Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2205/00—Polymer mixtures characterised by other features
  • C08L2205/22—Mixtures comprising a continuous polymer matrix in which are dispersed crosslinked particles of another polymer
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2207/00—Properties characterising the ingredient of the composition
  • C08L2207/53—Core-shell polymer
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2312/00—Crosslinking

Definitions

• the present invention relates to a polymeric resin composition
• a polymeric resin composition comprising a multistage polymer and a (meth) acrylic polymer and a composite material or part containing such a composition ..
• the present invention relates to a polymeric resin composition
• a polymeric resin composition comprising a multistage polymer in form of polymeric particles made by a multistage process and a
• (meth) acrylic polymer while the (meth) acrylic polymer possesses a medium molecular weight.
• the present invention relates to polymer composition
• Mechanical or structured parts or articles or structural adhesives that have to absorb high stresses during their use are widely manufactured from polymeric materials. While mechanical or structured parts or articles are usually composite materials, the structural adhesives can be purely polymeric.
• a composite material is a macroscopic combination of two or more non miscible materials. The composite material constitutes at least of a matrix material that forms a continuous phase for the cohesion of the structure and a reinforcing material with various architectures for the mechanical properties .
• composite materials are widely used in several industrial sectors as for example building, automotive, aerospace, transport, leisure, electronics, and sport notably due to their better mechanical performance (higher tensile strength, higher tensile modulus, higher fracture toughness) in comparison with homogenous materials and their low density.
• the principal matrix or continuous phase of a polymeric composite material is either a thermoplastic polymer or a thermosetting polymer.
• Thermosetting polymers consist of crosslinked three dimensional structures.
• the crosslinking is obtained by curing reactive groups inside the so called prepolymer. Curing for example can be obtained by heating the polymer chains in order to crosslink and harden the material permanently.
• prepolymer In order to prepare the polymeric composite material the prepolymer is mixed with the other component such as glass beads or fibres or the other component which is wetted or impregnated and cured afterwards.
• the other component such as glass beads or fibres or the other component which is wetted or impregnated and cured afterwards.
• prepolymers or matrix material for thermoset polymers are unsaturated polyesters, vinylesters, epoxy or phenolic ones.
• thermosetting resins once cured have excellent properties in view of dimensional stability, mechanical strength, electrical insulating properties, heat resistance, water resistance and chemical resistance.
• thermosetting resins are for example epoxy resins or phenolic resins.
• cured resins have small fracture toughness and are brittle.
• Thermoplastic polymers consist of linear or branched polymers, which are not crosslinked.
• the thermoplastic polymers can be heated in order to mix the constituents necessary (for example a fibrous substrate and thermoplastic polymer for matrix) for producing the composite material and to be cooled for setting.
• the wetting or correct impregnation of the fibers by the thermoplastic polymer can only be achieved, if the thermoplastic resin is sufficiently fluid.
• Another way for impregnating the fibrous substrate is to dissolve the thermoplastic polymer in an organic solvent or using a syrup based on monomers or a mixture or monomers and polymers .
• thermoplastic polymer matrix In order to guarantee and obtain a satisfying mechanical performance over a large temperature range, the impact performance of the thermoplastic polymer matrix has to be increased.
• impact modifiers in form of core-shell particles are made by a multistage process, with at least stage comprising a rubber like polymer. Afterwards the particles are incorporated in the brittle polymers for composite material or the one of the phases for the structural adhesives, in order to increase the impact resistance of the finished product.
• the present invention aims to obviate or at least mitigate the above described problems and/or to provide improvements generally .
• a resin system comprising at least one resin component, ii. a curative system, and
• a particle system comprising a multistage polymeric particle comprising a polymer composition (PCI) comprising
• one stage (A) comprising a polymer (Al) having a glass transition temperature of less than 10°C b)
• one stage (B) comprising a polymer (Bl) having a glass transition temperature of at least 60°C and c) and a polymer (CI) having a glass transition temperature of at least 30°C
• composition (PCI) wherein at least the component a) and the component b) of composition (PCI) are part of a multistage polymer (MP1), and characterized in that the polymer (CI) has a mass average molecular weight Mw of at least 100 OOOg/mol and that the component c) represents at most 40wt% of the composition based on the total weight of.
• MP1 multistage polymer
• An objective of the present invention is to propose a multistage polymer composition which is rapidly and easily dispersible in reactive epoxy resins, polyester resins or
• Another objective of the present invention is also to propose a multistage polymer composition which is easily dispersible in reactive epoxy resins, polyester resins or (meth) acrylic resins/polymers or liquid monomers or resins in form of a polymer powder .
