Composition, polymer composite article formed therewith, and method of preparing same

Patent metadata

Field	Value
Publication number	US-12060488-B2
Application number	US-201916966279-A
Country	US
Kind code	B2
Filing date	Feb 1, 2019
Priority date	Feb 1, 2018
Publication date	Aug 13, 2024
Grant date	Aug 13, 2024

Abstract

A composition and a method for preparing a polymer composite article. The composition comprises (A) a filler in an amount of from 10 to 90 wt. %. The composition also comprises (B) a polymer in an amount of from 10 to 90 wt. %, wherein the (B) polymer comprises a polyvinyl. Further, the composition comprises (C) an organopolysiloxane in an amount of from greater than 0 to 10 wt. %; the (C) organopolysiloxane having at least one silicon-bonded hydroxyl group and a viscosity of from 1,000 to 60,000 mPa·s at 25° C. The ranges for components (A)-(C) are based on the total weight of components (A), (B) and (C) in the composition.

First claim

What is claimed is:

1. A composition for preparing a polymer composite article, said composition consisting of:
(A) a filler in an amount of from 10 to 90 wt. %, wherein said (A) filler is selected from a mineral filler, a glass fiber, a carbon fiber, or combinations thereof;
(B) a polymer in an amount of from 10 to 90 wt. %, wherein said (B) polymer comprises polyvinyl chloride; and
(C) an organopolysiloxane in an amount of from greater than 0 to 10 wt. %; the (C) organopolysiloxane having at least one silicon-bonded hydroxyl group and a viscosity of from 1,000 to 60,000 mPa·s at 25° C.; and
optionally, one or more additives selected from (D) a compatibilizer, (E) a colorant, (F) a blowing agent, (G) a UV stabilizer, (H) an antioxidant, (I) a process aid, (J) a preservative, (K) a biocide, (L) a flame retardant, (M) an impact modifier, and combinations thereof;
each based on the total weight of components (A), (B) and (C) in said composition.

2. The composition of claim 1 , wherein: (i) said (C) organopolysiloxane is present as a liquid at 25° C.; (ii) said organopolysiloxane is present in said composition in a solid carrier component comprising said organopolysiloxane; (iii) said (C) organopolysiloxane has a viscosity of from 2,000 to 50,000 mPa s at 25° C.; or (iv) any combination of (i) to (iii).

3. The composition of claim 1 , wherein said (C) organopolysiloxane has the following average unit formula:
[R 1 3-n (OH) n SiO 1/2 ] a′ [R 1 2-m (OH) m SiO 2/2 ] b′ [R 1 SiO 3/2 ] c′ [SiO 4/2 ] d′ ;

wherein each R 1 is an independently selected hydrocarbyl group; n is 0, 1, 2, or 3, m is 0, 1 or 2, with the proviso that n and m are not simultaneously 0; 0<a′<1; 0<b′<1; 0≤c′≤0.1; and 0≤d′≤0.1, with the proviso that a′+b′+c′+d′=1.

4. The composition of claim 1 , wherein said (C) organopolysiloxane has the following average unit formula (I) or (II):
[R 1 3-n (OH) n SiO 1/2 ] a″ [R 1 2-m (OH) m SiO 2/2 ] b″   (I)

wherein each R 1 is an independently selected hydrocarbyl group; n is 0, 1, 2, or 3, m is 0, 1 or 2, with the proviso that n and m are not simultaneously 0; 0<a″<1; 0<b″<1; with the proviso that a″+b″=1; or
R 1 3-x (OH) x SiO[SiR 1 2 O] c″ Si(OH) y R 1 3-y   (II)

wherein each R 1 is an independently selected hydrocarbyl group; x is 0, 1, 2, or 3, y is 0, 1, 2, or 3, with the proviso that x and y are not simultaneously 0; and c″ is from 60 to 1,200.

5. The composition of claim 1 , wherein: (i) said (A) filler is present in an amount of from 40 to 80 wt. %; (ii) said (B) polymer is present in an amount of from 20 to 60 wt. %; and (iii) said (C) organopolysiloxane is present in an amount of from 0.8 to 4.0 wt. %.

6. The composition of claim 1 , wherein: (i) said (A) filler comprises a mineral filler and is present in an amount of from 10 to 50 wt. %; (ii) said (B) polymer is present in an amount of from 50 to 90 wt. %; (iii) said (C) organopolysiloxane is present in an amount of from 0.1 to 10 wt. %; and (iv) said (C) organopolysiloxane has a viscosity of from 1,000 to 50,000 mPa s at 25° C.

7. A method of preparing the composition of claim 1 , said method comprising:
combining (A) said filler, (B) said polymer, and (C) said organopolysiloxane, thereby preparing the composition.

8. A method of preparing a polymer composite article, said method comprising:
preparing the polymer composite article from the composition of claim 1 .

9. The method of claim 8 , wherein the method further comprises: (i) forming the composition; (ii) heating the (B) polymer to melt the (B) polymer prior to and/or during forming the composition; (iii) mixing a mixture of the (A) filler and (C) organopolysiloxane prior adding the (B) polymer or (iv) any combination of (i), (ii) or (iii).

10. The method of claim 8 , wherein the method comprises:
combining the (A) filler, the (B) polymer, and the (C) organopolysiloxane at an elevated temperature under mixing to give a flowable mixture; and
forming the polymer composite article from the flowable mixture.

11. The method of claim 10 , wherein: (i) the (C) organopolysiloxane is a liquid when forming the flowable mixture with the (C) organopolysiloxane; or (ii) the (C) organopolysiloxane is present within a solid carrier component and the method further comprises melting the solid carrier component when forming the flowable mixture with the (C) organopolysiloxane.

12. The method of claim 8 , wherein: (i) preparing the polymer composite article from the composition further comprises forming the composition into a desired shape; (ii) preparing the polymer composite article from the composition comprises extruding the composition; (iii) preparing the polymer composite article from the composition comprises molding the composition; or (iv) any combinations of (i) to (iii).

13. The method of claim 8 carried out in an extruder, wherein: (i) an extrusion processing temperature of the composition in the extruder is reduced as compared to an extrusion processing temperature of a mixture of the (A) filler and the (B) polymer without the (C) organopolysiloxane; and/or (ii) a torque of the extruder is reduced when mixing the composition as compared to a torque of the extruder when extruding a mixture of the (A) filler and the (B) polymer without the (C) organopolysiloxane.

14. A polymer composite article prepared by the method of claim 8 .

Assignees

• Dow Silicones Corp
• Dow Global Technologies Llc
• Rohm & Haas

Inventors

• Bruce Keith
• Chorvath Igor
• Courtemanche Marc-Andre
• Degroot Jr Jon V
• Gaal Sean
• Gross Craig
• Guo Hailan
• Keenihan James
• Mealey Shawn
• Miller Scott
• Parsons Tom
• Rapacki Steven R
• Schlader Andrew
• Serrat Cristina
• Tonge Lauren

Classifications

• C08L27/06 Primary

  Homopolymers or copolymers of vinyl chloride · CPC title

• C08K2003/265

  Calcium, strontium or barium carbonate · CPC title

• C08K5/0066

  Flame-proofing or flame-retarding additives · CPC title

• C08K5/0058

  Biocides; (macromolecular substances as carriers for biocide material A01N25/10) · CPC title

• C08K5/005

  Stabilisers against oxidation, heat, light, ozone · CPC title