MXPA00009553A - Polymer compositions - Google Patents

Abstract

Polymer compositions including an olefinic polymer, a polar polymer and a compatibilizer are disclosed. The compatibilizer can be a block or graft copolymer including polymer portions that are compatible with the olefinic polymer and polymer portions that are compatible with the polar polymer.

Description

IMERIC PO COMPOSITIONS BACKGROUND OF THE INVENTION The invention relates to polymer compositions. Polymeric compositions are known which include polar polymers and olefinic polymers. These polymeric compositions often include one or more additional compounds that act as compatibilizing agents for the polar and olefinic polymers. SUMMARY OF THE INVENTION The invention relates to polymeric compositions. These compositions may exhibit good flame retardancy and / or low smoke formation. The polymer compositions can provide good mechanical properties, such as tensile strength and elongation. The polymer compositions may contain small amounts of halogens. The compositions may be in the form of a physical mixture. In one aspect, the invention relates to a polymeric physical mixture that includes an olefin polymer, a polar polymer and an additional polymer that includes first and second polymer portions. The first polymer portion is compatible with the olefin polymer, and the second polymer portion is compatible with the polar polymer. In another aspect, the invention relates to a method of making a polymer composition. The method includes forming a polymer comprising first and second polymer portions in a mixture. The mixture includes an olefin polymer and a polar polymer. The first polymer portion is compatible with the olefin polymer, and the second polymer portion is compatible with the polar polymer. In another aspect, the invention relates to a method of forming a polymer composition. The method includes forming a polymer containing first and second polymer portions, and mixing the polymer in a mixture. The mixture includes an olefin polymer and a polar polymer. The first polymer portion is compatible with the olefin polymer, and the second polymer portion is compatible with the polar polymer. DESCRIPTION OF THE PREFERRED EMBODIMENTS The preferred compositions include an olefinic polymer, a polar polymer and a compatibilizing agent. The compatibilizing agent may be a block or graft copolymer. The compatibilizing agent includes at least a portion of olefinic polymer that is compatible with the olefinic polymer, and the compatibilizing agent includes at least a portion of polar polymer that is compatible with the polar polymer. The polymeric portions can be in the form of blocks. Typically, the compositions are in the form of a physical mixture in which the components of the composition are intermixed. The physical mixture can be a homogenous physical mixture. The olefinic polymers are formed primarily of olefin monomers which are hydrocarbon monomers having at least one carbon-carbon double bond. The olefin monomers may be straight chain, branched or cyclic hydrocarbons. Examples of olefin monomers include ethylene, propylene, butylene and pentene. Examples of olefinic polymers include polyethylene, copolymers of ethylene, polypropylene, copolymers of propylene, copolymers of ethylene and propylene and polymers of polymethylpentene. In addition to the olefin monomers, an olefin polymer may include a lesser amount of non-olefinic monomers, such as ethylene acrylic monomers. Preferably, an olefinic polymer includes less than about 20% by weight of non-olefinic monomers, more preferably less than about 10% by weight of non-olefinic monomers and most preferably less than about 5% by weight of monomers non-olefinic. Preferably, an olefinic polymer includes at least about 80% by weight of olefin monomers, more preferably at least about 90% by weight of olefin monomers, and most preferably at least about 95% by weight of olefin monomers. olefin monomers. The olefinic polymers preferably include less than about 2% by weight of halogen, more preferably less than about 1% by weight of halogen, and most preferably less than about 0.5% by weight of halogen. Preferably, an olefinic polymer includes at least about 80% by weight of olefin monomers, more preferably at least about 90% by weight of olefin monomers, and most preferably at least about 95% by weight of olefin monomers. olefin monomers. The olefinic polymers preferably include less than about 2% by weight of halogen, more preferably less than about 1% by weight of halogen, and most preferably less than about 0.5% by weight of halogen. Olefin polymers are available from, for example, Exxon, Mobil, Chevron, Amoco, Dow, Quantum, Solvay, Novador, Rexene, Aristech, Hoechst Celanese, Fina, Montall and Shell. A polar polymer includes olefin monomers and polar monomers having the formula CH2 = CH0C0R, where R is a hydrocarbon group which may be straight or branched chain, saturated or unsaturated, and substituted or unsubstituted. Typically, R is a straight-chain, saturated and unsubstituted alkyl group, having one to five carbon atoms, such as a methyl group, an ethyl group, or a butyl group. In a polar polymer, a portion of the polar monomers can be hydrolyzed. A polar polymer may include additional functional monomers such as carbon monoxide, acrylic monomers, acrylic glycidyl monomers, acidic monomers, anhydride monomers, and / or nitrile monomers. Preferably, a polar polymer includes from about 20 to about 90% by weight of olefinic monomers, more preferably from about 35 to about 85% by weight of olefinic monomers, and most preferably from about 50% by weight. about 80% by weight of olefinic monomers. Preferably, a polar polymer includes from about 10 to about 80% by weight of polar monomers, more preferably from about 15 to about 65% by weight of polar monomers, and most preferably from about 20 to 50% by weight. about 50% by weight of polar monomers. Preferably, a polar polymer includes at most about 15% by weight of additional functional monomers, more preferably from about 2.5 to about 10% by weight of additional functional monomers. The polar polymers preferably include less than about 2% by weight of halogen, more preferably less than about 1% by weight of halogen, and most preferably less than about 0.5% by weight of halogen. In a preferred embodiment, the polar polymer is a terpolymer of ethylene monomers, vinyl acetate monomers and carbon monoxide. Polar polymers are available from, for example, Exxon, Quantum, DuPont, Union Carbide, AT Plastics, Chevron, Bayer, Mitsubishi Petrochemicals and Sumitomo. The compatibilizing agent is typically a graft or block copolymer that includes at least a portion of olefinic polymer and at least a portion of polar polymer. The polymeric portions can be in the form of blocks. The olefin polymer portion is formed of an olefinic polymer, and the polar polymer portion is formed of a polar polymer. The olefin polymer