• An additional objective of the present invention is to propose a multistage polymer composition in form of a dry polymer powder which is easily dispersible in reactive epoxy resins, polyester resins or (meth) acrylic resins/polymers or liquid monomers or resins.
• Another objective of the present invention is to propose a method for making a multistage polymer composition which is easily dispersible in in reactive epoxy resins, polyester resins or
• Still another objective of the present invention is a method for manufacturing a dry multistage polymer composition which is easily dispersible in in reactive epoxy resins, polyester resins or (meth) acrylic resins/polymers or liquid monomers or resins.
• the document W02016/ 102666 discloses a composition comprising a multistage polymer and its method of preparation.
• the composition comprises as well a (meth) acrylic polymer that has a mass average molecular weight of less than 100 OOOg/mol.
• the document WO2016/102682 discloses a multistage polymer composition and its method of preparation.
• the multistage polymer comprises a last stage that comprises a (meth) acrylic polymer that has a mass average molecular weight of less than 100 OOOg/mol
• the document FR 2934866 discloses polymer preparation of a specific core shell polymers with functional shell comprising hydrophilic monomers, The core shell polymers are used as impact modifier in thermoset polymers .
• the document EP 1 632 533 describes a process for producing modified epoxy resin.
• the epoxy resin composition is having rubber like polymer particles dispersed in it by a process that brings the particles in contact with an organic medium that disperses the rubber particles.
• the document EP 1 666 519 discloses a process for producing rubbery polymer particle and process for resin composition containing the same.
• the document EP 2 123 711 discloses a thermosetting resin composition having a rubbery polymer particles dispersed therein and process for production thereof.
• None of the prior art documents discloses a multistage polymer combined with a (meth) acrylic polymer having a medium molecular weight.
• PCI polymer composition
• one stage (A) comprising a polymer (Al) having a glass transition temperature of less than 10°C b)
• one stage (B) comprising a polymer (Bl) having a glass transition temperature of at least 60°C and c) and a polymer (CI) having a glass transition temperature of at least 30°C
• composition (PCI) are part of a multistage polymer (MP1), and characterized in that the polymer (CI) has a mass average molecular weight Mw of at least 100 OOOg/mol and that the component c) represents at most 40wt% of the composition based on a) , b) and c) ; can be easily dispersed in a polymeric matrix material for thermosetting polymers or thermoplastic polymers or its precursors.
• MP1 multistage polymer
• PCI polymer composition
• the polymer (CI) has a mass average molecular weight Mw of at least 100 OOOg/mol and that the component c) represents at most 40wt% of the composition based on a) , b) and c) ; yields to a polymer composition in form of polymer particles that be easily dispersed in a polymeric matrix material for thermosetting polymers or thermoplastic polymers or its precursors .
• PCI polymer composition
• the polymer (CI) has a mass average molecular weight Mw of at least 100 OOOg/mol and that the component c) represents at most 40wt% of the composition obtained in steps a) , b) and c) ; yields to a polymer composition in form of polymer particles that be easily dispersed in a polymeric matrix material for thermosetting polymers or thermoplastic polymers or its precursors.
• a polymeric composition (PC2) comprising
• PCI polymer composition
• one stage (A) comprising a polymer (Al) having a glass transition temperature of less than 10°C b)
• one stage (B) comprising a polymer (Bl) having a glass transition temperature of at least 60°C and c) and a polymer (CI) having a glass transition temperature of at least 30°C
• composition (PCI) characterized in that at least the component a) and the component b) of composition (PCI) are part of a multistage polymer (MP1), and characterized that the polymer (CI) has a mass average molecular weight Mw of at least 100 OOOg/mol and that the component c) represents at most 40wt% of the composition based on a) , b) and c) ; possesses satisfying impact properties.
• MP1 multistage polymer
• a particle system comprising a multistage polymeric particle comprising a polymer composition (PCI) comprising
• one stage (A) comprising a polymer (Al) having a glass transition temperature of less than 10°C b)
• one stage (B) comprising a polymer (Bl) having a glass transition temperature of at least 60°C and c) and a polymer (CI) having a glass transition temperature of at least 30°C
• composition (PCI) characterized in that at least the component a) and the component b) of composition (PCI) are part of a multistage polymer (MP1), characterized that the polymer (CI) has a mass average molecular weight Mw of at least 100 OOOg/mol and that the component c) represents at most 40wt% of the composition based on a) , b) and c) .
• MP1 multistage polymer
• the polymer (CI) has a mass average molecular weight Mw of at least 100 OOOg/mol
• component c) represents at most 40wt% of the composition based on a) , b) and c) .
