Polymeric compositions having low glass transition temperatures

• US 8,080,612 B2
• Filed: 07/14/2005
• Issued: 12/20/2011
• Est. Priority Date: 08/26/2002
• Status: Active Grant

• Current Assignee: Rohm and Haas Company (Dow, Inc.)
• Original Assignee: Rohm and Haas Company (Dow, Inc.)
• Inventors: Troy, Edward Joseph, McDonald, David John, Weier, Jane Elizabeth
• Primary Examiner(s): MULLIS, JEFFREY C
• Application Number:
  US11/181,086
• Publication Number:
  US 20050250880A1
• Time in Patent Office: 2,350 Days
• Field of Search: 525/227, 525/228, 525/239, 525/71, 525/83, 525/85
• US Class Current: 525/71
• 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 33/08 Homopolymers or copolymers of acrylic acid esters
• CPC Class Codes: C08L 33/12 Homopolymers or copolymers of methyl methacrylate

Abstract

The present invention provides polymeric compositions having a high polymer size and a low Tg. These novel compositions are useful as plastic additives. Also provided is a method of improving the processing of a matrix resin by adding one or more of the novel polymeric compositions.

Claims

1. A polymeric composition consisting of

(i) a first polymeric stage, wherein said first polymeric stage consists of a first polymeric component and, optionally, one or more additional polymeric components, wherein said first polymeric component consists of a polymer consisting of units derived from one or more monomers selected from the group consisting of butadiene and C₁ to C₁₈ alkyl (meth)acrylates and having a glass transition temperature of less than 20°

C. and having Polymer Size Index of 2 or higher, and wherein the total weight of all said additional polymeric components does not exceed 50 weight percent of said first polymeric stage,

(ii) a second polymeric stage applied over said first polymeric stage, wherein said second polymeric stage has a Tg of at least 30°

C., wherein said second polymeric stage comprises at least 50 weight percent of units derived from methyl methacrylate or styrene, and

(iii) optionally, a third polymeric stage that is an intermediate layer between said first polymeric stage and said second polymeric stage, wherein said third polymeric stage comprises units derived from C₁ to C₁₈ alkyl (meth)acrylates,

wherein said polymeric composition reduces the time required for solid polyvinyl chloride resin to form a homogeneous melt upon exposure to heat and mechanical work, and

wherein said polymeric composition lubricates polyvinyl chloride resin.

2. The polymeric composition of claim 1, wherein said first polymeric component has units derived from one or more monomers selected from the group consisting of methyl acrylate, ethyl acrylate, butyl acrylate, hexyl acrylate, octyl acrylate, 2-ethylhexyl acrylate, and dodecyl acrylate.

3. The composition of claim 1, wherein said first polymeric component consists of units derived from one or more monomers selected from the group consisting of methyl acrylate, ethyl acrylate, and butyl acrylate.

8. A method for improving the processability of a matrix resin, comprising adding to said matrix resin the composition of claim 1.

9. The method as recited in claim 8, wherein said matrix resin is either a poly(vinyl halide) resin or a predominantly poly(vinyl halide) resin.

10. The method of claim 8, wherein said first polymeric component consists of units derived from one or more monomers selected from the group consisting of methyl acrylate, ethyl acrylate, and butyl acrylate.

11. The composition of claim 1, wherein said first polymeric stage consists of said first polymeric component.

13. The composition of claim 1, wherein said polymeric composition has Polymer Size Index of 3 or higher.

14. The composition of claim 1, wherein said polymeric composition has glass transition temperature of less than 0°

C.

15. The composition of claim 1, wherein said first polymeric component consists of units derived from ethyl acrylate.

17. The composition of claim 11, wherein said first polymeric component consists of units derived from one or more monomers selected from the group consisting of methyl acrylate, ethyl acrylate, butyl acrylate, hexyl acrylate, octyl acrylate, 2-ethylhexyl acrylate, and dodecyl acrylate.

18. The composition of claim 11, wherein said first polymeric component consists of units derived from one or more monomers selected from the group consisting of methyl acrylate, ethyl acrylate, and dodecyl acrylate.

19. The composition of claim 11, wherein said first polymeric component consists of units derived from ethyl acrylate.

4. An emulsion having solids portion which comprises a polymeric composition comprising a first population of polymeric particles and a second population of polymeric particles, wherein each of said populations has its own distinct particle composition, wherein said polymeric composition can be used as a plastic additive:

a) wherein said first population comprises a first ingredient comprising at least one polymer with Tg of 30°

C. or higher and polymeric particles of at least 30 nm, and

b) wherein said second population comprises a second ingredient comprising polymeric particles having an average particle size of at least 30 nm, said polymeric particles of said second ingredient consisting of

(i) a first polymeric stage, wherein said first polymeric stage consists of a first polymeric component and, optionally, one or more additional polymeric components, wherein said first polymeric component consists of a polymer consisting of units derived from one or more monomers selected from the group consisting of butadiene and C₁ to C₁₈ alkyl (meth)acrylates and having a glass transition temperature of less than 20°

C. and having Polymer Size Index of 2 or higher, and wherein the total weight of all said additional polymeric components does not exceed 50 weight percent of said first polymeric stage,

(ii) a second polymeric stage applied over said first polymeric stage, wherein said second polymeric stage has a Tg of at least 30°

C., wherein said second polymeric stage comprises at least 50 weight percent of units derived from methyl methacrylate or styrene, and

(iii) optionally, a third polymeric stage that is an intermediate layer between said first polymeric stage and said second polymeric stage, wherein said third polymeric stage comprises units derived from C₁ to C₁₈ alkyl (meth)acrylates,

wherein the weight ratio of said first ingredient to said second ingredient is from about 99.5/0.5 to about 50/50, wherein said polymeric composition reduces the time required for solid polyvinyl chloride resin to form a homogeneous melt upon exposure to heat and mechanical work, and wherein said polymeric composition lubricates polyvinyl chloride resin.

5. The composition of claim 4, wherein said polymeric particles of said first ingredient are selected from the group consisting of

i) impact modifier particles having:

1) a core portion with a Tg less than 0°

C.,

2) a shell portion with a Tg greater than 30°

C.; and

ii) hard processing aid particles having a Tg of 30°

C. or greater.

6. The polymeric composition of claim 4, wherein said first polymeric component of said second ingredient has units derived from at least one monomer selected from the group consisting of methyl acrylate, ethyl acrylate, butyl acrylate, hexyl acrylate, octyl acrylate, 2-ethylhexyl acrylate, and dodecyl acrylate.

7. The polymeric composition of claim 4, wherein said first polymeric component of said second ingredient consists of units derived from one or more monomers selected from the group consisting of methyl acrylate, ethyl acrylate, and butyl acrylate.

12. A powder isolated from the emulsion of claim 4.

16. A method for improving the processability of a matrix resin, comprising adding to said matrix resin the composition of claim 12.