portion must be selected to be compatible with the olefin polymer, and the polar polymer portion must be selected to be compatible with the polar polymer. Generally, the olefin polymer portion of the compatibilizer and the olefin polymer have substantially the same polarity, and the polar polymer portion of the compatibilizer and the polar polymer have substantially the same polarity. Preferably, the olefin polymer portion of the compatibilizer is the same polymer as the olefin polymer. For example, if the olefin polymer is polyethylene, the olefin polymer portion of the compatibilizing agent is also polyethylene. Preferably, the polar polymer portion of the compatibilizing agent includes functional groups that are the same as the functional groups in the polar polymer. For example, if the polar polymer is ethylene vinyl acetate, the polar polymer portion of the compatibilizing agent includes vinyl acetate monomers. The polymer compositions can include from about 15 to about 65% by weight of olefinic polymer, from about 20 to about 80% by weight of polar polymer, and from about 1 to about 40% by weight of compatibilizing agent . The olefin polymer portions and the polar polymer portions of the compatibilizing agent can be chemically bonded directly or can be connected by a linking agent that is chemically bonded to an olefin polymer portion and an adjacent portion of polar polymer. When a linking agent is not used, the compatibilizing agent can be formed by reacting two polymers containing functional groups that react to provide the compatibilizing agent. This reaction can occur in a mixture containing the olefinic polymer and the polar polymer. Alternatively, the compatibilizing agent may be first formed, then added to a mixture containing the olefinic polymer and the polar polymer. A polymer containing an amine and / or epoxy, such as a nitrile rubber, can be reacted with a polyolefin containing an acid or anhydride. A polymer containing an acid or anhydride, such as nitrile rubber, can be reacted with a polyolefin containing an amine and / or epoxy. A polyester containing isocyanate (typically having low molecular weight) can be reacted with a polyolefin containing an acid, anhydride or epoxy. A compatibilizing agent can be formed by reacting a terpolymer of ethylene, vinyl acetate and carbon monoxide containing epoxy with a polypropylene modified with maleic acid. A compatibilizing agent can be formed by reacting a polar polymer containing an ethylene methyl acrylate acid with a styrene-ethylene butylene styrene block copolymer containing an epoxy. Preferably, the functional groups that react to form the compatibilizing agent are at the terminus of the polymers. Examples of linking agents include diepoxides, diamines and diisocyanates that can be reacted with an acid-modified polar polymer and an acid modified olefinic polymer to provide a compatibilizing agent. The polymer compositions can be prepared using standard mixing methods. For example, polymer compositions can be formed using a Banbury mixer, a Brabender mixer and / or a twin screw mixer. Generally, twin screw mixers provide greater shear stress during blending, so that polymer compositions formed using a twin screw extruder can exhibit better elongation and tensile properties. The polymeric compositions may also include compounds that improve the hydrolytic stability of esters, silicones, stabilizers, flame retardants, plasticizers, colorants, reinforcing fillers and / or lubricants. Preferably, the total amount of these compounds in the polymer compositions is from about 50 to about 200 parts per 100 parts of the total amount of polymer (olefinic polymer, polar polymer and compatibilizing agent). When the composition includes anti-oxidants or lubricants, these compounds constitute from about 100 parts per million to about 10% by weight of the composition in relation to the total amount of polymer (olefinic polymer, polar polymer and compatibilizing agent). Examples of compounds that improve the stability of esters include polycarbodiimides, such as aromatic polycarbodiimides. These compounds are available, for example, from Bayer. Examples of dyes include organic and inorganic dyes. The dyes are available, for example, from Ciba Geigy, BASF, Ferro, ICI, Harwick and Teknor Apex. Examples of flame retardants include aluminum trihydrate, magnesium hydroxide, phosphorus compounds, nitrogen compounds, zinc borates, halogenated compounds, and Ultracarb (Microfine Minerals). Flame retardants are available, for example, from Lonza, Alcoa, Alean, Huber, Martin Marietta, Hoechst Celanese, U.S. Borax, Melamine Chemicals, Microfine Minerals and Anzon. Examples of stabilizers include thermal stabilizers, metal deactivators and ultraviolet stabilizers. Stabilizers are available, for example, from Ciba Geigy, Sandoz, Cytec, Eastman Chemicals, Fairmount Chemicals, Hoechst Celanese and General Electric. Examples of plasticizers include phosphate ester plasticizers, phosphoric esters, fatty acid esters, azelaic acid esters, sebacic acid esters, trimellitic esters and polymeric plasticizers. When the polymeric compositions are used in flame retardant applications, phosphate ester plasticizers are preferably used. Plasticizers are available, for example, from Solutia, Teknor Apex, Ferro, Exxon, Eastman Chemical and Uniflex Chemical. Lubricants are available, for example, from Akzo, Dow Corning, DuPont, Astor Wax, Henkel, Witco and Struktol. Silicones are available, for example, from General Electric, Wacker and Dow Corning. Examples of reinforcement fillers include clay, silica and calcium carbonate. Reinforcement fillers are available, for example, from Haber, Engelhard and PPG. The polymer compositions preferably have an elongation of at least about 100%, measured according to the standard method ASTM D-638. The polymer compositions preferably have a tensile strength of at least about 1,000, measured in accordance with the ASTM D-638 standard method. The polymer compositions preferably have a nominal peak smoke capacity of less than 3 / meter, measured using cone calorimetry according to the standard method ASTM E-1354. When used for flame retardant applications, the polymer compositions preferably have a limiting oxygen index of at least about 30, as measured by the ASTM D-2863 standard method. Table I lists polymer compositions and their properties. These compositions were prepared using a Brabender mixer (PL 2000 with roller-type blades). The speed was adjusted to maintain the mixture at around 180"C. The polymers were mixed, and the filling was added slowly, this mixture was mixed for about five minutes, and the stabilizing agent was added in. This mixture was mixed around One minute, removed from the Brabender mixer and pressed into a thin sheet using a cold press, the resulting material was compression molded at around 220"C. This material was then cooled and the properties of the material were evaluated.

