US2012175818A1PendingUtilityA1

Acrylic blends

47
Assignee: FRASER IANPriority: Apr 25, 2005Filed: Jan 24, 2012Published: Jul 12, 2012
Est. expiryApr 25, 2025(expired)· nominal 20-yr term from priority
Inventors:Ian FraserIan Robinson
C08L 2205/02C08L 33/04C08L 2205/025C08L 33/00
47
PatentIndex Score
0
Cited by
0
References
0
Claims

Abstract

An acrylic polymeric composition comprising a melt blend of a thermoplastic high molecular weight acrylic material (HMWA) and a thermoplastic low molecular weight acrylic material (LMWA) is described. At least 70% w/w of the HMWA and the LMWA comprises an alkyl (alk)acrylate (co)polymer. The HMWA has a weight average molecular weight (Mw) of between 40 k Daltons and 1000 k Daltons and the LMWA has a weight average molecular weight (Mw) of between the entanglement molecular weight (Me) (expressed in k Daltons) and 250 k Daltons. A method of producing an acrylic polymeric composition and the use of an acrylic polymeric composition are described together with thick section moulded products.

Claims

exact text as granted — not AI-modified
1 . An impact modified acrylic polymer composition comprising
 a. a base polymer of an acrylic polymeric composition comprising a melt blend of a thermoplastic high molecular weight acrylic material (HMWA) and a thermoplastic low molecular weight acrylic material (LMWA), at least 70% w/w, based on the total weight of the HMWA, of the said HMWA comprising an alkyl (alk)acrylate (co)polymer, the said (co)polymer comprising at least 80% w/w of a first polymer unit derived from C 1 -C 12  alkyl (C 1 -C 8  alk)acrylate monomer units and optionally, up to 20% w/w, based on the said alkyl (alk)acrylate (co)polymer of a first copolymer unit derived from C 1 -C 12  alkyl (C 0 -C 8  alk) acrylate and/or (C 0 -C 8  alk) acrylic acid monomer units, the said HMWA having a weight average molecular weight of between 40 k Daltons and 1000 k Daltons, at least 70% w/w, based on the total weight of the LMWA, of the said LMWA comprising an alkyl(alk)acrylate (co)polymer, the said (co)polymer comprising at least 80% w/w of a second polymer unit derived from C 1 -C 12  alkyl (C 1 -C 8  alk)acrylate monomer units and optionally, up to 20% w/w, based on the said alkyl (alk)acrylate (co)polymer of a second copolymer unit derived from C 1 -C 12  alkyl (C 0 -C 8  alk)acrylate and/or (C 0 -C 8  alk)acrylic acid monomer units, the said LMWA having a weight average molecular weight of between the entanglement molecular weight (M e ) (expressed in k Daltons) and 250 k Daltons, with the proviso that the HMWA has a higher M w  than the LMWA, wherein the first polymer unit of the HMWA and the second polymer unit of the LMWA are the same, and   b. a core-shell impact modifier, wherein the level of component (b) in the impact modified acrylic polymer composition is in the range 30-70% w/w.   
     
     
         2 . An acrylic composition comprising
 a. an impact modified acrylic polymer composition according to  claim 1 ; and   b. a suitable solvent.   
     
     
         3 . The impact modified acrylic polymer compositions of  claim 1 , wherein the w/w ratio of (a)b) is between 50:50 and 70:30. 
     
     
         4 . A method of producing the acrylic polymer composition of  claim 1  comprising the steps of:
 a) contacting a thermoplastic high molecular weight acrylic material (HMWA) with a thermoplastic low molecular weight acrylic material (LMWA); and 
 b) mixing the said HMWA and LMWA at an elevated temperature until a melt blend is produced; 
 wherein the said elevated temperature is above the glass transition temperature of both the HMWA and LMWA. 
 
     
     
