CA2000914A1 - Plastic pellets coated with processing aid and method of coating - Google Patents
Plastic pellets coated with processing aid and method of coatingInfo
- Publication number
- CA2000914A1 CA2000914A1 CA002000914A CA2000914A CA2000914A1 CA 2000914 A1 CA2000914 A1 CA 2000914A1 CA 002000914 A CA002000914 A CA 002000914A CA 2000914 A CA2000914 A CA 2000914A CA 2000914 A1 CA2000914 A1 CA 2000914A1
- Authority
- CA
- Canada
- Prior art keywords
- pellet
- processing aid
- carbon atoms
- blender
- weight percent
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B9/00—Making granules
- B29B9/16—Auxiliary treatment of granules
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/20—Compounding polymers with additives, e.g. colouring
- C08J3/203—Solid polymers with solid and/or liquid additives
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B9/00—Making granules
- B29B9/16—Auxiliary treatment of granules
- B29B2009/163—Coating, i.e. applying a layer of liquid or solid material on the granule
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2019/00—Use of rubber not provided for in a single one of main groups B29K2007/00 - B29K2011/00, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2021/00—Use of unspecified rubbers as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2035/00—Use of polymers of unsaturated polycarboxylic acids or derivatives thereof as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Processes Of Treating Macromolecular Substances (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
Abstract
ABSTRACT
Plastic pellets showing improved behavior upon extrusion, comprising coating the pellets with a fused layer of certain waxes or polymeric materials; and a method of preparation comprising heating the plastic pellets to a temperature just below the softening or fusing temperature of the additive while blending the pellet in a high intensity blender, introducing the additive and maintaining intense blending until the temperature is above the fusing temperature of the additive, and discharging the coated pellets from the blender.
36,241-F
Plastic pellets showing improved behavior upon extrusion, comprising coating the pellets with a fused layer of certain waxes or polymeric materials; and a method of preparation comprising heating the plastic pellets to a temperature just below the softening or fusing temperature of the additive while blending the pellet in a high intensity blender, introducing the additive and maintaining intense blending until the temperature is above the fusing temperature of the additive, and discharging the coated pellets from the blender.
36,241-F
Description
~0009lA
PLASTIC PELLETS COATED WITH PROCESSING
AID AND METHOD OF COATING
The present invention relates to pellets of a plastic having improved extrusion properties.
It is well-known to form a variety of articles fabricated from plastic pellets. In the past, the practice generally was to extrude the plastic directly - from the powder form in which it is recovered after polymerization. Because of the convenience of shipping and handling, it is desirable to form the plastic into pellets prior to final extrusion.
With the increased demand for pellets, the processing conditions to which pellets are exposed has become more demanding. Wh~n melt processed, conven-tional plastic pellets have a tendency to generate particulate degradation pr~ducts (i.e., carbonaceous material, gels or fish eyes) in the extrudate, partic-ularly when the plastic i5 exposed to relatively longresidence times in the melt processing equipment.
Proce~sing aids are conventionally blended into tne plascic prior co fabrication into a pellet.
However, it has been found that a certain lag time 36,241-F _1_ period exists, after exposure to desirable processing temperatures~ ~et~ore he blended processing aias func-tion e~ectively. lt is during tnc ld~ ~lme p that the plastic is particularly susceptible to decomposition upon exposure to desirable processing temperatures.
In some instances, plastic pellets have had processing aids applied to their surfaces. Generally, such processing aids are applied by spraying droplets of processing aid on the pellet surface. While such techniques have had some success, these techniques do not consistently provide uniform pellet surface coating.
Although conventionally coated pellets may be satisfactorily extrudable for a period, such pellets have not been found to be easily extrudable for commer-cially required periods. Specifically, when extruded, - the non-uniform coating on the pellet surface causes variations in extrusion rate, torque within the extruder and pressure within the extruder. Moreover, the non--fused coatings tend to flake off the pellet surface.
It is desirable to produce a plastic pellet, having its surface coated with lubricant, which is capable of being extruded without causing variations in torque of the extruder screw, melt pressure or rate of extrusion of the pellet. It is to these goals that the present invention is directed.
The present invention concerns a process for preparing a pellet having improved extrudability, which process comnrises the steps of: (a) providing a plastic in pellet form, and a processing aid having a softening 36,241-F -2-Z000~14 point between ambient temperatures and below the ?rocessing tem~ra~re or the plastlc ln pellet ~orm;
(Dj charging the pellet into a high intensity blender, said blender having an impeller; (c) rotating the blender impeller at a speed and for a period of time effective to raise the temperature of the pellet surface to between about 5C and 10C below the softening point of the processing aid; (d) charging the processing aid into the blender such that the processing aid contacts the heated pellet surface; and (e) rotating the blender impeller at a speed and for a period of time effective to raise the temperature of the pellet surface to a temperature above the softening point of the processing aid, and to coat a portion of the pellet surface by fusing the processing aid thereto.
Additionally, the present invention concerns a composition, in the form of an extrudable pellet, which - comprise-s a plastic, said pellet having a processing aid fused on the surface thereof at a level effective to improve the extrudability of the pellet.
Applicant has discovered that the process and composition aGcording to the present invention improves the extrudability of the plastic pellets. The pellets are considered to possess improved extrudability, i.e., less carbonaceous material contamination on the melt processing equipment, e.g., on an extruder screw heel;
and a lower mechanical energy to extrude than a pellet, which does not have processing aids coated on its sur-face in a manner according to the present invention.
The plastics which may be employed according to the present invention include any plastic which may be 36,241-F -3_ pelletized. The plastic is formed by blending a poly-~er. ?rior o pelle~i-ation, with a variety or additlves incorporate~ erewitn to rurm a lastic.
Exemplary of suitable polymers are the olefin polymers such as homopolymers and copolymers of a-mono-olefins (e.g., ethylene. propylene, butene-1, isobutyl-ene, 1-pentene, l-hexene, l-octene, and the like); and a-monoolefin/a-monoolefin copolymers (e.g., ethylene/propylene copolymers). Additional suitable polymers include those based on substituted a-monoolefins (e.g., a-monoolefins having from 4 to 12 carbon atoms wherein the substituents can be halo, alkyl or haloalkyl having from l to 12 carbon atoms; a-alkenyl having 2 to 12 carbon atoms; acyl having 1 to 12 carbon atoms; carboxylate having from l to 12 carbon atoms;
alkoxyl having from 1 to 12 carbon atoms; and aryloxy having from 6 to 12 carbon atoms). Exemplary - substituted a-monoolefins are vinyl chloride, vinyl bromide, vinylidene chloride, acrylic acid, methacrylic acid, ethyl acrylate, n-butyl acrylate, i-butyl acrylate, diethyl acrylate, diethyl maleate, ethyl hydrogen maleate, methyl ethacrylate, dibutyl itaconate, vinyl acetate., vinyl propionate, vinyl benzoate, vinyl ethyl ether, methyl vinyl ketone, acrylamide, acrylonitrile and the like.
Other suitable polymers include those based on carboxylic acids having from 3 to 8 carbon atoms (e.g., ethylene vinyl acetate and ethylene acrylic acid), and partially hydrolyzed copolymers thereof (e.g., ethylene vinyl alcohol); alkyl or haloalkyl esters of carboxylic acid wherein the alkyl or haloalkyl has from 1 to 12 carbon atoms; a-alkenyls having 2 to 12 carbon atoms;
36,241-F -4_ acyls having 1 to 12 ~arbon atoms; carboxylates having ~-rom 1 to l~ carbon atoms: alkoxyls havlng rrom 1 tO
12 carbon atoms; aryloxys havl~.b ;rum o t~ 1~ edrbOIl atoms; rubbery ethylene-propylene-diene terpolymers;
polyesters and copolyesters such as those polyesters and copolyesters whose synthesis employs at least one polyhydric alcohol and at least one dibasic acid (e.g., polyethylene terephthalate, and the like); the poly-etheramides; the polyamides (e.g., polycaprolactam); the polycarbonates (e.g., bisphenol A,); the polyester carbonates; the polyimides; the vinyl aromatics such as styrene; and polymers based on vinyl aromatics copolymerized with suitable monomers, including unsaturated nitriles (e.g., acrylonitrile, methacrylonitrile, and ethacrylonitrile~, and the conjugated 1,3-dienes (e.g., butadiene and isoprene).
