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
  • C08G63/85—Germanium, tin, lead, arsenic, antimony, bismuth, titanium, zirconium, hafnium, vanadium, niobium, tantalum, or compounds thereof
• • 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
  • C08K5/00—Use of organic ingredients
  • C08K5/16—Nitrogen-containing compounds
  • C08K5/34—Heterocyclic compounds having nitrogen in the ring
  • C08K5/3467—Heterocyclic compounds having nitrogen in the ring having more than two nitrogen atoms in the ring
  • C08K5/3477—Six-membered rings
  • C08K5/3492—Triazines
  • C08K5/34928—Salts
• • 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
  • Y10T428/31504—Composite [nonstructural laminate]
• • 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
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/31507—Of polycarbonate

Definitions

• the present invention pertains to a process for reducing acetaldehyde formation in polyesters susceptible to the formation of acetaldehyde, i.e., those containing -OCH 2 CH 2 O- in a repeat unit and in particular to polyethylene terephthalate (“PET”) and to PET prepared thereby.
• Polyesters can be prepared by melt polycondensation, with or without subsequent solid state polymerization.
• PET Polyethylene terephthalate
• IhV inherent viscosity
• IiV intrinsic viscosity
• acetaldehyde There are two types of acetaldehyde (AA) to be concerned about.
• the first is residual or free AA contained in the pellets or particles sent to preform molders.
• the second type of AA is preform AA or the AA generated when the PET pellets are melt processed to make bottle preforms.
• AA precursors in the pellets can be converted to AA upon melting and give unacceptable levels of AA in the preforms.
• Melt processing also forms more AA precursors, which can liberate AA.
• Acetaldehyde has a noticeable taste and can be detected by human taste buds at low levels. When the preforms are blown into bottles, unacceptably high AA levels are those that adversely impact the taste of the beverage contained in the said bottles.
• Relatively tasteless beverages such as water are particularly negatively impacted by the strong taste of AA.
• Many water bottle applications require lower levels of perform AA than carbonated soft drink (“CSD") bottle applications.
• Converters who take polyester particles and make bottle preforms would like to have one resin that could be used to make preforms for both water and CSD applications. This would simplify the materials handling process at the converter by allowing for one feed silo or one type of feed silo, one product storage area or one type of product storage area etc.
• Most resins sold into water bottle markets have a lower It.V. than those resins sold into CSD markets.
• a dual use resin would have to a high enough It.V. for CSD applications and a low enough AA generation rate upon melting for water bottle applications.
• AA scavengers In order to use one resin, some converters are adding AA scavengers to CSD resins to get acceptable perform AA for the water market. AA scavengers add significant cost to the container and often negatively impact the color of the container by making it either more yellow or darker as compared to an analogous container without AA scavenger added.
• the conventional PET production process begins with esterification of predominantly terephthalic acid and ethylene glycol, or ester exchange of predominantly dimethyl terephthalate and ethylene glycol.
• the esterification need not be catalyzed.
• Typical ester exchange catalysts which may be used separately or in combination, include titanium alkoxides, tin (II) or (IV) esters, zinc, manganese or magnesium acetates or benzoates and/or other such catalyst materials that are well known to those skilled in the art.
• the resulting mixture is then subjected to polycondensation in the melt at elevated temperature, for example 285°C, in the presence of a suitable catalyst.
• Solid state polymerization or "solid stating” takes place in a fluidized bed over a period of from 10 to 20 hours, at a temperature which is preferably in the range of 180 0 C to a temperature which is lower than the crystalline melt temperature by at least 10°C. Volatiles are removed in vacuo or by a flow of inert gas (e.g., nitrogen), or at lower temperatures, e.g. 180 0 C or lower, by means of a flow of air.
• inert gas e.g., nitrogen
• Solid stating has the advantage that relatively high inherent viscosities can be achieved. It has the further advantage that acetaldehyde content of the polymer is lowered substantially by the removal of acetaldehyde by volatilization. Solid stating has the considerable disadvantages of high energy usage and long processing time. Finally, solid state polymerization causes the pellets to develop shell-to-core molecular weight gradients, which results in a loss in inherent viscosity during the molding of articles that is theorized to be due to re- equilibration in the melt.
• antimony catalysts When antimony catalysts are used for polycondensation, phosphorous compounds have been added to assist in lowering acetaldehyde and acetaldehyde precursors.
• antimony is not the most active catalyst, and deactivation of antimony with phosphorus compounds, if not performed carefully, may generate haze in the product.
• Titanium compounds are known to be much more active polycondensation catalysts, and can reduce the polycondensation time significantly.
• titanium compounds when employed in PET production, often produce polymers with higher residual acetaldehyde, and can also result in greater generation of acetaldehyde downstream from polymer production per se, for example during the molding of preforms. Titanium catalysts also impart a distinct yellow cast to the product as well.
• U.S. Patent 5,656,716 discloses use of high surface area titanium catalysts followed by addition of triphenyl phosphate. Without the triphenyl phosphate, a high inherent viscosity but distinctly yellow product was obtained, while with triphenyl phosphate, less colored products are obtained, but only at a low inherent viscosity, thus requiring solid stating of these products with its disadvantages.
• polyesters are stabilized against generation of aldehydes through addition of one of a diverse population of stabilizers, including sterically hindered amines such as Tinuvin® 123 or Tinuvin® 622 during initial esterification or transesterification.
• sterically hindered amines such as Tinuvin® 123 or Tinuvin® 622 during initial esterification or transesterification.
• no salts of phosphorus-containing acids with these stabilizers are disclosed, nor is their addition late in a melt-phase polycondensation process.
• nitrogenous stabilizers selected from hydroxylamines, substituted hydroxylamines, nitrones, and amine oxides are employed to scavenge acetaldehyde generated during extrusion of polyesters or polyamides. No salts made from these nitrogenous- stabilizers with phosphorus-containing acids are disclosed, nor is addition late in the melt-phase polycondensation stage of polyester production.
• salts are made of hindered amine light stabilizers (HALS) derivatives and organophosphorus acids. Addition of amine salts to polyesters during the melt-phase manufacturing is not disclosed, nor is reduction of acetaldehyde.
• HALS hindered amine light stabilizers
• polyesters susceptible to acetaldehyde formation can be continuously produced in a melt phase process to have high inherent viscosity and low acetaldehyde content without solid stating polymerizing the polyester by polycondensing hydroxyl end groups of an ester linkage containing melt in the presence of a titanium polycondensation catalyst followed by adding a class of additives comprising phosphorus-containing acid salts of amines, preferably hindered amines containing both piperidine and triazine rings, late in the melt-phase polycondensation stager, i.e. after the It.V.
• the additives may be added anywhere between the last reactor and a pelletizer, such as after agear pump and prior to a filter.
• the additive may also be added near the end of last reactor.
• the additive may be introduced as a polymer concentrate or in a liquid carrier, or may be added neat (without dilution).
• the color of the Ti-catalyzed product is not adversely affected by the presence of the additives. If desired, the inherent viscosity may be further elevated by solid state polymerization.
• FIGURE 1 is a contour plot of acetaldehyde generation with respect to Ti catalyst level and temperature, without addition of any acetaldehyde reducing additive.
• FIGURE 2 is a contour plot similar to Figure 1 , but with 0.1 wt% of acetaldehyde-reducing additive. 5. Detailed Description Of The Invention
• polyesters are generally known in the art and may be formed from aromatic or aliphatic dicarboxylic acids, esters of dicarboxylic acids, anhydrides of dicarboxylic acids, acid chlorides of dicarboxylic acids, glycols, epoxides and mixtures thereof. More preferably the polyesters are formed from diacids such as terephthalic acid, isophthalic acid, and 2,6- naphthalenedicarboxylic acid, and mixtures thereof, and diols such as ethylene glycol, diethylene glycol, 1 ,4-cyclohexanedimethanol, 1 ,4-butanediol, and mixtures thereof.
• diacids such as terephthalic acid, isophthalic acid, and 2,6- naphthalenedicarboxylic acid, and mixtures thereof
• diols such as ethylene glycol, diethylene glycol, 1 ,4-cyclohexanedimethanol, 1 ,4-butane
• the process of the present invention can produce PET polyesters, which includes "modified” polyesters.
