Processing aid, vinyl chloride resin composition containing the same, and process for producing molded article with the same

• US 6,730,741 B1
• Filed: 02/01/2002
• Issued: 05/04/2004
• Est. Priority Date: 05/19/1999
• Status: Expired due to Term

• Current Assignee: Mitsubishi Chemical Corporation (Mitsubishi Chemical Group Corp.)
• Original Assignee: Mitsubishi Rayon Company Limited (Mitsubishi Chemical Holdings Corporation)
• Inventors: Nakata, Akira, Honda, Souichiro, Tsuchibe, Ken
• Primary Examiner(s): Buttner, David J.
• Application Number:
  US09/926,558
• Time in Patent Office: 823 Days
• Field of Search: 525/228
• US Class Current: 525/228
• CPC Class Codes: C08L 2666/04 Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
• CPC Class Codes: C08L 27/06 Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: C08L 33/06 of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
• CPC Class Codes: C08L 33/12 Homopolymers or copolymers of methyl methacrylate

Abstract

The present invention provides a processing aid that reduces ungelled products and flow marks generated on a sheet, and improves releasability of the sheet from the metallic surface of a roll, with the processing aid comprising:

a copolymer (A) obtained by copolymerizing a monomer mixture comprising 70 to 90% by weight of methyl methacrylate, 10 to 30% by weight of acrylate or methacrylate other than methyl methacryrate and a different type of monomer capable of being copolymerized with those monomers; and

a copolymer (B) obtained by copolymerizing a monomer mixture comprising at least 30% by weight of methyl methacrylate and a monomer having as constitutional units at least one type selected from methacrylates other than methyl methacrylate, acrylates, aromatic alkenyl compounds and other monomers.

Claims

1. A processing aid comprising:

a copolymer (A) whose mean weight molecular weight (Mw) measured with gel permeation chromatography is in the range of from 700,000 to 2,000,000, and molecular weight distribution (Mw/Mn) is 3.0 or smaller, which is obtained by copolymerizing a monomer mixture comprising 70 to 90% by weight of methyl methacrylate, 10 to 30% by weight of acrylate or methacrylate other than methyl methacrylate, and 3% by weight or less of a different type of monomer capable of being copolymerized with those monomers; and

a copolymer (B) whose mean weight molecular weight (Mw) measured with gel permeation chromatography is in the range of from 10,000 to 500,000, which is obtained by copolymerizing a monomer mixture comprising at least 30 to 50% by weight of methyl methacrylate, a monomer other than a polyfunctional monomer and having as constitutional units at least one type other than methyl methacrylate, and 2% by weight or less of polyfunctional monomers,

wherein copolymer (A) and copolymer (B) are present in a ratio of 100 parts by weight of copolymer (A) to 0.5-100 parts by weight of copolymer (B).

2. A vinyl chloride based resin composition comprising 100 parts by weight of vinyl chloride based resin and 0.2 to 20 parts by weight of the processing aid as set forth in claim 1.

3. A calender molded product obtained with the processing aid as set forth in claim 1.

4. A calender molded product obtained by calender molding the vinyl chloride based resin composition as set forth in claim 2.

5. A method of producing moldings comprising calender molding the vinyl chloride resin composition as set forth in claim 2.

6. The processing aid as set forth in claim 1, wherein the methylmethacrylate in the monomer mixture of copolymer (A) is present in an amount of 80-90% by weight.

7. The processing aid as set forth in claim 1, wherein the monomer other than a polyfunctional monomer in the monomer mixture of copolymer (B) is present in an amount of 45-70% by weight.

8. The processing aid as set forth in claim 7, wherein said amount is 50-60% by weight.

9. The vinyl chloride based resin composition as set forth in claim 2, wherein the vinyl chloride based resin has a mean degree of polymerization of from 300-5,000.

10. The vinyl chloride based resin composition as set forth in claim 9, wherein said mean degree of polymerization is 500-3,000.

11. The calender molded product as set forth in claim 3, wherein the methylmethacrylate in the monomer mixture of copolymer (A) is present in an amount of 80-90% by weight.

12. The calender molded product as set forth in claim 3, wherein the monomer other than a polyfunctional monomer in the monomer mixture of copolymer (B) is present in an amount of 45-70% by weight.

13. The calender molded product as set forth in claim 12, wherein said amount is 50-60% by weight.

14. The calender molded product as set forth in claim 4, wherein the methylmethacrylate in the monomer mixture of copolymer (A) is present in an amount of 80-90% by weight.

15. The calender molded product as set forth in claim 4, wherein the monomer other than a polyfunctional monomer in the monomer mixture of copolymer (B) is present in an amount of 45-70% by weight.

16. The calender molded product as set forth in claim 15, wherein said amount is 50-60% by weight.

17. The method as set forth in claim 5, wherein the vinyl chloride based resin has a mean degree of polymerization of from 300-5,000.

18. The method as set forth in claim 5, wherein the vinyl chloride based resin has a mean degree of polymerization of from 500-3,000.