This invention is advantageous for those plas-- tics wh;lch are commonly melt processed with processing aids, and;most advantageous for the extrusion of ther-mally sensitive plastics which are melt processed with processing aids. For the purposes of this invention, it is understood that the term "thermally sensitive" refers to any plastic which exhibits an undesirable change in properties, particularly physical properties, upon exposure to desirable processing temperatures.
Exemplary thermally sensitive plastics include polyvinylidene halide copolymers, polyvinyl halide copolymers and ethylene vinyl alcohol copolymers.
Suitable additives include, for example, colorants, pigments, non-elastomeric reinforcing agents, fillers, antiûxidants, stabilizers, etc., as long as these do not detrimentally affect the resulting 36,241-F -5_ uniformity of coating and completeness of surface cov-erage. ~ r~c~ mprlse~ phy~ically blending the n~;polymer wl~n ~he aaaltlves to ~orm a mlxtur~.
Methods of forming the plastic into pellets are well-known to those skilled in the art. Any method capable of forming the plastic into pellets is suitable for use in the present invention. For the purposes of this application, the terms "pellet" or "pellets" refer to particles having a minimum cross-sectional dimension of at least 1/32 inch, preferably at least 1/16 inch and most preferably at least 1/8 inch, said pellets suitably have a maximum cross-sectional dimension of at least 1/2 inch, preferably at least 3/8 inch and most preferably at least 1/4 inch. Exemplary of a method suitable for use in forming the pellets of the mixture is extru~ion through a strand die and pelletization by chopping the extruded strand into pellets.
~ .
By "processing aid" is meant any component which is employed to improve extrusion performance.
Although not intended to be bound by theory, it is believed that by applying the processing aid to the surface of the pellet the processing aid will, during melt processing, rapidly migrate to the metal surface of the melt processing equipment. Surface coated pro-cessing aids thereby provide relatively fast functioning compared to conventionally compounded processing aids, which require pellet melting prior to functioning.
Con~equently, a lower amount of the processing aid is necessary to achieve equivalent effects to the same processing aid blended with the plastic.
36,241-F -6-200079l4 Generally? the surface of the pellet will be ~oated with a processing id. wherein tne processing aid will b~ n amount OI DetWeen U.001 weight percent to 2 weight percent, said weight percents based on the weight of the pellet; preferably in an amount of between 0.01 weight percent to 1.5 percent, said weight percents based on the weight of the pellet; and most preferably in an amount of between 0.1 weight percent to 0.7 weight percent, said weight percents based on the weight of the pellet. Generally, within the suitable ranges, the higher the level of processing aid on the pellet sur-face, the more benefit one will see in terms of improv-ing extrudability of the plastic pellet.
Within the prescribed ranges, the choice of optimum amounts of processing aids will be dependent upon the the processing aid selected, the viscosity of the processing aid, the size of the pellet and the type - and size of the equipment through which the pellet is extruded.
Generally within the prescribed weight per-centage ranges for coating processing aids on the pellet surface, the inventor has found that the more processing aid which is coated on the pellet surface the more of a decrease in particulate degradation will be seen in the extrudate. Preferably, the pellet surface will be uniformly coated with the processing aid, that is to say, when compared to an uncoated pellet, 50 percent coverage of a pellet surface will produce somewhat decreased particulate degradation of the extrudate;
whereas 90 percent coverage of the same pellet will produce a still further ~mprovement in decreasing the particulate degradation in the extrudate. Similarly, 36,241-F -7-20009~4 within the ranges discussed above, the thicker the surface coating. the ~ore beneflt~ one Jill see .n terms of decreasing the particul~ a~gradallon ln the extrudate. If, however, the processing aid is applied in quantities excessive for the processing aid selected, the viscosity of the processing aid, the size of the pellet and the type and size of the equipment through which the pellet is extruded, the feeding of the pellet into the melt processing equipment may be impaired because of insufficient friction in the feed zone; or the excess amount of processing aid may form globules on the pellet surface.
The processing aids coated on the pe~let sur-face are those generally used for the conventional melt processing of plastics in either powder or pellet form.
The processing aid is ~elected to have a softening point between ambient temperatures and below the processing - tempera~ure of the plastic in pellet form. Preferably, the processing aid should have, within the preferred range, a softening point slightly above ambient temperatures to allow for rapid functioning and yet for easy handling, e.g., low pellet surface tackiness.
Within the above parameters, the specific processing ald selected will be a matter of choice for the skilled artisan, depending upon the desired results.
Exemplary processing aids include lubricants and olefin polymers. The choice of specific processing aids for specific plastics will be a matter of choice well within the means of one skilled in the art. Exem-plary factors in selecting a processing aid, although not all factors are important for all polymers, include 36,241-F -8-melt adhesion. fusion delay, viscosity reduction and an ~xtruslon l~te lncrease at a glven r?m.
Lubricants include both internal and external lubricants which improve extrusion performance of the plastic. By "internal lubricant" is meant any of the classes of compounds that have heretofore been employed as internal lubricants in plastics. Although not intended to be bound by theory, the lubricants are classified as "internal" because they increase the ease with which the polymer molecules slip past one another, resulting in reduced melt viscosity, better flow, and lower energy to extrude requirements for melt pro-cessing. The compositions may perform functi-ons in addition to that mechanism referred to as internal lubrication.
.
By "external lubricant" is meant any of the - class o-~ compounds that have heretofore been employed as external lubricants in plastics. Although not intended to be bound by theory, the lubricants are classified as "external" because they are believed to be at least partially incompatible with the molten polymer. The lubricant will therefore migrate to the surface of the molten polymer and form a film between the polymer and the heated metal surface of the extruder, mill or other equipment used to process the polymer composition. This film ~ignificantly reduces the tendency of the polymer to adhere to these metal surfaces and degrade. The compositions may perform functions in addition to that mechanism referred to as external lubrication.
Exemplary lubricants include fatty acids (e.g., stearic acid); esters (e.g., fatty esters, wax esters, 36,241-F _g_ glycerol esters. glycol esters, fatty alcohol esters, and the 'i'~); f`.~r,ty alcohols (e.g.. n-stearyl alcohol);
fa~y amlaes ~e.g., N,N'-ethylene bis stearamide);
metallic salts of fatty acids (e.g., calcium stearate, zinc stearate, magnesium stearate, aluminum stearate, sodium stearate, tin stearate, sodium lauryl sulfate, and the like); and polyolefin waxes (e.g., paraffinic, nonoxidized and oxidized polyethylene and the like).
The term "olefin polymer" includes homopolymers and copolymers of a-monoolefins and substituted a-mono-olefins, particularly a-monoolefins or substituted a-monoolefins having from 4 to 12 carbon atoms. Exem-plary a-monoolefin polymers include polyethylene (e.g., ultra-low density polyethylene, low density polyethyl-ene, linear low density polyethylene, medium density polyethylene, high density polyethylene); polypropylene;
poly(butene-1), poly(isobutylene); poly(1-pentene);
- poly(1-hexene) and poly(1-octene).
Substituted a-monoolefins include those wherein the sub~tituents can be halo, alkyl or haloalkyl having from 1 to 12 carbon atoms; carboxylic acid having from 3 to 8 carbon atoms; alkyl or haloalkyl ester of car-boxylic acid wherein alkyl or haloalkyl has from 1 to 12 carbon atoms; a-alkenyl having 2 to 12 carbon atoms;
acyl having 1 to 12 carbon atoms; carboxylate having from 1 to 12 carbon atoms; alkoxyl having from 1 to 12 carbon atoms;' and aryloxy having from 6 to 12 carbon atoms.