• suitable polyester polymers made by the process include polyalkylene terephthalate homopolymers and copolymers modified with one or more modifiers in an amount of 40 mole% or less, preferably less than 15 mole%, most preferably less than 10 mole%.
• a polymer includes both its homopolymer and copolymer variants.
• the preferred polyester polymer is a polyalkylene terephthalate polymer, and most preferred is polyethylene terephthalate polymer.
• modified it is meant that the preferred diacid component and/or diol component are substituted in part with one or more different diacid and/or diol components.
• the preferred diol component e.g., ethylene glycol in the case of PET
• the preferred dicarboxylic acid component e.g., terephthalic acid, in the case of PET
• the mole percentage for all the diacid component(s) totals 100 mole%, and the mole percentage for the entire diol component(s) totals 100 mole%.
• the dicarboxylic acid component of the polyester may optionally be substituted with up to about 20 mole percent of one or more different dicarboxylic acids.
• additional dicarboxylic acids include aromatic dicarboxylic acids preferably having 8 to 14 carbon atoms, aliphatic dicarboxylic acids preferably having 4 to 12 carbon atoms, or cycloaliphatic dicarboxylic acids preferably having 8 to 12 carbon atoms.
• dicarboxylic acids to be included with terephthalic acid include: phthalic acid, isophthalic acid, naphthalene-2,6-dicarboxylic acid, 1 ,4-cyclohexanedicarboxylic acid, 1 ,3- cyclohexanedicarboxylic acid, stilbene dicarboxylic acid, cyclohexanediacetic acid, 1 ,12-dodecanedioic acid, diphenyl-4,4'-dicarboxylic acid, succinic acid, glutaric acid, adipic acid, azelaic acid, sebacic acid, mixtures thereof and the like. Polyesters may be prepared from two or more of the above dicarboxylic acids. Moreover, the foregoing dicarboxylic acids, which exist as stereoisomers, may be in their c/s-form, ifrans-form, or as mixtures thereof.
• the glycol component may optionally be substituted with up to about 20 mole percent, of one or more diols other than ethylene glycol.
• additional diols include cycloaliphatic diols preferably having 6 to 20 carbon atoms or aliphatic diols preferably having 3 to 20 carbon atoms.
• diols examples include: diethylene glycol, triethylene glycol, 1 ,4- cyclohexanedimethanol, propane-1 ,2-diol, propane-1 ,3-diol, butane-1 ,4-diol, pentane-1 ,5-diol, hexane-1 ,6-diol, 3-methylpentane-2,4-diol, 2-methylpentane-1 ,4- diol, 2,2,4-trimethylpentane-1 ,3-diol, 2-ethylhexane-1 ,3-diol, 2,2-diethylpropane- 1 ,3-diol, hexane-1 ,3-diol, 1 ,4-di(hydroxyethoxy)-benzene, 2,2-bis-(4- hydroxycyclohexyl)-propane, 2,4-dihydroxy-1 ,1 ,3,3
• the foregoing diols which exist as stereoisomers, may be in their c/s-form, transform, or as mixtures thereof. It should be noted in this respect that presence of ethylene glycol residues, -OCH 2 CH 2 O-, is paramount, since in the absence of such residues, acetaldehyde generation is not problematic.
• the resins may optionally contain polyfu notional monomers, e.g., trifunctional or tetrafunctional comonomers such as trimellitic anhydride, trimellitic acid, trimethylolpropane, pyromellitic dianhydride, pentaerythritol, and the like. However, these are not generally preferred, and when used, are generally used in most minor amounts.
• polyester compositions of the invention can be prepared by polymerization procedures known in the art sufficient to effect esterification and polycondensation.
• Polyester melt phase manufacturing processes include condensation of at least one dicarboxylic acid with at least one diol, optionally in the presence of esterification catalysts in an esterification zone, followed by polycondensation in the presence of a polycondensation catalyst in a polymerization zone which may in some instances be divided into a prepolymer zone and in the finishing zone; or ester exchange, usually in the presence of a transesterification catalyst in the ester exchange zone, followed in the presence of a polycondensation catalyst by a prepolymehzation zone and finishing zone.
• Each of the polymers obtained may optionally be solid stated according to known methods.
• a mixture of one or more dicarboxylic acids, preferably aromatic dicarboxylic acids, or ester forming derivatives thereof, and one or more diols are continuously fed to an esterification reactor operated at a temperature of between about 200 0 C and 300°C, typically between 24O 0 C and 290 0 C, and at a pressure of between about 1 psig up to about 70 psig.
• the residence time of the reactants typically ranges from between about one and five hours.
• the dicarboxylic acid(s) is/are directly esterified with diol(s) at elevated pressure and at a temperature of about 24O 0 C to about 27O 0 C.
• the esterification reaction is continued until a degree of esterification of at least 60% is achieved, but more typically until a degree of esterification of at least 85% is achieved to make the desired monomer and/or oligomers.
• the monomer and/or oligomer reaction(s) are typically uncatalyzed in the direct esterification process and catalyzed in ester exchange processes.
• Polycondensation catalysts may optionally be added in the esterification zone along with esterification/ester exchange catalysts. If the catalyst forms an insoluble salt with the dicaroxylic acid(s), the catalyst is added after the esterification zone. If a polycondensation catalyst was added to the esterification zone, it is typically blended with the diol and fed into the esterification reactor.
• Typical ester exchange catalysts which may be added to the ester exchange zone or reactor(s), and which may be used separately or in combination, include titanium alkoxides, tin (II) or (IV) esters, manganese, or magnesium acetates or benzoates and/or other such catalyst materials as are well known to those skilled in the art.
• Phosphorus containing compounds and some colorants may also be present in the esterification zone. Phosphorus containing compounds are not recommended to be present in an ester exhange zone as the ester exchange catalysts will be deactivated prematurely. To maximize rate and the effectiveness of the salt, it is preferable to wait and add all the phosphorus in the form of the salt near or at the end of the melt-phase process.
• the resulting products formed in the esterification zone include bis(2-hydroxyethyl) terephthalate (BHET) monomer, low molecular weight oligomers, DEG, and water (or alcohol in the case of ester exchange) as the condensation by-product, along with other trace impurities formed by the reaction of the catalyst, if any, or by the reaction of starting materials and other compounds such as colorants, impurities in the starting materials or the phosphorus- containing compounds, if any.
• BHET bis(2-hydroxyethyl) terephthalate
• DEG low molecular weight oligomers
• water or alcohol in the case of ester exchange
• the relative amounts of BHET and oligomeric species will vary depending on whether the process is a direct esterification process in which case the amount of oligomeric species are significant and even present as the major species, or an ester exchange process in which case the relative quantity of BHET predominates over the oligomeric species.
• the water is removed as the esterification reaction proceeds to drive the equilibrium toward products.
• the esterification zone typically produces the monomer and oligomer mixture, if any, continuously in a series of one or more reactors. Alternately, the monomer and oligomer mixture could be produced in one or more batch reactors.
• the reaction mixture will contain the monomeric species bis(2-hydroxyethyl)naphthalate and its corresponding oligomers, in lieu of BHET and its corresponding oligomers which will be present when making PET.
• the reaction mixture is transported from the esterification reactors in the esterification zone to the polycondensation zone, which may comprise a prepolymer zone and a finishing zone.
• Polycondensation reactions are initiated and continued in the melt phase in the prepolymerization zone and finished in the melt phase in the finishing zone, after which the melt is solidified into product, or optionally precursor, solids in the form of chips, pellets, or any other shape.
• the solids can be optionally crystallized before or after cutting.
• Each zone may comprise a series of one or more distinct reaction vessels operating at different conditions, or the zones may be combined into one reaction vessel using one or more sub-stages operating at different conditions in a single reactor. That is, the prepolymer stage can involve the use of one or more reactors operated continuously, one or more batch reactors, or even one or more reaction steps or sub-stages performed in a single reactor vessel. In some reactor designs, the prepolymerization zone represents the first half of polycondensation in terms of reaction time, while the finishing zone represents the second half of polycondensation.
• each of the prepolymerization and the finishing zones comprise one or a series of more than one reaction vessel, and the prepolymerization and finishing reactors are sequenced in a series as part of a continuous process for the manufacture of the polyester polymer.
