WO2007019142A1 - Concentrés d’argile organique et leur utilisation - Google Patents

Concentrés d’argile organique et leur utilisation Download PDF

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Publication number
WO2007019142A1
WO2007019142A1 PCT/US2006/029939 US2006029939W WO2007019142A1 WO 2007019142 A1 WO2007019142 A1 WO 2007019142A1 US 2006029939 W US2006029939 W US 2006029939W WO 2007019142 A1 WO2007019142 A1 WO 2007019142A1
Authority
WO
WIPO (PCT)
Prior art keywords
concentrate
organoclay
weight percent
compound
sheet molding
Prior art date
Application number
PCT/US2006/029939
Other languages
English (en)
Inventor
David Jarus
Original Assignee
Polyone Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Polyone Corporation filed Critical Polyone Corporation
Publication of WO2007019142A1 publication Critical patent/WO2007019142A1/fr

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Classifications

    • 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
    • C08K9/00—Use of pretreated ingredients
    • C08K9/04—Ingredients treated with organic substances

Definitions

  • This invention relates to concentrates of organoclays in a polymer matrix and their use in making sheet molding compounds.
  • Sheet molding compounds generally are composite structures of pre-mixed the resin, filler, fibrous reinforcement, and other additives which then can be formed into a desired shape and cured in a heated, matched metal dye. Very large and complicated plastic parts can be made from these materials and by this method for use in a variety of industries such as transportation, electronics, appliances, etc.
  • Organoclays are exciting additives for a variety of purposes.
  • Organoclays are nanoclays surface treated with organic surfactants for later intercalation or exfoliation with polymers into nanocomposites. Nanocomposites can be concentrates for dilution or "let down” into other plastics or can be compounds themselves with the addition of other desired ingredients.
  • thermosetting resins In general, compounding of additives into thermosetting resins uses a batch mixing process. For example, when making sheet molding compounds, it is common practice in production of sheet molding compound to have a low viscosity compound to permit the liquid compound to be easily transferred by pumping or otherwise, and also for other reasons of easier handling and efficiency.
  • Sheet molding compound is not prepared using extruding equipment because such equipment is designed to run at very high torque to account for the high viscosity of the thermoplastic medium.
  • Extruders designed for processing thermoplastic resins such as twin screw extruder from major companies such as Coperion, Berstoff, or Leistritz, are machines are designed to impart work on the material for distributive and dispersive mixing with a high viscosity medium.
  • sheet molding compounds are generally not viscous enough to be processed in extruder equipment, which is known to have an advantage over batch process mixing vessels, such as those currently used for making sheet molding compounds, because the extruder equipment can be a continuous manufacturing process.
  • Organoclays are good viscosity enhancing materials, hi this invention, organoclays in the form of concentrates are used to raise the relatively low viscosity of the uncured thermoset resins to a level where the viscosity is high enough to impart work and dispersion in the extrusion equipment.
  • SEC specific energy consumption
  • Low viscosity materials such as a conventional sheet molding compound, do not create enough torque and therefore have a very low SEC, less than about 0.01 kW hr/kg.
  • a typical SEC number for a thermoplastic compound undergoing extrusion processing can range from about 0.08 to about 0.4 kW hr/kg. Therefore, low molecular weight themoset resins typically used in making sheet molding compounds would not provide enough viscosity to reach these levels of SEC in an extruder.
  • the present invention begins with the proposition for specific energy consumption that at least about 0.04 kW hr/kg would be required to achieve any level of mixing of a sheet molding compound in an extruder.
  • thermoplastics have as an SEC number.
  • the specific energy consumption can range from about 0.1 to about 0.25 kW hr/kg.
  • thermoset resins that adversely increase viscosity are avoided to minimize problems with resin transport through normal batch mixing equipment suitable for thermoset resins, such as pumps and pipes.
  • Organoclays suitable for use in the present invention are those organoclays with higher organic contents to maximize interaction of the clay with the resin. Suitable surfactants to achieve this could be quaternary ammonium surfactants.
  • Organoclays containing dimethyl, dihydrogenated tallow quaternary ammonium surfactants or octadecyl amine quaternary ammonium surfactants are more preferred that those surfactants that have less than about 14 carbon atoms because higher molecular weight surfactants generally increase the SEC value of a nanocomposite being processed in an extruder.
  • the amount of surfactant present in the organoclay can influence the interaction of the organoclay with the polymer resin(s) in the extruder, which causes increased viscosity.
  • the amount of surfactant present in the organoclay can range from about 30 weight percent to about 50 weight percent, and preferably from about 35 weight percent to about 50 weight percent.
  • the amount of surfactant present in the organoclay is a determinator for how much melt dispersion is possible to increase viscosity of the compound being worked in the extruder, whereas the identity or type of surfactant may change based on choice of thermoset resin to be made in to sheet molding compound or the carrier resin(s) for introducing the organoclay as a concentrate into that sheet molding compound.
