Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
  • C08G63/78—Preparation processes
  • C08G63/82—Preparation processes characterised by the catalyst used
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
  • C08G63/78—Preparation processes
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/34—Silicon-containing compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K7/00—Use of ingredients characterised by shape
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2650/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
  • C08G2650/28—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type
  • C08G2650/34—Oligomeric, e.g. cyclic oligomeric
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K2201/00—Specific properties of additives
  • C08K2201/016—Additives defined by their aspect ratio

Definitions

• This invention relates generally to thermoplastics and articles formed therefrom. More particularly, in certain embodiments, the invention relates to intimate physical mixtures of macrocyclic polyester oligomer and filler.
• Semi-crystalline polymers are useful as engineering thermoplastics because they possess advantageous chemical, physical, and electrical properties, and because they can be readily processed by thermal means.
• linear semi-crystalline polymers such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT) are processed by injection molding and extrusion in the manufacture of plastic components.
• PET polyethylene terephthalate
• PBT polybutylene terephthalate
• HDT Heat deflection temperature
• the heat deflection temperature distinguishes between materials that are able to sustain light loads at high temperatures and those that lose their rigidity over a narrow temperature range.
• a high heat deflection temperature is indicative of a material whose modulus (i.e. Young's modulus) is high over a wide temperature range.
• fillers have been added to polymer compositions in an attempt to increase heat deflection temperature.
• Fillers that have been added to polymer compositions include fibrous fillers with high modulus, such as fiberglass and carbon fiber, as well as non-fibrous fillers such as calcium carbonate, wollastonite, and mica.
• fibrous fillers with high modulus such as fiberglass and carbon fiber
• non-fibrous fillers such as calcium carbonate, wollastonite, and mica.
• the addition of filler to a polymer will generally have a negative impact on other properties of the resulting polymer composition, such as ductility, impact strength, and toughness.
• it is a general rule that the more filler that is added, the greater its impact on the properties of the polymer composition.
• Macrocyclic polyester oligomer (macrocyclic oligoester, MPO) has unique properties that make it attractive as a matrix-forming resin for engineering thermoplastic composites.
• MPO generally exhibits low melt viscosity and can polymerize at temperatures well below the melting point of the resulting polymer.
• An MPO of particular interest is macrocyclic poly(l ,4-butylene terephthalate) oligomer.
• anhydrous magnesium silicate is highly compatible with certain macrocyclic polyester oligomers (MPO), and may be homogeneously dispersed into MPO without undergoing modification by ion exchange or other surface treatment.
• MPO macrocyclic polyester oligomers
• the invention provides intimate physical mixtures of macrocyclic polyester oligomer (MPO) with unmodified, high-aspect-ratio filler, as well as methods for preparing and using such mixtures.
• the invention provides mixtures of MPO with anhydrous magnesium silicate (anhydrous talc), which can be polymerized to form polymer compositions having advantageous properties.
• the invention provides a mixture including an MPO and a filler, where the filler comprises a magnesium silicate.
• the magnesium silicate is preferably anhydrous.
• the mixture may be an intimate physical mixture or a nanocomposite, for example.
• the filler dissolves in the mixture.
• the filler may be present in the mixture in any amount, for example, in an amount of at least about 10 wt.%, at least about 20 wt.%, at least about 30 wt.%, or at least about 40 wt.%, greater than about 40 wt.%, greater than about 50 wt.%, greater than about 60 wt.%, greater than about 70 wt.%, or more.
• the polymer produced from the MPO-filler mixture exhibits a higher elastic modulus than the polymer produced from the unfilled MPO over a wide
• temperature range - for example, at least over a temperature range from about 25°C to about
• the MPO in the mixture may include one or more species.
• the species may have different degrees of polymerization.
• the MPO includes butylene terephthalate units and oxydiethylene terephthalate units.
• the mixture further includes an MPO polymerization catalyst - for example, a tin compound, such as butyltin chloride dihydroxide, or a titanate compound.
• Mixtures of the invention are preferably stable under ambient conditions (at room temperature in air) for at least a week, and may be stable at least a month, at least a year, or even longer under ambient conditions.
• the invention provides a polymer composition resulting from polymerization of one or more components of a mixture of the invention.
• the invention provides an article of manufacture produced by polymerizing a mixture of the invention.
• the invention provides a method for preparing an intimate physical mixture of MPO and anhydrous magnesium silicate, the method comprising the step of contacting the MPO and anhydrous magnesium silicate at a temperature at which the MPO is at least partially melted.