The a-monoolefins and substituted a-monoolefins may also be copolymerized with a variety of suitable comonomers such as carboxylic acids having from 3 to 8 36,241-F -10-carbon atoms (e.g.. ethylene vinyl acetate. and ethylene acryl.c acid)~ vl or haloalkyl esters QI car~oxyli~
acid wherein alkyl or Idlo~lKyl nas ~om l to l~ carbon atoms; ~-alkenyls having 2 to 12 carbon atoms; acyls having 1 to 12 carbon atoms; carboxylates having from l to 12 carbon atoms; alkoxyls having from 1 to 12 carbon atoms; aryloxys having from 6 to 12 carbon atoms; and a-monoolefin/a-monoolefin copolymers (e.g., ethylene/propylene copolymers).
The processing aid is then charged into the blender for fur~her mixing of the preheated pellet and processing aid until the processing aid fuses onto the pellet surface.
The oellets are prepared for coating by being mixed in a high intensity blender. By "high intensity"
blender is meant mixers that can apply about 10 horse - power per cubic foot of material with high ~hear rate, ~ith a maximum of 20,000 sec~l. Exemplary high intensity blenders include Banbury mixers, Prodex--Henschel mixers, and Welex-Papenmeier mixers.
Such blenders typicaily have an impeller for mixing and applying energy to the batch, and a baffle for directing the motion of the product to the center of the vortex. Such blenders also have a jacket sur-rounding the mixing bowl so that cooling may be applied.
Generally, the blender impeller is run at a tip speed of between 2000 feet per minute (fpm) to 4000 fpm, preferably between 2500 fpm to 3000 fpm. The degree o~ deflection of the blender baffle may be 36,241-F -11-2~)00914 adjusted from 45 to 0~. and preferably between 15 to !`, wnere ~ e~ers ~o a ~adial orientation.
The pellet surface will be heated to a tem-perature of at least about 10C, preferably about 5C, below the temperature at which the processing aid will soften and fuse. Persons skilled in the art recognize that mixing times will vary with the blending technique, apparatus and the choice of processing aid.
The pellets will be mixed until their surface temperature is above that of the temperature required to soften the processing aid, but below the softening point of the plastic. Water may be passed through a water jacket to maintain control of the heating of the pellet surface at a temperature of between the softening point of the processing aid and below the softening point of the plastic.
, After being surface coated, the pellet then may be melt processed and extruded into any suitable final product. The process of the present invention can be used to form a variety of films or other articles.
As is well-known in the art, the films and articles may be fabricated with conventional coextru-sion, e.g, feedblock coextrusion, multimanifold die coextrusion or combinations of the two; injection molding; extrusion molding and lamination techniques.
Articles formed therefrom include blown and cast, mono and multilayer, films; rigid and foam sheet; tubes;
pipes; rods; fibers and various profiles. Lamination techniques are particularly suited to produce multi-ply sheets. As is known in the art, specific laminating 36,241-F -12---l 3--techniques include fusion, wet combining or heat reac-t,vatlon. ~uslon ;~omprises ~?ona ng seiI-sustaining ;dmlna together~ by applications oY heat and pressure.
Wet combining comprises laminating two or more plies by using a tie coat adhesive, which is applied wet;
driving off the liquid and combining, by subsequent pressure laminating, in one continuous process. Heat reactivation comprises combining a precoated film with another film by heating and reactivating the precoat adhesive so that it becomes receptive to bonding after subsequent pressure laminating.
The present invention is illustrated in further detail by the following examples. The e~amples are for the purposes of illustration only, and are not to be construed as limiting the scope of the present inven-tion. All parts and percentages are by weight unless otherwise specifically noted.
36,241-F -13_ 20009~4 Examples TA~L~ I
Code Polymer comPonents PVdC A pellet of a polymeric composition compris-Pellet ing a 96.5% base resin, 1.5% ethylene vinyl acetate, 1.2% tetrasodium pyrophosphate and 0.8% epoxidized soybean oil. The base resin is polymerized from a monomer mixture con-taining 80 weight percent vinylidene chloride and 20 weight percent vinyl chloride, said resin having a major melting point of 164G, and a molecular weight of 80,000.
L-1 An oxidized polyethylene commercially avail-able under the trade designation as Allied 629A from Allied Corp. The oxidized polyeth-ylene has a density (ASTM Test D-1505) of 0.93 grams per cubic centimeter ~ 20C, a drop point of 104C and a Brookfield Viscosity of 200 cps @ 140C.
L-2 A polyethylene wax commercially available from _ Allied Corp. under the trade designation Allied 617A. The polyethylene wax has a density (ASTM Test D-1505) of 0.91 grams per cubic centimeter, a drop point of 102C and a Brookfield Viscosity of 180 cps @ 140C.
L-3 An ethylene/vinyl acetate copolymer having polymerized therein 72 weight percent ethylene and-28 weight percent vinyl acetate, both percentages being based upon copolymer weight.
The copolymer has a melt index (ASTM Test D-1238) of 22 to 27 decigrams per minute and a density (ASTM Test D-1238) of 0.98 grams per cubic centimeter. The copolymer is commercially available from DuPont under the trade designation Elvax 3180.
36,241-F -14--- l 5--Sample Preparation ~ r. ~ ll; ~h ~n~ e~
which is commercially available under the trade desig-nation Welex Model 35 from F. H. Papenmeier K.G. Com-pany. The mixer has a diameter of 35 cm, and a nominalcapacity of 1 cubic foot. The baffle of the mixer is adjusted in the radial direction, the impeller is started and the tip speed is adjusted to about 2700 feet per minute (fpm). When the pellet temperature reaches 75C, various processing aids, coded in Table I, are charged in the mixer in quantities set forth in Table II. The pellets and processing aids are blended for a period of about eight minutes and discharged. The discharged material is cooled to about 65C, by circulating 20C air.
_ Fusion Testin~
Extrudability is determined by measuring the fusion time of the pellet as it is melt processed. The pellets are placed in the bowl of a Brabender~ torque rheometer. The bowl is maintained at a temperature of 170C and the speed of the blades is about 60 rpm.
A sample of coated pellets, weighing 80 grams is charged in the rheometer, and the fusion times are determined. The fusion time for the pellets is 60 sec-3 onds, and the maximum torque is 960 meters/gram. Arelatively short Pusion time will cause degradation and discoloration of the molten polymer, resulting from a prolonged exposure to heat while in the molten state.
The maximum torque value, a measure of the mechanical energy necessary to cause fusion, should be from about 36,241-F -15-1800 to about 2500 meter grams. Higher torque values will resul~. in an e~cessiYely hig~ current demand and posslDly a~mage to the extruder motor.
The results are set forth in Table II.
36,241-F -16-~- ~. r~ . r, I
Coatinq3 Exam- Pellet ProcessingWeightFusion Fusion e~ Code~Aid PercentTime~Torque3 PVdC L-l 0.33 >600 NF
Pellet 2 PVdC L-1 0.06 >600 NF
Pellet 3 PVdC L-2 0.33 >600 NF
Pellet 4 PVdC L-2 0.3 -- --Pellet PVdC L-3 0 33 30-40 770 1 5 Pellet 6 PVdC L-3 0.3 15 820 Pellet 7 PVdC L- 1 0.06 30-40 680 Pellet L-3 0.3 -- = not measured.
Pellet type as set forth in Table I.
Coating = (a) processing aid and (b) amount of processing aid coating on pellet in weight percent.
~ Fusion Time in sec.
Fusion Torque in sec. "NF" means that no fusion occurs by the time the test is terminated after 600 seconds.
Examples 8-16 The procedures of Examples 1-7, respectively, are repeated with the following exception: instead of 36,241-F -17-the vinylidene chloride-vinyl chloride copolymer, the pellets are :llaàe of a polyme.ic composition comprlslng a 9~.~ percent base resin, 1.5 per~ elnylene vlllyl acetate, 1.2 percent tetrasodium pyrophosphate and 0. 8 percent epoxidized soybean oil. The base resin is polymerized from a monomer mixture containing 94 weight percent vinylidene chloride and 6 weight percent methyl acrylate, said resin having a major melting point of 164C, and a molecular weight of 90,000.