         5 . A method of producing a higher melt flow index melt blended composition or moulded polymer product, as compared with the HMWA not blended with the LMWA, by use of an impact modified acrylic polymer composition comprising
 a. a base polymer of an acrylic polymeric composition comprising a melt blend of a thermoplastic high molecular weight acrylic material (HMWA) and a thermoplastic low molecular weight acrylic material (LMWA), at least 70% w/w, based on the total weight of the HMWA, of the said HMWA comprising an alkyl (alk)acrylate (co)polymer, the said (co)polymer comprising at least 80% w/w of a first polymer unit derived from C 1 -C 12  alkyl (C 1 -C 8  alk)acrylate monomer units and optionally, up to 20% w/w, based on the said alkyl (alk)acrylate (co)polymer of a first copolymer unit derived from C 1 -C 12  alkyl (C 0 -C 8  alk) acrylate and/or (C 0 -C 8  alk) acrylic acid monomer units, the said HMWA having a weight average molecular weight of between 40 k Daltons and 1000 k Daltons, at least 70% w/w, based on the total weight of the LMWA, of the said LMWA comprising an alkyl(alk)acrylate (co)polymer, the said (co)polymer comprising at least 80% w/w of a second polymer unit derived from C 1 -C 12  alkyl (C 1 -C 8  alk)acrylate monomer units and optionally, up to 20% w/w, based on the said alkyl (alk)acrylate (co)polymer of a second copolymer unit derived from C 1 -C 12  alkyl (C 0 -C 8  alk)acrylate and/or (C 0 -C 8  alk)acrylic acid monomer units, the said LMWA having a weight average molecular weight of between the entanglement molecular weight (M e ) (expressed in k Daltons) and 250 k Daltons, with the proviso that the HMWA has a higher M w  than the LMWA, wherein the first polymer unit of the HMWA and the second polymer unit of the LMWA are the same, and   b. a core-shell impact modifier.   
     
     
         6 . The composition of  claim 1 , wherein there is a first copolymer unit and a second copolymer unit and wherein the first copolymer unit and the second copolymer unit are the same. 
     
     
         7 . The composition of  claim 6 , wherein the weight ratio of the first polymer unit:first copolymer unit is within ±30% of the ratio of the second polymer unit:second copolymer unit. 
     
     
         8 . The composition of  claim 1 , wherein the weight ratio of HMWA:LMWA in the composition is greater than 1:1. 
     
     
         9 . The composition, of  claim 1 , wherein the acrylic polymeric composition comprises, based on the weight of the acrylic polymeric composition, up to 55% w/w of LMWA and at least 40% w/w of HMWA. 
     
     
         10 . The composition of  claim 1 , wherein the melt blend is a homogeneous melt blend. 
     
     
         11 . The composition of  claim 1 , wherein the composition includes a second or further HMWA component, defined in the same manner as the first HMWA component, but having a third or further polymer unit and optionally a third or further copolymer unit, which has a weight average molecular weight greater than the LMWA but which is less or greater than the first HMWA component(s). 
     
     
         12 . The composition of  claim 11 , wherein the second or further HMWA component is present at a level, based on the acrylic polymeric composition, of at least 5% w/w. 
     
     
         13 . The composition of  claim 11 , wherein the first polymer unit of the HMWA and the third or further polymer unit of the second or further HMWA are the same. 
     
     
         14 . The composition of  claim 11 , having a first copolymer unit and third copolymer unit, wherein the first copolymer unit and third copolymer unit are the same. 
     
     
         15 . The composition of  claim 11 , wherein the ratio of the first polymer unit:first copolymer unit is within ±30% of the ratio of the third polymer unit:third copolymer unit. 
     
     
         16 . The composition of  claim 1 , wherein the LMWA has a weight average molecular weight (M w ) in excess of 11 k Daltons. 
     
     
         17 . The acrylic composition of  claim 2 , wherein the solvent (b):polymer (a) ratio w/w is between 10:90 and 60:40. 
     
     
         18 . A method of providing a melt blended composition or moulded polymer product having a T g  in the range of 80-110° C. by use of an impact modified acrylic polymer composition comprising
 a. a base polymer of an acrylic polymeric composition comprising a melt blend of a thermoplastic high molecular weight acrylic material (HMWA) and a thermoplastic low molecular weight acrylic material (LMWA), at least 70% w/w, based on the total weight of the HMWA, of the said HMWA comprising an alkyl (alk)acrylate (co)polymer, the said (co)polymer comprising at least 80% w/w of a first polymer unit derived from C 1 -C 12  alkyl (C 1 -C 8  alk)acrylate monomer units and optionally, up to 20% w/w, based on the said alkyl (alk)acrylate (co)polymer of a first copolymer unit derived from C 1 -C 12  alkyl (C 0 -C 8  alk) acrylate and/or (C 0 -C 8  alk) acrylic acid monomer units, the said HMWA having a weight average molecular weight of between 40 k Daltons and 1000 k Daltons, at least 70% w/w, based on the total weight of the LMWA, of the said LMWA comprising an alkyl(alk)acrylate (co)polymer, the said (co)polymer comprising at least 80% w/w of a second polymer unit derived from C 1 -C 12  alkyl (C 1 -C 8  alk)acrylate monomer units and optionally, up to 20% w/w, based on the said alkyl (alk)acrylate (co)polymer of a second copolymer unit derived from C 1 -C 12  alkyl (C 0 -C 8  alk)acrylate and/or (C 0 -C 8  alk)acrylic acid monomer units, the said LMWA having a weight average molecular weight of between the entanglement molecular weight (M e ) (expressed in k Daltons) and 250 k Daltons, with the proviso that the HMWA has a higher M w  than the LMWA, wherein the first polymer unit of the HMWA and the second polymer unit of the LMWA are the same, and 
 b. a core-shell impact modifier. 
 