• the temperature is within a range from about 150°C
• the MPO may be contacted with the talc before, during, or after the MPO
• the mixture may be polymerized, for example, in a two-part system, where the polymer-filler mixture is exposed to a temperature sufficient to melt the MPO, and the resulting mixture is contacted with a polymerization catalyst whereupon polymerization and crystallization occur substantially isothermally, thereby forming a polymeric composition comprising polymer and filler.
• the polymerization may take place in any molding, casting, or forming process, for example, an injection molding process, a rotational molding process, a resin film infusion process, a solvent prepreg process, a hot melt prepreg process, an extrusion process, a pultrusion process, a resin transfer molding process, a filament winding process, a compression molding process, a roll wrapping process, a powder coating process, and combinations thereof.
• the time and expense required to thermally cycle a tool is favorably reduced, for example, because demolding can take place immediately following polymerization, without first cooling the mold.
• the MPO-filler mixture may be stored as a one-part, ready-to-polymerize blend comprising MPO, filler, and a polymerization catalyst.
• the one-part blend remains stable for at least a week, for at least a month, or for at least a year or more, without significant premature polymerization of MPO and without significant deactivation of catalyst.
• the one-part blend is exposed to a temperature sufficient to melt and polymerize the MPO, whereupon polymerization and crystallization occur substantially isothermally.
• the invention provides a method for polymerizing an MPO, the method comprising the steps of providing a mixture comprising MPO, a polymerization catalyst, and a layered mineral, and heating the mixture to polymerize at least one component of the mixture.
• the layered mineral preferably comprises a silicate, and more preferably comprises magnesium silicate.
• the layered mineral is present in the mixture in an amount of at least about 10 wt.%, at least about 20 wt.%, at least about 30 wt.%, at least about 40 wt.%), greater than about 40 wt.%, greater than about 50 wt.%, greater than about 60 wt.%, or greater than about 70 wt.%, although amounts less than 10 wt.%, and amounts greater than 70 wt.% may be used as well.
• anhydrous magnesium silicate with MPO may be related to the surface energy, charge neutrality, and/or the non-polarity of platelets of anhydrous magnesium silicate.
• the polar -OH groups of anhydrous talc reside in the interior of the structure of a talc layer and, therefore, are not chemically accessible to the molecules at or near the surface of the talc layer.
• Other factors that may be related to the compatibility of the filler with MPO include the platyness, softness, hydrophobicity, organophilicity, inertness, and mineralogical composition of the filler.
• the invention is directed to an intimate physical mixture comprising an MPO and a layered mineral, where the layered mineral has a non-polar, charge- neutral surface.
• the layered mineral comprises at least one of molybdenum sulfide, graphite, magnesium, iron, calcium, potassium, sodium, manganese, titanium, zirconium, copper, berylium, and zinc.
• the intimate physical mixture may also contain a catalyst, and may be stable at ambient conditions for at least one week, at least one month, or longer.
• the invention provides a mixture including an MPO and talc.
• the mixture contains other compounds in addition to MPO and talc.
• the talc typically contains magnesium silicate, but may additionally contain other compounds.
• the talc is magnesium silicate.
• the talc is anhydrous magnesium silicate.
• the mixture may be an intimate physical mixture or a nanocomposite, for example. In a preferred embodiment, the talc dissolves in the mixture.
• the talc may be present in the mixture in any amount, for example, in an amount of at least about 10 wt.%, at least about 20 wt.%, at least about 30 wt.%, or at least about 40 wt.%, greater than about 40 wt.%, greater than about 50 wt.%, greater than about 60 wt.%, greater than about 70 wt.%, or more.
• a polymer composition produced from the MPO-talc mixture exhibits a higher elastic modulus than polymer produced from the MPO without the talc over a wide temperature range - for example, at least over a temperature range from about 25°C to
• the polymer composition exhibits a higher elastic modulus than polymer produced from the MPO without the talc at temperatures above about 10°C, above about 25°C, or above about 50°C, for example. In one embodiment, the polymer composition exhibits a higher elastic modulus than polymer produced from the MPO without the talc at temperatures below about 200°C, below about
• the polymer composition exhibits a higher heat deflection temperature (HDT) than polymer produced from the MPO without the talc.
• the MPO in the mixture may include one or more species. The species may have different degrees of polymerization.
• the MPO includes butylene terephthalate units and oxydiethylene terephthalate units.
• the mixture further includes an MPO polymerization catalyst - for example, a tin compound, such as butyltin chloride dihydroxide.
• the catalyst comprises a titanate compound.
• Mixtures of the invention are preferably stable under ambient conditions (at room temperature in air) for at least a week, and may be stable at least a month, at least a year, or even longer under ambient conditions.
• the invention provides a polymer composition resulting from polymerization of one or more components of a mixture of the invention.
• the polymer composition is a nanocomposite.
• the invention provides an article of manufacture produced by polymerizing a mixture of the invention.