Table I 15 20 (1) Elvax 265, commercially available from DuPont (2) Elvax 470, commercially available from DuPont (3) Profax SR 256 M, commercially available from Montell (4) Fortilene KB 4104, commercially available from Solvay (5) Unite MP 1000, commercially available from Aristech (6) Elvaloy AS, commercially available from DuPont (7) Silicone resin 4-7051, commercially available from Dow Corning 10 (8) Silicone resin 4-7105, commercially available from Dow Corning (9) Magnifin H5GV , commercially available from Lonza (10) Stearic acid, commercially available from Harwick Chemical Corporation (11) Irganox / BNX 1010, commercially available from Ciba-Geigy (12) Irganox / MD 1024, commercially available from Ciba-Geigy 15 (13) ASTM D-2240 (14) ASTM D-638 (15) ASTM D-2863 (16) ASTM D-150 20 Table II lists polymer compositions and their properties. These compositions were prepared using a twin screw extruder (Berstoff model 40). All ingredients were dosed and added into the throat feed. The temperature was controlled such that the temperatures in the mixing zones were more than about 420 'F. The mixing speed was around 170 rpm. The compositions were cast using the same method using for the compositions in Table I. As shown in Table II, materials prepared using a twin screw extruder exhibited better elongation properties relative to materials prepared using lower shear methods.

