Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L25/00—Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
  • C08L25/02—Homopolymers or copolymers of hydrocarbons
  • C08L25/04—Homopolymers or copolymers of styrene
  • C08L25/08—Copolymers of styrene
  • C08L25/14—Copolymers of styrene with unsaturated esters
• • 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
  • C08J11/00—Recovery or working-up of waste materials
  • C08J11/04—Recovery or working-up of waste materials of polymers
• • 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
  • C08J3/22—Compounding polymers with additives, e.g. colouring using masterbatch techniques
  • C08J3/226—Compounding polymers with additives, e.g. colouring using masterbatch techniques using a polymer as a carrier
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
  • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
  • C08L33/04—Homopolymers or copolymers of esters
  • C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
  • C08L33/062—Copolymers with monomers not covered by C08L33/06
  • C08L33/068—Copolymers with monomers not covered by C08L33/06 containing glycidyl groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
  • C08L33/04—Homopolymers or copolymers of esters
  • C08L33/14—Homopolymers or copolymers of esters of esters containing halogen, nitrogen, sulfur, or oxygen atoms in addition to the carboxy oxygen
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L7/00—Compositions of natural rubber
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L15/00—Compositions of rubber derivatives
• • 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
  • C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P20/00—Technologies relating to chemical industry
  • Y02P20/141—Feedstock
  • Y02P20/143—Feedstock the feedstock being recycled material, e.g. plastics
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/50—Reuse, recycling or recovery technologies
  • Y02W30/62—Plastics recycling; Rubber recycling
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
  • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
  • Y10T428/139—Open-ended, self-supporting conduit, cylinder, or tube-type article

