Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Reexamination Certificate
1999-07-20
2004-01-20
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...
C524S247000, C524S424000, C524S436000, C524S128000, C524S349000, C524S351000
Reexamination Certificate
active
06680351
ABSTRACT:
FIELD OF INVENTION
This invention relates to the field of polyolefin compositions and manufactures. Particularly, this invention relates to the field of polyolefin compositions and manufactures produced by combining components comprising at least one polyolefin component produced from a transition metal halide catalyst, bis(2,4-dicumylphenyl)pentaerythritol diphosphite, triisopropanolamine, at least one hydrotalcite component, and at least one phenol component.
BACKGROUND OF THE INVENTION
Polyolefins 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. Polyolefins could not perform such diverse functions without the assistance of a very broad range of additives. Without additives, polyolefins 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 a final polyolefin product. One type of additive is antioxidants which usually are used to retard the degradation of polymers.
Degradation can be initiated when free radicals, highly reactive species with an unpaired electron, are created in polyolefins by heat, ultraviolet radiation, mechanical shear, or metallic impurities. It is believed when a free radical is formed, a chain reaction can begin that initiates oxidation of the polyolefin component. 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 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, polyolefins can have a more yellow color than unstabilized polyolefins, therefore decreasing the commercial value of the polyolefins. Secondary antioxidants, such as phosphite compounds, often are utilized to increase the stability and whiteness of polyolefins.
Bis(2,4-dicumylphenyl)pentaerythritol diphosphite is a secondary antioxidant that provides excellent resistance against polyolefin degradation. However, when the polyolefin component containing bis(2,4-dicumylphenyl)pentaerythritol diphosphite is exposed to high temperature and humidity, as much as 80% of the bis(2,4-dicumylphenyl)pentaerythritol diphosphite can degrade over a period of twelve weeks. For example, these conditions can occur when a polyolefin component is transported from a polyolefin polymerization facility to a facility where the polyolefin component is used to make various products.
There is a need in the industry to provide a process for producing a polyolefin composition comprising at least one polyolefin component produced from a transition metal halide catalyst and bis(2,4-dicumylphenyl)pentaerythritol diphosphite where the bis(2,4-dicumylphenyl)pentaerythritol diphosphite does not degrade as quickly in the polyolefin composition.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a process for producing a polyolefin composition having high resistance to degradation.
It is another object of this invention to provide a polyolefin composition having high resistance to degradation.
It is another object of this invention to provide a process for producing a manufacture from the polyolefin composition.
It is yet another object of this invention to provide a manufacture produced from the polyolefin composition.
In a first embodiment of this invention, a process for producing a polyolefin composition having high resistance to degradation is provided, said process comprising combining components comprising at least one polyolefin component produced from a transition metal halide catalyst, bis(2,4-dicumylphenyl)pentaerythritol diphosphite, triisopropanolamine, at least one hydrotalcite component, and at least one phenol component.
In a second embodiment of this invention, a polyolefin composition having high resistance to degradation is provided, said composition formed by combining components comprising at least one polyolefin component produced from a transition metal halide catalyst, bis(2,4-dicumylphenyl)pentaerythritol diphosphite, triisopropanolamine, at least one hydrotalcite component, and at least one phenol component.
In a third embodiment of this invention, a process of producing a manufacture from the polyolefin composition is provided.
In a fourth embodiment of this invention, a manufacture produced from the polyolefin composition is provided.
DETAILED DESCRIPTION OF INVENTION
In a first embodiment of this invention, a process of producing a polyolefin composition having high resistance to degradation is provided, said process comprising combining components comprising at least one polyolefin component produced from a transition metal halide catalyst, bis(2,4-dicumylphenyl)pentaerythritol diphosphite, triisopropanolamine, at least one hydrotalcite, and at least one phenol component.
The term “polyolefin component”, as used in this disclosure, includes homopolymers as well as copolymers of olefinic compounds produced using a transition metal halide catalyst. Generally, the transition metal halide catalyst comprises a metal halide compound and a transition metal compound. The metal halide compound is selected from the group consisting of metal dihalides and metal hydroxyhalides. Suitable transition metal halide catalysts are disclosed and claimed in U.S. Pat. Nos. 4,325,837 and 4,394,291. Currently, titanium is the preferred transition metal and magnesium dichloride is the preferred metal halide.
Usually, the polyolefin component is selected from the group consisting of homopolymers comprising polymerized monomers having from 2 to about 10 carbon atoms per molecule and copolymers comprising at least two different polymerized monomers having from 2 to about 16 carbon atoms per molecule. Exemplary monomers, that can be polymerized to produce homopolymers and copolymers with excellent properties, are selected from the group consisting of ethylene, propylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, and other higher olefins and conjugated or non-conjugated diolefins such as 1,3-butadiene, isoprene, piperylene, 2,3-dimethyl-1,3-butadiene, 1,4-pentadiene, 1,7-hexadiene, and other such diolefins and mixtures thereof. Preferably, said copolymer comprises polymerized ethylene and a polymerized higher alpha-olefin having from about 3 to about 16 carbon atoms per molecule. Propylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, and 1-octene are especially preferred monomers for use with ethylene due to ease of copolymerization and best resultant copolymer properties.
Generally, the polyolefin component can be obtained through polymerization of an olefinic compound or compounds by conventional techniques known in the art. For example, the polyolefin component can be produced by solution polymerization, slurry polymerization, or gas phase polymerization using conventional equipment and contacting processes.
Bis(2,4-dicumylphenyl)pentaerythritol has the formula:
Bis(2,4-dicumylphenyl)pentaerythritol can be obtained commercially under the trademark name of Doverphos S-9228 from Dover Chemical Company in Dover, Ohio.
Bis(2,4-dicumylphenyl)pentaerythritol is present in the polyolefin composition in a suitable amount to prevent degradation of the polyolefin component. Generally, bis(2,4-dicumylphenyl)pentaerythritol can be present in an amount within a range of about 100 mg/kg to about 5,000 mg/kg based on the mass of the polyolefin component without additives. Concen
Battiste David R.
Russell Mark K.
Kilpatrick & Stockton LLP
Phillips Petroleum Company
Szekely Peter
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