• a method for manufacturing the polymer composition (PCI) comprising the steps of a) polymerizing by emulsion polymerization of a monomer or monomer mixture (A m ) to obtain one layer in stage (A) comprising polymer (Al) having a glass transition temperature of less than 10°C
• the polymer (CI) has a mass average molecular weight Mw of at least 100 OOOg/mol and that the component c) represents at most 40wt% of the composition based on a) , b) and c) .
• PCI polymer composition
• a particle system comprising a polymeric composition (PC2) comprising
• PCI polymer composition
• one stage (A) comprising a polymer (Al) having a glass transition temperature of less than 10°C b)
• one stage (B) comprising a polymer (Bl) having a glass transition temperature of at least 60°C and c) and a polymer (CI) having a glass transition temperature of at least 30°
• the polymer (CI) has a mass average molecular weight Mw of less than 100 OOOg/mol and that the component c) represents at most 40wt% of the composition based on a) , b) and c) .
• polymer powder as used is denoted a polymer comprising powder grain in the range of at least ⁇ obtained by agglomeration of primary polymer comprising particles in the nanometer range.
• system as used is denoted a single component or a mixture of multiple components.
• resin system as used is denoted a single resin component or a mixture of multiple resin components or resins.
• curative system as used is denoted a single curative component or a mixture of multiple curative components or curatives.
• particle system as used denoted a single particle or a mixture of multiple particles.
• primary particle as used is denoted a spherical polymer particle comprising particle in the nanometer range.
• the primary particle has a weight average particle size between 50nm and 500nm.
• particle size is denoted the volume average diameter of a particle considered as spherical.
• thermoplastic polymer as used is denoted a polymer that turns to a liquid or becomes more liquid or less viscous when heated and that can take on new shapes by the application of heat and pressure.
• intermediate molecular weight as used is denoted a mass average molecular weight Mw in the range from 100 OOOg/mol to 1 000 OOOg/mol.
• thermosetting polymer as used is denoted a prepolymer in a soft, solid or viscous state that changes irreversibly into an infusible, insoluble polymer network by curing .
• polymer composite as used is denoted a multicomponent material comprising multiple different phase domains in which at least one type of phase domain is a continuous phase and in which at least one component is a polymer.
• copolymer as used is denoted that the polymer consists of at least two different monomers.
• multistage polymer as used is denoted a polymer formed in sequential fashion by a multi-stage polymerization process.
• Preferred is a multi-stage emulsion polymerization process in which the first polymer is a first-stage polymer and the second polymer is a second-stage polymer, i.e., the second polymer is formed by emulsion polymerization in the presence of the first emulsion polymer, with at least two stages that are different in composition .
• (meth) acrylic as used is denoted all kind of acrylic and methacrylic monomers.
• (meth) acrylic polymer as used is denoted that the (meth) acrylic) polymer comprises essentially polymers comprising (meth) acrylic monomers that make up 50wt% or more of the (meth) acrylic polymer.
• dry as used is denoted that the ratio of residual water is less than 1.5wt and preferably less than lwt% .
• PCI polymer composition
• the polymer composition (PCI) comprises a) a polymer (Al) having a glass transition temperature of less than 10°C, b) a polymer (Bl) having a glass transition temperature of at least 60°C and c) and a polymer (CI) having a glass transition temperature of at least 30°C.
• the component c) represents at most 40wt% of the composition based on the total weight of.
• the component c) represents at most 35wt% of the composition based on a) , b) and c) ; more preferably at most 30wt%, still more preferably less than 30wt%, advantageously less than 25wt% and more advantageously less than 20wt%.
• the component c) represents more than 4wt% of the composition based on a) , b) and c) .
• the component c) represents more than 5wt% of the composition based on a) , b) and c) ; more preferably more than 6wt%, still more preferably more than 7wt%, advantageously more than 8wt% and more advantageously more than 10wt%.
• the component c) represents between 4wt% and 40wt% of the composition based on the total weight of.
• the component c) represents between 5wt% and 35wt% of the composition based on a) , b) and c) ; more preferably between 6wt% and 30wt%, still more preferably between 7wt% and less than 30wt%, advantageously between 7wt% and less than 25wt% and more advantageously between 10wt% and less than 20wt%.
• At least the component a) and the component b) of composition (PCI) are part of a multistage polymer (MP1) .
• At least the component a) and the component b) are obtained by a multistage process comprising at least two stages; and these two polymer (Al) and polymer (Bl) form a multistage polymer.
• the multistage polymer (MPl) of the composition (PCI) according to the invention has at least two stages that are different in its polymer composition.