• the invention provides a method for preparing an intimate physical mixture of MPO and talc, the method comprising the step of contacting the MPO and talc (and, optionally, one or more additional compounds) at a temperature at which the MPO is at least partially melted.
• the temperature is within a range from about 150°C to
• the temperature is below about 250°C, below about 200°C,
• the MPO may be contacted with the talc before, during, or after the MPO melts.
• the talc dissolves in the mixture.
• the talc typically contains magnesium silicate, but may additionally contain other compounds.
• the talc is magnesium silicate.
• the talc is anhydrous magnesium silicate.
• the talc has a substantially charge-neutral surface.
• the intimate physical mixture contains at least about 10 wt.% talc, at least about 20 wt.% talc, at least about 30 wt.% talc, at least about 40 wt.% talc, greater than about 40 wt.% talc, greater than about 50 wt.% talc, greater than about 60 wt.% talc, greater than about 70 wt.%) talc, or more.
• the MPO is at least partially melted prior to the contacting step. In one embodiment, the MPO melts during the contacting step.
• the intimate physical mixture is a nanocomposite. In one embodiment, the intimate physical mixture further comprises a polymerization catalyst.
• the method further includes the step of heating the intimate physical mixture to polymerize the MPO.
• the polymerized product is a nanocomposite.
• the method produces polymer composition that exhibits a higher heat deflection temperature (HDT) than a polymer resulting from the polymerization of the MPO without the talc.
• the mixture may be polymerized, for example, in a two-part system, where the MPO- talc mixture is exposed to a temperature sufficient to melt the MPO, and the resulting mixture is contacted with a polymerization catalyst whereupon polymerization and crystallization occur substantially isothermally, thereby forming a polymeric composition comprising polymer and talc.
• the polymerization may take place in any molding, casting, or forming process, for example, an injection molding process, a rotational molding process, a resin film infusion process, a solvent prepreg process, a hot melt prepreg process, an extrusion process, a pultrusion process, a resin transfer molding process, a filament winding process, a compression molding process, a roll wrapping process, a powder coating process, and combinations thereof.
• the time and expense required to thermally cycle a tool is favorably reduced, for example, because demolding can take place immediately following polymerization, without first cooling the mold.
• the MPO-talc mixture may be stored as a one-part, ready-to-polymerize blend comprising MPO, talc, and a polymerization catalyst.
• the one-part blend remains stable for at least a week, for at least a month, or for at least a year or more, without significant premature polymerization of MPO and without significant deactivation of catalyst.
• the one-part blend is exposed to a temperature sufficient to melt and polymerize the MPO, whereupon polymerization and crystallization occur substantially isothermally.
• the compatibility of talc with MPO may be related to the surface energy, charge neutrality, and/or the non-polarity of platelets of talc, or, preferably, anhydrous talc.
• the polar -OH groups of talc reside in the interior of the structure of a talc layer and, therefore, are not chemically accessible to the molecules at or near the surface of the talc layer.
• Other factors that may be related to the compatibility of the filler with MPO include the platyness, softness, hydrophobicity, organophilicity, inertness, and mineralogical composition of the filler.
• the invention is directed to an intimate physical mixture comprising an MPO and a layered mineral, where the layered mineral has a substantially non- polar, substantially charge-neutral surface, and the layered mineral is present in the intimate physical mixture in an amount of at least about 10 wt.%.
• the MPO may comprise one or more species.
• the intimate physical mixture is a nanocomposite.
• the layered mineral comprises at least one of molybdenum sulfide, graphite, magnesium, iron, calcium, potassium, sodium, manganese, titanium, zirconium, copper, berylium, and zinc.
• the layered mineral comprises a layered silicate.
• the layered silicate is talc.
• the layered mineral may be present in the mixture in an amount of at least about 10 wt.%, at least about 20 wt.%, at least about 30 wt.%, at least about 40 wt.%, greater than about 40 wt.%, greater than about 50 wt.%, greater than about 60 wt.%, greater than about 70 wt.%, or more.
• the intimate physical mixture may also contain a catalyst. The intimate physical mixture (with or without the catalyst) may be stable at ambient conditions for at least one week, at least one month, or longer.
• Figure 1 shows a graph depicting results of dynamic mechanical thermal analysis (DMT A) tests of illustrative polymer compositions of the invention containing 0 wt.%, 10 wt.%, and 30 wt.% anhydrous magnesium silicate.
• Figure 2 shows a graph depicting results of DMT A tests of illustrative polymer compositions of the invention containing 0 wt.%, 30 wt.%, and 60 wt.% milled glass.