• the low molecular weight monomers and oligomers are polymerized via polycondensation to form polyethylene terephthalate polyester (or PEN polyester, etc.) in the presence of a catalyst. If the polycondensation catalyst was not added in the esterification stage, the catalyst is added at this stage to catalyze the reaction between the monomers and low molecular weight oligomers to form prepolymer and split off the diol as a by-product.
• Other compounds such as phosphorus containing compounds, cobalt compounds, and colorants can also be added in the prepolymerization zone.
• phosphorus containing compounds are preferably added near the end or at the end of the melt-phase process in the form of salts of the invention.
• phosphorus compounds vary from a typical direct esterification process.
• polycondensation takes place in the presence of a titanium catalyst, preferably in the presence of from about 3 ppm (parts per million) to about 35 ppm of titanium from the catalyst, more preferably about 6 - 15 ppm titanium from the catalyst, in each case based on the weight of titanium in the polymer.
• an amine salt of a phosphorus-containing acid is added, preferably in amounts to supply of about 250 ppm phosphorus or less, more preferably about 5 to 90 ppm, and most preferably 15 to 80 ppm. The amounts are calculated in terms of the weight of elementalphosphorus relative to the weight of the polymer.
• the mole ratio of phosphorus to Ti is preferably from about 1 to about 15, more preferably from 2.5 to 13.
• the titanium catalyst may be any titanium compound which exhibits a reasonable polycondensation rate.
• the catalyst exhibits at least the same rate of polycondensation as is achieved using antimony triacetate or antimony trioxide, and more preferably exhibits a considerably greater rate of polycondensation in the absence of phosphorus compounds, for example a rate from 10 to 50 times higher than antimony triacetate or antimony trioxide, based in part on the weight of the catalytic element relative to the weight of the polymer.
• a polyester of suitable inherent viscosity can be produced under similar conditions in shorter time than in an antimony catalyzed polycondensation, while also using much less catalyst.
• the titanium catalyst can be added anywhere in the melt phase process, such as into the esterification zone or the polycondensation zone. It is preferably added after at least 90% conversion in the esterification zone, or after completing esterification (which includes ester exchange), or between the esterification zone and the polycondensation zone, or to the beginning of polycondensation, or during prepolymerization.
• Preferred titanium catalysts include, in general, titanium (IV) compounds which are alkoxides, glycolates, acetates, oxalates, etc. Alkoxides and mixed glycolate alkoxides are preferred. Titanium (IV) isopropoxide is an example of a preferred catalyst. Many such catalysts are available commercially, i.e., under the trademark Tyzor® titanates from DuPont. Solid titanium compounds which serve as heterogenous catalysts are also suitable, including those disclosed in U.S. Patent 5,656,716, incorporated herein by reference. Titanium oxides and hydrated oxides may become solubilized during the course of the polymerization, for example by complexation and/or reaction with the glycol component.
• catalysts remain insoluble, at least in part, catalytic activity would be a concern, as would haze (lack of clarity).
• Soluble catalysts are preferred, more preferably, those catalysts which are soluble at the outset of the reaction.
• the titanium catalysts may be introduced into the reaction in any convenient manner.
• a solution of the catalyst in alcohol or a slurry of the catalyst in ethylene glycol may be used, for example, as may be a solution or slurry of the catalyst in an oligomer mixture.
• the catalyst may also be added alone, and distributed by agitation, i.e., by mechanical mixing or by use of a static mixer.
• This prepolymer polycondensation stage generally employs a series of one or more vessels and is operated at a temperature of between about 250 0 C and 305° C for a period between about five minutes to four hours. During this stage, the It.V.of the monomers and oligomers is increased up to about no more than 0.48 dL/g.
• the diol byproduct is removed from the prepolymer melt using an applied vacuum ranging from 4 to 70 torr to drive the reaction to completion. In this regard, the polymer melt is sometimes agitated to promote the escape of the diol from the polymer melt. As the polymer melt is fed into successive vessels, the molecular weight and thus the inherent viscosity of the polymer melt increases.
• each vessel is generally decreased to allow for a greater degree of polymerization in each successive vessel or in each successive zone within a vessel.
• the reactors are typically run under a vacuum or purged with an inert gas.
• Inert gas is any gas which does not cause unwanted reaction or product characteristics at reaction conditions. Suitable gases include, but are not limited to argon, helium and nitrogen.
• the prepolymer is fed from the prepolymer zone to a polycondensation finishing zone where the polycondensation is continued further in one or more finishing vessels generally, but not necessarily, ramped up to higher temperatures than present in the prepolymerization zone, to a value within a range of from 27O 0 C to 305 0 C until the It.V. of the melt is increased from the It.V. of the melt in the prepolymerization zone (typically 0.20 to 0.30 dL/g but usually not more than 0.48 dL/g) to an It.V in the range of from about 0.54 dL/g to about 1.2 dL/g.
• the final vessel is operated at a pressure lower than used in the prepolymerization zone, e.g. within a range of between about 0.2 and 4.0 torr.
• the finishing zone typically involves the same basic chemistry as the prepolymer zone, the fact that the size of the molecules, and thus the viscosity differs, means that the reaction conditions also differ.
• each of the finishing vessel(s) is operated under vacuum or inert gas, and each is typically agitated to facilitate the removal of ethylene glycol.
• the melt is generally processed to convert the molten PET into amorphous solid pellets.
• the technique used for making a pellet is not limited.
• a suitable It.V. from the melt phase can range from 0.5 dL/g to 1.15 dL/g.
• one advantage of the present process is that the solid stating step can optionally be avoided. Solid stating is commonly used for increasing the molecular weight (and the It.V.) of the pellets in the solid state, usually by at least 0.05 units, and more typically from 0.1 to 0.5 units. Therefore, in order to avoid a solid stating step, a preferred It.V.
• from the melt phase which can be measured on the amorphous pellets, is from at least 0.7 dL/g, or at least 0.72 dL/g, or at least 0.75dL/g, or at least 0.78 dL/g, and up to about 1.15 dL/g to 1.20 dL/g.
• the method and equipment for converting molten polymer in the melt phase reactors to pellets is not limited, and any conventional system used for making pellets is suitable in the practice of the invention.
• strands of the polyester polymer melt are at least surface cooled to below the T 9 of the polymer to form a cooled polyester polymer, followed by pelletizing the cooled polyester polymer to form solid amorphous pellets.
• These pellets may be optionally crystallized.
• the molten polymer may be extruded through a die and instantly cut into pellets before the polyester polymer cools below its T 9 .
• These pellets may be optionally crystallized before the polymer cools below its T 9 .
• the It.V of a polyester of this invention is from about 0.70 dL/g to about 1.2 dL/g.
• the It.V. can be determined from the inherent viscosity is measured at 25° C. using 0.50 grams of polymer per 100 ml_ of a solvent consisting of 60% by weight phenol and 40% by weight 1 ,1 ,2,2-tetrachloroethane.
• the intrinsic viscosity is typically reported as the It.V. of the polymer, which is a number calculated from the measured Ih.V. according to the equation set forth in the Example section.
• additives normally used in polyesters may be used if desired.
• additives include, but are not limited to colorants, pigments, carbon black, glass fibers, fillers, impact modifiers, antioxidants, stabilizers, flame retardants, reheat aids, and the like.
• a bluing toner can be added to the melt in order to reduce the b* of the resulting polyester polymer melt phase product.
• Such bluing agents include blue inorganic and organic toners.
• red toners can also be used to adjust the a* color.
• Organic toners e.g., blue and red organic toners, such as those described in U.S. Pat. Nos. 5,372,864 and 5,384,377, which are incorporated by reference in their entirety, can be used.
• the organic toners can be fed as a premix composition.
• the premix composition may be a neat blend of the red and blue compounds or the composition may be pre-dissolved or slurried in one of the polyester's raw materials, e.g., ethylene glycol.
• inorganic bluing agents can also be added to the melt to reduce its yellow hue.
• Cobalt (II) compounds such as cobalt (II) carboxylates, are one of the most widely used toners in the industry to mask the yellow color of polymers.
• the cobalt carboxylate can be added to the ester exchange reactor to also act as an ester exchange catalyst.