• the multistage polymer is preferably in form of polymer particles considered as spherical particles. These particles are also called core shell particles. The first stage forms the core, the second or all following stages the respective shells. Such a multistage polymer which is also called core/shell particle is preferred .
• the particle system may comprise a primary particle.
• the particles according to the invention which is the primary particle, may have a weight average particle size between 15nm and 900nm.
• the weight average particle size of the polymer is between 20nm and 800nm, more preferably between, more preferably between 25nm and 600nm, still more preferably between 30nm and 550nm, again still more preferably between 35nm and 500nm, advantageously between 40nm and 400nm, even more advantageously between 75nm and 350nm and advantageously between 80nm and 300nm.
• the primary polymer particles can be agglomerated giving the polymer powder of the invention.
• the primary polymer particle according to the invention has a multilayer structure comprising at least one stage (A) comprising a polymer (Al) having a glass transition temperature below 10°C, at least one stage (B) comprising a polymer (Bl) having a glass transition temperature over 60°C and at least one stage (C) comprising a polymer (CI) having a glass transition temperature over 30°C.
• stage (A) is the first stage of the at least two stages and the stage (B) comprising polymer (Bl) is grafted on stage (A) comprising polymer (Al) or another intermediate layer.
• stage (A) There could also be another stage before stage (A) , so that stage (A) would also be a shell.
• the polymer (Al) having a glass transition temperature below 10°C comprises at least 50wt% of polymeric units coming from alkyl acrylate and the stage (A) is the most inner layer of the polymer particle having the multilayer structure.
• the stage (A) comprising the polymer (Al) is the core of the polymer particle, as shown schematically in figure 1.
• the polymer (Al) of the first preferred embodiment is a (meth) acrylic polymer comprising at least 50wt% of polymeric units coming from acrylic monomers. Preferably 60wt% and more preferably 70wt% of the polymer (Al) are acrylic monomers .
• the acrylic momonomer in polymer (Al) comprises monomers chosen from CI to C18 alkyl acrylates or mixtures thereof. More preferably acrylic monomer in polymer (Al) comprises monomers of C2 to C12 alkyl acrylic monomers or mixtures thereof Still more preferably acrylic monomer in polymer (Al) comprises monomers of C2 to C8 alkyl acrylic monomers or mixtures thereof.
• the polymer (Al) can comprise a comonomer or comonomers which are copolymerizable with the acrylic monomer, as long as polymer (Al) is having a glass transition temperature of less than 10°C.
• the comonomer or comonomers in polymer (Al) are preferably chosen from (meth) acrylic monomers and/or vinyl monomers.
• the acrylic or methacrylic comonomers of the polymer (Al) are chosen from methyl acrylate, propyl acrylate, isopropyl acrylate, butyl acrylate, tert-butyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate and mixtures thereof, as long as polymer (Al) is having a glass transition temperature of less than 10°C.
• polymer (Al) is a homopolymer of butyl acrylate.
• the glass transition temperature Tg of the polymer (Al) comprising at least 70wt% of polymeric units coming from C2 to C8 alkyl acrylate is between -100°C and 10°C, even more preferably between -80°C and 0°C and advantageously between -80°C and -20°C and more advantageously between -70°C and -20°C.
• the polymer (Al) having a glass transition temperature below 10°C comprises at least 50wt% of polymeric units coming from isoprene or butadiene and the stage
• stage (A) is the most inner layer of the polymer particle having the multilayer structure.
• the stage (A) comprising the polymer (Al) is the core of the polymer particle.
• the polymer (Al) of the core of the second embodiment mention may be made of isoprene homopolymers or butadiene homopolymers, isoprene-butadiene copolymers, copolymers of isoprene with at most 98 wt% of a vinyl monomer and copolymers of butadiene with at most 98 wt% of a vinyl monomer.
• the vinyl monomer may be styrene, an alkylstyrene, acrylonitrile, an alkyl (meth) acrylate, or butadiene or isoprene.
• the core is a butadiene homopolymer.
• the glass transition temperature Tg of the polymer (Al) comprising at least 50wt% of polymeric units coming from isoprene or butadiene is between -100°C and 10°C, even more preferably between -90°C and 0°C, advantageously between -80°C and 0°C and most advantageously between -70°C and -20°C.
• the polymer (Al) is a silicone rubber based polymer.
• the silicone rubber for example is polydimethyl siloxane.
• the glass transition temperature Tg of the polymer (Al) of the second embodiment is between -150°C and 0°C, even more preferably between -145°C and - 5°C, advantageously between -140°C and -15°C and more advantageously between -135°C and -25°C.