     
     
         19 . A thick section mould of an impact modified acrylic polymer composition comprising
 a. a base polymer of an acrylic polymeric composition comprising a melt blend of a thermoplastic high molecular weight acrylic material (HMWA) and a thermoplastic low molecular weight acrylic material (LMWA), at least 70% w/w, based on the total weight of the HMWA, of the said HMWA comprising an alkyl (alk)acrylate (co)polymer, the said (co)polymer comprising at least 80% w/w of a first polymer unit derived from C 1 -C 12  alkyl (C 1 -C 8  alk)acrylate monomer units and optionally, up to 20% w/w, based on the said alkyl (alk)acrylate (co)polymer of a first copolymer unit derived from C 1 -C 12  alkyl (C 0 -C 8  alk) acrylate and/or (C 0 -C 8  alk) acrylic acid monomer units, the said HMWA having a weight average molecular weight of between 40 k Daltons and 1000 k Daltons, at least 70% w/w, based on the total weight of the LMWA, of the said LMWA comprising an alkyl(alk)acrylate (co)polymer, the said (co)polymer comprising at least 80% w/w of a second polymer unit derived from C 1 -C 12  alkyl (C 1 -C 8  alk)acrylate monomer units and optionally, up to 20% w/w, based on the said alkyl (alk)acrylate (co)polymer of a second copolymer unit derived from C 1 -C 12  alkyl (C 0 -C 8  alk)acrylate and/or (C 0 -C 8  alk)acrylic acid monomer units, the said LMWA having a weight average molecular weight of between the entanglement molecular weight (M e ) (expressed in k Daltons) and 250 k Daltons, with the proviso that the HMWA has a higher M w  than the LMWA, wherein the first polymer unit of the HMWA and the second polymer unit of the LMWA are the same, and   b. a core-shell impact modifier.   
     
     
         20 . A moulded polymer product comprising an acrylic polymeric composition according to  claim 1 . 
     
     
         21 . A method of melt blending an impact modified acrylic polymer composition comprising the steps of:
 melt blending the following separate components in a single melt blending step:
 1. a) a HMWA according to  claim 1 ; 
 b) a LMWA according to  claim 1 ; and 
 c) a core-shell impact modifier; or 
 2.a) a HMWA according to  claim 1 ; and 
 b) a LMWA according to  claim 1  pre blended with a core-shell impact modifier; or 
 3.a) a HMWA and LMWA blended according to  claim 1 ; and 
 b) a core-shell impact modifier. 
   
     
     
         22 . A process for reducing cycle time of a moulding composition comprising the step of:
 injection moulding or extrusion moulding an impact modified acrylic polymer composition comprising
 a. a base polymer of an acrylic polymeric composition comprising a melt blend of a thermoplastic high molecular weight acrylic material (HMWA) and a thermoplastic low molecular weight acrylic material (LMWA), at least 70% w/w, based on the total weight of the HMWA, of the said HMWA comprising an alkyl (alk)acrylate (co)polymer, the said (co)polymer comprising at least 80% w/w of a first polymer unit derived from C 1 -C 12  alkyl (C 1 -C 8  alk)acrylate monomer units and optionally, up to 20% w/w, based on the said alkyl (alk)acrylate (co)polymer of a first copolymer unit derived from C 1 -C 12  alkyl (C 0 -C 8  alk) acrylate and/or (C 0 -C 8  alk) acrylic acid monomer units, the said HMWA having a weight average molecular weight of between 40 k Daltons and 1000 k Daltons, at least 70% w/w, based on the total weight of the LMWA, of the said LMWA comprising an alkyl(alk)acrylate (co)polymer, the said (co)polymer comprising at least 80% w/w of a second polymer unit derived from C 1 -C 12  alkyl (C 1 -C 8  alk)acrylate monomer units and optionally, up to 20% w/w, based on the said alkyl (alk)acrylate (co)polymer of a second copolymer unit derived from C 1 -C 12  alkyl (C 0 -C 8  alk)acrylate and/or (C 0 -C 8  alk)acrylic acid monomer units, the said LMWA having a weight average molecular weight of between the entanglement molecular weight (M e ) (expressed in k Daltons) and 250 k Daltons, with the proviso that the HMWA has a higher M w  than the LMWA, wherein the first polymer unit of the HMWA and the second polymer unit of the LMWA are the same, and 
 b. a core-shell impact modifier, wherein the cycle time is reduced compared to a comparative copolymer with the same MFI which is derived from the same type and equivalent amount of C 1 -C 12  alkyl(C 1 -C 8  alk) acrylate monomer(s) but a higher amount of C 1 -C 12  alkyl acrylate monomer(s) to thereby give the MFI increase necessary and which is not a melt blended HMWA and LMWA in accordance with  claim 1  wherein the “equivalent amount” of C 1 -C 12  alkyl C 1 -C 8  alk acrylate is the same amount reduced by the proportionate increase in the C 1 -C 12  alkyl acrylate amount in the comparative copolymer. 
   