Definitions

• the present invention relates generally to concentrates employed in the formation of step-growth polymers, and in particular, to a chain extension concentrate for step-growth polymers.
• step-growth polymers including polyesters, polyamides, polycarbonates, and polyurethanes are widely used to make plastic products such as films, bottles, sheet and other molded and extruded products.
• the mechanical and physical properties of these polymers are highly dependent on their molecular weights.
• these materials may experience a synthesis process, followed by an extrusion step, and a final processing step which may be another compounding extrusion operation followed by thermoforming, blow molding, or fiber spinning, or they can be injection molded in the molten state, with all of these steps occurring under high temperature conditions.
• a final processing step which may be another compounding extrusion operation followed by thermoforming, blow molding, or fiber spinning, or they can be injection molded in the molten state, with all of these steps occurring under high temperature conditions.
• increased attention has been focused on improved methods of recycling the articles made from these polymers, with an eye toward resource conservation and environmental protection.
• the processing steps involved in producing and recycling these polymers also involve high temperatures.
• the chain extender has two or more chemical groups that are reactive to the chemical groups formed during the molecular weight degradation process.
• reacting the chain extender molecule to two or more polycondensate fragments it is possible to re-couple them (by bridging them), thus decreasing or even reverting the molecular weight degradation process.
• chain extender types and compositions, polycondensate formulations, and processing conditions described to this end there are numerous chain extender types and compositions, polycondensate formulations, and processing conditions described to this end.
• Di- or poly-functional epoxides epoxy resins or other chemicals having two or more epoxy radicals, are an example of chain extending modifiers that have been used to increase the molecular weight of recycled polymers.
• These di- or poly-functional epoxides are generally made using conventional methods by reacting a epichlorohydrin with a molecule having two or more terminal active hydrogen groups.
• chain extenders examples include bis-phenol type epoxy compounds prepared by the reaction of bisphenol A with epichlorohydrin, novolak type epoxy compounds prepared by reacting novolak resins with epichlorohydrin, polyglycidyl esters formed by reacting carboxylic acids with epicholorhydrin, and glycidyl ethers prepared from aliphatic alcohols and epichlorohydrin.
• various acrylic copolymers have been used as polymer additives to improve the melt strength and melt viscosity of polyesters and polycarbonates. These additives generally include copolymers derived from various epoxy containing compounds and olef ⁇ ns, such as ethylene.
• chain extenders have met with limited success in solving the problem of molecular weight degradation in reprocessed polymers.
• the shortcomings of these copolymer chain extenders can be attributed, at least in part, to the fact that they are produced by conventional polymerization techniques which produce copolymers with physical characteristics which limit their capacity to act as chain extenders.
• chain extender that has been effective in overcoming the problems encountered by the prior art are those based on epoxy-functional styrene acrylic copolymers produced from monomers of at least one epoxy-functional acrylic monomer and at least non-functional styrenic and/or acrylate monomer.
• chain extenders are the subject US Patent Application entitled OLIGOMERIC CHAIN EXTENDERS FOR PROCESSING, POSTPROCESSING AND RECYCLING OF CONDENSATION POLYMERS, SYNTHESIS, COMPOSITIONS AND APPLICATIONS, Serial No. 10/342,502, filed January 15, 2003, inventors William Blasius, Gary A. Deeter, and Marco A. Nillalobos.
• the present invention is directed to a solid concentrate composition useful in modifying the molecular weight of a step-growth polymer comprising at least one epoxy-functional styrene acrylic copolymer and at least one non-reactive carrier resin.
• a solid concentrate composition includes at least one epoxy-functional styrene acrylic copolymer and at least one co-reactive epoxy functional carrier resin.
• the present invention is also directed to a method for preparing a polymer by reacting at least one epoxy-functional styrene acrylic copolymer with a carrier, wherein said carrier is selected from the group consisting of a non-reactive carrier resin and a co-reactive epoxy functional resin and melt compounding said composition with at least one polymer having at least one oxirane functional group.
• the solid concentrate composition of the present invention prevents premature reaction of the epoxy- functional styrene acrylic copolymer chain extender within the let down polymer by increasing the time required to melt the concentrate. This delayed reaction time permits the chain extender to be fully dispersed throughout the polymer, resulting in homogeneous chain extension.
• the present invention is directed to a solid concentrate or masterbatch composition
• a solid concentrate or masterbatch composition comprising at least one epoxy-functional styrene acrylic copolymer chain extender and at least one carrier resin.
• the carrier resin is either a non reactive resin, a co-reactive epoxy functional resin or mixtures thereof.
• the solid concentrate composition may be used to increase chain extension in any polymer having at least one oxirane functional group, but finds particular application in conjunction with condensate polymers.
• the epoxy functional styrene acrylic copolymer chain extender is preferably selected from those disclosed in United States Patent Application, entitled OLIGOMERIC CHAIN EXTENDERS FOR PROCESSING, POSTPROCESSING AND RECYCLING OF CONDENSATION POLYMERS, SYNTHESIS, COMPOSITIONS AND APPLICATIONS, Serial No. 10/342,502, filed January 15, 2003, inventors William Blasius, Gary A. Deeter, and Marco A. Nillalobos, the entire disclosure of which is hereby incorporated herein by reference.
• non limiting examples of epoxy functional acrylic monomers for use in the epoxy functional styrene acrylic copolymer include both acrylates and methacrylates.
• Suitable acrylate and methacrylate monomers include, but are not limited to, methyl acrylate, ethyl acrylate, n-propyl acrylate, i- propyl acrylate, nbutyl acrylate, s-butyl acrylate, i-butyl acrylate, t-butyl acrylate, n-amyl acrylate, iamyl acrylate, isobornyl acrylate, n-hexyl acrylate, 2-ethylbutyl acrylate, 2-ethylhexyl acrylate, n-octyl acrylate, n-decyl acrylate, methylcyclohexyl acrylate, cyclopentyl acrylate, cyclohexyl acrylate, cyclohexyl acrylate, cyclopentyl acrylate, cyclohexyl acrylate, cyclohexyl
• the preferred non-functional acrylate and non-functional methacrylate monomers are butyl acrylate, butyl methacrylate, methyl methacrylate, iso-butyl methacrylate, cyclohexyl acrylate, cyclohexyl methacrylate, isobornyl acrylate and isobornyl methacrylate and combinations thereof.
• Styrenic monomers for use in the present invention include, but are not limited to, styrene, alpha- methyl styrene, vinyl tolulene, p-methyl styrene, t-butyl styrene, o- chlorostyrene, vinyl pyridine, and mixtures of these species.
• Preferred styrenic monomers include styrene and alpha-methyl styrene.
• the chain extenders can be produced by continuously charging into a reactor at least one epoxy functional acrylic monomer and at least one non-functional free radical polymerizable monomer, including a non-functional acrylate monomer, a non-functional methacrylate monomer, a non-functional styrenic monomer, and combinations thereof.
• the reactor may also optionally be charged with at least one free radical polymerization initiator and/or one or more solvents.
• the reactor is maintained at an effective temperature for an effective period of time to cause polymerization of the monomers to produce a polymeric product for the monomers formed substantially free of gel particles within the reactor.
• the non reactive carrier resin for use with the solid concentrate composition includes, but are not limited to, polyethylene, polyethylene-norbornene copolymers, polypropylene, polybutylene, polymethyl pentene, polyethylene- vinyl acetate copolymers, polystyrene, polystyrene block copolymers, butadiene, isoprene, ethylene-butylene, polymethacrylates, polyacrylates, polyvinyl chloride, chlorinated polyethylene, polyvinylidene chloride, polyethylene-acrylate copolymers.
• the most preferred non-reactive carrier resin is polystyrene-methylmethacrylate copolymers.
• the epoxy functional co- reactive resins capable for use as a carrier resin include, but are not limited to, glycidal methacrylate co and terpolymers, and epoxidized natural rubber.
• the most preferred epoxy functional co-reactive carrier resin is polyethylene- methyl acrylate-glycidal methacrylate.
• non-reactive carrier resin is utilized, as the non reactive carrier resin provides an inert carrier, thereby preventing the chain extender from reacting until the concentrate is dispersed within the let down polymer. That is, the chain extender does not react with the non-reactive carrier resin to cause any appreciable chain extension within the non-reactive carrier resin.
• Preferred carrier resins for use in conjunction with the solid concentrate composition include low density polyethylene, polystyrene co-methylmethacrylate, polyethylene co-butylacrylate co-glycidal methacrylate and behenamide wax.
• the exact ratio of chain extender to carrier resin in the concentrate composition is application specific, depending upon the activity of the carrier resin and the desired degree of chain extension in final polymeric product.
• the epoxy function styrene acrylic copolymer chain extender may be present in the solid concentrate composition in amount between approximately 0.01 to 99.9 wt%, preferably between approximately 5.0 and 50.0wt%; and most preferably between approximately 10.0 to 25.0%.
• Other materials which are substantially chemically inert may be added to the solid concentrate depending upon the desired properties of the polymer.
• Representative examples of such materials include anti-static agents, foaming agents, flame retardants, color concentrates, anti-oxidants, UN stabilizers, antiblocking agents, anti-flog agents, anti-slip agents, anti-microbial agents,and slip additives.
• the method by which the solid concentrate is made is not particularly limiting and can be accomplished by any known masterbatching process.
• the concentrate of the present invention can be formed in a variety of geometrical shapes, including, but not limited to, pellets, spheres, flakes, agglomerates, prills and the like.
• the solid concentrate may be used to impart chain extension properties on any let down polymer with at least one oxirane reactive group.
• Representative examples of such polymers include step-growth polymers such as, for example, polyamides, polyesters and polycarbonates.
• the polymer can also be an addition polymer such as, for example, polyurethanes, polystyrene co-maleic anhydride or polyethylene co-acrylic acid.
• the solid concentrate composition is melt compounded with the let down polymer in any thermoplastic forming apparatus normally employed in the industry, and is melted at a temperature appropriate for the let down polymer, in accordance with normal molding techniques.
• concentration of the solid concentrate composition is dependent upon the desired end characteristics of the let down polymer, and is therefore application specific.
• the amount of solid concentrate composition may range from 0.1 to 100 wt%, per weight of the total batch.
• the solid concentrate composition of the present invention may be used in the manufacture of various polymeric articles, non limiting examples of which include, polymeric sheets, films, bottles, fibers or multidimensional articles.
• EXAMPLE 1 [00027] Two formulations were injection molded in accordance with normal industry procedure using an Arburg Allrounder 320 Molding Machine and a Standard Color Chip mold. The formulations were as follows:
• Formulation A 0.25% epoxy functional styrene acrylic copolymer chain extender, and 99.75% Industrial Grade PET.
• Formulation B 1.25% 20% Chain Extender Concentrate of the present invention, and 98.75 Industrial Grade PET.
• the epoxy functional styrene acrylic copolymer chain extender was JoncrylTM ADR 4367
• the Concentrate was a mixture of Eastman DurastarTM DS 2010 Polyester JoncrylTM ADR 4367 and NovaTM NAS 21.
• Formulation B a. Process stabilized quickly. b. Significant plate out of Chain Extender was effectively eliminated. c. After approximately 200 shots formulation B remained processable.