The pellets exhibited a relatively long fusion time and low fusion torque.
ExamPle 17 The procedures of Example 5, respectively, are repeated with the following exception: Instead of the _ vinylidene chloride-vinyl chloride copolymer, the pel-lets are made of a polyvinyl chloride copolymer.
The pellets exhibited a relatively long fusion time and low fusion torque.
Example 18 The procedures of Example 5 are repeated with the following exception: instead of the vinylidene 3 chloride-vinyl chloride copolymer, the pellets are made of polyethylene terephthalate copolymer.
The pellets exhibited a relatively long fusion time and low fusion torque.
36,241-F -18-,9 Example l~
The procedures of Example 5 are repeated with the following exceptions: instead of the vinylidene chloride-vinyl chloride copolymer, the pellets are made of polypropylene.
The pellets exhibited a relatively long fusion time and low fusion torque.
Example 20 The procedures of Example 5 are repeated with the following exceptions: instead of the vinylidene chloride-vinyl chloride copolymer, the pGi;ets are made of a polystyrene.
.
The pellets exhibited a relatively long fusion t'ime and low fusion torque.
Example 21 The procedures of Example 5 are repeated with the following exceptions: instead of the vinylidene chloride-vinyl chloride copolymer, the pellets are made of a high impact polystyrene.
3o The pellets exhibited a relatively long fusion time and low fusion torque.
36,241-F -19-Example 22 The ~ h the following exception: instead of the vinylidene chloride-vinyl chloride copolymer, the pellets are made of polycarbonate.
The pellets exhibited a relatively long fusion time and low fusion torque.
Although the invention has been described in considerable detail, with reference to certain preferred embodiments thereof, it will be understood that variations and modifications can be affected within the spirit and scope of the invention as described above and as defined in the appended claims.
3o 36,241-F -20-
PLASTIC PELLETS COATED WITH PROCESSING
AID AND METHOD OF COATING
The present invention relates to pellets of a plastic having improved extrusion properties.
It is well-known to form a variety of articles fabricated from plastic pellets. In the past, the practice generally was to extrude the plastic directly - from the powder form in which it is recovered after polymerization. Because of the convenience of shipping and handling, it is desirable to form the plastic into pellets prior to final extrusion.
With the increased demand for pellets, the processing conditions to which pellets are exposed has become more demanding. Wh~n melt processed, conven-tional plastic pellets have a tendency to generate particulate degradation pr~ducts (i.e., carbonaceous material, gels or fish eyes) in the extrudate, partic-ularly when the plastic i5 exposed to relatively longresidence times in the melt processing equipment.
Proce~sing aids are conventionally blended into tne plascic prior co fabrication into a pellet.
However, it has been found that a certain lag time 36,241-F _1_ period exists, after exposure to desirable processing temperatures~ ~et~ore he blended processing aias func-tion e~ectively. lt is during tnc ld~ ~lme p that the plastic is particularly susceptible to decomposition upon exposure to desirable processing temperatures.
In some instances, plastic pellets have had processing aids applied to their surfaces. Generally, such processing aids are applied by spraying droplets of processing aid on the pellet surface. While such techniques have had some success, these techniques do not consistently provide uniform pellet surface coating.
Although conventionally coated pellets may be satisfactorily extrudable for a period, such pellets have not been found to be easily extrudable for commer-cially required periods. Specifically, when extruded, - the non-uniform coating on the pellet surface causes variations in extrusion rate, torque within the extruder and pressure within the extruder. Moreover, the non--fused coatings tend to flake off the pellet surface.
It is desirable to produce a plastic pellet, having its surface coated with lubricant, which is capable of being extruded without causing variations in torque of the extruder screw, melt pressure or rate of extrusion of the pellet. It is to these goals that the present invention is directed.
The present invention concerns a process for preparing a pellet having improved extrudability, which process comnrises the steps of: (a) providing a plastic in pellet form, and a processing aid having a softening 36,241-F -2-Z000~14 point between ambient temperatures and below the ?rocessing tem~ra~re or the plastlc ln pellet ~orm;
(Dj charging the pellet into a high intensity blender, said blender having an impeller; (c) rotating the blender impeller at a speed and for a period of time effective to raise the temperature of the pellet surface to between about 5C and 10C below the softening point of the processing aid; (d) charging the processing aid into the blender such that the processing aid contacts the heated pellet surface; and (e) rotating the blender impeller at a speed and for a period of time effective to raise the temperature of the pellet surface to a temperature above the softening point of the processing aid, and to coat a portion of the pellet surface by fusing the processing aid thereto.
Additionally, the present invention concerns a composition, in the form of an extrudable pellet, which - comprise-s a plastic, said pellet having a processing aid fused on the surface thereof at a level effective to improve the extrudability of the pellet.
Applicant has discovered that the process and composition aGcording to the present invention improves the extrudability of the plastic pellets. The pellets are considered to possess improved extrudability, i.e., less carbonaceous material contamination on the melt processing equipment, e.g., on an extruder screw heel;
and a lower mechanical energy to extrude than a pellet, which does not have processing aids coated on its sur-face in a manner according to the present invention.
The plastics which may be employed according to the present invention include any plastic which may be 36,241-F -3_ pelletized. The plastic is formed by blending a poly-~er. ?rior o pelle~i-ation, with a variety or additlves incorporate~ erewitn to rurm a lastic.
Exemplary of suitable polymers are the olefin polymers such as homopolymers and copolymers of a-mono-olefins (e.g., ethylene. propylene, butene-1, isobutyl-ene, 1-pentene, l-hexene, l-octene, and the like); and a-monoolefin/a-monoolefin copolymers (e.g., ethylene/propylene copolymers). Additional suitable polymers include those based on substituted a-monoolefins (e.g., a-monoolefins having from 4 to 12 carbon atoms wherein the substituents can be halo, alkyl or haloalkyl having from l to 12 carbon atoms; a-alkenyl having 2 to 12 carbon atoms; acyl having 1 to 12 carbon atoms; carboxylate having from l to 12 carbon atoms;
alkoxyl having from 1 to 12 carbon atoms; and aryloxy having from 6 to 12 carbon atoms). Exemplary - substituted a-monoolefins are vinyl chloride, vinyl bromide, vinylidene chloride, acrylic acid, methacrylic acid, ethyl acrylate, n-butyl acrylate, i-butyl acrylate, diethyl acrylate, diethyl maleate, ethyl hydrogen maleate, methyl ethacrylate, dibutyl itaconate, vinyl acetate., vinyl propionate, vinyl benzoate, vinyl ethyl ether, methyl vinyl ketone, acrylamide, acrylonitrile and the like.
Other suitable polymers include those based on carboxylic acids having from 3 to 8 carbon atoms (e.g., ethylene vinyl acetate and ethylene acrylic acid), and partially hydrolyzed copolymers thereof (e.g., ethylene vinyl alcohol); alkyl or haloalkyl esters of carboxylic acid wherein the alkyl or haloalkyl has from 1 to 12 carbon atoms; a-alkenyls having 2 to 12 carbon atoms;
36,241-F -4_ acyls having 1 to 12 ~arbon atoms; carboxylates having ~-rom 1 to l~ carbon atoms: alkoxyls havlng rrom 1 tO
12 carbon atoms; aryloxys havl~.b ;rum o t~ 1~ edrbOIl atoms; rubbery ethylene-propylene-diene terpolymers;
polyesters and copolyesters such as those polyesters and copolyesters whose synthesis employs at least one polyhydric alcohol and at least one dibasic acid (e.g., polyethylene terephthalate, and the like); the poly-etheramides; the polyamides (e.g., polycaprolactam); the polycarbonates (e.g., bisphenol A,); the polyester carbonates; the polyimides; the vinyl aromatics such as styrene; and polymers based on vinyl aromatics copolymerized with suitable monomers, including unsaturated nitriles (e.g., acrylonitrile, methacrylonitrile, and ethacrylonitrile~, and the conjugated 1,3-dienes (e.g., butadiene and isoprene).