     
     
         23 . A process for reducing cooling cycle times of a moulding composition comprising the step of:
 injection moulding or extrusion moulding an impact modified acrylic polymer composition comprising
 a. a base polymer of an acrylic polymeric composition comprising a melt blend of a thermoplastic high molecular weight acrylic material (HMWA) and a thermoplastic low molecular weight acrylic material (LMWA), at least 70% w/w, based on the total weight of the HMWA, of the said HMWA comprising an alkyl (alk)acrylate (co)polymer, the said (co)polymer comprising at least 80% w/w of a first polymer unit derived from C 1 -C 12  alkyl (C 1 -C 8  alk)acrylate monomer units and optionally, up to 20% w/w, based on the said alkyl (alk)acrylate (co)polymer of a first copolymer unit derived from C 1 -C 12  alkyl (C 0 -C 8  alk) acrylate and/or (C 0 -C 8  alk) acrylic acid monomer units, the said HMWA having a weight average molecular weight of between 40 k Daltons and 1000 k Daltons, at least 70% w/w, based on the total weight of the LMWA, of the said LMWA comprising an alkyl(alk)acrylate (co)polymer, the said (co)polymer comprising at least 80% w/w of a second polymer unit derived from C 1 -C 12  alkyl (C 1 -C 8  alk)acrylate monomer units and optionally, up to 20% w/w, based on the said alkyl (alk)acrylate (co)polymer of a second copolymer unit derived from C 1 -C 12  alkyl (C 0 -C 8  alk)acrylate and/or (C 0 -C 8  alk)acrylic acid monomer units, the said LMWA having a weight average molecular weight of between the entanglement molecular weight (M e ) (expressed in k Daltons) and 250 k Daltons, with the proviso that the HMWA has a higher M w  than the LMWA, wherein the first polymer unit of the HMWA and the second polymer unit of the LMWA are the same, and 
 b. a core-shell impact modifier, wherein the cooling cycle time is reduced compared to a comparative copolymer with the same MFI which is derived from the same type and equivalent amount of C 1 -C 12  alkyl(C 1 -C 8  alk) acrylate monomer(s) but a higher amount of C 1 -C 12  alkyl acrylate monomer(s) to thereby give the MFI increase necessary and which is not a melt blended HMWA and LMWA in accordance with  claim 1  wherein the “equivalent amount” of C 1 -C 12  alkyl C 1 -C 8  alk acrylate is the same amount reduced by the proportionate increase in the C 1 -C 12  alkyl acrylate amount in the comparative copolymer. 
   
     
     
         24 . An acrylic polymer composition according to  claim 1  wherein the HMWA and the LMWA together form more than 80% w/w of the acrylic polymer composition. 
     
     
         25 . An acrylic polymer composition according to  claim 1 , wherein the HMWA and the LMWA together form at least 95% w/w of the acrylic polymeric composition. 
     
     
         26 . An acrylic composition according to  claim 2 , wherein the HMWA and the LMWA together form more than 80% w/w of the acrylic polymeric composition. 
     
     
         27 . An acrylic composition according to  claim 2 , wherein the HMWA and the LMWA together form at least 95% of the acrylic polymeric composition. 
     
     
         28 . An impact modified acrylic polymer composition according to  claim 3 , wherein the HMWA and the LMWA together form more than 80% w/w of the acrylic polymeric composition. 
     
     
         29 . An impact modified acrylic polymer composition according to  claim 3 , wherein the HMWA and the LMWA together form at least 95% w/w of the acrylic polymeric composition. 
     
