Polymer composition by continuous filler slurry extrusion

Patent metadata

Field	Value
Publication number	US-2016289397-A1
Application number	US-201415038620-A
Country	US
Kind code	A1
Filing date	Dec 17, 2014
Priority date	Dec 23, 2013
Publication date	Oct 6, 2016
Grant date	—

Abstract

An inventive process for the production of a polymer composition is provided, said process comprising the incorporation of a filler into a polymer material, wherein said polymer material during incorporation of the filler is in at least partially molten state and wherein said filler is incorporated as a slurry.

First claim

1 . A process for the continuous production of a polymer composition, the process comprising the steps of:
(a) providing a filler; (b) providing a polymer material; (c) forming a polymer composition comprising the filler of step (a) and the polymer material of step (b) by use of an extruder; characterized in that said process comprises the incorporation of said filler into said polymer material, wherein said polymer material during incorporation of the filler is in at least partially molten state and wherein said filler is incorporated as a slurry.

2 . The process according to claim 1 , characterized in that the filler slurry has a solids content in the range from 10 to 90 wt.-%, preferably from 15 to 88.5 wt.-% and more preferably from 20 to 78 wt.-%, based on the total weight of said filler slurry.

3 . The process according to claim 1 , characterized in that the filler content of the polymer composition is in the range from 0.5 to 90 wt.-%, preferably from 5 to 85 wt.-%, more preferably from 10 to 80 wt.-% and most preferably from 20 to 75 wt.-%, based on the total weight of said polymer composition.

4 . The process according to claim 1 , characterized in that the filler provided in step (a) is selected from the group consisting of a calcium carbonate containing mineral, chalk, limestone, marble, dolomite, barium sulfate, talc, kaolin, clay, mica, titan dioxide or mixtures thereof, wherein the filler preferably is a calcium carbonate containing mineral.

5 . The process according to claim 1 , characterized in that the filler provided in step (a) is a ground calcium carbonate (GCC), a precipitated calcium carbonate (PCC), a modified calcium carbonate (MCC), or a mixture thereof.

6 . The process according to claim 5 , characterized in that the precipitated calcium carbonate (PCC) is ground prior to incorporation into the polymer material.

7 . The process according to claim 1 , characterized in that the filler provided in step (a) comprises a coated filler, an uncoated filler, or a mixture of both, wherein the filler preferably comprises an uncoated filler and more preferably comprises an uncoated calcium carbonate containing mineral filler.

8 . The process according to claim 1 , characterized in that the filler provided in step (a) has a weight median particle size d 50 in the range from 0.001 to 50 μm, preferably from 0.05 to 10 μm, more preferably from 0.07 to 5 μm and most preferably from 0.1 to 2.5 μm.

9 . The process according to claim 1 , characterized in that the filler provided in step (a) has a particle top cut d 98 in the range from 0.25 to 50 μm, preferably from 0.35 to 30 μm and more preferably from 0.4 to 15 μm.

10 . The process according to claim 1 , characterized in that the polymer material provided in step (b) comprises a thermoplastic resin, wherein the thermoplastic resin preferably comprises a polyolefin.

11 . The process according to claim 10 , characterized in that the polyolefin is selected from the group of homo- and/or copolymers of polyethylene, homo- and/or copolymers of polypropylene, homo- and/or copolymers of polybutylene, or mixtures thereof.

12 . The process according to claim 1 , characterized in that the extruder is a twin-screw extruder, wherein the screws preferably are co-rotating or counter-rotating screws and more preferably are co-rotating screws.

13 . A polymer composition obtainable by a process according to claim 1 .

14 . The polymer composition according to claim 13 , characterized in that the obtained polymer composition has a water content which is equal to or less than 2 wt.-%, preferably equal to or less than 1 wt.-% and more preferably equal to or less than 0.5 wt.-%, based on the total weight of said polymer composition.

15 . A polymer product comprising the polymer composition according to claim 13 .

16 . The polymer product according to claim 15 , selected from one or more of flexible packaging for industrial and consumer applications, including roll stocks, bags, pouches, labels, wraps, liddings, shrink sleeves and stretch films; rigid packaging for industrial and consumer applications including plastic bottles, cups and containers; building and construction materials, including pipes and conduits, cladding and profiles, insulations, seals and gaskets, geotextiles; agriculture and horticulture materials including greenhouse materials, mulch films, tunnels, silages, bale wraps, boxes and crates; transportation and automotive applications including interior parts, such as instrument and door panels, consoles, pillars and seating; exterior parts, such as bumper fascia, fenders, tailgates as well as under the hood applications including air ducts, air intake manifolds, radiators and cooling hoses; electrical and electronic applications including CD players, DVD systems, personal computers and TV sets, notebooks, tablets, smartphones, cookers, refrigerators and freezers, washing machines, dishwashers, tools and office equipment; medical and health applications including disposable caps, gowns, masks, scrub suits and shoe covers, drapes, wraps and packs, sponges, dressings and wipes, bed linen, contamination control gowns, examination gowns, lab coats, isolation gowns, diagnostic medical machinery and medical devices; personal care products including absorbent hygiene products (AHP), baby diapers, feminine hygiene products and adult incontinence products, wipes, skin care products, depilatory strips; household and furniture products, including wood composites, decorative foils, floor coverings, flooring, kitchen ware, cleaners, pet care, lawn and garden articles; toys, sports and leisure articles including playhouses, building kits, play vehicles, sports and fitness devices, shoes, clothing and sportswear, safety equipment (helmets, kneepads), sports equipment, and suit cases.

17 . A method for the production of a polymer composition comprising incorporating, within an extruder, a filler in a form of a slurry into a polymer material being in at least partially molten state.

18 . The method according to claim 17 , characterized in that the slurry has a solids content in the range from 10 to 90 wt.-%, preferably from 15 to 88.5 wt.-% and more preferably from 20 to 78 wt.-%, based on the total weight of said slurry.

19 . The method according to claim 17 , characterized in that the filler content of the polymer composition is in the range from 0.5 to 90 wt.-%, preferably from 5 to 85 wt.-%, more preferably from 10 to 80 wt.-% and most preferably from 20 to 75 wt.-%, based on the total weight of said polymer composition.

20 . The method according to claim 17 , characterized in that the filler is selected from the group consisting of a calcium carbonate containing mineral, chalk, limestone, marble, dolomite, barium sulfate, talc, kaolin, clay, mica, titan dioxide or mixtures thereof, wherein the filler preferably is a calcium carbonate containing mineral.

21 . The method according to claim 17 , characterized in that the filler is a ground calcium carbonate (GCC), a precipitated calcium carbonate (PCC), a modified calcium carbonate (MCC), or a mixture thereof.

22 . The method according to claim 21 , characterized in that the precipitated calcium carbonate (PCC) is ground prior to incorporation into the polymer material.

23 . The method according to claim 17 , characterized in that the filler comprises a coated filler, an uncoated filler, or a mixture of both, wherein the filler preferably comprises an un

Assignees

• Omya Int Ag
• Fraunhofer Ges Forschung

Inventors

• Tinkl Michael
• Brunner Martin
• Burkhalter René
• Fornera Tazio
• Schirosi Giuseppe
• Pfaendner Rudolf
• Barth Jan
• Dillmann Bernd
• Dörr Harald

Classifications

• C08J2323/06

  Polyethene · CPC title

• B29C48/022

  characterised by the choice of material · CPC title

• B29C48/288

  in solid form, e.g. powder or granules · CPC title

• C08J2323/08

  Copolymers of ethene (C08J2323/16 takes precedence) · CPC title

• B29B9/12

  characterised by structure or composition · CPC title