• Figure 3 shows a graph depicting further results of DMT A tests of illustrative polymer compositions of the invention containing 0 wt.%, 30 wt.%, and 60 wt.% milled glass.
• substantially pure, anhydrous magnesium silicate dissolves in molten macrocyclic poly(l,4-butylene terephthalate) oligomer at a temperature within a range from about 150°C to about 190°C, resulting in a homogeneous, transparent liquid.
• the discovery is unexpected, because attempts to incorporate aluminosilicate fillers into polymers have required that the aluminosilicate platelet surface be modified in order to compatibilize the filler with the polymer matrix.
• the magnesium silicate of the present invention does not require modification by cation exchange prior to incorporation with MPO.
• an average-sized filler particle in the resulting intimate physical mixture has at least one dimension (i.e. length, width, and/or height) that is less than roughly 400 nm (0.4 micron), the shortest wavelength of visible light.
• a near-molecular blend of MPO and filler is achieved, and the intimate physical mixture is a nanocomposite.
• a nanocomposite is a near-molecular blend of (1) polymer molecules and (2) nano-scale particles, where a nanoscale particle is a material with at least one dimension in the nanometer range.
• the intimate physical mixture is stable, and the filler remains dispersed in the mixture for at least a week, for at least a month, or for at least a year or more under ambient conditions.
• a long shelf life enhances the versatility of the mixture.
• the mixture may be stored for a long period of time, without requiring refrigeration or storage in an oxygen-free environment, before the mixture is polymerized in the manufacture of a plastic component.
• polymer compositions formed from intimate physical mixtures of magnesium silicate and MPO exhibit increased Young's modulus (E 1 ) over
• the invention provides methods of filling polymer so as to increasing its HDT value by 10%, 20%, 30%, 40%, 50%, 75%, 100%, or more.
• the filler and MPO are highly compatible (depending on the filler used, the filler may actually dissolve in the MPO), (2) the filler can be melt-mixed with MPO at a relatively low temperature, and (3) the MPO has a very low melt viscosity. Since MPO melts at relatively low temperatures, it is possible to avoid or limit the exposure of the mixture components to high temperature during incorporation of filler and/or catalyst.
• the presence of the filler in the blend (1) does not substantially decrease the rate of polymerization of the MPO contained in the blend, (2) does not substantially reduce the ultimate conversion of MPO to polymer, and (3) does not affect the ability of the blend to polymerize and crystallize essentially isothermally at polymerization temperatures.
• the invention also provides mixtures of MPO with certain other fillers, such as milled glass fiber, in which the presence of the filler increases HDT and increases the elastic modulus of the mixture over a wide temperature range.
• these fillers may be used alone, or in combination, at levels of up to about 30 wt.%, greater than about 30 wt.%, greater than about 40 wt.%, greater than about 50 wt.%, greater than about 60 wt.%, greater than about 70 wt.%, greater than about 80 wt.%, greater than about 90 wt.%, or even more, where weight percent is based on the total weight of the MPO- filler mixture.
• compositions, mixtures, blends, and composites are described as having, including, or comprising specific components, or where processes and methods are described as having, including, or comprising specific steps, it is contemplated that, additionally, there are compositions, mixtures, blends, and composites of the present invention that consist essentially of, or consist of, the recited components, and that there are processes and methods of the present invention that consist essentially of, or consist of, the recited processing steps.
• steps or order for performing certain actions is immaterial so long as the invention remains operable. Moreover, two or more steps or actions may be conducted simultaneously.
• macrocyclic is understood to mean a cyclic molecule having at least one ring within its molecular structure that contains 5 or more atoms covalently connected to form the ring.
• an "oligomer” is understood to mean a molecule that contains one or more identifiable structural repeat units of the same or different formula.
• a "macrocyclic polyester oligomer” is understood to mean a macrocyclic oligomer containing structural repeat units having an ester functionality.
• a macrocyclic polyester oligomer typically refers to multiple molecules of one specific repeat unit formula. However, a macrocyclic polyester oligomer also may include multiple molecules of different or mixed formulae having varying numbers of the same or different structural repeat units.
• a macrocyclic polyester oligomer may be a co-polyester or multi-component polyester oligomer, i.e., an oligomer having two or more different structural repeat units having ester functionality within one cyclic molecule.
• substantially homo- or co-polyester oligomer is understood to mean a polyester oligomer wherein the structural repeat units are substantially identical or substantially composed of two or more different structural repeat units, respectively.
• an "alkylene group” is understood to mean -C n H 2n -, where n > 2.
• a "cycloalkylene group” is understood to mean a cyclic alkylene group, -C n H 2n-x -, where x represents the number of H's replaced by cyclization(s).
