Sizing agentcomprising functionalized polyolefins

Abstract

A sizing agent and the use of the sizing agent as a coating on a reinforcing fiber. A sizing composition comprising the sizing agent. A sized reinforcing fiber comprising a reinforcing fiber being coated with the sizing agent and a process for preparing the sized reinforcing fiber. A polymer composite comprising the sized reinforcing fiber.

1 . A sizing agent comprising:
 at least one functionalized polyolefin polymer;   at least one base compound, wherein the base compound is selected from the group consisting of:
 i. an inorganic base; 
 ii. an organic base; and 
 iii. any combination thereof; 
   at least one non-ionic surfactant; and   at least one ionic surfactant.   
     
     
         2 . The sizing agent according to  claim 1 , wherein the base compound is selected from any one of:
 the inorganic base present in an amount of from 1.0 wt. % to less than 12.5 wt. %, based on the total weight of the sizing agent; or   the organic base present in an amount from 8.0 wt. % to 30.0 wt. %, based on the total weight of the sizing agent.   
     
     
         3 . The sizing agent according to  claim 1 , wherein:
 the functionalized polyolefin polymer is present in an amount from 50.0 wt. % to 90.0 wt. %;   the non-ionic surfactant is present in an amount from 10.0 wt. % to 25.0 wt; and   the ionic surfactant is present in an amount from 0.5 wt. % to 5.0 wt. %, based on the total weight of the sizing agent.   
     
     
         4 . The sizing agent according to  claim 1 , wherein the functionalized polyolefin polymer is selected from the group consisting of maleic anhydride grafted polyolefin, maleic anhydride based polyolefin co-polymers, maleic anhydride based polyolefin terpolymers, glycidyl (meth)acrylate based polyolefin copolymer, glycidyl (meth)acrylate grafted polyolefin, itaconic anhydride grafted polyolefin, citraconic anhydride grafted polyolefin, allylsuccinic anhydride grafted polyolefin, and combinations thereof. 
     
     
         5 . The sizing agent according to  claim 1 , wherein
 the inorganic base is selected from the group consisting of potassium hydroxide, sodium hydroxide, cesium hydroxide, barium hydroxide, ammonium hydroxide, and any combinations thereof; and/or   the organic base is selected from the group consisting of N,N-dimethyl aminoethanol (DMAE), 2-(methylamino) ethanol, 2-(ethylamino)ethanol, 2-(propylamino)ethanol, 2-(butylamino)ethanol, N-butyldiethanolamine, N-tert-butyldiethanolamine, triisopropanolamine, bis(2-hydroxypropyl)amine, N,N-bis(2-hydroxypropyl)ethanolamine, 1-[N,N-bis(2-hydroxyethyl)amino]-2-propanol, N,N,N′,N′-tetrakis(2-hydroxyethyl)ethylenediamine, N,N,N′,N′-tetrakis(2-hydroxypropyl)ethylene diamine, morpholine, diethanol amine, diethylmethanol amine, N,N-dimethyl-dihydrosphingosine, and any combinations thereof.   
     
     
         6 . The sizing agent according to  claim 1 , wherein the non-ionic surfactant is selected from the group consisting of a linear or branched alkylphenol ethoxylate, alkylphenol, polyoxyalkylene alylphenylether, octylphenoxy poly(ethyleneoxy)ethanol, sorbitan oleate, polyethylene glycol sorbitan monooleate, polyethylene glycol sorbitan monolaurate, t-octylphenoxypolyethoxyethanol, polyoxyethylene (10) isooctylcyclohexyl ether, alpha-[3,5-Dimethyl-1-(2-methylpropyl)hexyl]-omega-hydroxypolyloxy-1,2-ethanediyl, polyethylene glycol monoalkyl ether, and any combinations thereof. 
     
