Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – At least one aryl ring which is part of a fused or bridged...
Reexamination Certificate
2002-11-27
2004-01-13
Wu, David W. (Department: 1713)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
At least one aryl ring which is part of a fused or bridged...
C524S495000, C526S348000, C526S348200, C526S348400, C526S348600, C526S348700, C526S243000, C526S351000, C525S515000
Reexamination Certificate
active
06677395
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to irradiated, oxidized olefin polymer dispersing aids for use in the manufacture of additive concentrates and additive-containing olefin polymer compositions.
BACKGROUND
The effective use of olefin-based polymers often requires the incorporation of additives into the polymer composition to enhance the polymer's performance, aesthetic appeal and/or impart desirable properties. For example, pigments are often added to meet aesthetic requirements, or to improve heat resistance, heat absorption, and fade resistance. Halogenated flame retardants may be incorporated to improve flame-retardancy in the end-use product. Other additives, such as anti-acids, anti-microbial agents, and conductive carbon black are also often included in polymer compositions.
Improving the dispersion of additives in polymer compositions enhances the performance of those additives. In U.S. Pat. No. 6,384,148, oxidates of polyethylene produced using metallocene catalysts have been disclosed for the dispersion of pigments. In U.S. Pat. No. 5,079,283, organic peroxides and azo compounds were used to promote propylene polymer scission in polypropylene-based compositions containing flame retardants. The resulting higher melt flow material possessed improved flame retardancy. Still another approach to dispersion is to use polyethylene waxes, however, these compounds can result in polymer blooming, and an associated decrease in the useful life of products made from the polymer. Thus, there continues to be a need for improved dispersion of additives in olefin polymer compositions.
The dispersion of additives in olefin polymer compositions using the irradiated, oxidized olefin polymer dispersants of this invention provides a more homogenous distribution of the additive, and promotes desirable flexibility in the formulation of commercial olefin polymer materials. For example, at the same additive concentration, an olefin polymer composition containing an additive dispersed therein using the irradiated, oxidized polymer dispersants of this invention provides improved performance over the same olefin polymer composition without the dispersants of this invention. Alternately, a polymer manufacturer could take advantage of the performance enhancement provided by the irradiated, oxidized polymer dispersants of this invention, by reducing the additive levels in the olefin polymer compositions containing the dispersants, while maintaining equivalent additive performance of the same olefin polymer composition containing higher additive levels without the dispersants of this invention.
The irradiation of olefin polymers has been described in a number of patents. For example, U.S. Pat. No. 5,688,839 discloses irradiating colored olefin polymer resin particles and mixing the irradiated, colored resin particles with a background component, where the colored resin particles only partially disperse, so as to impart a marbleized appearance. U.S. Pat. No. 5,508,319 discloses the irradiation of polyethylene. U.S. Pat. Nos. 5,508,318, 5,554,668, 5,731,362, and 5,591,785 disclose irradiated propylene polymer material having long chain branching, high melt strength, and strain hardening elongational viscosity. U.S. Pat. Nos. 5,820,981 and 5,804,304 disclose a polymer that is subjected to irradiation in the substantial absence of oxygen, followed by a multistage treatment in the presence of a controlled amount of oxygen. However, none of these references disclose irradiated, oxidized olefin polymer dispersing aids for use in the manufacture of additive concentrates and additive-containing olefin polymer compositions. It has unexpectedly been found that the dispersants of the present invention provide distinct advantages in the dispersion of additives in olefin polymer compositions.
SUMMARY OF THE INVENTION
In one embodiment, the present invention relates to an additive-containing olefin polymer composition comprising:
A. 2.0 to 30.0 wt % of an irradiated, oxidized olefin polymer material;
B. 0.1 to 40.0 wt % of an additive selected from the group consisting of colorants, halogenated flame retardants, conductive carbon black, anti-microbial agents, anti-acids and mixtures thereof; and
C. 30.0 to 97.9 wt % of a non-irradiated, non-oxidized olefin polymer material;
wherein the sum of components A+B+C is equal to 100 wt %.