• the total amount of toner components added depends, of course, on the amount of inherent yellow color in the base polyester and the efficacy of the toner. Generally, a concentration of up to about 15 ppm of combined organic toner components and a minimum concentration of about 0.5 ppm are used.
• the total amount of bluing additive typically ranges from 0.5 to 10 ppm.
• the toners can be added to the esterification zone or to the polycondensation zone.
• the toners are added to the esterification zone or to the early stages of the polycondensation zone, such as to a prepolymerization reactor.
• the subject process differs substantially from prior processes in that it is capable of producing a product of sufficiently high inherent viscosity directly in the melt phase, without involving any necessity for a subsequent solid state polymerization, usually termed "solid stating.” Avoidance of solid stating also may even allow direct molding from the melt.
• titanium catalysts in conjunction with amine salts of phosphorus-containing acids, which are added late in the polycondensation stage. It has been surprisingly discovered that the present method allows a reduced polycondensation time, creates a product of suitable inherent viscosity without solid stating, and produces a solid product exhibiting reduced acetaldehyde content and reduced acetaldehyde generation upon melting.
• the amine component of the amine salts of a phosphorus-containing acid can be chosen from all organic amines capable of salt formation, i.e. primary, secondary, and tertiary organic amines.
• the amines may be cyclic or acyclic, may be monomeric, oligomeric, or polymeric, and should be selected so as to minimize haze and/or solubility when the latter are issues.
• the organic constituents of the amine may in principle be any organic group. Organic groups which bear toxicologically suspect groups, or which decompose into toxic substances are generally undesirable. Groups which generate odiferous substances upon heating, or which cause excessive coloration, are also generally not desirable.
• Ammonia and related compounds like ammonium hydroxide are also suitable for use in the invention.
• some salts are more effective than others in terms of the % reduction in AA generation upon melting relative to a control (no additive).
• the selection of a salt and its amount for a given application depends on the required % reduction in AA generation upon melting. In general, the selected salt is the least expensive one that will give the required % reduction in AA generation upon melting, and the amount of salt is the lowest that will give the desired % reduction in AA generation upon melting. If reduced AA content rather than AA generation is the requirement, selection proceeds in an analogous manner.
• Suitable organic groups on the amine include linear and branched alkyl, cycloalkyl, aryl, aralkyl, alkaryl, heteroaryl, etc. Each of these
• organic groups may be substituted or unsubstituted, i.e. with hydroxy, carboxy, alkoxy, halo, and like groups.
• the organic groups may also contain carbonate, keto, ether, and thioether linkages, as well as amide, ester, sulfoxide, sulfone, epoxy, and the like. This list is illustrative and not limiting.
• Preferred amines are cyclic amines having a 5 to 7 membered ring, preferably a six membered ring. These rings may constitute a single "monomeric" species, or may be part of a larger oligomer or polymer.
• Preferred cyclic amines are hindered amines which have organic groups substituted at ring positions adjacent to the ring nitrogen.
• the ring nitrogen itself may also be substituted, i.e. by alkyl, aryl, aralkyl, alkaryl, and other groups.
• the hindered amines may also comprise a portion of an oligomeric moiety or polymeric moiety.
• Another type of preferred amines are amino acids. Amino acids with decomposition points at or above polymerization temperatures are especially preferred.
• the L-enantiomer, the D-enantiomer or any mixture thereof, including racemic mixtures, may be used.
• the amine group and the carboxylic acid group do not have to be attached to the same carbon.
• the amino acids may be alpha, beta or gamma. Substituted amino acids may be used. Amino acids with some solubility in water are especially preferred as this allows the synthesis of the salt to be done in water, i.e., without VOCs (volatile organic compounds).
• the carboxylic acid group of the amino acid opens up the possibility that the compound might be reacted into the polyester chain. Reaction into the polyester chain should result in less volatility and less extractability. Reaction into the polyester chain can also be accomplished if the organic portion of the salt contains a hydroxyl and/or a carboxyl group. If there is only 1 carboxyl or hydroxyl group, the salt could function as an end-
• the salt may not always be at the end of the chain.
• the addition point of the phosphorous salt is desirably late in the melt-phase polymerization process.
• the late addition of the phosphorus salt occurs when the It.V. of the polymer is at least 0.45 dL/g.
• the It.V. of the polymer when the salt is added also increases due to rate concerns.
• Various more specific embodiments include adding the salt:
• the polycondensation time is the total time starting from initiating polycondensation to the point in time at which polycondensation is terminated or when the desired It. V. is obtained.
• the final It.V. is obtained even though it is recognized that a very minor It.V. lift or break may occur between the final reactor and cutter;. d. to the polyester melt in the melt phase process at a point within 0.03 dl/g, or within 0.015 dL/g, of the final It.V. exiting the melt phase process; or e. at a point within 10 minutes of less of solidifying the melt.
• the additive is added too early in the polymerization process, as defined by the ItV of the polymer, it may be more difficult or impossible to reach a high target ItV in a reasonable process time.
• the additive is incorporated at a late stage in the polycondensation, preferably in the finisher or just prior to peptization or other means of solidification from the melt to reduce the AA content in the formed solids.
• the precursor to the phosphorous moiety of the phosphorus salt may be any oxyphosphorus acid, including but not limited to hypophosphorous acid, phosphorous acid, phosphoric acid, polyphosophoric acid, polyphosphorous acids, pyrophosphoric acid, phosphinic acids, phosphonic acids, phosphate monoesters, phosphate diesters, phosphonate monoesters, pyrophosphate monoesters, pyrophosphate diesters, pyrophosphate triesters, or salts or compounds which still bear at least one acid hydrogen, etc.
• Compounds with more than one acidic hydrogen may have one or more acidic hydrogens substituted with organic groups such as alkyl, aryl, aralkyl, alkaryl, etc., by polyether oligomers, polyester oligomers, etc. At least one salt-forming acidic hydrogen must remain, however.
• the organic groups may be substituted.
• the amines must contain at least one nitrogen capable of salt formation with a phosphorus-containing acid.
• salt formation may involve the piperidinyl nitrogen, generating species such as (but not limited to):
• one mole of phosphorus-containing acid is used per mole of amine compound.
• two or more nitrogen atoms in the amine compound that can form salts two or more moles of acid can be used per mole of amine compound, up to an amount of acid, which creates salts having no remaining neutralizable nitrogen, or slightly in excess of this amount.
• the salts are prepared by the reaction of one or more acidic phosphorus- containing compounds with one or more basic organic compounds containing nitrogen, wherein the phosphorus-containing compounds are preferably selected from compounds having the formulas:
• Ri and Ra are independently selected from hydrogen, C r C 22 -alkyl, substituted Ci-C 2 2-alkyl, C 3 -C 8 -cycloalkyl, substituted C 3 -C 8 -cycloalkyl, heteroaryl, and aryl; n is 2 to 500; and
• X is selected from hydrogen and hydroxy; and wherein the basic organic compounds containing nitrogen are selected from compounds having the formulas:
• Ri and R 2 are independently selected from hydrogen, CrC2 2 -alkyl, substituted Ci-C 22 -alkyl, C 3 -C8-cycloalkyl, substituted C 3 -Cs-cycloalkyl, heteroaryl, and aryl;
• organic groups may be substituted or unsubstituted, i.e. with hydroxy, carboxy, alkoxy, halo, and/or like groups, and any combination thereof.
• the organic groups may also contain carbonate, keto, ether, and thioether linkages, as well as amide, ester, sulfoxide, sulfone, epoxy, and the like. This list is illustrative and not limiting.