     
         30 . The composition according to  claim 1 , wherein the HMWA and LMWA have been produced by bulk, emulsion or suspension polymerisation. 
     
     
         31 . The composition according to  claim 2 , wherein the HMWA and LMWA have been produced by bulk, emulsion or suspension polymerisation. 
     
     
         32 . The composition of  claim 3 , wherein the HMWA and LMWA have been produced by bulk, emulsion or suspension polymerisation. 
     
     
         33 . The method of  claim 4 , wherein the HMWA and LMWA have been produced by bulk, emulsion or suspension polymerisation. 
     
     
         34 . The method of  claim 18 , wherein the HMWA and LMWA have been produced by bulk, emulsion or suspension polymerisation. 
     
     
         35 . The method of  claim 5 , wherein the HMWA and LMWA have been produced by bulk, emulsion or suspension polymerisation. 
     
     
         36 . The thick section mould according to  claim 19 , wherein the HMWA and LMWA have been produced by bulk, emulsion or suspension polymerisation. 
     
     
         37 . A moulded polymer product according to  claim 20 , wherein the HMWA and LMWA have been produced by bulk, emulsion or suspension polymerisation. 
     
     
         38 . A method of melt blending according to  claim 21 , wherein the HMWA and LMWA have been produced by bulk, emulsion or suspension polymerisation. 
     
     
         39 . A process for reducing cycle time according to  claim 22 , wherein the HMWA and LMWA have been produced by bulk, emulsion or suspension polymerisation. 
     
     
         40 . A process for reducing cooling cycle times according to  claim 23 , wherein the HMWA and LMWA have been produced by bulk, emulsion or suspension polymerisation. 
     
     
         41 . The composition according to  claim 2 , wherein there is a first copolymer unit and a second copolymer unit and wherein the first copolymer unit and the second copolymer unit are the same. 
     
     
         42 . The method of  claim 5 , wherein there is a first copolymer unit and a second copolymer unit and wherein the first copolymer unit and the second copolymer unit are the same. 
     
     
         43 . The method of  claim 4 , wherein there is a first copolymer unit and a second copolymer unit and wherein the first copolymer unit and the second copolymer unit are the same. 
     
     
         44 . The method of  claim 18 , wherein there is a first copolymer unit and a second copolymer unit and wherein the first copolymer unit and the second copolymer unit are the same. 
     
     
         45 . The thick section mould according to  claim 19 , wherein there is a first copolymer unit and a second copolymer unit and wherein the first copolymer unit and the second copolymer unit are the same. 
     
     
         46 . A moulded polymer product according to  claim 20 , wherein there is a first copolymer unit and a second copolymer unit and wherein the first copolymer unit and the second copolymer unit are the same. 
     
     
         47 . A process for reducing cycle time according to  claim 22 , wherein there is a first copolymer unit and a second copolymer unit and wherein the first copolymer unit and the second copolymer unit are the same. 
     
     
         48 . A process for reducing cooling cycle times according to  claim 23 , wherein there is a first copolymer unit and a second copolymer unit and wherein the first copolymer unit and the second copolymer unit are the same. 
     
     
         49 . A method of melt blending according to  claim 21 , wherein there is a first copolymer unit and a second copolymer unit and wherein the first copolymer unit and the second copolymer unit are the same. 
     
     
         50 . The composition according to  claim 1 , wherein the HMWA and the LMWA are single phase polymers. 
     
     
         51 . The composition according to  claim 2 , wherein the HMWA and the LMWA are single phase polymers. 
     
     
         52 . The method of  claim 5 , wherein the HMWA and the LMWA are single phase polymers. 
     
     
         53 . The method of  claim 4 , wherein the HMWA and the LMWA are single phase polymers. 
     
     
         54 . The method of  claim 18 , wherein the HMWA and the LMWA are single phase polymers. 
     
     
         55 . The thick section mould according to  claim 19 , wherein the HMWA and the LMWA are single phase polymers. 
     
     
         56 . A moulded polymer product according to  claim 20 , wherein the HMWA and the LMWA are single phase polymers. 
     
     
         57 . A process for reducing cycle time according to  claim 22 , wherein the HMWA and the LMWA are single phase polymers. 
     
     
         58 . A process for reducing cooling cycle times according to  claim 23 , wherein the HMWA and the LMWA are single phase polymers. 
     
     
         59 . A method of melt blending according to  claim 21 , wherein the HMWA and the LMWA are single phase polymers.

Join the waitlist — get patent alerts

Track US2012175818A1 — get alerts on status changes and closely related new filings.

We store only your email — no account needed. See our privacy policy.