of polyvinyl chloride formulations were prepared using the proportion of ingredients listed in Table 10 to evaluate the effect of hydrated alumina on weatherability. Accelerated weathering tests (FSBL and Q W) described in Example 1 were used and the results obtained are summarized in Table 11.
Each of the formulations of this example were milled for 5 minutes at 350F after bonding. Formulations 1 to 5 were prepared by individually adding each of the ingredients and formulation 6 was prepared by preblending the impact modifier, stabilizer, processing aid, Tio2 and hydrated alumina were prepared by individually adding each of the ingredients and formulation 6 was prepared by preblending the impact modifier, stabilizer, processing aid, TiO2 and hydrated alumina.
It can be seen from the results shown in Table 11 that the addition of a hydrated alumina having an average particle size of 0.5u and O.9u to polyvinyl chloride formulations enhanced the weathering characteristics thereof as compared to a formulation which did not contain the hydrated alumina filler. It can also be seen from the results that hydrated alumina having an average particle size of 0.5u enhanced the weatherability of PVC formulations which contained an impact modifier and these advantageous results were obtained with the compounding ingredients being added individually or as a preblended mixture.

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Yellowness Index Formulations l 2 3 4 5 6 Initial Y.I. 7.6 7.8 8.4 9.2 8.2 11.5 ~Y.I. 168 hrs. 5.4 3.8 3.8 2.0 4.0 3.1 336 hrs. 16.0 8.9 8.4 5.1 9.4 5.9 420 hrs. 19.0 10.9 10.8 5.8 10.9 6.1 FSBL ACCFLERATED WEATHERING
Yellow~ess Index Formulations Initial Y.I. 7.6 7.8 8.4 9.2 8.2 11.5 QY.I. 168 hrs. 2.3 1.4 1.0 1.0 1.7 1.5 336 h~s. 4.1 1.8 2.3 l.0 3.0 1.4

Claims (9)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A method for increasing the impact resistance of a polymeric vinyl halide material which comprises incorporating into a polymeric vinyl halide material a) an impact modifier which is a synthetic high molecular weight polymeric rubbery material; and b) alumina hydrate having an average particle size of less than about one micron;
in amount which forms a synergistic combination for increasing the impact resistance of said polyvinyl halide material.

2. A method in accordance with claim 1, wherein the tempera-ture during said blending is maintained below about 230°C.

3. A method in accordance with claim 1, wherein said hydrated alumina has an average particle size of from about 0.4 micron to about 0.6 micron.

4. A method in accordance with claim 1, wherein said hydrated alumina is added in a weight ratio to impact modifier of from about 1:2 to about 8:1.

5. A method in accordance with claim 1, wherein said hydrated alumina is added in a weight ratio to impact modifier of from about 1:1 to about 4:1.

6. A composition for improving the impact resistance of polymeric vinyl halide material which comprises an impact modifier which is a synthetic high molecular weight polymeric rubbery material and hydrated alumina having an average particle size of less than about 1µ in relative proportions of said impact modifier and said hydrated alumina which is sufficient to form a synergistic combination thereof.

7. The combination of claim 6, wherein said hydrated alumina and said impact modifier are present in a weight ratio of hydrated alumina to impact modifier of from about 1:2 to about 8:1.

8. The composition of claim 7, wherein said hydrated alumina and said impact modifier are present in a weight ratio of hydrated alumina to impact modifier of from about 1:1 to about 4:1.

9. The composition of claim 6, wherein said hydrated alumina has an average particle size of from about 0.4µ to about 0.6µ.