     
         7 . The sizing agent according to  claim 1 , wherein the ionic surfactant is selected from the group consisting of alkali metal salt of dioctyl sulphosuccinate, alkali metal salt of 1,4-bis[(2-ethylhexyl)oxy]-1,4-dioxo-2-butanesulfonate, alkali metal salt of dicyclohexyl sulfosuccinate, alkali metal salt of dihexyl sulfosuccinate, alkali metal salt of dibutyl sulfosuccinate, alkali metal salt of bis(2-ethylhexyl) sulfosuccinate, alkali metal salt of dodecylbenzenesulfonate, 4-dodecylbenzenesulfonic acid, alkali metal salt of sulfosuccinic acid, alkali metal salt of poly(ethylene glycol) 4-nonylphenyl 3-sulfopropyl ether, alkali metal salt of dodecyl sulfate, cholesteryl sodium sulfate, alkali metal salt of desoxycholic acid, and any combinations thereof. 
     
     
         8 . The sizing agent according to  claim 1 , wherein the sizing agent further comprises at least one compound (A) selected from the group consisting of sodium metabisulfite, potassium metabisulfite, sodium hypochlorite, calcium hypochlorite, monochloramine, trichloroisocyanuric acid, sodium benzoate, 4-hexylresorcinol, chloroxylenol, and any combinations thereof. 
     
     
         9 . The sizing agent according to  claim 1 , wherein the base compound is an inorganic base and wherein:
 the functionalized polyolefin polymer is maleic-anhydride grafted polypropylene present in an amount from 65.0 wt. % to 75.0 wt. %;   the inorganic base is potassium hydroxide present in an amount from 2.0 wt. % to 10.0 wt. %;   the non-ionic surfactant is polyoxyethylene (9) nonylphenylether branched present in an amount from 10.0 wt. % to 20.0 wt. %;   the ionic surfactant is an alkali metal salt of 1,4-bis[(2-ethylhexyl)oxy]-1,4-dioxo-2-butanesulfonate, present in an amount from 0.5 wt. % to 5.0 wt. %; and   the compound (A) is sodium metabisulfite present in an amount from 0.1 wt. % to 1.0 wt. %;   based on the total weight of the sizing agent.   
     
     
         10 . The sizing agent according to  claim 1 , wherein the base compound is an organic base and wherein:
 the functionalized polyolefin polymer is maleic-anhydride grafted polypropylene present in an amount from 60.0 wt. % to 70.0 wt. %;   the organic base is N,N-dimethyl aminoethanol (DMAE) present in an amount from 10.0 wt. % to 20.0 wt. %;   the non-ionic surfactant is polyoxyethylene (9) nonylphenylether present in an amount from 10.0 wt. % to 20.0 wt. %;   the ionic surfactant is an alkali metal salt of 1,4-bis[(2-ethylhexyl)oxy]-1,4-dioxo-2-butanesulfonate, present in an amount from 0.5 wt. % to 5.0 wt. %; and   the compound (A) is sodium metabisulfite present in an amount from 0.1 wt. % to 1.0 wt. %;   based on the total weight of the sizing agent.   
     
     
         11 . A sizing composition, comprising (i) the sizing agent according to  claim 1 , and (ii) a dispersion medium, wherein the sizing composition has a pH of greater than 7.0. 
     
     
         12 . A sized reinforcing fiber, comprising a reinforcing fiber selected from the group consisting of carbon fiber, basalt fiber, glass fiber, polymer fiber, and metal fiber, wherein at least a portion of the reinforcing fiber is provided with the sizing agent according to  claim 1 . 
     
     
         13 . A process for producing the sized reinforcing fiber of  claim 12 , comprising the steps of:
 providing the reinforcing fiber;   contacting the reinforcing fiber with a sizing composition comprising (i) the sizing agent, and (ii) a dispersion medium, wherein the sizing composition has a pH of greater than 7.0 and obtaining a precursor sized reinforcing fiber; and   drying the precursor sized reinforcing fiber to obtain the sized reinforcing fiber.   
     
     
         14 . A polymer composite comprising:
 a polymer matrix comprising a polyolefin polymer; and   one or more sized reinforcing fiber according to  claim 12 , wherein the one or more sized reinforcing fiber is dispersed in the polymer matrix.   
     
     
         15 . A method for improving the adhesion between a reinforcing fiber and a polymer matrix in which the reinforcing fiber is dispersed, the method comprising coating the sizing agent according to  claim 1  on at least a portion of the reinforcing fiber.