This invention is advantageous for those plas-- tics wh;lch are commonly melt processed with processing aids, and;most advantageous for the extrusion of ther-mally sensitive plastics which are melt processed with processing aids. For the purposes of this invention, it is understood that the term "thermally sensitive" refers to any plastic which exhibits an undesirable change in properties, particularly physical properties, upon exposure to desirable processing temperatures.
Exemplary thermally sensitive plastics include polyvinylidene halide copolymers, polyvinyl halide copolymers and ethylene vinyl alcohol copolymers.
Suitable additives include, for example, colorants, pigments, non-elastomeric reinforcing agents, fillers, antiûxidants, stabilizers, etc., as long as these do not detrimentally affect the resulting 36,241-F -5_ uniformity of coating and completeness of surface cov-erage. ~ r~c~ mprlse~ phy~ically blending the n~;polymer wl~n ~he aaaltlves to ~orm a mlxtur~.
Methods of forming the plastic into pellets are well-known to those skilled in the art. Any method capable of forming the plastic into pellets is suitable for use in the present invention. For the purposes of this application, the terms "pellet" or "pellets" refer to particles having a minimum cross-sectional dimension of at least 1/32 inch, preferably at least 1/16 inch and most preferably at least 1/8 inch, said pellets suitably have a maximum cross-sectional dimension of at least 1/2 inch, preferably at least 3/8 inch and most preferably at least 1/4 inch. Exemplary of a method suitable for use in forming the pellets of the mixture is extru~ion through a strand die and pelletization by chopping the extruded strand into pellets.
~ .
By "processing aid" is meant any component which is employed to improve extrusion performance.
Although not intended to be bound by theory, it is believed that by applying the processing aid to the surface of the pellet the processing aid will, during melt processing, rapidly migrate to the metal surface of the melt processing equipment. Surface coated pro-cessing aids thereby provide relatively fast functioning compared to conventionally compounded processing aids, which require pellet melting prior to functioning.
Con~equently, a lower amount of the processing aid is necessary to achieve equivalent effects to the same processing aid blended with the plastic.
36,241-F -6-200079l4 Generally? the surface of the pellet will be ~oated with a processing id. wherein tne processing aid will b~ n amount OI DetWeen U.001 weight percent to 2 weight percent, said weight percents based on the weight of the pellet; preferably in an amount of between 0.01 weight percent to 1.5 percent, said weight percents based on the weight of the pellet; and most preferably in an amount of between 0.1 weight percent to 0.7 weight percent, said weight percents based on the weight of the pellet. Generally, within the suitable ranges, the higher the level of processing aid on the pellet sur-face, the more benefit one will see in terms of improv-ing extrudability of the plastic pellet.
Within the prescribed ranges, the choice of optimum amounts of processing aids will be dependent upon the the processing aid selected, the viscosity of the processing aid, the size of the pellet and the type - and size of the equipment through which the pellet is extruded.
Generally within the prescribed weight per-centage ranges for coating processing aids on the pellet surface, the inventor has found that the more processing aid which is coated on the pellet surface the more of a decrease in particulate degradation will be seen in the extrudate. Preferably, the pellet surface will be uniformly coated with the processing aid, that is to say, when compared to an uncoated pellet, 50 percent coverage of a pellet surface will produce somewhat decreased particulate degradation of the extrudate;
whereas 90 percent coverage of the same pellet will produce a still further ~mprovement in decreasing the particulate degradation in the extrudate. Similarly, 36,241-F -7-20009~4 within the ranges discussed above, the thicker the surface coating. the ~ore beneflt~ one Jill see .n terms of decreasing the particul~ a~gradallon ln the extrudate. If, however, the processing aid is applied in quantities excessive for the processing aid selected, the viscosity of the processing aid, the size of the pellet and the type and size of the equipment through which the pellet is extruded, the feeding of the pellet into the melt processing equipment may be impaired because of insufficient friction in the feed zone; or the excess amount of processing aid may form globules on the pellet surface.
The processing aids coated on the pe~let sur-face are those generally used for the conventional melt processing of plastics in either powder or pellet form.
The processing aid is ~elected to have a softening point between ambient temperatures and below the processing - tempera~ure of the plastic in pellet form. Preferably, the processing aid should have, within the preferred range, a softening point slightly above ambient temperatures to allow for rapid functioning and yet for easy handling, e.g., low pellet surface tackiness.
Within the above parameters, the specific processing ald selected will be a matter of choice for the skilled artisan, depending upon the desired results.
Exemplary processing aids include lubricants and olefin polymers. The choice of specific processing aids for specific plastics will be a matter of choice well within the means of one skilled in the art. Exem-plary factors in selecting a processing aid, although not all factors are important for all polymers, include 36,241-F -8-melt adhesion. fusion delay, viscosity reduction and an ~xtruslon l~te lncrease at a glven r?m.
Lubricants include both internal and external lubricants which improve extrusion performance of the plastic. By "internal lubricant" is meant any of the classes of compounds that have heretofore been employed as internal lubricants in plastics. Although not intended to be bound by theory, the lubricants are classified as "internal" because they increase the ease with which the polymer molecules slip past one another, resulting in reduced melt viscosity, better flow, and lower energy to extrude requirements for melt pro-cessing. The compositions may perform functi-ons in addition to that mechanism referred to as internal lubrication.
.
By "external lubricant" is meant any of the - class o-~ compounds that have heretofore been employed as external lubricants in plastics. Although not intended to be bound by theory, the lubricants are classified as "external" because they are believed to be at least partially incompatible with the molten polymer. The lubricant will therefore migrate to the surface of the molten polymer and form a film between the polymer and the heated metal surface of the extruder, mill or other equipment used to process the polymer composition. This film ~ignificantly reduces the tendency of the polymer to adhere to these metal surfaces and degrade. The compositions may perform functions in addition to that mechanism referred to as external lubrication.
Exemplary lubricants include fatty acids (e.g., stearic acid); esters (e.g., fatty esters, wax esters, 36,241-F _g_ glycerol esters. glycol esters, fatty alcohol esters, and the 'i'~); f`.~r,ty alcohols (e.g.. n-stearyl alcohol);
fa~y amlaes ~e.g., N,N'-ethylene bis stearamide);
metallic salts of fatty acids (e.g., calcium stearate, zinc stearate, magnesium stearate, aluminum stearate, sodium stearate, tin stearate, sodium lauryl sulfate, and the like); and polyolefin waxes (e.g., paraffinic, nonoxidized and oxidized polyethylene and the like).
The term "olefin polymer" includes homopolymers and copolymers of a-monoolefins and substituted a-mono-olefins, particularly a-monoolefins or substituted a-monoolefins having from 4 to 12 carbon atoms. Exem-plary a-monoolefin polymers include polyethylene (e.g., ultra-low density polyethylene, low density polyethyl-ene, linear low density polyethylene, medium density polyethylene, high density polyethylene); polypropylene;
poly(butene-1), poly(isobutylene); poly(1-pentene);
- poly(1-hexene) and poly(1-octene).
Substituted a-monoolefins include those wherein the sub~tituents can be halo, alkyl or haloalkyl having from 1 to 12 carbon atoms; carboxylic acid having from 3 to 8 carbon atoms; alkyl or haloalkyl ester of car-boxylic acid wherein alkyl or haloalkyl has from 1 to 12 carbon atoms; a-alkenyl having 2 to 12 carbon atoms;
acyl having 1 to 12 carbon atoms; carboxylate having from 1 to 12 carbon atoms; alkoxyl having from 1 to 12 carbon atoms;' and aryloxy having from 6 to 12 carbon atoms.
