Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Reexamination Certificate
1998-10-21
2003-09-02
Szekely, Peter (Department: 1714)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Processes of preparing a desired or intentional composition...
C524S349000, C524S350000, C524S351000, C524S352000, C524S353000
Reexamination Certificate
active
06613823
ABSTRACT:
FIELD OF INVENTION
This invention is related to the field of polyolefins. Particularly, this invention relates to the field of phosphite additives to polyolefins.
BACKGROUND OF THE INVENTION
Polymers are used in a variety of diverse applications. For example, such applications include food packaging, electronic components, automobile parts, fibers and fabrics, and medical equipment. Polymers could not perform such diverse functions without the assistance of a very broad range of polymer additives. Without additives, polymers can degrade during processing and over time can lose impact strength, discolor, and become statically charged. Additives not only overcome these and other limitations, but also can impart improved performance properties to the final product.
One type of additive is antioxidants which usually are used to retard the oxidative degradation of polymers. Degradation can be initiated when free radicals, highly reactive species with an unpaired electron, are created in polymers by heat, ultraviolet radiation, mechanical shear, and/or metallic impurities. It is believed when a free radical is formed, a chain reaction can begin that initiates polymeric oxidation. Subsequent reaction of the radical with an oxygen molecule can yield a peroxy radical, which then can react with an available hydrogen atom to form an unstable hydroperoxide and another free radical. In the absence of an antioxidant, these reactions can become self-propagating and can lead to polymer degradation.
There are two basic types of antioxidants, primary and secondary antioxidants. It is believed that primary antioxidants can intercept and stabilize free radicals by donating active hydrogen atoms. It also is believed that secondary antioxidants can prevent formation of additional free radicals by decomposing unstable hydroperoxides into a stable product. When primary antioxidants, such as hindered phenols, are utilized, polymers can have a more yellow color than unstabilized polymers, therefore decreasing the commercial value of polymers. Secondary antioxidants, such as phosphite compounds, often are utilized to increase the stability and whiteness of polymers.
Unfortunately, phosphite additives also can create difficulties in polymer production and applications. First, some phosphite additives are hygroscopic and upon absorption of water, phosphites can clump and can be difficult to feed into the polymer production process. Some phosphites are hydrolytically unstable and can react with water resulting in a lower active phosphite concentration for stabilizing polymers. Furthermore, this hydrolysis reaction can leave moisture and acidic residues in polymers. There is a need in the polyolefin industry for a hydrolytically stable phosphite additive product that increases polymer stability and improves the whiteness of polymers.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a composition comprising a polyolefin that has improved color and stability.
It is another object of this invention to provide a process to produce a composition comprising a polyolefin that has improved color and stability.
It is a further object of this invention to provide a process to improve the hygroscopic nature and hydrolytic stability of phosphites.
It is yet another object of this invention to provide a process to improve the melt strength of recycled polyolefins.
It is yet another object of this invention to provide an article of manufacture prepared from said polyolefin produced by this invention.
In accordance with the present invention, a composition of matter is formed by combining components comprising:
a) a polyolefin;
b) a first phosphite, which is an arylalkyl diphosphite having a formula,
wherein R
1
, R
2
, R
3
, R
4
, R
5
, R
6
, R
7
, R
8
, R
9
, and R
10
can be the same or different and are selected from the group consisting of hydrogen and straight-chained or branched, cyclic or acyclic, aromatic or aliphatic, and mixed aliphatic, aromatic, and/or cycloaliphatic organic radicals having from about 1 to about 20 carbon atoms per radical;
c) a second phosphite selected from the group consisting of:
(i) a second arylalkyl diphosphite of formula (I), wherein R
1
, R
2
, R
3
, R
4
, R
5
, R
6
, R
7
, R
8
, R
9
, and R
10
can be the same or different and are selected from the group consisting of hydrogen and straight-chained or branched, cyclic or acyclic, aromatic or aliphatic, and mixed aliphatic, aromatic, and/or cycloaliphatic organic radicals having from about 1 to about 20 carbon atoms per radical, which is different from said first arylalkyl diphosphite and
(ii) a triarylphosphite having a formula,
wherein R
1
, R
2
, R
3
, R
4
, and R
5
are selected from the group consisting of hydrogen and straight-chained or branched, cyclic or acyclic, aromatic or aliphatic, and mixed aliphatic, aromatic, and/or cycloaliphatic organic radicals having from about 1 to about 20 carbon atoms per radical;
d) a hindered phenol; and
e) water.