• a "mono- or polyoxyalkylene group” is understood to mean [-(CH 2 ) m - O-] n -(CH 2 ) -, wherein m is an integer greater than 1 and n is an integer greater than 0.
• a "divalent aromatic group” is understood to mean an aromatic group with links to other parts of the macrocyclic molecule.
• a divalent aromatic group may include a meta- or para- linked monocyclic aromatic group (e.g., benzene).
• an "alicyclic group” is understood to mean a non-aromatic hydrocarbon group containing a cyclic structure within.
• a "C ⁇ - primary alkyl group” is understood to mean an alkyl group having 1 to 4 carbon atoms connected via a primary carbon atom.
• a "C MO alkyl group” is understood to mean an alkyl group having 1 to 10 carbon atoms, including straight chain or branched radicals.
• a "methylene group” is understood to mean -CH 2 -.
• an "ethylene group” is understood to mean -CH 2 -CH 2 -.
• a "C 2-3 alkylene group” is understood to mean -C n H 2n -, where n is 2 or 3.
• a "C 2-6 alkylene group” is understood to mean -CnH 2n -, where n is 2-6.
• substitute phenyl group is understood to mean a phenyl group having one or more substituents.
• a substituted phenyl group may have substitution pattern that is recognized in the art. For example, a single substituent may be in the ortho, meta or para positions.
• typical substitution patterns include, for example, 2,6-, 2,4,6-, and, 3,5- substitution patterns.
• a "filler” is understood to mean a material other than a macrocyclic polyester oligomer or a polymerization catalyst that may be included in the blend material.
• a filler may be used to achieve a desired purpose or property, and may be present or transformed into known and/or unknown substances in the resulting polyester polymer.
• the purpose of the filler may be to provide stability, such as chemical, thermal, or light stability, to the blend material or the polyester polymer product (i.e. to increase E' over a wide temperature range and/or to increase HDT), and/or to increase the strength of the polyester polymer product.
• a filler also may provide or reduce color, provide weight or bulk to achieve a particular density, provide reduced gas and vapor permeability, provide flame or smoking resistance (i.e., be a flame retardant), be a substitute for a more expensive material, facilitate processing, and/or provide other desirable properties.
• fillers are, among others, anhydrous magnesium silicate (anhydrous talc), fumed silica, titanium dioxide, calcium carbonate, wollastonite, chopped fibers, fly ash, glass, glass fiber, milled glass fiber, glass microspheres, micro-balloons, crushed stone, nanoclay, linear polymers, and monomers.
• a "polymer composition” is understood to mean a polymeric material comprising filler.
• the following headers are provided as a general organizational guide and do not serve to limit support for any given element of the invention to a particular section of the Description.
• One of the ingredients of the mixtures of the invention is a macrocyclic polyester oligomer.
• Many different macrocyclic polyester oligomers can readily be made and are useful in the practice of this invention.
• the appropriate macrocyclic polyester oligomer(s) can be selected for use in its manufacture.
• Macrocyclic polyester oligomers that may be employed in this invention include, but are not limited to, macrocyclic poly(alkylene dicarboxylate) oligomers having a structural repeat unit of the formula: O O
• A is an alkylene, or a cycloalkylene or a mono- or polyoxyalkylene group; and B is a divalent aromatic or alicyclic group.
• Preferred macrocyclic polyester oligomers include macrocyclic poly( 1 ,4-butylene terephthalate) (PBT), ⁇ oly( 1 ,3 -propylene terephthalate) (PPT), poly( 1 ,4- cyclohexylenedimethylene terephthalate) (PCT), poly(ethylene terephthalate) (PET), and poly(l,2-ethylene 2,6-naphthalenedicarboxylate) (PEN) oligomers, and copolyester oligomers comprising two or more of the above monomer repeat units.
• Macrocyclic polyester oligomers may be prepared by known methods. Synthesis of the preferred macrocyclic polyester oligomers may include the step of contacting at least one diol of the formula HO-A-OH with at least one diacid chloride of the formula:
• a and B are as defined above.
• the reaction typically is conducted in the presence of at least one amine that has substantially no steric hindrance around the basic nitrogen atom.
• An illustrative example of such amines is l,4-diazabicyclo[2.2.2]octane (DABCO).
• DABCO l,4-diazabicyclo[2.2.2]octane
• the reaction usually is conducted under substantially anhydrous conditions in a substantially water immiscible organic solvent such as methylene chloride.
• the temperature of the reaction typically is between about -25°C and about 25°C. See, e.g., U.S. Patent No. 5,039,783 to Brunelle et al.
