Filled polymer compositions

• US 6,103,803 A
• Filed: 06/08/1999
• Issued: 08/15/2000
• Est. Priority Date: 06/26/1997
• Status: Expired due to Fees

• Current Assignee: The Dow Chemical Company (Dow, Inc.)
• Original Assignee: The Dow Chemical Company (Dow, Inc.)
• Inventors: Thoen, Johan A., Guest, Martin James, Gathers, John Joseph, Cheung, Yunwa Wilson, Bieser, John O.
• Primary Examiner(s): Cain, Edward J.
• Application Number:
  US09/327,685
• Time in Patent Office: 434 Days
• Field of Search: 524/425, 524/451, 524/494
• US Class Current: 524/425
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2607/02 Wall papers, wall coverings
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/28 comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
• CPC Class Codes: B32B 27/302 comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: C08J 2323/08 Copolymers of ethene C08J2323/16 takes precedence
• CPC Class Codes: C08J 5/18 Manufacture of films or sheets
• CPC Class Codes: C08K 3/01 characterized by their specific function
• CPC Class Codes: C08L 23/08 Copolymers of ethene C08L23/16 takes precedence
• CPC Class Codes: C08L 23/0815 Copolymers of ethene with aliphatic 1-olefins
• CPC Class Codes: C08L 23/0838 Copolymers of ethene with aromatic monomers
• CPC Class Codes: C08L 2314/06 Metallocene or single site catalysts
• CPC Class Codes: C08L 25/08 Copolymers of styrene C08L29/08, C08L35/06, C08L55/02 take precedence
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials

Abstract

A filled polymer composition which comprises

A) from about 5 to about 90 percent of one or more thermoplastic substantially random interpolymers prepared by polymerizing one or more a-olefin monomers with one or more vinylidene aromatic monomers and/or one or more hindered aliphatic or cycloaliphatic vinylidene monomers, and optionally with other polymerizable ethylenically unsaturated monomer(s), and

(B) from about 10 to about 95 percent of one or more inorganic fillers,

the amounts of (A) and (B) being based on the total weight of (A) and (B).

Fabricated articles made from the filled polymer compositions are useful as sound insulating or energy absorbing films or sheets or as floor, wall or ceiling coverings.

Claims

1. A filled polymer composition comprising

(A) from about 5 to about 90 percent of one or more thermoplastic substantially random interpolymers prepared by polymerizing one or more α

-olefin monomers with one or more vinylidene aromatic monomers and/or one or more hindered aliphatic or cycloaliphatic vinylidene monomers, and optionally with other polymerizable ethylenically unsaturated monomer(s), and

(B) from about 10 to about 95 percent of one or more inorganic fillers, the amounts of (A) and (B) being based on the total weight of (A) and (B),

wherein said one or more interpolymers contain interpolymerized from about 35 to about 99.5 mole percent of one or more α

-olefin monomers and from about 0.5 to about 65 mole percent of one or more vinylidene aromatic monomers and/or one or more hindered aliphatic or cycloaliphatic vinylidene monomers, and optionally other polymerizable ethylenically unsaturated monomer(s).

2. The filled polymer composition of claim 1 wherein said one or more interpolymers contain interpolymerized from about 50 to about 80 mole percent of one or more α

-olefin monomers and from about 20 to about 50 mole percent of one or more vinylidene aromatic monomers and/or one or more hindered aliphatic or cycloaliphatic vinylidene monomers, and optionally other polymerizable ethylenically unsaturated monomer(s).

3. The filled polymer composition of claim 1 wherein the filler is alumina trihydrate or magnesium hydroxide.

4. The filled polymer composition of claim 1 wherein the filler is alumina trihydrate or magnesium hydroxide and the amount of the filler is from about 40 to about 90 percent, based on the total weight of the interpolymer(s) and filler.

5. A filled polymer composition comprising

(A) from about 5 to about 90 percent of one or more thermoplastic substantially random interpolymers prepared by polymerizing one or more α

-olefin monomers with one or more vinylidene aromatic monomers and/or one or more hindered aliphatic or cycloaliphatic vinylidene monomers, and optionally with other polymerizable ethylenically unsaturated monomer(s),

(B) from about 10 to about 95 percent of one or more inorganic fillers, the amounts of (A) and (B) being based on the total weight of (A) and (B), and

(C) a coupling agent.

6. The composition of claim 5 wherein the coupling agent is selected from the group consisting of maleic anhydride grafted polyethylenes, maleic anhydride grafted polypropylenes, silicon coupling agents and silane coupling agents.

7. The composition of claim 5 which further comprises a peroxide.

8. The composition of claim 5 wherein the filler is an ignition resistant filler.

9. A filled polymer composition comprising

(A) from about 5 to about 90 percent of one or more thermoplastic substantially random interpolymers prepared by polymerizing one or more α

-olefin monomers with one or more vinylidene aromatic monomers and/or one or more hindered aliphatic or cycloaliphatic vinylidene monomers, and optionally with other polymerizable ethylenically unsaturated monomer(s),

(B) from about 10 to about 95 percent of one or more inorganic fillers, the amounts of (A) and (B) being based on the total weight of (A) and (B), and

(C) an additive selected from the group consisting of an antioxidant, a hindered phenol, a hindered phosphite, a light stabilizer, a plasticizer, a tackifier, a wax, a processing aid, a crosslinking agent, a colorant, and a pigment.

10. The composition of claim 9 wherein the light stabilizer is a hindered amine.

11. The composition of claim 9 wherein the plasticizer is selected from the group consisting of dioctylphthalate and epoxidized soy bean oil.

12. The composition of claim 9 wherein the tackifier is a hydrocarbon tackifier.

13. The composition of claim 9 wherein the wax is polyethylene wax.

14. The composition of claim 9 wherein the processing aid is selected from the group consisting of oils, stearic acid, and metal salts of stearic acid.

15. The composition of claim 14 wherein the processing aid is selected from the group consisting of stearic acid and metal salts of stearic acid.

19. The filled polymer composition of any one of claims 5-18 wherein said one or more interpolymers is an interpolymer of ethylene and styrene.

20. The filled polymer compositions of any one of claims 5-18 further comprising up to about 50 weight percent of one or more additional polymeric components(s), based on the total weight of the filled polymer composition.

21. A fabricated article made from the polymer composition of any one of claims 5-18.

16. A filled polymer composition comprising

(A) from about 5 to about 90 percent of one or more thermoplastic substantially random interpolymers prepared by polymerizing one or more α

-olefin monomers with one or more vinylidene aromatic monomers and/or one or more hindered aliphatic or cycloaliphatic vinylidene monomers, and optionally with other polymerizable ethylenically unsaturated monomer(s),

(B) from about 10 to about 95 percent of one or more inorganic fillers, the amounts of (A) and (B) being based on the total weight of (A) and (B), wherein the inorganic filler is selected from the group consisting of alumina trihydrate, marble dust, cement dust, clay, feldspar, silica, glass, fumed silica, alumina, magnesium oxide, magnesium hydroxide, antimony oxide, zinc oxide, aluminum silicate, calcium silicate, titanium dioxide, titanates, glass microspheres, and chalk.

17. The composition of claim 16 wherein the filler is aluminum trihydrate or magnesium hydroxide.

18. The composition of claim 17 which further comprises a silane coupling agent.