• polymer (Bl) With regard to the polymer (Bl) , mention may be made of homopolymers and copolymers comprising monomers with double bonds and/or vinyl monomers. Preferably the polymer (Bl) is a (meth) acrylic polymer.
• the polymer (Bl) comprises at least 70wt% monomers chosen from CI to C12 alkyl (meth) acrylates . Still more preferably the polymer (Bl) comprises at least 80 wt% of monomers CI to C4 alkyl methacrylate and/or CI to C8 alkyl acrylate monomers.
• the acrylic or methacrylic monomers of the polymer (Bl) are chosen from methyl acrylate, ethyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate and mixtures thereof, as long as polymer (Bl) is having a glass transition temperature of at least 60°C.
• the polymer (Bl) comprises at least 70wt% of monomer units coming from methyl methacrylate.
• the glass transition temperature Tg of the polymer (Bl) is between 60°C and 150°C.
• the glass transition temperature of the polymer (Bl) is more preferably between 80°C and 150°C, advantageously between 90°C and 150°C and more advantageously between 100°C and 150°C.
• the polymer (Bl) is grafted on the polymer made in the previous stage.
• the polymer (Bl) is crosslinked.
• the polymer (Bl) comprises a functional comonomer.
• the functional copolymer is chosen from acrylic or methacrylic acid, the amides derived from this acids, such as for example dimethylacrylamide, 2-methoxy-ethyl acrylate or methacrylate, 2-aminoethyl acrylate or methacrylate which are optionally quaternized, polyethylene glycol (meth) acrylates, water soluble vinyl monomers such as N-vinyl pyrrolidone or mixtures thereof.
• the polyethylene glycol group of polyethylene glycol (meth) acrylates has a molecular weight ranging from 400g/mol to 10 000 g/mol.
• the polymer (CI) has a mass average molecular weight Mw of at least 100 OOOg/mol, preferably more than 100 OOOg/mol, more preferably more than 105 OOOg/mol, still more preferably more than 110 OOOg/mol, advantageously more than 120 000 g/mol, more advantageously more than 130 000 g/mol and still more advantageously more than 140 000 g/mol.
• the polymer (CI) has a mass average molecular weight Mw below 1 000 OOOg/mol, preferably below 900 OOOg/mol, more preferably below 800 OOOg/mol, still more preferably below 700 OOOg/mol, advantageously below 600 000 g/mol, more advantageously below 550 000 g/mol and still more advantageously below 500 000 g/mol and most advantageously below 450 000 g/mol.
• the mass average molecular weight Mw of polymer (CI) is between 100 OOOg/mol and 1 000 OOOg/mol, preferable between 105 000 g/mol and 900 000 g/mol and more preferably between 110 OOOg/mol and 800 OOOg/mol advantageously between 120 OOOg/mol and 700 OOOg/mol, more advantageously between 130 OOOg/mol and 600 OOOg/mol and most advantageously between 140 OOOg/mol and 500 OOOg/mol.
• the polymer (CI) is a copolymer comprising (meth) acrylic monomers. More preferably the polymer (CI) is a (meth) acrylic polymer.
• the polymer (CI) comprises at least 70wt% monomers chosen from CI to C12 alkyl (meth) acrylates .
• the polymer (CI) comprises at least 80wt% of monomers CI to C4 alkyl methacrylate and/or CI to
• the glass transition temperature Tg of the polymer (CI) is between 30°C and 150°C.
• the glass transition temperature of the polymer (CI) is more preferably between 40°C and 150°C, advantageously between 45°C and 150°C and more advantageously between 50°C and 150°C.
• the polymer (CI) is not crosslinked.
• the polymer (CI) is not grafted on any of the polymers (Al) or (Bl) .
• the polymer (CI) comprises also a functional comonomer.
• the functional comonomer has the formula (1)
• wherin Ri is chosen from H or CH3 and R2 is H or an aliphatic oraromatic radical having at least one atom that is not C or H.
• the functional monomer is chosen from glycidyl (meth) acrylate , acrylic or methacrylic acid, the amides derived from these acids, such as, for example, dimethylacrylamide, 2- methoxyethyl acrylate or methacrylate, 2-aminoethyl acrylates or methacrylates are optionally quaternized, polyethylene glycol (meth) acrylates.
• the polyethylene glycol group of polyethylene glycol (meth) acrylates has a molecular weight ranging from 400g/mol to 10 000 g/mol.
• the polymer (CI) comprises from 80wt% to 100wt% methyl methacrylate, preferably from 80wt% to 99.8wt% methyl methacrylate and from 0.2wt% to 20wt% of a CI to C8 alkyl acrylate monomer.