The a-monoolefins and substituted a-monoolefins may also be copolymerized with a variety of suitable comonomers such as carboxylic acids having from 3 to 8 36,241-F -10-carbon atoms (e.g.. ethylene vinyl acetate. and ethylene acryl.c acid)~ vl or haloalkyl esters QI car~oxyli~
acid wherein alkyl or Idlo~lKyl nas ~om l to l~ carbon atoms; ~-alkenyls having 2 to 12 carbon atoms; acyls having 1 to 12 carbon atoms; carboxylates having from l to 12 carbon atoms; alkoxyls having from 1 to 12 carbon atoms; aryloxys having from 6 to 12 carbon atoms; and a-monoolefin/a-monoolefin copolymers (e.g., ethylene/propylene copolymers).
The processing aid is then charged into the blender for fur~her mixing of the preheated pellet and processing aid until the processing aid fuses onto the pellet surface.
The oellets are prepared for coating by being mixed in a high intensity blender. By "high intensity"
blender is meant mixers that can apply about 10 horse - power per cubic foot of material with high ~hear rate, ~ith a maximum of 20,000 sec~l. Exemplary high intensity blenders include Banbury mixers, Prodex--Henschel mixers, and Welex-Papenmeier mixers.
Such blenders typicaily have an impeller for mixing and applying energy to the batch, and a baffle for directing the motion of the product to the center of the vortex. Such blenders also have a jacket sur-rounding the mixing bowl so that cooling may be applied.
Generally, the blender impeller is run at a tip speed of between 2000 feet per minute (fpm) to 4000 fpm, preferably between 2500 fpm to 3000 fpm. The degree o~ deflection of the blender baffle may be 36,241-F -11-2~)00914 adjusted from 45 to 0~. and preferably between 15 to !`, wnere ~ e~ers ~o a ~adial orientation.
The pellet surface will be heated to a tem-perature of at least about 10C, preferably about 5C, below the temperature at which the processing aid will soften and fuse. Persons skilled in the art recognize that mixing times will vary with the blending technique, apparatus and the choice of processing aid.
The pellets will be mixed until their surface temperature is above that of the temperature required to soften the processing aid, but below the softening point of the plastic. Water may be passed through a water jacket to maintain control of the heating of the pellet surface at a temperature of between the softening point of the processing aid and below the softening point of the plastic.
, After being surface coated, the pellet then may be melt processed and extruded into any suitable final product. The process of the present invention can be used to form a variety of films or other articles.
As is well-known in the art, the films and articles may be fabricated with conventional coextru-sion, e.g, feedblock coextrusion, multimanifold die coextrusion or combinations of the two; injection molding; extrusion molding and lamination techniques.
Articles formed therefrom include blown and cast, mono and multilayer, films; rigid and foam sheet; tubes;
pipes; rods; fibers and various profiles. Lamination techniques are particularly suited to produce multi-ply sheets. As is known in the art, specific laminating 36,241-F -12---l 3--techniques include fusion, wet combining or heat reac-t,vatlon. ~uslon ;~omprises ~?ona ng seiI-sustaining ;dmlna together~ by applications oY heat and pressure.
Wet combining comprises laminating two or more plies by using a tie coat adhesive, which is applied wet;
driving off the liquid and combining, by subsequent pressure laminating, in one continuous process. Heat reactivation comprises combining a precoated film with another film by heating and reactivating the precoat adhesive so that it becomes receptive to bonding after subsequent pressure laminating.
The present invention is illustrated in further detail by the following examples. The e~amples are for the purposes of illustration only, and are not to be construed as limiting the scope of the present inven-tion. All parts and percentages are by weight unless otherwise specifically noted.
36,241-F -13_ 20009~4 Examples TA~L~ I
Code Polymer comPonents PVdC A pellet of a polymeric composition compris-Pellet ing a 96.5% base resin, 1.5% ethylene vinyl acetate, 1.2% tetrasodium pyrophosphate and 0.8% epoxidized soybean oil. The base resin is polymerized from a monomer mixture con-taining 80 weight percent vinylidene chloride and 20 weight percent vinyl chloride, said resin having a major melting point of 164G, and a molecular weight of 80,000.
L-1 An oxidized polyethylene commercially avail-able under the trade designation as Allied 629A from Allied Corp. The oxidized polyeth-ylene has a density (ASTM Test D-1505) of 0.93 grams per cubic centimeter ~ 20C, a drop point of 104C and a Brookfield Viscosity of 200 cps @ 140C.
L-2 A polyethylene wax commercially available from _ Allied Corp. under the trade designation Allied 617A. The polyethylene wax has a density (ASTM Test D-1505) of 0.91 grams per cubic centimeter, a drop point of 102C and a Brookfield Viscosity of 180 cps @ 140C.
L-3 An ethylene/vinyl acetate copolymer having polymerized therein 72 weight percent ethylene and-28 weight percent vinyl acetate, both percentages being based upon copolymer weight.
The copolymer has a melt index (ASTM Test D-1238) of 22 to 27 decigrams per minute and a density (ASTM Test D-1238) of 0.98 grams per cubic centimeter. The copolymer is commercially available from DuPont under the trade designation Elvax 3180.
36,241-F -14--- l 5--Sample Preparation ~ r. ~ ll; ~h ~n~ e~
which is commercially available under the trade desig-nation Welex Model 35 from F. H. Papenmeier K.G. Com-pany. The mixer has a diameter of 35 cm, and a nominalcapacity of 1 cubic foot. The baffle of the mixer is adjusted in the radial direction, the impeller is started and the tip speed is adjusted to about 2700 feet per minute (fpm). When the pellet temperature reaches 75C, various processing aids, coded in Table I, are charged in the mixer in quantities set forth in Table II. The pellets and processing aids are blended for a period of about eight minutes and discharged. The discharged material is cooled to about 65C, by circulating 20C air.
_ Fusion Testin~
Extrudability is determined by measuring the fusion time of the pellet as it is melt processed. The pellets are placed in the bowl of a Brabender~ torque rheometer. The bowl is maintained at a temperature of 170C and the speed of the blades is about 60 rpm.
A sample of coated pellets, weighing 80 grams is charged in the rheometer, and the fusion times are determined. The fusion time for the pellets is 60 sec-3 onds, and the maximum torque is 960 meters/gram. Arelatively short Pusion time will cause degradation and discoloration of the molten polymer, resulting from a prolonged exposure to heat while in the molten state.
The maximum torque value, a measure of the mechanical energy necessary to cause fusion, should be from about 36,241-F -15-1800 to about 2500 meter grams. Higher torque values will resul~. in an e~cessiYely hig~ current demand and posslDly a~mage to the extruder motor.
The results are set forth in Table II.
36,241-F -16-~- ~. r~ . r, I
Coatinq3 Exam- Pellet ProcessingWeightFusion Fusion e~ Code~Aid PercentTime~Torque3 PVdC L-l 0.33 >600 NF
Pellet 2 PVdC L-1 0.06 >600 NF
Pellet 3 PVdC L-2 0.33 >600 NF
Pellet 4 PVdC L-2 0.3 -- --Pellet PVdC L-3 0 33 30-40 770 1 5 Pellet 6 PVdC L-3 0.3 15 820 Pellet 7 PVdC L- 1 0.06 30-40 680 Pellet L-3 0.3 -- = not measured.
Pellet type as set forth in Table I.
Coating = (a) processing aid and (b) amount of processing aid coating on pellet in weight percent.
~ Fusion Time in sec.
Fusion Torque in sec. "NF" means that no fusion occurs by the time the test is terminated after 600 seconds.
Examples 8-16 The procedures of Examples 1-7, respectively, are repeated with the following exception: instead of 36,241-F -17-the vinylidene chloride-vinyl chloride copolymer, the pellets are :llaàe of a polyme.ic composition comprlslng a 9~.~ percent base resin, 1.5 per~ elnylene vlllyl acetate, 1.2 percent tetrasodium pyrophosphate and 0. 8 percent epoxidized soybean oil. The base resin is polymerized from a monomer mixture containing 94 weight percent vinylidene chloride and 6 weight percent methyl acrylate, said resin having a major melting point of 164C, and a molecular weight of 90,000.
The pellets exhibited a relatively long fusion time and low fusion torque.