• Macrocyclic polyester oligomers have also been prepared via the condensation of a diacid chloride with at least one bis(hydroxyalkyl) ester such as bis(4-hydroxybutyl) terephthalate in the presence of a highly unhindered amine or a mixture thereof with at least one other tertiary amine such as triethylamine, in a substantially inert organic solvent such as methylene chloride, chlorobenzene, or a mixture thereof. See, e.g., U.S. Patent No. 5,231,161 to Brunelle et al.
• Another method for preparing macrocyclic polyester oligomers or macrocyclic copolyester oligomers is to depolymerize linear polyester polymers in the presence of an organotin or titanate compound.
• linear polyesters are converted to macrocyclic polyester oligomers by heating a mixture of linear polyesters, an organic solvent, and a trans- esterification catalyst such as a tin or titanium compound.
• the solvents used such as o-xylene and o-dichlorobenzene, usually are substantially free of oxygen and water. See, e.g., U.S. Patent Nos. 5,407,984 to Brunelle et al. and 5,668,186 to Brunelle et al.
• Macrocyclic polyester oligomers have been prepared from intermediate molecular weight polyesters by contacting a dicarboxylic acid or a dicarboxylate in the presence of a catalyst to produce a composition comprising a hydroxyalkyl-terminated polyester oligomer.
• the hydroxyalkyl-terminated polyester oligomer is heated to produce a composition comprising an intermediate molecular weight polyester which preferably has a molecular weight between about 20,000 Daltons and about 70,000 Daltons.
• the intermediate molecular weight polyester is heated and a solvent is added prior to or during the heating process to produce a composition comprising an MPO. See, e.g., U.S. Patent No.
• Macrocyclic polyester oligomers that are substantially free from macrocyclic co-oligoesters have been prepared by depolymerizing polyesters using the organo-titanate catalysts described in co-owned U.S. Patent Application No. 09/974,722, by Phelps et al., published as U.S. Patent Application Publication No. US 2003/0114640, the text of which is incorporated by reference herein in its entirety.
• macrocyclic ester homo- and co-oligomers used in this invention include oligomers having a general structural repeat unit of the formula: O I I O— A'— C where A' is an alkylene, cycloalkylene, or mono- or polyoxyalkylene group, and where A' may be substituted, unsubstituted, branched, and/or linear.
• Example MPO's of this type include butyrolactone and caprolactone, where the degree of polymerization is one, and 2,5-dioxo-l,4- dioxane, and lactide, where degree of polymerization is two.
• the degree of polymerization may alternatively be 3, 4, 5, or higher.
• a macrocyclic polyester oligomer (MPO) used in a mixture of the invention includes species of different degrees of polymerization.
• a degree of polymerization (DP) with respect to the MPO means the number of identifiable structural repeat units in the oligomeric backbone.
• the structural repeat units may have the same or different molecular structure.
• an MPO may include dimer, trimer, tetramer, pentamer, and/or other species.
• Polymerization catalysts employed in the invention are capable of catalyzing the polymerization of the macrocyclic polyester oligomer.
• organotin and organotitanate compounds are the preferred catalysts, although other catalysts may be used.
• organotin compound l,l,6,6-tetra-n-butyl-l,6-distanna-2,5,7,10-tetraoxacyclodecane may be used as polymerization catalyst.
• organotin compounds include n-butyltin(IV) chloride dihydroxide, dialkyltin(IV) oxides, such as di-n-butyltin(IV) oxide and di-n-octyltin oxide, and acyclic and cyclic monoalkyltin (IV) derivatives such as n-butyltin tri-n-butoxide, dialkyltin(IV) dialkoxides such as di-n-butyltin(IV) di-n-butoxide and 2,2-di-n-butyl-2-stanna-l,3-dioxacycloheptane, and trialkyltin alkoxides such as tributyltin ethoxide.
• dialkyltin(IV) oxides such as di-n-butyltin(IV) oxide and di-n-octyltin oxide
• trisstannoxanes having the general formula (I) shown below can be used as a polymerization catalyst to produce branched polyester polymers.
• R 2 is a C primary alkyl group and R 3 is Cj.io alkyl group.
• organotin compounds with the general formula (II) shown below can be used as a polymerization catalyst to prepare branched polyester polymers from macrocyclic polyester oligomers.
• R 3 is defined as above.
• titanate compounds tetra(2-ethylhexyl) titanate, tetraisopropyl titanate, tetrabutyl titanate, and titanate compounds with the general formula (III) shown below can be used as polymerization catalysts.
• each R is independently an alkyl group, or the two R 4 groups taken together form a divalent aliphatic hydrocarbon group;
• R 5 is a C 2 - 10 divalent or trivalent aliphatic hydrocarbon group;
• R 6 is a methylene or ethylene group; and
• n is 0 or 1.