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• Chemical & Material Sciences (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Life Sciences & Earth Sciences (AREA)
• Sustainable Development (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Processes Of Treating Macromolecular Substances (AREA)
• Other Resins Obtained By Reactions Not Involving Carbon-To-Carbon Unsaturated Bonds (AREA)
• Epoxy Resins (AREA)
• Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)
• Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
• Polyurethanes Or Polyureas (AREA)

Priority Applications (7)

Applications Claiming Priority (2)

Publications (1)

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Citations (3)

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• 2003
  • 2003-01-29 US US10/354,134 patent/US20040147678A1/en not_active Abandoned
• 2004
  • 2004-01-27 CN CNB2004800029979A patent/CN1331937C/zh not_active Expired - Fee Related
  • 2004-01-27 KR KR1020057013863A patent/KR20050099510A/ko not_active Ceased
  • 2004-01-27 AT AT04705416T patent/ATE531762T1/de active
  • 2004-01-27 BR BRPI0407075-5A patent/BRPI0407075B1/pt not_active IP Right Cessation
  • 2004-01-27 EP EP04705416A patent/EP1590402B8/en not_active Expired - Lifetime
  • 2004-01-27 TW TW93101696A patent/TW200418923A/zh unknown
  • 2004-01-27 WO PCT/EP2004/000697 patent/WO2004067629A1/en not_active Ceased
  • 2004-01-27 PL PL37801704A patent/PL378017A1/pl not_active Application Discontinuation
  • 2004-01-27 ES ES04705416T patent/ES2373716T3/es not_active Expired - Lifetime
  • 2004-01-27 MX MXPA05007981A patent/MXPA05007981A/es unknown
  • 2004-01-27 CA CA 2513247 patent/CA2513247A1/en not_active Abandoned
  • 2004-01-27 AU AU2004207058A patent/AU2004207058A1/en not_active Abandoned
• 2005
  • 2005-07-13 ZA ZA200505640A patent/ZA200505640B/en unknown
  • 2005-07-27 IN IN1708CH2005 patent/IN2005CH01708A/en unknown
• 2008
  • 2008-01-28 US US12/011,521 patent/US20080206503A1/en not_active Abandoned

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