In another embodiment, the present invention relates to an additive concentrate composition, the composition comprising:
A. 9.0 to 85.0 wt % of an additive selected from the group consisting of colorants, halogenated flame retardants, conductive carbon black, anti-microbial agents, anti-acids and mixtures thereof; and
B. 15 to 91 wt % of an irradiated, oxidized olefin polymer material;
wherein the sum of components A+B is equal to 100 wt %.
DETAILED DESCRIPTION OF THE INVENTION
Suitable olefin polymers useful as the irradiated and oxidized or non-irradiated and non-oxidized olefin polymers are propylene polymer materials, ethylene polymer materials, butene-1 polymer materials, and mixtures thereof.
When a propylene polymer material is used as the non-irradiated and non-oxidized olefin polymer material or as the starting material for making the irradiated, oxidized olefin polymer of the present invention, the propylene polymer material can be:
(A) a crystalline homopolymer of propylene having an isotactic index greater than 80%, preferably about 90% to about 99.5%;
(B) a crystalline random copolymer of propylene and an olefin selected from the group consisting of ethylene and C
4
-C
10
&agr;-olefins, provided that when the olefin is ethylene, the maximum polymerized ethylene content is 10% by weight, preferably about 4%, and when the olefin is a C
4
-C
10
&agr;-olefin, the maximum polymerized content thereof is 20% by weight, preferably about 16%, the copolymer having an isotactic index greater than 60%, preferably at least 70%;
(C) a crystalline random terpolymer of propylene and two olefins selected from the group consisting of ethylene and C
4
-C
8
&agr;-olefins, provided that the maximum polymerized C
4
-C
8
&agr;-olefin content is 20% by weight, preferably about 16%, and when ethylene is one of the olefins, the maximum polymerized ethylene content is 5% by weight, preferably about 4%, the terpolymer having an isotactic index greater than 85%;
(D) an olefin polymer composition comprising:
(i) about 10 parts to about 60 parts by weight, preferably about 15 parts to about 55 parts, of a crystalline propylene homopolymer having an isotactic index at least 80%, preferably about 90 to about 99.5%, or a crystalline copolymer selected from the group consisting of (a) propylene and ethylene, (b) propylene, ethylene and a C
4
-C
8
&agr;-olefin, and (c) propylene and a C
4
-C
8
&agr;-olefin, the copolymer having a propylene content of more than 85% by weight, preferably about 90% to about 99%, and an isotactic index greater than 60%;
(ii) about 3 parts to about 25 parts by weight, preferably about 5 parts to about 20 parts, of a copolymer of ethylene and propylene or a C
4
-C8 &agr;-olefin that is insoluble in xylene at ambient temperature; and
(iii) about 10 parts to about 80 parts by weight, preferably about 15 parts to about 65 parts, of an elastomeric copolymer selected from the group consisting of (a) ethylene and propylene, (b) ethylene, propylene, and a C
4
-C
8
&agr;-olefin, and (c) ethylene and a C
4
-C
8
&agr;-olefin, the copolymer optionally containing about 0.5% to about 10% by weight of a diene, and containing less than 70% by weight, preferably about 10% to about 60%, most preferably about 12% to about 55%, of ethylene and being soluble in xylene at ambient temperature and having an intrinsic viscosity of about 1.5 to about 4.0 dl/g;
the total of (ii) and (iii), based on the total olefin polymer composition being from about 50% to about 90%, and the weight ratio of (ii)/(iii) being less than 0.4, preferably 0.1 to 0.3, wherein the composition is prepared by polymerization in at least two stages;
(E) a thermoplastic olefin comprising:
(
Dang Vu A.
Fezza Richard J.
Schneckenburger Daniel E.
Song Cheng Q.
Basell Poliolefine Italia S.p.A.
Cheung William
Wu David W.
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