• Titanate ester compounds having at least one moiety of the following general formula have also been used as polymerization catalysts:
• each R is independently a C 2- alkylene group
• R 8 is a C ⁇ -6 alkyl group or unsubstituted or substituted phenyl group
• each R 9 is independently a C 2-6 alkylene group
• q is O or l.
• polymer-containing organo-metal catalysts may be used in the invention. These include the polymer-containing catalysts described in co-owned U.S. Patent Application No. 10/040,530, published as U.S. Patent Application Publication No. US 2003/0162654, the text of which is incorporated by reference herein in its entirety. III.
• MPO macrocyclic polyester oligomer
• the filler is added to MPO before polymerization of the MPO, as this is found to enhance the ultimate dispersion of certain fillers, including anhydrous talc and milled glass fiber, in the polymerized product.
• the MPO is partially polymerized at the time of introduction of the filler.
• the filler is preferably added to MPO by contacting the filler with molten MPO. Contact of the filler with MPO should take place at a temperature in which all, substantially all, or a significant proportion (for example, more than about 30 wt.%, more than about 60 wt.%, or, preferably, more than about 90 wt.%) of the MPO is melted.
• the MPO comprises macrocyclic poly(butylene terephthalate) oligomer in a substantial proportion
• filler is
• extrusion or any other process that enhances the dispersion of filler into MPO.
• the process may be a batch process, or it may be continuous or semi-continuous.
• "melt- mixing" occurs as a mixture of MPO and filler is extruded, and the extrudate is quenched.
• An appropriate catalyst - for example, a zinc-, titanium-, or tin-containing polymerization catalyst such as those described herein above - may be added before, during, or after the filler is contacted (and preferably mixed) with the macrocyclic oligoester to produce a one-part, ready-to-use material.
• the amount of polymerization catalyst employed is generally an amount from about 0.01 to about 10.0 mole percent, preferably from about 0.1 to about 2 mole percent, and more preferably from about 0.2 to about 0.6 mole percent, based on total moles of repeat units of the MPO.
• the MPO-filler mixture does not contain polymerization catalyst.
• the MPO-filler mixture may consist essentially of MPO and filler. This type of mixture gives rise to a "two-part" polymerization system, where the polymerization catalyst is provided separately.
• the filler-MPO mixture can be added to a reaction vessel at a different time, or via a different mechanism, than the polymerization catalyst.
• the filler-MPO mixture is extruded or injection-molded together with a separately- provided polymerization catalyst.
• the mixtures of the invention may be used in any combination of one or more processes - for example (and without limitation), rotational molding, injection molding, powder coating, compression molding, extrusion, pultrusion, resin film infusion, solvent prepreg, hot melt prepreg, resin transfer molding, filament winding, and roll wrapping processes.
• Articles produced by these processes are encompassed within the scope of this invention. Examples of these processes are provided in co-owned U.S. Patent No. 6,369,157, by Winckler et al., and co- owned U.S. Patent No. 6,420,047, by Winckler et al., the texts of which are incorporated by reference herein, in their entirety.
• the MPO-filler mixtures of the invention exhibit moderately higher melt viscosities than unfilled MPO. Therefore, these mixtures may be particularly well-suited for use in low-pressure processes such as rotational molding, powder coating, low-pressure molding, gas-assist molding, short-shot molding, co-injection molding, reaction-injection molding, blow molding, thermoforming, and combinations thereof, where a higher melt viscosity is desired.
• Examples of MPO-filler mixtures and polymer compositions formed from polymerization of the mixtures are described in the following Experimental Examples section. IV. Experimental Examples [0090] Examples 1-12 illustrate methods of preparing a stable, one-part, ready-to-polymerize, intimate physical mixture comprising an MPO, a filler, and a polymerization catalyst. Properties of the polymer compositions resulting from the polymerization of these mixtures are shown in Tables 2-5 and in Figures 1-3.
• Examples 1-12 employ the use of macrocyclic polyester oligomers manufactured by Cyclics Corporation of Schenectady, NY, that are primarily composed of macrocyclic poly(l,4- butylene terephthalate) oligomer.
• the MPO used in Examples 1-3 is referred to herein as MPO- 2 and contains about 93 mol.% (1,4-butylene terephthalate) units and about 7 mol.% (2,2'- oxydiethylene terephthalate) units.
• the MPO used in Examples 4-12 is referred to herein as MPO-3 and contains about 100 mol.% (1,4-butylene terephthalate) units.
• MPO-2 and MPO-3 each contain about 40.2 wt.% dimer species, about 39.0 wt.% trimer species, about 5.5 wt.% tetramer species, about 12.9 wt.% pentamer species, and about 2.4 wt.% higher oligomer species.