• R 3 , R 4 , and R 5 are independently selected from hydrogen, C- ⁇ -C 22 -alkyl, substituted CrC 22 -alkyl, C3-C 8 -cycloalkyl, and substituted C 3 -C 8 -cycloalkyl wherein preferably, at least one of R 3 , R 4 , and R 5 is a substituent other than hydrogen; R 3 and R 4 or R 4 and R 5 collectively may represent a divalent group forming a ring with the nitrogen atom to which they are attached, e.g., morpholino, piperidino and the like;
• R ⁇ , R7, Rs, and R 9 are independently selected from hydrogen, C 1 -C 22 - alkyl, substituted Ci-C 22 -alkyl, C 3 -C 8 -cycloalkyl, substituted C 3 -C 8 -cycloalkyl, heteroaryl, aryl;
• R 1 0 is selected from hydrogen, -OR 6 , C 1 -C 22 -alkyl, substituted C 1 -C 22 - alkyl, C 3 -C 8 -cycloalkyl, substituted C 3 -C 8 -cycloalkyl;
• R 1 I is selected from hydrogen, Ci-C 22 -alkyl, substituted C- ⁇ -C 22 -alkyl, C 3 -C 8 -cycloalkyl, substituted C 3 -C 8 -cycloalkyl, heteroaryl, aryl, -Y 1 -R 3 or a succinimido group having the formula wherein
• R- 12 is selected from hydrogen, Ci-C2 2 -alkyl, substituted CrC ⁇ -alkyl, C 3 -C 8 -cycloalkyl, substituted C 3 -C 8 -cycloalkyl, heteroaryl, aryl and may be located at the 3 4 or 5 positions on the aromatic ring;
• the -N(Rs)(R 4 ) group may be located at the 3, 4 or 5 positions on the pyridine ring of nitrogen compound (5);
• the -CO2R3 and Ri groups may be located at any of the 2, 3, 4, 5, 6 positions of the pyridine ring of nitrogen compound (6);
• L 1 is a divalent linking group selected from C 2 -C 22 -alkylene; -(CH 2 CH 2 - Yi) 1-3 -CH 2 CH 2 -; C 3 -C 8 -cycloalkylene; arylene; Or -CO-L 2 -OC-;
• L 2 is selected from C-i-C 22 -alkylene, arylene, -(CH 2 CH 2 -Y- I ) 1-3 -CH 2 CH 2 - and C 3 -C 8 -cycloalkylene;
• Y 1 is selected from -OC(O)-, -NHC(O)-, -O-, -S-, -N(R 1 )-;
• Y 2 is selected from -O- or -N(Ri)-;
• R 13 and R 14 are independently selected from -0-R 2 , and -N(R 2 ) 2 ;
• Z is a positive integer of up to about 20, preferably up to about 6;
• n1 is a positive integer selected from 2 to about 12;
• Ri 5 , and R 16 are independently selected from hydrogen, CrC- 22 -alkyl, substituted Ci-C 22 -alkyl, C 3 -C 8 -cycloalkyl, substituted C 3 -C 8 -cycloalkyl, heteroaryl, aryl, and radical A wherein radical A is selected from the following structures:
• At least one of R 15 and R 16 is an A radical; and wherein the ratio of the number of phosphorus atoms in the acidic phosphorus-containing compound to the number of basic nitrogen atoms in the basic organic compound is about 0.05 to about 2, preferably from about 0.25 to about 1.1.
• CrC ⁇ -alkyl denotes a saturated hydrocarbon radical which contains one to twenty-two carbons and which may be straight or branched-chain.
• Such C 1 -C 22 alkyl groups can be methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, isopropyl, isobutyl, tertbutyl, neopentyl, 2- ethylheptyl, 2-ethylhexyl, and the like.
• Ci-C 22 -alkyl refers to Ci-C 22 -alkyl radicals as described above which may be substituted with one or more substituents selected from hydroxy, carboxy, halogen, cyano, aryl, heteroaryl, C 3 -C 8 -cycloalkyl, substituted C 3 -C 8 -cycloalkyl, CrC 6 - alkoxy, C 2 -C 6 alkanoyloxy and the like.
• C 3 -C 8 -cycloalkyl is used to denote a cycloaliphatic hydrocarbon radical containing three to eight carbon atoms.
• substituted C 3 -C 8 -CyClOaI kyl is used to describe a C 3 -C 8 -cycloalkyl radical as detailed above containing at least one group selected from C- ⁇ -C 6 -alkyl, CrC 6 - alkoxy, hydroxy, carboxy, halogen, and the like.
• aryl is used to denote an aromatic radical containing 6, 10 or 14 carbon atoms in the conjugated aromatic ring structure and these radicals are optionally substituted with one or more groups selected from Cr C 6 -alkyl; Ci-C 6 -alkoxy; phenyl, and phenyl substituted with CrC 6 -alkyl; CrC 6 - alkoxy; C 3 -C 8 -cycloalkyl; halogen; hydroxy, carboxy, cyano, trifluoromethyl and the like.
• Typical aryl groups include phenyl, naphthyl, phenylnaphthyl, anthryl (anthracenyl) and the like.
• heteroaryl is used to describe conjugated cyclic radicals containing at least one hetero atom selected from sulfur, oxygen, nitrogen or a combination of these in combination with from two to about ten carbon atoms and these heteroaryl radicals substituted with the groups mentioned above as possible substituents on the aryl radical.
• Typical heteroaryl radicals include: 2-and 3-furyl, 2- and 3-thienyl, 2- and 3- pyrrolyl, 2-, 3-, and 4-pyridyl, benzothiophen-2-yl; benzothiazol-2-yl, benzoxazol-2-yl, benzimidazol-2-yl, 1 , 3, 4-oxadiazol-2-yl, 1 , 3, 4-thiadiazol-2- yl, 1 ,2,4-thiadiazol-5-yl, isothiazol-5-yl, imidazol-2-yl, quinolyl and the like.
• CrC 6 -alkoxy and “C 2 -C 6 -alkanoyloxy” are used to represent the groups -O-CrC 6 -alkyl and -OCOCrC 6 -alkyl, respectively, wherein “CrC 6 -alkyl” denotes a saturated hydrocarbon that contains 1-6 carbon atoms, which may be straight or branched-chain, and which may be further substituted with one or more groups selected from halogen, methoxy, ethoxy, phenyl, hydroxy, carboxy, acetyloxy and propionyloxy.
• halogen is used to represent fluorine, chlorine, bromine, and iodine; however, chlorine and bromine are preferred.
• C 2 -C 22 -alkylene is used to denote a divalent hydrocarbon radical that contains from two to twenty-two carbons and which may be straight or branched chain and which may be substituted with one or more substituents selected from hydroxy, carboxy, halogen, Ci-C 6 -alkoxy, C 2 - C 6 -alkanolyloxy and aryl.
• C 3 -C 8 -cycloalkylene is used to denote divalent cycloaliphatic radicals containing three to eight carbon atoms and these are optionally substituted with one or more Ci-C 6 -alkyl groups.
• arylene is used to denote 1 ,2-, 1 ,3-, and 1 ,4-phenylene radicals and these optionally substituted with C-i-C ⁇ - alkyl, Ci-C ⁇ -alkoxy and halogen.
• Preferred hindered amines contain alkyl-substituted piperidinyl moieties and/or triazine moieties, more preferably hindered amines where at least one amine group is substituted by both a triazine moiety and an alkyl- substituted piperidine moiety.
• amino group-containing moieties are linked by an alkylene group, preferably a (-CH 2 -) n group where n is from 2 to 12, preferably from 4-10, and most preferably 6 or 8.
• the most preferred hindered amine is Cyasorb® UV-3529, containing repeat units of the formula:
• the salt of the amine component of the novel compositions provided by the present invention may be prepared by bringing together the acidic phosphorus-containing compound and the basic nitrogen-containing organic compound in a suitable manner.
• a suitable manner is any procedure that involves contacting the acidic phosphorus-containing acid with the basic organic compound.
• the acidic phosphorus-containing compound and the basic nitrogen-containing organic compound may be dissolved in appropriate solvents and the solutions mixed followed by precipitation of the reaction product; mixing the phosphorus-containing acid and the basic organic compound without solvent; and the like.
• the ratio of the number of acidic oxyphosphorus groups in the acidic phosphorus-containing compound to the number of basic nitrogen atoms in the basic organic compound may be in the range of about 0.05 to about 2, preferably from about 0.25 to about 1.1.
• Compositions that contain a large excess of unreacted phosphorus-containing acidic compounds may result in corrosion of process equipment during polyester manufacture, concentrate manufacture (if any) or preform manufacture.
• the salt or salts typically are present in concentrations ranging from about 0.0001 to about 0.25 weight percent based on the weight of the polyester.
• the acidic phosphorus-containing compounds preferably are phosphorous acid, phosphoric acid and polyphosphoric acid, most preferably phosphorous acid and phosphoric acid.