  • organoclays are available from Nanocor, Inc., Southern Clay, and Sued Chemie. Of these suppliers of organoclays, it is known that Southern Clay's Cloisite 1OA and 15A brand organoclays are treated with tallow-based surfactants that would satisfy the goal of interacting with the polymer resin(s) in the extruder and increase SEC and viscosity to a level acceptable for compounding sheet molding compound in an extruder.
  • the polymer resin(s) to serve as a carrier for the organoclay in the concentrate can be any polymer that is compatible with any thermosettable polymer(s) that are to be used to make a sheet molding compound.
  • thermoplastic polymer(s) as carrier resin(s) for the organoclay in an analogous manner to the selection of carrier resin(s) for other additives employed in a batch processing of sheet molding compound.
  • U.S. Pat. No. 3,959,209 (Koppers), incorporated by reference herein, lists polymeric thermoplastics which reduce the shrinkage of thermosetting resin formulations as they are cured and thus effectively produce articles having smooth, high quality cosmetic surfaces.
  • thermosettable sheet molding compounds such as Ashland Specialty Chemical Division of Ashland, Inc.
  • carrier resin(s) are particularly suitable for use with such compounds from that company.
  • the amount of organoclay in the concentrate can range from about 20 to about 80 weight percent.
  • the amount of carrier resin(s) can range from about 80 to about 20 weight percent.
  • ingredients are desired as additives in the sheet molding compound and are otherwise compatible with the organoclays and the carrier resin(s).
  • optional additives include fillers, antioxidants, stabilizers, lubricants, pigments, biocides, and the like. Each of these additives is commercially available from well-known sources known to those skilled in the art.
  • Compounding the concentrate of the present invention can take any number of routes according to preferences of those familiar with the compounding of thermoplastic materials.
  • each ingredient is mixed into a large vessel, hi another route, batches of ingredients are first formed and then the batches are combined.
  • blenders containing ingredients feeding a hopper upstream from an extruder, usually twin-screw, co- rotating.
  • the ingredients are thoroughly mixed under sufficient heat to melt the carrier resin(s).
  • the mixing equipment is a co-rotating twin-screw extruder commercially available from Coperion/Werner-Pfleiderer.
  • the extruder should be capable of screw speeds ranging from about 50 to about 2,000 rpm.
  • the temperature profile from the barrel number two to the die should range from the melting temperature of the carrier resin to about 270°C.
  • the composite can be pelletized for later use in the formation of articles as described below.
  • any type of extruder equipment that achieves sufficient mixing of ingredients can be used to mix the concentrate into the ingredients of the sheet molding compound, either pre-mixed or introduced individually.
  • the same or similar extruder equipment as used to make the concentrate can also be used in the processing of the thermosettable sheet molding compound, hi addition to the concentrate, one can add the thermosettable resin(s), the reinforcing ingredients, the stabilizers, and other conventional materials common in formulations of sheet molding compound.
  • one skilled in the art can adapt a formulation for a thermosettable sheet molding compound made in a batch process mixing vessel into a formulation for a thermosettable sheet molding compound to be made in an extruder.
  • thermosettable sheet molding compound in a continuous process, it is also possible to place in modular arrangement a molding machine in relative close proximity to the extruder, such that continuous flow of thermosettable sheet molding compound can be directed to one or more molding machines for automated or nearly automated compounding and molding operations into a final molded product.
  • An example of that modular arrangement is shown in U.S. Pat. No. 6,852,268 (Valyi et al.).
  • Organoclay concentrates of the present invention not only increase viscosity of thermosettable sheet molding compounds to a level sufficient to use extruding equipment for compounding, but also the organoclays provide performance benefits for the ultimate molded product.
  • molded articles have reinforcing additives and other materials to improve impact resistance. Replacement, at least in part, of these reinforcing additives with organoclays can reduce weight while maintaining strength and durability of the molded article. Alternatively, addition of these organoclays can increase strength and durability of the molded articles beyond that currently known.
  • Organoclays in compounds result in lighter weight, stiffer, and tougher molded plastic articles than compounds without such organoclays in them.
  • Organoclays in them For example, it is known from NanoblendTM LST thermoplastic compounds that Izod Impact and Tensile Modulus are higher than the same thermoplastic compounds without organoclay present.
  • Articles made from concentrates of the present invention are more valuable because organoclays provide increased lightness and stiffness while retaining toughness.
  • Such articles can be made into any number of shapes,- among them, automobile and truck parts, large appliance parts, and the like.
  • the amount of organoclay in the final sheet molding compound can range from about 3 to about 15 weight percent, with appropriate dilution or "let-down" in a thermosettable sheet molding compound formulation.
  • the invention is not limited to these embodiments. The claims follow.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