• the MPO of the blend material is a composition comprising from about 30 to about 45 wt.% dimer species, from about 30 to about 45 wt.% trimer species, from about 0 to about 10 wt.% tetramer species, and from about 5 wt.% to about 20 wt.%) pentamer species. MPO formulations outside these ranges may be used, as well.
• Certain embodiments of the invention may include modifying compositions of MPO's.
• modifying compositions of MPO's are described in co-owned U.S. Patent No. 6,436,548, by Phelps, the text of which is incorporated by reference herein in its entirety.
• Example 1 [0093] A first formulation containing 5 wt.% anhydrous magnesium silicate was prepared by melt-mixing 95.0 grams of MPO-2), 5.0 grams of Ultra Talc 609 (manufactured by Barretts Minerals Inc. of Barretts, MT), and 0.20 grams of stabilizer Irganox 1010 (CAS number 6683- 19-8, manufactured by Ciba-Geigy Corp. of Ardsley, NY). The three components were added in finely pulverized form into a 250-ml, three-neck flask fitted with a vacuum adapter and a
• Butyltin chloride dihydroxide powder (0.371 grams, 0.35 mol.% based on molar amount of total repeat units in MPO-2) was added over a period of about one minute. The resulting mixture was further stirred for an additional 10 minutes and was then poured onto an aluminum plate to quench. Upon cooling to room temperature, the solution became a transparent glass, indicating the silicate particles were dispersed in the mixture well enough to allow light to penetrate the mixture. The resulting tacky solid was annealed in an
• Example 4 A fourth formulation containing about 10 wt.% magnesium silicate was prepared by melt-mixing 90.0 grams of MPO-3, 10.0 grams of Ultra Talc 609, and 0.20 gram of Irganox 1010 stabilizer. The three components were added in finely-pulverized form into a 250-ml, three neck flask fitted with a vacuum adapter and a magnetic stirrer. The flask was first flushed with argon and then heated under vacuum at 100°C for one hour to dry the mixture. The flask was then heated under vacuum in an oil bath maintained at 165°C. The mixture completely melted within 30 minutes to form a homogeneous, clear liquid.
• Example 5 A fifth formulation containing 30 wt.% magnesium silicate was prepared following the procedures of Example 4 using MPO-3. A control mixture containing no magnesium silicate was also prepared. Samples for DMTA testing were cut from cured plaques of both formulations. Examples 6 and 7
• Microglass® 3032 manufactured by Fibertec Inc. of Bridgewater, MA were prepared according to
• Microglass® 3032 A seventh formulation containing 30 wt.% milled glass fiber (1/16", sized,
• DMTA Dynamic mechanical thermal analysis
• Figure 1 depicts DMTA results for the polymer compositions of Examples 4 and 5 containing 10 wt.% and 30 wt.% magnesium silicate, respectively, along with the unfilled control.
• the polymer compositions of Examples 4 and 5 exhibit higher elastic modulus (E') over
• grater heat resistance HDT
• improved processibility increased stiffness, and greater strength due to the presence of the well-dispersed filler in the polymer matrix.
• E' and hysteresis are typically tradeoffs between E' and hysteresis (as measured by the total area under the tangent delta curve), depending on the total amount of filler used.
• proportionate increase in E' for the talc-filled polymer compositions of Examples 4 and 5 is significantly greater than the proportionate increase in hysteresis, and the trade-off between E' and hysteresis may be entirely acceptable for many applications.
• Figures 2 and 3 show graphs depicting DMTA results for the polymer compositions of Examples 6 and 7 containing 30 wt.% and 60 wt.% milled glass fiber, respectively, along with the control sample containing no filler.
• the polymer compositions of Examples 6 and 7 exhibit
• Figure 3 indicates the filled polymer compositions of Examples 6 and 7 have a lower tangent delta than the unfilled control sample over a significant portion of the temperature range tested.
• a lower tangent delta generally indicates higher resilience and lower hysteresis.
• a 100-mm diameter cylindrical mold was fitted with a 44-mm steel core positioned along the center axis.
• Two separate parts were molded by polymerizing MPO-3 filled with 15 wt.% talc (Ultra Talc 609 manufactured by Barretts Minerals Inc. of Barretts, MT) and 60 wt.%
• milled glass fiber (Microglass® 3032, manufactured by Fibertec Inc. of Bridgewater, MA),
• control parts were molded - one control part made by
• a Shore durometer test was conducted on the parts made with 15 wt.% talc, 60 wt.% milled glass fiber, and 5 wt.% polycaprolactone, respectively.
• the durometer Shore D hardness value was highest for the milled-glass-filled MPO-3 part, followed by the part filled with talc, and the polycaprolactone- filled part had the lowest hardness value.
• Table 5 summarizes the results of the Shore durometer tests. Table 5.

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