Table II 15 20 (1) Elvax 265, commercially available from DuPont (2) Elvax 470, commercially available from DuPont (3) Profax SR 256 M, commercially available from Montell (4) Unite MP 1000, commercially available from Aristech (5) Elvaloy AS, commercially available from DuPont 15 (6) Zinc Stearate, commercially available from Harwick Chemical Corporation (7) Irganox / BNX 1010, commercially available from Ciba-Geigy (8) Irganox / MD 1024, commercially available from Ciba-Geigy (9) Chemsorb 944 FL, commercially available from Ciba-Geigy (10) Silicone resin 4-7051 , commercially available from Dow Corning 20 (11) (12) ASTM D-2240 (13) ASTM D-638 (14) (15) ASTM D-150 25 (16) ASTM D-2863 (17) ASTM E-1354 ( cone calorimetry) Table III lists polymer compositions and their properties. These compositions were made according to the method discussed above with respect to Table I.

Table III 15 twenty (i Elvax 265, commercially available from DuPont (2 Elvax 470, commercially available from DuPont (3 Profax SR 256 M, commercially available from Montell (4 Fortilene KB 4104, commercially available from Solvay (5 Unite MP 1000, commercially available from Aristech ( 6 Elvaloy AS, commercially available from DuPont 10 (7 Stearic acid, commercially available from Harwic Chemical Corporation (8 Chimsorb 944 FL, commercially available from Ciba-Geigy (9 Irganox 1010, commercially available from Ciba-Geigy (10) Irganox 1024, commercially available from Ciba-Geigy (11) ASTM D-2240 15 (12) ASTM D-638 (13) ASTM D-3863 (14) ASTM D-150 Table IV lists polymer compositions and their properties. These compositions were prepared by mixing the olefinic polymers and the polar polymers in a Banbury mixer (Farrel Midget Banbury mixer) using an average rotor speed. When the mixture reached a temperature of about 10"C more than the melting temperature of the polyethylene, it was added and mixed about half the filling (ATH), then the remaining half of the filler (ATH) was added. mixing speed was reduced, and the mixture was mixed for about five minutes.Stabilizing agents were added to this mixture while maintaining a low rotor speed, and this mixture was mixed for about one minute.The resulting compositions were molded as described for the compositions of Table I.

Table IV 15 20 (1) Elvax 265, commercially available from DuPont (2) Elvaloy AS, commercially available from DuPont (3) Fusabond C MC 250D, commercially available from DuPont (4) Fusabond E MB 100D, commercially available from DuPont (5) Engage 8480, commercially available from Dow DuPont (6) Hydral 710, commercially available from Alcoa (7) Irganox 1010, commercially available from Ciba-Geigy (9) ASTM D-2240 15 (10) ASTM D-638 ( 11) ASTM D-150 (12) ASTM D-2863 (13) ASTM E-1354 (cone calorimetry) 20

Claims (39)

