Processing aids and polymer formulations containing the same and method for producing the same

Patent metadata

Field	Value
Publication number	US-2016152750-A1
Application number	US-201615015098-A
Country	US
Kind code	A1
Filing date	Feb 3, 2016
Priority date	Oct 5, 2007
Publication date	Jun 2, 2016
Grant date	—

Abstract

A multi-stage emulsion processing aid polymer comprising one or more functionalized ethylenically unsaturated monomer into the emulsion polymerization reactor, wherein the functionality is selected from the group consisting of β-keto esters, β-keto amides, β-diketones, cyanoacetic esters, malonates, nitroalkanes, β-nitro esters, sulfonazides, thiols, thiol-s-triazines, and amine, where the functionality is incorporated into polymers by polymerizing, ethylenically unsaturated monomers containing these functionalities or by post functionalization of a polymer with additional reactions after polymerization in one of the first or second stages. Foamable halogenated polymers comprising the multi-stage emulsion processing aid polymer is also provided. Also provided are methods for making the multi-stage emulsion processing aid polymer and foamable halogenated polymers.

First claim

1 .- 6 . (canceled)

7 . A multi-stage emulsion processing aid polymer comprising from 25 to 75 percent by weight first stage polymer which comprises 0 to 99.6 mole % units derived from one or more non-functional ethylenically unsaturated monomer(s) and 0.4 to 100 mole % units derived from one or more functionalized ethylenically unsaturated monomer(s), wherein the functionality is selected from the group consisting of β-keto esters, β-keto amides, β-diketones, cyanoacetic esters, malonates, nitroalkanes, β-nitro esters, sulfonazides, thiols, thiol-s-triazines, and amine, where the functionality is incorporated into polymers by polymerizing, ethylenically unsaturated monomers containing these functionalities or by post functionalization of a polymer with additional reactions after polymerization; and
from 25 to 75 percent by weight second stage polymer which comprises units derived from non-functional ethylenically unsaturated monomer and no units derived from functionalized monomers; and
wherein the processing aid polymer has a Mw equal to or greater than 700,000 and a mean particle diameter size in the range of from 50 to 500 microns.

8 . The multi-stage emulsion processing aid polymer according to claim 7 wherein the functionalized ethylenically unsaturated monomer is acetoacetoxyethyl(meth)acrylate, wherein the processing aid polymer has a Tg between 10° C. and 150° C.

9 . The multi-stage emulsion processing aid polymer according to claim 8 wherein the functionalized ethylenically unsaturated monomer is acetoacetoxyethyl(meth)acrylate, wherein the processing aid polymer has a Tg is between 55° C. and 150° C.

10 . The multi-stage emulsion processing aid polymer according to claim 7 wherein the functionalized ethylenically unsaturated monomer is acetoacetoxyethyl(meth)acrylate, wherein the processing aid polymer has a Mw equal to or greater than 1.6 million.

11 .- 13 . (canceled)

14 . A formulation comprising (a) from 20 to 99% by weight of one or more halogenated polymers (A) selected from homopolymers or copolymers comprising at least 80% by weight of the halogenated polymer of one or more monomers selected from vinyl chloride, vinyl fluoride, vinylidene chloride, and vinylidene fluoride, and chlorinated polyvinyl chloride, and chlorinated polyethylene; and (b) from 0.5 to 20% by weight of one or more multi-stage processing aid polymers according to claim 7 wherein the one or more the processing aid polymers is used at a level in the formulation to provide 0.00040 to 0.0056 moles of functionalized monomer repeat units per 100 g of halogenated polymers.

15 . (canceled)

16 . A multi-stage emulsion polymerization process comprising:
feeding water, one or more functionalized ethylenically unsaturated monomer into the emulsion polymerization reactor, wherein the functionality is selected from the group consisting of β-keto esters, β-keto amides, β-diketones, cyanoacetic esters, malonates, nitroalkanes, β-nitro esters, sulfonazides, thiols, thiol-s-triazines, and amine, where the functionality is incorporated into polymers by polymerizing, ethylenically unsaturated monomers containing these functionalities or by post functionalization of a polymer with additional reactions after polymerization, and surfactant into an emulsion polymerization reactor, thereby forming a first stage polymer of a multi-stage emulsion polymer wherein the first stage polymer comprises from 25% to 75% by weight of the total weight of the multistage emulsion polymer; feeding at least one non-functionalized ethylenically unsaturated monomer and no functionalized monomers into the emulsion polymerization reactor, to form a second stage polymer, in the presence of the first stage polymer, wherein the second stage polymer comprises from 25% to 75% by weight of the total weight of the multistage emulsion polymer, and drying, or allowing to dry, the multistage emulsion polymer thereby forming the multi-stage emulsion processing aid polymer of claim 7 .

17 .- 18 . (canceled)

Assignees

• Rohm & Haas

Inventors

• Van Rheenen Paul R
• Broadwater Steven J

Classifications

• C08J2203/02

  CO2-releasing, e.g. NaHCO3 and citric acid · CPC title

• C08J2327/08

  Homopolymers or copolymers of vinylidene chloride · CPC title

• C08L27/14

  Homopolymers or copolymers of vinyl fluoride · CPC title

• C08J2433/12

  Homopolymers or copolymers of methyl methacrylate · CPC title

• C08J2203/04

  N2 releasing, ex azodicarbonamide or nitroso compound · CPC title