ExamPle 17 The procedures of Example 5, respectively, are repeated with the following exception: Instead of the _ vinylidene chloride-vinyl chloride copolymer, the pel-lets are made of a polyvinyl chloride copolymer.
The pellets exhibited a relatively long fusion time and low fusion torque.
Example 18 The procedures of Example 5 are repeated with the following exception: instead of the vinylidene 3 chloride-vinyl chloride copolymer, the pellets are made of polyethylene terephthalate copolymer.
The pellets exhibited a relatively long fusion time and low fusion torque.
36,241-F -18-,9 Example l~
The procedures of Example 5 are repeated with the following exceptions: instead of the vinylidene chloride-vinyl chloride copolymer, the pellets are made of polypropylene.
The pellets exhibited a relatively long fusion time and low fusion torque.
Example 20 The procedures of Example 5 are repeated with the following exceptions: instead of the vinylidene chloride-vinyl chloride copolymer, the pGi;ets are made of a polystyrene.
.
The pellets exhibited a relatively long fusion t'ime and low fusion torque.
Example 21 The procedures of Example 5 are repeated with the following exceptions: instead of the vinylidene chloride-vinyl chloride copolymer, the pellets are made of a high impact polystyrene.
3o The pellets exhibited a relatively long fusion time and low fusion torque.
36,241-F -19-Example 22 The ~ h the following exception: instead of the vinylidene chloride-vinyl chloride copolymer, the pellets are made of polycarbonate.
The pellets exhibited a relatively long fusion time and low fusion torque.
Although the invention has been described in considerable detail, with reference to certain preferred embodiments thereof, it will be understood that variations and modifications can be affected within the spirit and scope of the invention as described above and as defined in the appended claims.
3o 36,241-F -20-
Claims (20)
1. A process for preparing a pellet having improved extrudability, which process comprises the steps of:
(A) providing a plastic in pellet form, and a processing aid having a softening point between ambient temperatures and below the processing temperature of the plastic in pellet form;
(B) charging the pellet into a high intensity blender, said blender having an impeller;
(C) rotating the blender impeller at a speed and for a period of time effective to raise the temperature of the pellet surface to between about 5°C and 10°C below the softening point of the processing aid;
(D) charging the processing aid into the blender such that the processing aid contacts the heated pellet surface; and (E) rotating the blender impeller at a speed and for a period of time effective to raise the temperature of the pellet surface 36,241-F -21-to a temperature above the softening point of the processing aid, and to coat a portion of the pellet surface by fusing the processing aid thereto.
(A) providing a plastic in pellet form, and a processing aid having a softening point between ambient temperatures and below the processing temperature of the plastic in pellet form;
(B) charging the pellet into a high intensity blender, said blender having an impeller;
(C) rotating the blender impeller at a speed and for a period of time effective to raise the temperature of the pellet surface to between about 5°C and 10°C below the softening point of the processing aid;
(D) charging the processing aid into the blender such that the processing aid contacts the heated pellet surface; and (E) rotating the blender impeller at a speed and for a period of time effective to raise the temperature of the pellet surface 36,241-F -21-to a temperature above the softening point of the processing aid, and to coat a portion of the pellet surface by fusing the processing aid thereto.
2. The process of Claim 1, wherein the plas-tic comprises a polymer formed from a monomer selected from the group consisting of .alpha.-monoolefins, substituted .alpha.-monoolefins and copolymers formed therewith; carbox-ylic acids having from 3 to 8 carbon atoms, and par-tially hydrolyzed copolymers thereof; alkyl or haloalkyl esters of carboxylic acid wherein the alkyl or haloalkyl has from 1 to 12 carbon atoms; .alpha.-alkenyls having 2 to 12 carbon atoms; acyls having 1 to 12 carbon atoms;
carboxylates having from 1 to 12 carbon atoms; alkoxyls having from 1 to 12 carbon atoms; aryloxys having from 6 to 12 carbon atoms; rubbery ethylene-propylene-diene terpolymers; polyesters and copolyesters; the polyetheramides; the polyamides; the polycarbonates; the polyester carbonates; the polyimides; and the vinyl aromatics such as styrene, and copolymers formed therewith.
carboxylates having from 1 to 12 carbon atoms; alkoxyls having from 1 to 12 carbon atoms; aryloxys having from 6 to 12 carbon atoms; rubbery ethylene-propylene-diene terpolymers; polyesters and copolyesters; the polyetheramides; the polyamides; the polycarbonates; the polyester carbonates; the polyimides; and the vinyl aromatics such as styrene, and copolymers formed therewith.
3. The process of Claim 1, wherein the pro-cessing aid is selected from the group consisting of lubricants and olefin polymers.
4. The process of Claim 3, wherein the lub-ricant is selected from the group consisting of fatty acids; esters; fatty alcohols; fatty amides; metallic stearates; and polyolefin waxes.
36,241-F -22-
36,241-F -22-
5. The process of Claim 1, wherein the blender impeller in step (c) is run at a tip speed of between 1000 fpm and 6000 fpm.
6. The process of Claim 5, wherein the blender impeller in step (e) is run at a tip speed of between 1000 fpm and 4000 fpm.
7. The process of Claim 1, wherein the pro-cessing aid is coated on the pellet surface at a level of between 0.001 weight percent and 2 weight percent, said weight percents based on the total weight of the pellet.
8. The process of Claim 7, wherein the pro-cessing aid is coated on the pellet surface at a level of between 0.01 weight percent and 1.5 weight percent, said weight percents based on the total weight of the pellet.
9. The process of Claim 8, wherein the pro-cessing aid is coated on the pellet surface at a level of between about 0.1 weight percent and about 0.7 weight percent, said weight percents based on the total weight of the pellet.
10. A process for preparing a pellet having improved extrudability, which process comprises the steps of:
(A) providing a plastic in pellet form, and a processing aid, said processing aid being selected from the group consisting of fatty 36,241-F -23-acids; esters; fatty alcohols; fatty amides;
metallic stearates: and polyolefin waxes;
(B) charging the pellet into a high intensity blender, said blender having an impeller;
(C) rotating the blender impeller at a speed of between 2000 fpm and 3000 fpm for a period of time effective to raise the temperature of the pellet surface to between 5°C and 10°C below the softening point of the processing aid;
(D) charging the processing aid into the blender such that the processing aid contacts the heated pellet surface; and (E) rotating the blender impeller at a speed of between 2500 fpm and 3000 fpm for a period of time effective to raise the temperature of the pellet surface to a temperature above the softening point of the processing aid, and to coat a portion of the pellet surface by fusing the processing aid thereto.
(A) providing a plastic in pellet form, and a processing aid, said processing aid being selected from the group consisting of fatty 36,241-F -23-acids; esters; fatty alcohols; fatty amides;
metallic stearates: and polyolefin waxes;
(B) charging the pellet into a high intensity blender, said blender having an impeller;
(C) rotating the blender impeller at a speed of between 2000 fpm and 3000 fpm for a period of time effective to raise the temperature of the pellet surface to between 5°C and 10°C below the softening point of the processing aid;
(D) charging the processing aid into the blender such that the processing aid contacts the heated pellet surface; and (E) rotating the blender impeller at a speed of between 2500 fpm and 3000 fpm for a period of time effective to raise the temperature of the pellet surface to a temperature above the softening point of the processing aid, and to coat a portion of the pellet surface by fusing the processing aid thereto.
11. A pellet made by the process of Claim 1.
12. A pellet made by the process of Claim 4.
13. A pellet made by the process of Claim 10.
14. A composition, in the form of an extrudable pellet, which comprises a plastic, said pellet having a processing aid fused on the surface thereof at a level effective to improve the extrudability of the pellet.