• suitable basic organic compounds containing nitrogen include amino acids, ammonium salts and alkyl amines such as triethylamine and 2,2,6,6-tetramethylpiperidine, pyridine and substituted pyridines, piperidine and substituted piperidines, morpholine and substituted morpholines and the like.
• the preferred basic organic compounds are hindered amine light stabilizers (HALS) such as: Cyasorb UV-3346 (Cytec Industries, CAS# 90751-07-8), Cyasorb UV-3529 (Cytec Industries, CAS# 193098-40-7), Cyasorb UV-3641 (Cytec Industries, CAS# 106917-30-0), Cyasorb UV-3581 (Cytec Industries, CAS# 79720-19-7), Cyasorb UV-3853 (Cytec Industries, CAS# 167078-06-0), Cyasorb UV-3853S (Cytec Industries, CAS# 24860-22-8), Tinuvin 622 (Ciba Specialty Chemicals, CAS# 65447-77- 0), Tinuvin 770 (Ciba Specialty Chemicals, CAS# 52829-07-9), Tinuvin 144 (Ciba Specialty Chemicals, CAS# 63843-89-0), Tinuvin 123 (Ciba Specialty Chemicals, CAS#
• the hindered amine light stabilizers having above formulas (2), (3), (7), (8), (9), (12), (13), (14), (15), (16), (17), (18), (19) and (20), and especially (21 ), represent the preferred basic compounds.
• Chimassorb 944 (Ciba Specialty Chemicals, CAS# 71878-19-8), Cyasorb UV-3529 (Cytec Industries, CAS# 193098-40-7), Chimassorb 119 (Ciba Specialty Chemicals, CAS# 106990-43-6) and Tinuvin 770 (Ciba Specialty Chemicals, CAS# 52829-07-9) and any equivalents thereof are specific examples of the preferred basic compounds.
• a more preferred groups of the basic nitrogen compounds are the hindered amine light stabilizers having above formulas (2), (3), (7), (8), (9), (12), (13), (14), (15), (16), (17), (18) and (19) wherein radical R 10 is hydrogen or C1 - C22 alkyl and formula (15) wherein at least one of R 15 and R 16 represents radical A wherein R 10 is hydrogen or C1 - C22 alkyl.
• the most preferred are high molecular weight HALS wherein the molecular weight is greater than about 1000 such as Cyasorb UV-3529 (Cytec Industries, CAS# 193098-40-7).
• hindered amine light stabilizers having above formulas (12), (13), (14), (15), (16), (17), (18) and (19) wherein radical R 10 is hydrogen or C1 - C22 alkyl and formula (15) wherein at least one of R 15 and R 16 represents radical A wherein R 10 is hydrogen or C1 - C22 alkyl are particularly preferred as the basic organic component of a salt with an oxyphosphorus acid, which can be used to lower residual AA in pellets and/or AA generation upon melting for polyester compositions containing - OCH 2 CH 2 O- in a repeat unit.
• Suitable amines include ammonia and its salts, alkyl and cycloalkyl amines such as methylamine, ethyl amine, n-propylamine, i-propylamine butylamine, n-hexylamine, 2-ethylhexylamine, dimethylamine, diethylamine, di(n-propyl)amine, di(i-propyl)amine, di-(n-hexyl)amine, di(n- octyl)amine, cyclopentylamine, dicyclopentylamine, cyclohexylamine, dicyclohexylamine, cycloheptylamine, cyclooctylamine, adamantane amine, trimethylamine, triethylamine, tri(n-butyl)amine, ethylene diamine, 1 ,3- propylenediamine, triethylenediamine, and polyalkylenepolyamines in general,
• Hetrocyclic amines include piperine, piperidine, morpholine, aminopyridine, and in particular, heterocyclic, non-aromatic amines substituted in one or more ring positions adjacent to the ring nitrogen, for example 2,6-dimethylpiperidine, 2-methyl-6-ethylpiperidine, 2,6- di(isopropyl)piperidine, 2,2,6,6-tetramethyl piperidine, and the like.
• the same types of substitution patterns are useful with other cyclic amines.
• the substituent and substituent patterns are illustrative and not limiting.
• the amines used be of relatively high vapor pressure, and thus it is not preferred to employ low molecular weight alkylamines such as methylamine, dimethylamine, ethylamine, and the like, since they may be lost due to volatility when the position of the equilibrium results in the unsalted form and/or these might pose a migration problem.
• Low molecular weight alkylamines that are substituted with carboxy and/or hydroxyl functionality(ies), which may react into the polyester chain are preferred.
• Amino acids are examples of this class of compounds. The inner salt nature of amino acids results in high melting/decomposition points and, in some cases, gives some solubility in water, which eliminates volatile organic compounds (VOC) during the salt synthesis.
• polymers with suitably high It.V. may be obtained in relatively short overall process times, and produce polyester product, for example in the form of pellets, which not only do not require the expense and increased process time of solid stating, but also contain less AA and generate less AA during future processing. If yet higher It.V. polymers are desired, the molecular weight may be increased further by solid stating. While this additional process step does involve extra time and expense, this is partially compensated by reduction in overall polymerization time in the melt phase;. Moreover, solid stating will further reduce the AA content.
• the amine salts of the invention may be added to molten polyester and blended with a static mixer or any effective mixing apparatus.
• the amine salts may be added near the end of the finisher reactor.
• the amine salts may be added neat (without dilution), in a slip stream of molten polyester, as a master batch in polyester pellets, i.e. a concentrate, or in a liquid carrier.
• the polyesters according to the present invention can be used in forming a variety of articles including sheets, films, tubing, profiles, preforms, fibers, woven and shaped articles, such as containers, and thermoformed articles such as trays and the like.
• Free acetaldehyde content in the polymer following addition of the respective additives is assessed as follows. Following the end of the array or lab preparation, the polymer is cooled for about 15 min., separated from the glass flask, cooled for about 10 min. and then placed immediately into liquid nitrogen. The polymer is ground cryogenically to pass a 3 mm screen. The residual or free AA sample is kept frozen.
• the AA level from ASTM # F2013-00 on preforms cannot be compared directly to the AA level from the AA generation test on pellets or powders; however, two methods are correlated, and similar trends should be seen in each test.
• a commercial polyester sold to make carbonated soft drink (“CSD") bottles (CB-12) is submitted every time the AA generation test is done on experimental samples.
• the AA level in preforms made from commercial pellet samples is usually well known at typical processing conditions and considered acceptable for CSD applications.
• the AA generation results on the commercial polyester are considered as a benchmark: AA generation rates less than or equal to the AA generation value of the commercial pellets should indicate an acceptable level of preform AA for CSD applications at the time that the testing was done.
• the water bottle market can necessitate lower AA generation rates than those acceptable in the CSD bottle market.
• the acetaldehyde generation rate can be measured on the solid particles and the free AA can be measured on solid particles or preforms. The following method is used to measure acetaldehyde generation on solid particles.
• the method used to determine the level of free AA in the polyester polymer composition is the test method ASTM # F2013-00. This test method is used to measure the level of free acetaldehyde in particles, powders, preforms, bottles, and any other form the polyester polymer composition may take.
• ASTM # F2013-00 The method used to determine the level of free AA in the polyester polymer composition is the test method ASTM # F2013-00. This test method is used to measure the level of free acetaldehyde in particles, powders, preforms, bottles, and any other form the polyester polymer composition may take.
• the sample is tested according to the method described below. However, for purposes of measuring the acetaldehyde generation, the sample has to undergo a second melt history in order to determine the level of acetaldehyde generated.
• the sample is a particle or powder which has not undergone a melt step in addition to a prior melt phase polycondensation step, the sample is first treated according to the Sample Preparation procedure described below, after which the sample is submitted to the ASTM # F2013-00 test method for analysis.
• the test procedure for measuring the level of free acetaldehyde on a sample, whether a preform, pellet, powder, or other form is the ASTM # F2013-00 test method.
• Samples are cryogenically ground through a Wiley Mill equipped with a 1.0 mesh screen.
• the final ground material has a particle size less than 800 ⁇ m.
• a portion of a sample (0.20 g) is weighed into a 20-mL head-space vial, sealed and then heated at 150 0 C for sixty minutes. After heating, the gas above the sealed sample of PET polymer is injected onto a capillary GC column.