La présente invention concerne un concentré d’argile organique convenant à un mélange à mouler en feuille. L’argile organique confère des caractéristiques de rigidité et de résistance à un poids inférieur à celui du mélange lorsque celui-ci utilise des charges de renfort. L’argile organique confère également une viscosité plus importante au mélange à mouler en feuille, de sorte que le mélange peut être traité à l’intérieur de l’extrudeuse.
PCT/US2006/029939 2005-08-03 2006-07-31 Concentrés d’argile organique et leur utilisation WO2007019142A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US70499105P 2005-08-03 2005-08-03
US60/704,991 2005-08-03

Publications (1)

Publication Number Publication Date
WO2007019142A1 true WO2007019142A1 (fr) 2007-02-15

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2006/029939 WO2007019142A1 (fr) 2005-08-03 2006-07-31 Concentrés d’argile organique et leur utilisation

Country Status (1)

Country Link
WO (1) WO2007019142A1 (fr)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7871696B2 (en) 2006-11-21 2011-01-18 Kraft Foods Global Brands Llc Peelable composite thermoplastic sealants in packaging films
US7871697B2 (en) 2006-11-21 2011-01-18 Kraft Foods Global Brands Llc Peelable composite thermoplastic sealants in packaging films
US8389596B2 (en) 2010-02-26 2013-03-05 Kraft Foods Global Brands Llc Low-tack, UV-cured pressure sensitive adhesive suitable for reclosable packages
US8398306B2 (en) 2005-11-07 2013-03-19 Kraft Foods Global Brands Llc Flexible package with internal, resealable closure feature
US8763890B2 (en) 2010-02-26 2014-07-01 Intercontinental Great Brands Llc Package having an adhesive-based reclosable fastener and methods therefor
US9532584B2 (en) 2007-06-29 2017-01-03 Kraft Foods Group Brands Llc Processed cheese without emulsifying salts
US9533472B2 (en) 2011-01-03 2017-01-03 Intercontinental Great Brands Llc Peelable sealant containing thermoplastic composite blends for packaging applications

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020156171A1 (en) * 2001-02-20 2002-10-24 Marta Drewniak High melt-strength polyolefin composites and methods for making and using same
US20030092816A1 (en) * 2001-09-06 2003-05-15 Mehta Sameer D. Propylene polymer composites having improved melt strength
US20030100657A1 (en) * 2001-10-23 2003-05-29 Helena Twardowska Thermosetting inorganic clay nanodispersions and their use
EP1424362A1 (fr) * 2002-11-27 2004-06-02 DSM IP Assets B.V. Procédé de préparation d'une composition

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020156171A1 (en) * 2001-02-20 2002-10-24 Marta Drewniak High melt-strength polyolefin composites and methods for making and using same
US20030092816A1 (en) * 2001-09-06 2003-05-15 Mehta Sameer D. Propylene polymer composites having improved melt strength
US20030100657A1 (en) * 2001-10-23 2003-05-29 Helena Twardowska Thermosetting inorganic clay nanodispersions and their use
EP1424362A1 (fr) * 2002-11-27 2004-06-02 DSM IP Assets B.V. Procédé de préparation d'une composition

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8398306B2 (en) 2005-11-07 2013-03-19 Kraft Foods Global Brands Llc Flexible package with internal, resealable closure feature
US9309027B2 (en) 2006-11-21 2016-04-12 Intercontinental Great Brands Llc Peelable composite thermoplastic sealants in packaging films
US7871697B2 (en) 2006-11-21 2011-01-18 Kraft Foods Global Brands Llc Peelable composite thermoplastic sealants in packaging films
US8110286B2 (en) 2006-11-21 2012-02-07 Kraft Foods Global Brands Llc Peelable composite thermoplastic sealants in packaging films
US8470397B2 (en) 2006-11-21 2013-06-25 Kraft Foods Global Brands Llc Peelable composite thermoplastic sealants in packaging films
US7871696B2 (en) 2006-11-21 2011-01-18 Kraft Foods Global Brands Llc Peelable composite thermoplastic sealants in packaging films
US9532584B2 (en) 2007-06-29 2017-01-03 Kraft Foods Group Brands Llc Processed cheese without emulsifying salts
US8763890B2 (en) 2010-02-26 2014-07-01 Intercontinental Great Brands Llc Package having an adhesive-based reclosable fastener and methods therefor
US9096780B2 (en) 2010-02-26 2015-08-04 Intercontinental Great Brands Llc Reclosable fasteners, packages having reclosable fasteners, and methods for creating reclosable fasteners
US9382461B2 (en) 2010-02-26 2016-07-05 Intercontinental Great Brands Llc Low-tack, UV-cured pressure sensitive adhesive suitable for reclosable packages
US8389596B2 (en) 2010-02-26 2013-03-05 Kraft Foods Global Brands Llc Low-tack, UV-cured pressure sensitive adhesive suitable for reclosable packages
US10287077B2 (en) 2010-02-26 2019-05-14 Intercontinental Great Brands Llc Low-tack, UV-cured pressure sensitive adhesive suitable for reclosable packages
US9533472B2 (en) 2011-01-03 2017-01-03 Intercontinental Great Brands Llc Peelable sealant containing thermoplastic composite blends for packaging applications

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