• the CI to C8 alkyl acrylate monomer is chosen from methyl acrylate, ethyl acrylate or butyl acrylate .
• the polymer (CI) comprises between 0wt% and 50wt% of a functional monomer.
• the meth) acrylic polymer (PI) comprises between 0wt% and 30wt% of the functional monomer, more preferably between lwt% and 30wt%, still more preferably between 2wt% and 30wt%, advantageously between 3wt% and 30wt%, more advantageously between 5wt% and 30wt% and most advantageously between 5wt% and 30wt%.
• the functional monomer of the second preferred embodiment is a (meth) acrylic monomer.
• the functional monomer has the formula (2) or (3
• the functional monomer (2) or (3) is chosen from glycidyl (meth) acrylate, acrylic or methacrylic acid, the amides derived from these acids, such as, for example, dimethylacrylamide, 2-methoxyethyl acrylate or methacrylate, 2- aminoethyl acrylates or methacrylates are optionally quaternized, acrylate or methacrylate monomers comprising a phosphonate or phosphate group, alkyl imidazolidinone (meth) acrylates, polyethylene glycol (meth) acrylates.
• the polyethylene glycol group of polyethylene glycol (meth) acrylates has a molecular weight ranging from 400g/mol to 10 000 g/mol [0101]
• the primary polymer particle according to the invention is obtained by a multistage process comprising at least two stages. At least the component a) and the component b) of composition (PCI) are part of a multistage polymer (MP1) .
• the polymer (Al) having a glass transition temperature below 10°C made during the stage (A), is made before stage (B) or is the first stage of the multistage process.
• the polymer (Bl) having a glass transition temperature over 60 °C made during the stage (B) is made after the stage (A) of the multistage process.
• the polymer (Bl) having a glass transition temperature of at least 30°C is an intermediate layer of the polymer particle having the multilayer structure.
• the polymer (CI) having a glass transition temperature over 30 °C made during the stage (C) is made after the stage (B) of the multistage process.
• the polymer (CI) having a glass transition temperature over 30°C made during the stage (C) is the external layer of the primary polymer particle having the multilayer structure.
• stage (A) and stage (B) There could be additional intermediate stages, either between stage (A) and stage (B) and/or between stage (B) and stage (C) .
• the polymer (CI) and the polymer (Bl) are not the same polymer, even if their composition could be very close and some of their characteristics are overlapping.
• the essential difference is that the polymer (Bl) is always part of the multistage polymer (MP1) .
• the weight ratio r of the polymer (CI) of the external layer comprised in stage (C) in relation to the complete polymer particle is at least 5wt%, more preferably at least 7wt% and still more preferably at least 10wt%.
• the ratio r of the external stage (C) comprising polymer (CI) in relation to the complete polymer particle is at most 30w%.
• the ratio of polymer (CI) in view of the primary polymer particle is between 5wt% and 30wt% and preferably between 5wt% and 20wt%.
• the polymer (Bl) having a glass transition temperature of at least 30°C is the external layer of the primary polymer particle having the multilayer structure in other words the multistage polymer (MP1) .
• (B) is grafted on the polymer made in the previous layer. If there are only two stages (A) and (B) comprising polymer (Al) and (Bl) respectively, a part of polymer (Bl) is grafted on polymer (Al) . More preferably at least 50wt% of polymer (Bl) is grafted.
• the ratio of grafting can be determined by extraction with a solvent for the polymer (Bl) and gravimetric measurement before and after extraction to determine the non-grafted quantity.
• the glass transition temperature Tg of the respective polymers can be estimated for example by dynamic methods as thermo mechanical analysis.
• the polymer composition of the invention comprises no solvents.
• no solvents is meant that eventually present solvent make up less than lwt% of the composition.
• the monomers of the synthesis of the respective polymers are not considered as solvents.
• the residual monomers in the composition present less than 2wt% of the composition.
• the polymer composition according to the invention is dry.
• dry is meant that the polymer composition according to the present invention comprises less than 3 t% humidity and preferably less than 1.5 t% humidity and more preferably less than 1.2 t% humidity.
• the humidity can be measured by a thermo balance that heats the polymer composition and measures the weight loss.
• composition according to the invention comprising the does not comprise any voluntary added solvent. Eventually residual monomer from the polymerization of the respective monomers and water are not considered as solvents.
• PCI polymer composition
• the polymer (CI) has a mass average molecular weight Mw of at least 100 OOOg/mol and that the component c) represents at most 30wt% of the composition based on the total weight of.