36,241-F -24-
36,241-F -24-
15. The composition of Claim 16, wherein the plastic comprises a polymer formed from a monomer selected from the group consisting or .alpha.-monoolefins, substituted .alpha.-monoolefins, and copolymers formed there-with; carboxylic acids having from 3 to 8 carbon atoms, and partially hydrolyzed copolymers thereof; alkyl or haloalkyl esters of carboxylic acid wherein the alkyl or haloalkyl has from 1 to 12 carbon atoms; .alpha.-alkenyls having 2 to 12 carbon atoms; acyls having 1 to 12 carbon atoms; carboxylates having from 1 to 12 carbon atoms;
alkoxyls having from 1 to 12 carbon atoms; aryloxys having from 6 to 12 carbon atoms; rubbery ethylene--propylene-diene terpolymers; polyesters and copolyesters; the polyetheramides; the polyamides; the polycarbonates; the polyester carbonates; the poly-imides; and the vinyl aromatics such as styrene, and copolymers formed therewith.
alkoxyls having from 1 to 12 carbon atoms; aryloxys having from 6 to 12 carbon atoms; rubbery ethylene--propylene-diene terpolymers; polyesters and copolyesters; the polyetheramides; the polyamides; the polycarbonates; the polyester carbonates; the poly-imides; and the vinyl aromatics such as styrene, and copolymers formed therewith.
16. The composition of Claim 15, wherein the processing aid is coated on the pellet surface at a level of between about 0.001 weight percent and about 2 weight percent, said weight percents based on the total weight of the pellet.
17. The composition of Claim 16, wherein the processing aid is coated on the pellet surface at a level of between 0.01 weight percent and 1.5 weight percent, said weight percents based on the total weight of the pellet.
18. The composition of Claim 17, wherein the processing aid is coated on the pellet surface at a level of between 0.1 weight percent and 0.7 weight 36,241-F -25-percent, said weight percents based or the total weight of the pellet.
19. The composition of Claim 14, wherein the processing aid is selected from the group consisting of lubricants and olefin polymers.
20. The composition of Claim 19, wherein the lubricant is selected from the group consisting of fatty acids; esters; fatty alcohols; fatty amides; metallic stearates; and polyolefin waxes.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US25993788A | 1988-10-19 | 1988-10-19 | |
| US259,937 | 1988-10-19 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2000914A1 true CA2000914A1 (en) | 1990-04-19 |
Family
ID=22987070
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002000914A Abandoned CA2000914A1 (en) | 1988-10-19 | 1989-10-18 | Plastic pellets coated with processing aid and method of coating |
Country Status (6)
| Country | Link |
|---|---|
| EP (1) | EP0439491A4 (en) |
| JP (1) | JPH04501089A (en) |
| KR (1) | KR900701406A (en) |
| AU (1) | AU4415189A (en) |
| CA (1) | CA2000914A1 (en) |
| WO (1) | WO1990004463A1 (en) |
Families Citing this family (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE4229088A1 (en) * | 1992-09-01 | 1994-03-03 | Du Pont Deutschland | Lubricant-containing pellets based on thermoplastic materials, process for their production and their use |
| DE4341628C2 (en) * | 1993-12-07 | 1996-05-30 | Rehau Ag & Co | Process for the production of medical work equipment |
| CA2232146A1 (en) * | 1997-06-30 | 1998-12-30 | Basf Corporation | Improved process for producing customized thermoplastic resins |
| US5846607A (en) * | 1997-06-30 | 1998-12-08 | Basf Corporation | Process for producing customized thermoplastic resins |
| US5919530A (en) * | 1997-06-30 | 1999-07-06 | Basf Corporation | Process for producing customized thermoplastic resins |
| CA2232148A1 (en) * | 1997-06-30 | 1998-12-30 | Basf Corporation | Improved process for producing customized thermoplastic resins |
| CA2232108A1 (en) * | 1997-06-30 | 1998-12-30 | Mary E. Tuttle | Reduced cost process for producing customized thermoplastic resins |
| JP4527818B2 (en) * | 1999-03-16 | 2010-08-18 | 日本合成化学工業株式会社 | Saponified pellet of ethylene-vinyl acetate copolymer |
| JP5272354B2 (en) * | 2007-08-30 | 2013-08-28 | 住友化学株式会社 | Method for producing methacrylic resin molding material |
| WO2023106330A1 (en) * | 2021-12-08 | 2023-06-15 | 三菱ケミカル株式会社 | Methacrylic resin molding material, resin molded article, vehicle member, housing equipment member, optical member, medical member, container, and method for manufacturing resin molded article |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2839422A (en) * | 1956-02-17 | 1958-06-17 | Dow Chemical Co | Method for lubricating polystyrene granules and enhanced molding granules thereby obtained |
| GB1237144A (en) * | 1968-07-26 | 1971-06-30 | Pfizer Ltd | Coating method |
| NL7605062A (en) * | 1975-05-15 | 1976-11-17 | Bayer Ag | PROCESS FOR THE PREPARATION OF AN ADDITIONAL PLASTIC GRANULATE. |
| JPS5856568B2 (en) * | 1977-02-04 | 1983-12-15 | 日立化成工業株式会社 | Novel expandable styrenic resin particles and their manufacturing method |
| US4483886A (en) * | 1982-05-27 | 1984-11-20 | Exxon Research & Engineering Co. | Method for making free-flowing, melt-coated rubber pellets |
-
1989
- 1989-10-13 JP JP1510938A patent/JPH04501089A/en active Pending
- 1989-10-13 WO PCT/US1989/004575 patent/WO1990004463A1/en not_active Application Discontinuation
- 1989-10-13 KR KR1019900701291A patent/KR900701406A/en active IP Right Grant
- 1989-10-13 EP EP19890911670 patent/EP0439491A4/en not_active Withdrawn
- 1989-10-13 AU AU44151/89A patent/AU4415189A/en not_active Abandoned
- 1989-10-18 CA CA002000914A patent/CA2000914A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| EP0439491A1 (en) | 1991-08-07 |
| AU4415189A (en) | 1990-05-14 |
| EP0439491A4 (en) | 1991-11-27 |
| WO1990004463A1 (en) | 1990-05-03 |
| JPH04501089A (en) | 1992-02-27 |
| KR900701406A (en) | 1990-12-03 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US5236649A (en) | Extrudable thermoplastic particulates | |
| US5006368A (en) | Plastic particle coated with processing aid and method of coating | |
| US4239679A (en) | High bulk density rigid poly(vinyl chloride) resin powder composition and preparation thereof | |
| JPS5891736A (en) | Granulation of filler | |
| US3645931A (en) | Blowing agent compositions | |
| EP1395407B1 (en) | Method of compounding a multimodal polyethylene composition | |
| CA2000914A1 (en) | Plastic pellets coated with processing aid and method of coating | |
| EP0330153A2 (en) | Rigid thermoplastic compositions capable of forming articles with matte surface | |
| JPH0579086B2 (en) | ||
| EP0275003A2 (en) | Incorporation of chemically reactive agents on resin particles | |
| KR100595352B1 (en) | Vinylidene chloride polymer compositions, and the structure and rigid container comprising the same | |
| JP2000264972A (en) | Pellet of saponified material of ethylene-vinyl acetate copolymer | |
| CN104125974A (en) | Process of incorporating solid inorganic additives into solid polymers using a liquid dispersion | |
| AU3768999A (en) | Extrudable vinylidene chloride polymer compositions | |
| JPH03504023A (en) | Extrusion formulation package for thermosensitive resins and polymer compositions comprising said package | |
| WO2010030590A2 (en) | Soft, pelletized poly(vinyl chloride) plastisol | |
| AU640627B2 (en) | Extrudable thermoplastic pellet | |
| JPS6356894B2 (en) | ||
| JPS641493B2 (en) | ||
| JP3073758B2 (en) | Vinylidene chloride resin composition | |
| CN113912929A (en) | Foaming master batch and preparation method and application thereof | |
| CN116194530A (en) | High molecular weight acrylic processing aid concentrate for thermoplastic processing | |
| EP0434763A4 (en) | Vinylidene chloride interpolymer | |
| JP2003515649A (en) | Use of substituted polyethyleneimines for the continuous improvement of adhesion and / or coating compatibility of polyolefin-based moldings, fibers and films | |
| JPH06157885A (en) | Polybutylene terephthalate resin composition |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |