Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Mixing of two or more solid polymers; mixing of solid...
Reexamination Certificate
1996-08-21
2002-11-05
Buttner, David J. (Department: 1712)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Mixing of two or more solid polymers; mixing of solid...
C525S064000, C525S067000, C525S072000, C525S133000, C525S146000, C525S148000, C525S166000, C525S175000, C525S176000, C525S179000, C525S183000, C525S189000, C525S193000, C525S194000, C525S199000, C525S200000, C525S276000
Reexamination Certificate
active
06476125
ABSTRACT:
The present invention relates to a fluorine-containing polymer alloy wherein a fluorine-containing polymer and a polymer containing no fluorine atoms are uniformly dispersed and mixed.
As represented by a tetrafluoroethylene polymer, a fluorine-containing polymer is excellent in heat resistance, flame retardancy, chemical resistance, weather resistance, non-tackiness, low friction and low dielectric properties, and it is used in a wide range of fields including fields of a coating material for a heat and flame resistant electrical wire, a corrosion resistant piping material for a semiconductor washing line, a corrosion resistant piping material for a chemical plant, a material for agricultural green houses, a release coating material for kitchen utensils and various materials for sliding action.
However, it is poor in the compatibility with other polymer materials containing no fluorine atom, and it thus has had a problem that a satisfactory polymer alloy can hardly be obtained. To improve the compatibility of the fluorine-containing polymer with a polyolefin, there has been proposed a method wherein a polyolefin is modified with an alkyl acrylate for use (Japanese Examined Patent Publication No. 73459,1992) or a method wherein a carbonyl group, a hydroxyl group or an epoxy group is incorporated to the fluorine-containing polymer (Japanese Unexamined Patent Publication No. 57448/1987).
The former method is effective in a case where the fluorine-containing polymer is, for example, a vinylidene fluoride polymer or a vinyl fluoride polymer which has a high polarity, but the compatibility with a fluorine-containing polymer having a low polarity such as a tetrafluoroethylene polymer or copolymer, or a chlorotrifluoroethylene polymer or copolymer, can not thereby be improved.
The latter method may, for example, be (1) a method of blending a fluorine-containing polymer with a non-fluorine type thermoplastic polymer containing a functional group, (2) a method of incorporating to a fluorine-containing polymer, polymer units derived from a polymerizable monomer having a functional group, (3) a method of reacting reactive groups present in a fluorine-containing polymer, with a compound having a functional group or with a compound which is capable of forming a functional group by the reaction, or (4) a method of modifying a fluorine-containing polymer by oxidation, hydrolysis or thermal decomposition.
However, with respect to a fluorine-containing polymer such as a tetrafluoroethylene polymer or copolymer, or a chlorotrifluoroethylene polymer or copolymer, the method (1) is not effective like the above-mentioned method, since no compatibility will be obtained as between such a fluorine-containing polymer and a non-fluorine type thermoplastic polymer containing a functional group. The method (2) is expensive as the monomer to be used for the copolymerization reaction is very limited, and such a method is not practical. The method (3) can not be employed since such a fluorine-containing polymer usually does not have reactive groups. The method (4) is not practical, since such a fluorine-containing polymer is stable, and it is difficult to form a carboxyl group, a hydroxyl group or an epoxy group by oxidation, hydrolysis or thermal decomposition.
On the other hand, it has been proposed to use as a molding material, a grafted fluorine-containing polymer comprising a fluorine-containing polymer having hydrogen atoms bonded to carbon atoms of its main chain and a grafting compound having a functional group and a linking group capable of grafting to the fluorine-containing polymer, grafted to the fluorine-containing polymer, and to prepare a molded product by a conventional molding method, such as a film or sheet, or a laminate by coextrusion molding, or a laminate prepared by laminating such a film or sheet with other molded product (Japanese Unexamined Patent Publications No. 173230/1995, No. 173446/1995 and No. 173447/1995).
It is an object of the present invention to prepare a polymer alloy excellent in the compatibility between a fluorine-containing polymer and a polymer containing no fluorine atoms, by a simple method.
The present inventors have found it very effective to employ as a compatibilizing agent a grafted fluorine-containing polymer (a) comprising a fluorine-containing polymer (d) having hydrogen atoms bonded to carbon atoms of its main chain and a grafting compound having a linking group capable of grafting to the fluorine-containing polymer (d) and a functional group capable of providing an adhesive property, grafted to the fluorine-containing polymer (d). The present invention has been accomplished on the basis of this discovery.
By using such a grafted fluorine-containing polymer (a) as a compatibilizing agent, it is possible to improve not only the compatibility with the polymer (c) containing no fluorine atoms but also the adhesive property between the fluorine-containing polymer (d) and the polymer (c) containing no fluorine atoms, whereby the compatibility will be improved, and it will be possible to obtain a fluorine-containing polymer alloy which can be uniformly dispersed with a small dispersed particle size.
Namely, the present invention provides such a fluorine-containing polymer alloy, a method for producing the fluorine-containing polymer alloy, and a molding method employing it, as follows.
A fluorine-containing polymer alloy comprising a grafted fluorine-containing polymer (a) and a polymer (c) containing no fluorine atom, said grafted fluorine-containing polymer (a) comprising a fluorine-containing polymer (d) having hydrogen atoms bonded to carbon atoms of its main chain and a grafting compound having a linking group capable of grafting to the fluorine-containing polymer (d) and a functional group capable of providing an adhesive property, grafted to the fluorine-containing polymer (d).
The above fluorine-containing polymer alloy which further contains a fluorine-containing polymer (b) other than the grafted fluorine-containing polymer (a).
A method for preparing a fluorine-containing polymer alloy, which comprises melt-mixing, at a radical-forming temperature, a fluorine-containing polymer (d) having hydrogen atoms bonded to carbon atoms of its main chain, a grafting compound having a linking group capable of grafting to the fluorine-containing polymer (d) and a functional group capable of providing an adhesive property, a radical-forming agent, and a polymer (c) containing no fluorine atom.
A method for preparing a fluorine-containing polymer alloy, which comprises melt-mixing, at a radical-forming temperature, a fluorine-containing polymer (d) having hydrogen atoms bonded to carbon atoms of its main chain, a grafting compound having a linking group capable of grafting to the fluorine-containing polymer (d) and a functional group capable of providing an adhesive property, a radical-forming agent, a polymer (c) containing no fluorine atom, and a fluorine-containing polymer (b′) other than the fluorine-containing polymer (d).
A method for molding a fluorine-containing polymer alloy, which comprises melt-mixing and molding in a molding machine at a radical-forming temperature, a fluorine-containing polymer (d) having hydrogen atoms bonded to carbon atoms of its main chain, a grafting compound having a linking group capable of grafting to the fluorine-containing polymer (d) and a functional group capable of providing an adhesive property, a radical-forming agent, and a polymer (c) containing no fluorine atom.
A method for molding a fluorine-containing polymer alloy, which comprises melt-mixing and molding in a molding machine at a radical-forming temperature, a fluorine-containing polymer (d) having hydrogen atoms bonded to carbon atoms of its main chain, a grafting compound having a linking group capable of grafting to the fluorine-containing polymer (d) and a functional group capable of providing an adhesive property, a radical-forming agent, a polymer (c) containing no fluorine atom, and a fluorine-containing polymer (b′) other than the fluorine-c
Iura Jun-ichi
Nishi Eiichi
Yokota Masataka
Asahi Glass Company Ltd.
Buttner David J.
Oblon & Spivak, McClelland, Maier & Neustadt P.C.
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