• step a) is made before step b) .
• step b) is performed in presence of the polymer (Al) obtained in step a) .
• the first preferred method for manufacturing the polymer composition (PCI) according to the invention is a multistep process comprises the steps one after the other of a) polymerizing by emulsion polymerization of a monomer or monomer mixture (A m ) to obtain one layer in stage (A) comprising polymer (Al) having a glass transition temperature of less then 10°C
• the polymer (CI) has a mass average molecular weight Mw of at least 100 OOOg/mol.
• the respective monomers or monomer mixtures (A m ) , (B m ) and (Cm) for forming the layers (A) , (B) and (C) respectively comprising the polymers (Al), (Bl) and (CI) respectively, are the same as defined before.
• the characteristics of the polymers (Al), (Bl) and (CI) respectively, are the same as defined before.
• the first preferred method for manufacturing the polymer composition according to the invention comprises the additional step d) of recovering of the polymer composition.
• recovering is meant partial or separation between the aqueous and solid phase, latter comprises the polymer composition.
• the recovering of the polymer composition is made by coagulation or by spray-drying.
• Spray drying is the preferred method for the recovering and/or drying for the manufacturing method for a polymer powder composition according to the present invention if the polymer (Al) having a glass transition temperature below 10 °C comprises at least 50wt% of polymeric units coming from alkyl acrylate and the stage (A) is the most inner layer of the polymer particle having the multilayer structure.
• Coagulation is the preferred method for the recovering and/or drying for the manufacturing method for a polymer powder composition according to the present invention if the polymer (Al) having a glass transition temperature below 10 °C comprises at least 50wt% of polymeric units coming from isoprene or butadiene and the stage (A) is the most inner layer of the polymer particle having the multilayer structure.
• the method for manufacturing the polymer composition according to the invention can comprise optionally the additional step e) of drying of the polymer composition.
• drying step e) is made if the step d) of recovering of the polymer composition is made by coagulation.
• the polymer composition comprises less than 3wt%, more preferably less than 1.5wt% advantageously less than 1% of humidity or water.
• the humidity of a polymer composition can be measure with a thermo balance.
• the drying of the polymer can be made in an oven or vacuum oven with heating of the composition for 48hours at 50°C.
• PCI polymeric composition
• MP1 multi stage polymer
• step a) wherein the polymer (CI) and the multi stage polymer (MP1) in step a) are in form of a dispersion in aqueous phase.
• the multi stage polymer (MP1) of the second preferred method for manufacturing the polymeric composition (PCI) is made according the first preferred method without performing step c) of the said first preferred method.
• the quantities of the aqueous dispersion of the polymer (CI) and the aqueous dispersion of the multi stage polymer (MP1) are chosen in a way that the weight ratio of the multi stage polymer based on solid part only in the obtained mixture is at least 5wt%, preferably at least 10wt%, more preferably at least 20wt% and advantageously at least 50wt%.
• the quantities of the aqueous dispersion of the polymer (CI) and the aqueous dispersion of the multi stage polymer (MP1) are chosen in a way that the weight ratio of the multi stage polymer based on solid part only in the obtained mixture is at most 99wt%, preferably at most 95wt% and more preferably at most 90wt%.
• the quantities of the aqueous dispersion of the polymer (CI) and the aqueous dispersion of the multi stage polymer are chosen in a way that the weight ratio of the multi stage polymer based on solid part only in the obtained mixture is between 5wt% and 99wt%, preferably between 10wt% and 95wt% and more preferably between 20wt% and 90wt%.
• the polymer composition (PCI) is obtained as an aqueous dispersion of the polymer particles, if recovering step b) takes not place.
• the solid content of the dispersion is between 10wt% and 65wt%.
• the recovering step b) of the process for manufacturing the polymer composition comprising the polymer (CI) and the multi stage polymer (MP1) is not optional and is preferably made by coagulation or by spray drying.
• the process of the second preferred method for manufacturing the polymer composition (PCI) comprising the polymer (CI) and the multi stage polymer can optionally comprise the additional step c) for drying the polymer composition.
• dry is meant that the polymer composition according to the present invention comprises less than 3wt% humidity and preferably less than 1.5wt% humidity and more preferably less than 1.2wt% humidity.
• the humidity can be measured by a thermo balance that heats the polymer composition and measures the weight loss.
• the second preferred method for manufacturing the polymer composition comprising the polymer (CI) and the multi stage polymer yields preferably to a polymer powder.
• the polymer powder of the invention is in form of particles.
• a polymer powder particle comprises agglomerated primary polymer particles made by multistage process and the polymer (CI) .