• the acetaldehyde is separated, and the ppm of acetaldehyde present in the sample is then calculated.
• the amount of acetaldehyd ⁇ calculated represents the amount of free or residual acetaldehyde present in the sample.
• Sample Preparation For the purpose of measuring the acetaldehyde generation rate, and if the sample has not seen a melt history subsequent to melt phase polycondensation, it is prepared according to this method prior to submitting the sample to the ASTM # F2013-00 test. Samples of polymer powder ground to pass a 3 mm screen are heated in an oven at
• Any suitable acetaldehyde devolatization technique can be employed on pellets which reduces the level of free acetaldehyde down to about 1 ppm or less, including passing hot inert gas over the pellets for a time period sufficient to reduce the residual acetaldehyde to the desired level.
• the acetaldehyde devolatization temperature should not exceed 17O 0 C.
• the sample is then packed in a preheated Tinius Olsen extrusion plastometer using a steel rod.
• the orifice die is calibrated according to ASTM D 1238. A small amount of material is purged out the bottom, which is then plugged.
• the piston rod assembly is put in the top of the barrel.
• a 225 g weight may be placed on top of the piston rod to hold the rod down inside of the barrel.
• the polymer is held at 295 0 C for 5 min.
• the orifice plug is then removed from the bottom of the barrel.
• the extrudate is pushed out of the barrel into an ice water bath.
• the extrudate is patted dry, sealed in a bag and placed in a freezer until the ASTM # F2013-00 test is performed.
• a CEAST Model 7027 Modular Melt Flow instrument is used.
• An AA generation program is initiated that will maintain a temperature of 295 0 C and will extrude the melted PET material in 5 minutes at a constant flow rate as defined in the firmware of the instrument.
• the sample is collected, patted dry, sealed in a bag and placed in a freezer until the ASTM # F2013-00 test is performed.
• Acetaldehyde can be generated in polyester resins with the Ceast Model 7027 Modular Melt Flow or any similar extrusion plastometer instrument.
• the automated functions of this instrument reduce test variability by maintaining consistent contact times for the polymer inside the extrusion barrel.
• This particular model of instrument incorporates automated packing of the resin at the start of the test procedure.
• the instrument is equipped with a motorized platform that will push the material out of the barrel until the piston is at a specified height above the bottom of the barrel. The platform will then hold the piston rod in place, allowing the resin to heat up and generate acetaldehyde. At the end of the specified hold time, the platform extrudes the remainder of the resin out of the barrel while traveling at a constant speed.
• L*, a* and b* color values are conducted on polyester polymers ground to a powder passing a 3 mm screen. Color measurements were performed in reflectance (specular included) using a HunterLab UltraScan XE (Hunter Associates Laboratory, Inc., Reston VA), which employs diffuse/8° (illumination/view angle) sphere optical geometry. Results were reported using the CIELAB scale with the D65 illuminant and 10° observer. The spectrophotometer is standardized regularly and UV control was employed and maintained in calibration following the HunterLab recommendations. An optional glass port plate is installed at the reflectance port to minimize contamination of the sphere. Powders are placed in an optical glass cell.
• the optical-grade glass is recessed from the front of the cell by 0.062" and the glass itself is 0.092" thick.
• the sample area is 0.71" deep, 1.92 " wide, 2.35" tall.
• the powders are allowed to settle by vibrating the sample for 20 seconds using a laboratory Mini-Vortexer (VWR International, West Chester, PA).
• the glass cell is maintained flush against the reflectance port and covered with a black opaque cover.
• a single cell packing is evaluated and the cell is removed and replaced for three replicate measurements for each sample. The reported value should be the average of the triplicates.
• the It.V. values described throughout this description are set forth in dL/g units as calculated from the inherent viscosity measured at 25°C in 60% phenol and 40% 1 ,1 ,2,2-tetrachloroethane by weight. Polymer samples are dissolved in the solvent at a concentration of 0.25 g/50 ml_. The viscosity of the polymer solutions is determined using a Viscotek Modified Differential Viscometer. A description of the operating principle of the differential viscometers can be found in ASTM D 5225. The inherent viscosity is calculated from the measured solution viscosity. The following equations describe such solution viscosity measurements and subsequent calculations to Ih. V. and from Ih. V. to It.V:
• ⁇ inh Inherent viscosity at 25 0 C at a polymer concentration of 0.5 g/ 100 mL of 60% phenol and 40% 1 ,1 ,2,2-tetrachloroethane by weight
• Instrument calibration involves triplicate testing of a standard reference material and then applying appropriate mathematical equations to produce the "accepted" Ih.V. values.
• the three values used for calibration shall be within a range of 0.010; if not, correct problems and repeat testing of standard until three consecutive results within this range are obtained.
• Calibration Factor Accepted Ih.V. of Reference Material / Average of
• the corrected Ih.V. based on calibration with standard reference materials, is calculated as follows:
• PET oligomer prepared from terephthalic acid and ethylene glycol, and also containing about 1.5 mole percent of about 35% cis/65% trans 1 ,4-cyclohexanedimethanol was employed in the polycondensation.
• the oligomer also contains about 1.2 weight percent of diethylene glycol, which was generated during esterification. This oligomer has about 95% conversion of acid groups via NMR/titration of acid groups, a M n of about 766 g/mole, and a M w of 1478 g/mole.
• ground oligomer (103 g) is weighed into a half-liter, single-necked, round-bottomed flask.
• the catalyst employed is titanium tetrabutoxide and it is added to the flask.
• a 316 L stainless steel paddle stirrer and glass polymer head were attached to the flask. After attaching the polymer head to a side arm and a purge hose, two nitrogen purges are completed.
• the polymerization reactor is operated under control of a CAMILETM automation system, programmed to implement the following array (Table 1 ).
• a molten bath of Belmont metal is raised to surround the flask, and the CAMILETM array is implemented.
• a "ramp" is defined as a linear change of vacuum, temperature, or stir speed during the specified stage time.
• the stirring system is automatically calibrated between stages 4 and 5. After stage 6 ends, the vacuum level was ramped up to 140 torr, and then a 2 minute phosphorus addition stage (stage 8) begins.
• a phosphorus compound (not the amine salt of the present invention) is only added to the Sb controls.
• the finisher stage (13) is terminated when the stirrer torque is such that it reaches the target (predetermined for a given temperature and polymer rig) three times.
• the finisher stage time is referred to as "Time to IV.”
• the polymer is cooled for about 15 min., separated from the glass flask, cooled for about 10 min. and then placed immediately into liquid nitrogen.
• the polymer is ground cryogenically to pass a 3 mm screen.
• the residual or free AA sample is kept frozen.
• the ground polymer is analyzed for acetaldehyde generation rate (AAGen), inherent viscosity, L*, a*, and b* color.
• AGEN acetaldehyde generation rate
• L* inherent viscosity
• a* a*
• b* color
• the data can be seen in Table 2.
• the contour plot of Figure 1 indicates the acetaldehyde generation rate (at 295 0 C for 5 minutes) for different combinations of titanium levels and polycondensation temperatures at a vacuum level of 1.1 torr.
• the average AAGen of commercial PET pellets at the same time was 25.5 ppm. None of these are subject invention Examples; all are Comparative examples.
• the slurry is heated to 6O 0 C and stirred until a homogeneous solution was obtained, lsopropyl alcohol (370 g) is added to the reaction vessel.
• a solution of 115.46 g (1.41 mol) of phosphorous acid dissolved into 370 g of isopropyl alcohol is added in a small steady stream (fast dropwise) via an addition funnel to the Cyasorb UV-3529 solution with rapid stirring over approximately 30 minutes.
• a homogeneous solution is obtained and stirred for 15 min once the addition is complete.
• the reaction mixture was pumped at about 5 mL/min into a 12 L reaction vessel that contained about 7 L of rapidly stirred heptane (4768 g) over a period of approximately 50 minutes.
• the feed rate of the reaction mixture into the heptane-containing vessel has some affect on the particle size of the final product. Slow feeds tend to produce a finer powder while higher feed rates will results in a larger particle that almost appears to be agglomerated. This needs to be balanced by the tendency for the salt to get sticky in the drowning vessel if the feed rate is too rapid.
