Process for producing acrylate rubber with reduced coagulate formation

Patent metadata

Field	Value
Publication number	US-2017145201-A1
Application number	US-201515300037-A
Country	US
Kind code	A1
Filing date	Mar 26, 2015
Priority date	Mar 31, 2014
Publication date	May 25, 2017
Grant date	—

Abstract

A process for producing a thermoplastic molding composition comprising: 10% to 40% by weight of a graft copolymer A comprising 50% to 70% by weight, based on A, of a graft base A1 formed from an elastomeric, crosslinked acrylic ester polymer and 30% to 50% by weight of a graft shell A2, 50% to 90% by weight of a hard matrix B formed from copolymers of styrene or α-methylstyrene and acrylonitrile, 0% to 50% by weight of a further graft copolymer C, 0% to 15% by weight of additives D, wherein the reaction for preparation of the acrylic ester polymer A and/or the reaction for preparation of C is conducted in the presence of 0.01 to 4 times the molar amount of sodium carbonate, based on the sum total of the molar amount of initiator used in the preparation of the graft base and graft shell, leads to lower coagulate formation.

First claim

1 - 15 . (canceled)

16 . A process for the production of a thermoplastic molding composition comprising:
from 10 to 40% by weight of at least one graft copolymer A comprising from 50 to 70% by weight, based on A, of a graft base A1 made of an elastomeric, crosslinked acrylate polymer and from 30 to 50% by weight, based on A, of a graft shell A2 made of a vinylaromatic monomer and of a polar, copolymerizable, ethylenically unsaturated monomer, in a ratio by weight of from 80:20 to 65:35, from 50 to 90% by weight of a hard matrix B made of one or more copolymers of styrene, α-methylstyrene, acrylonitrile, methyl methacrylate, and/or phenylmaleimide, from 0 to 50% by weight of another graft copolymer C which differs from the graft copolymer A and which has an average particle diameter (weight average) in the range from 200 to 800 nm, comprising from 50 to 80% by weight, based on C, of an elastomeric crosslinked acrylate polymer C1 which differs from A1, from 2.5 to 25% by weight, based on C, of a first graft shell C2 made of a vinylaromatic monomer and of from 10 to 45% by weight, based on C, of a second graft shell C3 made of a mixture of a vinylaromatic monomer C31 and of a polar, copolymerizable, ethylenically unsaturated monomer C32, where the ratio by weight of C31 to C32 is from 90:10 to 60:40, and from 0 to 15% by weight of one or more additives D, where the entirety of A and B, and optionally C and D, gives 100% by weight, and where the reaction for the production of the acrylate polymer A and the reaction for the production of the copolymer C is carried out in the presence of a molar quantity of sodium carbonate which is from 0.01 to 4 times the total molar quantity of initiator, in particular PPS, used in the production of the graft base and graft shell.

17 . The process for the production of a thermoplastic molding composition as claimed in claim 16 , where the graft base A1 is composed of from 55 to 65% by weight, based on A, of acrylate polymer particles with average size from 50 to 120 nm and the graft shell A2 is composed of from 35 to 45% by weight, based on A, of styrene and acrylonitrile.

18 . The process for the production of a thermoplastic molding composition as claimed in claim 16 , where the particle size distribution factor Q of the graft base A1 is from 0.01 to 0.5, in particular from 0.1 to 0.4.

19 . The process for the production of a thermoplastic molding composition as claimed in claim 16 , where the average size of the particles of component A after the graft reaction is in the range from 70 to 150 nm.

20 . The process for the production of a thermoplastic molding composition as claimed in claim 16 , where the quantity of coagulate formed in connection with the graft shell A2 is in the range from 0.01 to 0.5% by weight, based on the total weight of the graft copolymer.

21 . The process for the production of a thermoplastic molding composition as claimed in claim 16 , where the quantity of sodium carbonate used in the production of the graft copolymers A and/or C is from 0.01 to 2.5 mol, in particular from 0.1 to 2.5 mol, based on the sum of the molar quantities of initiator, in particular PPS, used in the graft base and graft shell.

22 . The process for the production of a thermoplastic molding composition as claimed in claim 16 , where the molding composition comprises from 1 to 50% by weight of at least one graft copolymer C which differs from the graft copolymer A.

23 . The process for the production of a thermoplastic molding composition as claimed in claim 16 , where the molding composition comprises from 0.1 to 15% by weight, in particular from 0.1 to 5% by weight, of at least one additive D.

24 . The process for the production of a thermoplastic molding composition as claimed in claim 16 , where the molding composition comprises from 1 to 50% by weight of at least one graft copolymer C and the average size of the particles of component C after the graft reaction is in the range from 300 to 700 nm.

25 . The process for the production of a thermoplastic molding composition as claimed in claim 16 , where the appropriate quantity of sodium carbonate is first dissolved in a starting material and then is introduced into the polymerization.

26 . The process for the production of a thermoplastic molding composition as claimed in claim 16 , where a sodium carbonate solution is added together with a PPS solution continuously during the graft copolymerization.

27 . The process for the production of a thermoplastic molding composition comprising:
from 50 to 90% by weight of a hard matrix B made of one or more copolymers of styrene, α-methylstyrene, acrylonitrile, methyl methacrylate, and/or phenylmaleimide, from 10 to 50% by weight of a graft copolymer C with an average particle size (weight average) in the range from 200 to 800 nm, comprising from 50 to 80% by weight, based on C, of an elastomeric crosslinked acrylate polymer C1, from 2.5 to 25% by weight, based on C, of a first graft shell C2 made of a vinylaromatic monomer and of from 10 to 45% by weight, based on C, of a second graft shell C3 made of a mixture of a vinylaromatic monomer C31 and of a polar, copolymerizable, ethylenically unsaturated monomer C32, where the ratio by weight of C31 to C32 is from 90:10 to 60:40, and from 0 to 15% by weight, in particular from 0.1 to 5% by weight, of one or more additives D, where the entirety of B and C, and optionally D, gives 100% by weight, and where the reaction for the production of the acrylate polymer C is carried out in the presence of a molar quantity of sodium carbonate which is from 0.01 to 4 times, in particular from 0.1 to 2.5 times, the total molar quantity of initiator, in particular PPS, used in the production of the graft base and graft shell of C.

28 . The process for the production of a thermoplastic molding composition as claimed in claim 27 , where the coagulate formation of the graft shell of component C is in the range from 0.01 to 0.5% by weight, based on the total weight of the graft copolymer C.

29 . A method of use for the production of moldings, films, or coatings of the thermoplastic molding composition obtained as claimed in claim 16 .

30 . A molding, a film, or a coating made of a thermoplastic molding composition produced by the process as claimed in claim 16 .

Assignees

• Ineos Styrolution Group Gmbh

Inventors

• Boeckmann Philipp
• Fischer Wolfgang
• Hausser Hans-Juergen

Classifications

• C08L25/12 Primary

  with unsaturated nitriles · CPC title

• C08F265/04 Primary

  on to polymers of esters · CPC title

• C08L2205/03

  containing three or more polymers in a blend · CPC title

• C08F2/002

  Scale prevention in a polymerisation reactor or its auxiliary parts · CPC title

• C08K3/26

  Carbonates; Bicarbonates · CPC title