• the polymer composition (PCI) according to the invention can also be in form of larger polymer particles: a polymer powder.
• the polymer powder particle comprises agglomerated primary polymer particles made by the multistage process according the first preferred method or agglomerated primary polymer particles made by blending the multistage polymer
• the polymer powder of the invention has a volume median particle size D50 between ⁇ and 500 ⁇ .
• the volume median particle size of the polymer powder is between ⁇ and 400 ⁇ , more preferably between 15 ⁇ and 350 ⁇ and advantageously between 20 ⁇ and 300 ⁇ .
• the D10 of the particle size distribution in volume is at least 7 ⁇ and preferably ⁇ .
• the D90 of the particle size distribution in volume is at most 500 ⁇ and preferably 400 ⁇ , more preferably at most 250 ⁇ .
• the present invention relates also to the use of the polymer composition (PCI) in form of the polymer powder according to the invention as an impact modifier in polymers, in order to obtain an impact modified polymer composition.
• the polymers are thermosetting polymers or thermoplastic polymers or its precursors .
• the present invention relates also to the use of the polymer composition (PCI) in form of the polymer powder according to the invention as an impact modifier in structural adhesives.
• the adhesives are thermosetting polymers of epoxy type or (meth) acrylic type.
• PC2 impact modified polymer composition
• PCI polymer composition
• a polymer composition comprising a) one stage (A) comprising a polymer (Al) having a glass transition temperature of less then 10°C b) , one stage (B) comprising a polymer (Bl) having a glass transition temperature of at least 60°C and c) a polymer (CI) having a glass transition temperature of at least 30°C
• the polymer (CI) has a mass average molecular weight Mw of at least 100 OOOg/mol.
• PCI polymer composition
• the impact modified polymer composition (PC2) according to the invention comprises between lwt% and 50wt% of polymercomposition (PCI) .
• the polymer (P2) can be a thermoset polymer or its precursor, or a thermoplastic polymer.
• the polymer (P2) can also be an adhesive and more preferably a structural adhesive.
• thermoset polymers mention may be made, by way of examples, of unsaturated polyesters resins, polyacrylics , polyurethanes , cyanoacrylates , bismaleimides and epoxy resins crosslinked by a hardener.
• thermoplastic polymers mention may be made by way of example of (meth) acrylic polymers or polyesters.
• epoxy resin polymer With regard to the epoxy resin polymer, mention may be made of: resorcinol diglycidyl ether, bisphenol A diglycidyl ether, triglycidyl-p-amino- phenol, bromobisphenol F diglycidyl ether, the triglycidyl ether of m-amino- phenol, tetraglycidylmethylenedianiline, the triglycidyl ether of (trihydroxy- phenyl ) methane, polyglycidyl ethers of phenol- formaldehyde novolak, poly- glycidyl ethers of ortho-cresol novolak and tetraglycidyl ethers of tetraphenyl- ethane.
• the epoxy resin composition according to the invention it comprises between lwt% and 50wt%, preferably between 2 wt% and 30wt% and more preferably between 5 and 20% of polymer obtained by the multistage process.
• the glass transitions (Tg) of the polymers are measured with equipment able to realize a thermo mechanical analysis.
• a RDAII "RHEOMETRICS DYNAMIC ANALYSER” proposed by the Rheometrics Company has been used.
• the thermo mechanical analysis measures precisely the visco-elastics changes of a sample in function of the temperature, the strain or the deformation applied.
• the apparatus records continuously, the sample deformation, keeping the stain fixed, during a controlled program of temperature variation.
• the results are obtained by drawing, in function of the temperature, the elastic modulus (G' ) , the loss modulus and the tan delta.
• the Tg is higher temperature value read in the tan delta curve, when the derived of tan delta is equal to zero.
• the mass average molecular weight (Mw) of the polymers is measured with by size exclusion chromatography (SEC) . [0146] Particle size analysis
• the particle size of the primary particles after the multistage polymerization is measured with a Zetasizer.
• the particle size of the polymer powder after recovering is measured with Malvern Mastersizer 3000 from MALVERN.

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• Chemical & Material Sciences (AREA)
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• Organic Chemistry (AREA)
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• 2018
  • 2018-07-11 EP EP18736945.9A patent/EP3652250A1/de not_active Withdrawn
  • 2018-07-11 WO PCT/EP2018/068787 patent/WO2019011984A1/en unknown
  • 2018-07-11 CN CN201880046380.9A patent/CN110914363A/zh active Pending
  • 2018-07-11 JP JP2020501140A patent/JP2020526635A/ja active Pending

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