• the resulting slurry was stirred for about 60 minutes. The precipitate was collected by suction filtration. The filter cake was washed twice with 137 g of heptane and then sucked dry on the filter paper overnight. The solid was placed in a metal pan and dried overnight in a vacuum oven at 5O 0 C with a slight ingress of dry nitrogen. The dry product weighed approximately 531.8 g (101 % of theory). Typical bulk density of the dry salt has been between 0.4 and 0.6 g/mL.
• melt blending in a glass flask achieves a uniform distribution of additive within the polymer simulating the mixing of an additive near the end of or after the final polycondensation reactor.
• the polyester powders prepared above are weighed into 500 ml_ round bottom flasks. The powders are dried at 120 0 C under full vacuum overnight (about 16 hours) in a vacuum oven. After cooling the flask to about room temperature in a desiccator (about 1.5 hours), the additive is weighed into the flask. The additive was targeted at the 0.1 wt. % level.
• the blending parameters are set forth in Table 3.
• a polymer head with stirrer is attached and the flask purged twice with nitrogen.
• the CAMILETM automation system is programmed for the following array, as set forth in Table 3.
• the contour plot of Figure 2 illustrates the AA generation rates at 295 0 C after 5 minutes, after blending about 0.1 wt. % of the phosphorous acid salts of Cyasorb UV 3529 into PET made with various Ti levels, temperature and vacuum levels.
• This contour plot demonstrates the dramatic improvement in AA generation rate with the additive present as compared to the previous contour plot (Fig. 1 ), which was prior to blending in the additive.
• Reductions in the AA generation rate ranged from 75 to 83%. These were calculated per the method described in Example B.
• the average AAGen of commercial PET pellets tested at the same time was 24.8 ppm, much higher than the examples with the additive.
• the examples with the additive have low enough AA generation rates upon melting to be used in water bottle applications and/or or dual water/CSD applications. A slight improvement in yellowness or b* color was seen with about 0.1 wt.% of the additive present.
• the % reduction in AA generation at 295 0 C for 5 minutes was calculated as follows: 1 ) an average AAGen for the runs with no additive was calculated to be 35.68 ppm, 2) the AAGen for a given run was divided by 35.68 ppm, 3) the quotient was multiplied by 100, and 4) the product was subtracted from 100. As can be seen from the Table 5, % reduction in AA GEN 295/5 was around 75% for around 55 ppm P from phosphorous acid salts of Cyasorb UV 3529 ("Cyasorb UV 3529-H3PO3").
• the average AAGen of production control PET pellets tested at the same time was 23.5 ppm, much higher than the 8.5-9.3 ppm in the examples with an additive of this invention.
• the average L* color of the blends with phosphorus- containing additives were brighter by about one L* unit than the average of those without the additive.
• the average a* color of the blends with phosphorus-containing additives were more green by about 0.4a* unit than those without the additive.
• the average b* color of the blends with phosphorus-containing additives were less yellow by about one b* unit than the average of those without additive.
• the inherent viscosities dropped moderately ( ⁇ 0.05 dL/g) at the additive levels tested.
• Example 6 uses the melting blending procedure in Table 3 and the polymer described in Example B. A further series of polymers were prepared, employing the same phosphorous acid salt of CYASORB UV 3529 as used in the previous Example A and Example B. The results are presented in Table 6.
• Table 6 indicates that even at the very low concentration of 0.02 weight percent, the phosphorous acid salts of Cyasorb UV 3529 provides for a dramatic lowering (> 70% reduction relative to no additive) of both residual acetaldehyde as well as acetaldehyde generated upon melting.
• the slurry is
• the filter cake is washed with seven 40 ml_ portions of heptane and then sucked dry on the filter paper for 2 h.
• the solid is placed in a metal pan and dried over the weekend at 5O 0 C with a slight ingress of dry nitrogen.
• the dry product weighs approximately 36.48 g (66% of theory; fines in filtrate were not isolated).
• a further series of polymers were prepared, employing the phosphoric acid salt of CYASORB UV 3529 ("Cyasorb UV 3529-H3PO4"). These examples use the melt-blending procedure outlined in Table 3 and the polymer described in Example B.
• the phosphorous acid salt of CYASORB UV 3529 is one described in Example A.
• Table 7 indicates that the levels of residual AA and AA generated upon melting were very similar for both the phosphoric acid salts of Cyasorb UV 3529 and the phosphorous acid salts of Cyasorb UV 3529.
• the average AAGen of production control PET pellets tested at the same time was 22.6 ppm.
• the runs with the phosphoric acid salt turned out to have a somewhat higher P level.
• the b* color, or yellowness, of the blends with the phosphoric acid salts may be slightly higher.
• the reaction mixture was pumped at about 5 ml_/min over a period of approximately 40 minutes into a 2 L reaction vessel, fitted with a mechanical stirrer, that contained about 700 ml_ of rapidly stirred heptane (476.8 g). After addition was complete, the resulting solution was stirred for about 50 minutes. Suction filtration was initiated and then stopped when the product was determined to be a yellow oil containing some fine white solids.
• the solvent was rotavapped off using a vacuum pump and 55 0 C water bath. The filter paper and flask were rinsed with heptane. The solvent was removed on a rotary evaporator. The oil was dried over night and then for about 5 hours at about 5O 0 C with a slight ingress of dry nitrogen.
• the product weighed 7.5 g (12.75 g theory).
• the filter cake is washed with eight approximately 40 mL portions of heptane and then sucked dry on the filter paper for 3 h.
• the solid is placed in a metal pan and dried over night and
• amine portion of the salt may scavenge some AA as shown in Example C20 in Table 8, without being bound to a theory, it is thought that the predominant mechanism is thought to be catalyst deactivation.
• the aqueous solvent was removed by freeze drying. The liquid was frozen while manually rotating in a dry ice/acetone bath. A lyophilizer was used for 3 days, 4 hours and 17 min.
• the white solid weighed 24.829 g (theory 24.722 g). By XRF, wt./wt. % P in the white solid was 17.17% (theory 17.6%).
• phosphoric acid salts of L-alanine one mole of phosphoric acid are used per mole of L-alanine, and reacted according to the following procedure.
• a 500-mL, round-bottomed flask equipped with a magnetic stir bar, thermocouple, and a heating mantle is added 6.275 g of L-alanine and 94.5 g of Millipore water.
• the slurry is heated to 6O 0 C and stirred until a homogeneous solution was obtained.
• a solution of 8.201 g of phosphoric acid dissolved into 37.01 g of Millipore water is added in a small steady stream (fast dropwise) via an addition funnel to the L-alanine solution with rapid stirring over approximately 17 minutes.
• the solution is stirred for at least 15 min once the addition is complete.
• the clear solution was transferred to a single-necked, 500 ml_ round-bottomed flask.
• the aqueous solvent was removed by freeze drying.
• the liquid was frozen while manually rotating in a dry ice/acetone bath.
• a lyophilizer was used for 1 days, 19 hours and 15 min.
• the clear, viscous oil weighed 14.808 g (theory 13.17 g).
• wt./wt. % P in the clear oil was 11.92% (theory 16.6%).
• a further series of polymers were prepared, employing the phosphoric acid salt of L-histidine, phosphoric acid salt of L-alanine, both described above in this example, and the phosphoric acid salt of CYASORB UV 3529 ("Cyasorb UV 3529-H3PO4") described in Example D. These examples use the melt-blending procedure outlined in Table 3 and the polymer described in Example B.
• Table 9 indicates the two amino acid salts of phosphoric acid reduce residual AA by 79-83% and AA generation upon melting by 65-66%.
• the CYASORB UV 3529 salt of phosphoric acid reduces residual AA by about 87%, AA generation upon melting by about 75%, and has the best color. While the % reduction in AA generation is about 10% less for the amino acid salts than for the Cyasorb UV 3529 salt, the amino acids are less expensive, copolymerizable (less extractability), and water soluble (no VOC during salt preparation). The color and clarity are better for Example 34 with the L- alanine salt than for Example 33 with the L-histidine salt.
• L-alanine is also more water soluble than L-histidine, which requires more dilute conditions to get it into aqueous solution.
• the phosphoric acid salt of L-alanine is an oil, which may make it more economical to add than a solid salt like the phosphoric acid salt of L-histidine.

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