1. CLAIMS 1. A composition, comprising: a physical mixture, which includes: an olefinic polymer; a polar polymer; and a third polymer comprising first and second polymer portions, the first polymer portion being compatible with the olefin polymer and the second polymer portion being compatible with the polar polymer, wherein the ratio of the weight percent of the polar polymer to the weight percentage of the polymer Olefinic acid is 1: 1 or greater, and wherein both the olefin polymer and the polar polymer are substantially free of halogen. The composition according to claim 1, wherein the third polymer is selected from the group consisting of a graft copolymer and a block copolymer. 3. The composition according to claim 2, wherein the polar polymer includes ethylene monomers and vinyl acetate monomers. 4. The composition according to claim 3, wherein the second polymer portion includes ethylene monomers and vinyl acetate monomers. The composition according to claim 3, wherein the polar polymer further includes carbon monoxide monomers. 6. The composition according to claim 5, wherein the second polymer portion includes ethylene monomers and vinyl acetate monomers. The composition according to claim 1, wherein the olefinic polymer includes ethylene monomers. The composition according to claim 7, wherein the first polymer portion includes ethylene monomers. 9. The composition according to claim 1, wherein the olefin polymer comprises polyethylene. The composition according to claim 9, wherein the first polymer portion includes ethylene monomers. The composition according to claim 1, wherein the olefinic polymer includes propylene monomers. The composition according to claim 11, wherein the first polymer portion includes propylene monomers. The composition according to claim 1, wherein the olefinic polymer comprises polypropylene. The composition according to claim 13, wherein the first polymer portion includes propylene monomers. 15. The composition according to claim 1, wherein the polar polymer includes ethylene monomers and vinyl acetate monomers. 16. The composition according to claim 15, wherein the second polymer portion includes ethylene monomers and vinyl acetate monomers. - - 17. The composition according to claim 15, wherein the polar polymer further includes carbon monoxide monomers. 18. The composition according to claim 17, wherein the second polymer portion includes ethylene monomers and vinyl acetate monomers. 19. The composition according to claim 15, wherein the olefin polymer is selected from the group consisting of polyethylene, ethylene copolymers, polypropylene, propylene copolymers, ethylene propylene copolymers, and polymethylpentene. The composition according to claim 19, wherein the first polymer portion includes ethylene monomers. 21. The composition according to claim 19, wherein the first polymer portion includes propylene monomers. 22. The composition according to claim 15, wherein the olefinic polymer includes ethylene monomers. 23. The composition according to claim 22, wherein the first polymer portion includes ethylene monomers. The composition according to claim 15, wherein the olefinic polymer comprises polyethylene. 25. The composition according to claim 24, wherein the first polymer portion includes ethylene monomers. 26. The composition according to claim 15, wherein the olefinic polymer includes propylene monomers. 27. The composition according to claim 26, wherein the first polymer portion includes propylene monomers. 28. The composition according to claim 15, wherein the olefinic polymer comprises polypropylene. 29. The composition according to claim 28, wherein the first polymer portion includes propylene monomers. The composition according to claim 1, wherein the composition comprises from about 20 to about 70% by weight of the olefinic polymer, from about 30 to about 80% by weight of polar polymer, and from about 1 to about 40% by weight of the third polymer. The composition according to claim 1, wherein the composition comprises from about 35 to about 50% by weight of the olefinic polymer, from about 50 to about 65% by weight of the polar polymer and from about 5% by weight. to about 20% by weight of the third polymer. 32. The composition according to claim 1, further comprising a compound selected from the group consisting of a filler, a stabilizer, a plasticizer and a lubricant. The composition according to claim 1, wherein the olefinic polymer is substantially free of halogen and the polar polymer is substantially free of halogen 34. A method of forming a composition, comprising: forming a polymer comprising polymeric portions first and second in a mixture comprising an olefin polymer and a polar polymer, wherein the first polymer portion is compatible with the olefin polymer and the second polymer portion is compatible with the polar polymer, where the ratio of the weight percent of the polar polymer to the Percent by weight of the olefinic polymer is 1: 1 or greater, and wherein both the olefin polymer and the polar polymer are substantially free of halogen 35. The method according to claim 34, wherein the composition is a physical mixture. A method of forming a composition, comprising: forming a polymer comprising polymeric portions first and second; and mixing the polymer in a mixture comprising an olefin polymer and a polar polymer, wherein the first polymer portion is compatible with the olefin polymer and the second polymer portion is compatible with the polar polymer, where the weight percent ratio of the polar polymer the weight percent of the olefin polymer is 1: 1 or greater, and where both the olefin polymer and the polar polymer are substantially free of halogen. 37. The method according to claim 36, wherein the composition is a physical mixture. 38. The composition according to claim 1, wherein the weight ratio of the polar polymer to the weight ratio of the olefinic polymer ranges from 1.5: 1 to about 2: 1. 39. The composition according to claim 1, wherein the second polymer portion of the third polymer and the polar polymer both include the same functional groups. Esumen Polymer compositions are disclosed which include an olefinic polymer, a polar polymer and a compatibilizing agent. The compatibilizing agent can be a block or graft copolymer, including polymeric portions that are compatible with the olefinic polymer and polymeric portions that are compatible with the polar polymer.