A second embodiment of this invention provides a process comprising blending:
a) a polyolefin;
b) a first phosphite, which is an arylalkyl diphosphite having a formula,
wherein R
1
, R
2
, R
3
, R
4
, R
5
, R
6
, R
7
, R
8
, R
9
, and R
10
can be the same or different and are selected from the group consisting of hydrogen and straight-chained or branched, cyclic or acyclic, aromatic or aliphatic, and mixed aliphatic, aromatic, and/or cycloaliphatic organic radicals having from about 1 to about 20 carbon atoms per radical;
c) a second phosphite selected from the group consisting of:
(i) a second arylalkyl diphosphite of formula (I), wherein R
1
, R
2
, R
3
, R
4
, R
5
, R
6
, R
7
, R
8
, R
9
, and R
10
can be the same or different and are selected from the group consisting of hydrogen and straight-chained or branched, cyclic or acyclic, aromatic or aliphatic, and mixed aliphatic, aromatic, and/or cycloaliphatic organic radicals having from about 1 to about 20 carbon atoms per radical, which is different from said first arylalkyl diphosphite and
(ii) a triarylphosphite having a formula,
wherein R
1
, R
2
, R
3
, R
4
, and R
5
are selected from the group consisting of hydrogen and straight-chained or branched, cyclic or acyclic, aromatic or aliphatic, and mixed aliphatic, aromatic, and/or cycloaliphatic organic radicals having from about 1 to about 20 carbon atoms per radical;
d) a hindered phenol; and
e) water.
A third embodiment of this invention provides a process to reduce the hygroscopic nature and to improve the hydrolytic stability of phosphites comprising blending:
a) a first phosphite, which is an arylalkyl diphosphite having a formula,
wherein R
1
, R
2
, R
3
, R
4
, R
5
, R
6
, R
7
, R
8
, R
9
, and R
10
can be the same or different and are selected from the group consisting of hydrogen and straight-chained or branched, cyclic or acyclic, aromatic or aliphatic, and mixed aliphatic, aromatic, and/or cycloaliphatic organic radicals having from about 1 to about 20 carbon atoms per radical and
b) a triarylphosphite having a formula,
wherein R
1
, R
2
, R
3
, R
4
, and R
5
are selected from the group consisting of hydrogen and straight-chained or branched, cyclic or acyclic, aromatic or aliphatic, and mixed aliphatic, aromatic, and/or cycloaliphatic organic radicals having from about 1 to about 20 carbon atoms per radical.
A fourth embodiment of this invention provides a process to improve the stability of recycled polyolefins comprising blending:
a) a polyolefin;
b) a first phosphite, which is an arylalkyl diphosphite having a formula,
wherein R
1
, R
2
, R
3
, R
4
, R
5
, R
6
, R
7
, R
8
, R
9
, and R
10
can be the same or different and are selected from the group consisting of hydrogen and straight-chained or branched, cyclic or acyclic, aromatic or aliphatic, and mixed aliphatic, aromatic, and/or cycloaliphatic organic radicals having from about 1 to about 20 carbon atoms per radical;
c) a second phosphite selected from the group consisting of:
(i) a second arylalkyl diphosphite of formula (I), wherein R
1
, R
2
, R
3
, R
4
, R
5
, R
6
, R
Battiste David R.
Coutant William R.
Harder Joseph R.
Russell Mark K.
Kilpatrick & Stockton LLP
Phillips Petroleum Company
Szekely Peter
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