Surface-treated compacted material

Patent metadata

Field	Value
Publication number	US-2017355104-A1
Application number	US-201515526788-A
Country	US
Kind code	A1
Filing date	Nov 25, 2015
Priority date	Dec 2, 2014
Publication date	Dec 14, 2017
Grant date	—

Abstract

The present invention relates to a process for producing a compacted material comprising the steps of providing a powder material and a polymer binder, simultaneously or subsequently feeding the powder material and the polymer binder into a high speed mixer unit, mixing the powder material and the polymer binder in the high speed mixer unit until formation of a compacted material, and reducing the temperature of the obtained compacted material below the melting point or glass transition temperature of the polymer binder.

First claim

1 . A process for producing a compacted material comprising the following steps:
a) providing at least one powder material, b) providing a polymer binder, c) simultaneously or subsequently feeding the at least one powder material of step a) and the polymer binder of step b) into a high speed mixer unit, d) mixing the at least one powder material of step a) and the polymer binder of step b) in the high speed mixer unit until formation of a compacted material, and e) reducing the temperature of the compacted material obtained from step d) below the melting point or glass transition temperature of the polymer binder, wherein the at least one powder material comprises a surface-treated filler material product comprising a calcium carbonate-comprising filler material and a treatment layer on at least a part of the surface of the calcium carbonate-comprising filler material, wherein the treatment layer comprises i) at least one mono-substituted succinic anhydride and/or at least one mono-substituted succinic acid and/or salty reaction products thereof, and/or ii) a phosphoric acid ester or blend of one or more phosphoric acid mono-ester and salty reaction products thereof and/or one or more phosphoric acid di-ester and salty reaction products thereof.

2 . The process of claim 1 , wherein the calcium carbonate-comprising filler material is natural ground calcium carbonate, precipitated calcium carbonate, surface-modified calcium carbonate, or a mixture thereof, and preferably natural ground calcium carbonate.

3 . The process of claim 1 , wherein the calcium carbonate-comprising filler material has a weight median particle size d 50 from 0.05 to 10 μm, preferably from 0.1 to 7 μm, more preferably from 0.25 to 5 μm, and most preferably from 0.5 to 4 μm.

4 . The process of claim 1 , wherein the at least one mono-substituted succinic anhydride consists of succinic anhydride mono-substituted with a group selected from a linear, branched, aliphatic and cyclic group having a total amount of carbon atoms from C2 to C30, preferably from C3 to C25, and most preferably from C4 to C20 in the substituent.

5 . The process of claim 1 , wherein
I) the one or more phosphoric acid mono-ester consists of an o-phosphoric acid molecule mono-esterified with one alcohol molecule selected from unsaturated or saturated, branched or linear, aliphatic or aromatic alcohols having a total amount of carbon atoms from C6 to C30, preferably from C8 to C22, more preferably from C8 to C20, and most preferably from C8 to C18 in the alcohol substituent, and/or II) the one or more phosphoric acid di-ester consists of an o-phosphoric acid molecule di-esterified with two alcohol molecules selected from the same or different, unsaturated or saturated, branched or linear, aliphatic or aromatic fatty alcohols having a total amount of carbon atoms from C6 to C30, preferably from C8 to C22, more preferably from C8 to C20, and most preferably from C8 to C18 in the alcohol substituent.

6 . The process of claim 1 , wherein the surface-treated filler material product comprises the treatment layer in an amount of at least 0.1 wt.-%, based on the total dry weight of the at least one calcium carbonate-comprising filler material, preferably in an amount from 0.1 to 3 wt.-%.

7 . The process of claim 1 , wherein the at least one powder material is added in an amount from 50 to 99 wt.-%, based on the total weight of the compacted material, preferably from 60 to 98 wt.-%, more preferably from 80 to 92 wt.-%, and most preferably from 87 to 90 wt.-%.

8 . The process of claim 1 , wherein the polymer binder has a rotational viscosity from 100 to 400 000 mPa·s, preferably from 1 000 to 100 000 mPa·s, and more preferably from 5 000 to 50 000 mPa·s, at 190° C.

9 . The process of claim 1 , wherein the polymer binder is selected from the group consisting of polyolefins, ethylene copolymers, e.g. ethylene-1-octene copolymers, metallocene based polypropylenes, polypropylene homo- or co-polymers, preferably amorphous polypropylene homopolymers, and combinations thereof.

10 . Compacted material obtained by a process according to claim 1 .

11 . Use of a compacted material according to claim 10 as additive in a polymer composition.

12 . Use of a compacted material according to claim 10 in a process for producing a polymer composition, wherein the compacted material is added to at least one polymer, said at least one polymer preferably being selected from at least one thermoplastic polymer.

13 . The use of claim 12 , wherein the at least one thermoplastic polymer is selected from the group consisting of homopolymers and/or copolymers of polyolefins, polyamides, polystyrenes, polyacrylates, polyvinyls, polyurethanes, halogen-containing polymers, polyesters, polycarbonates, and mixtures thereof.

14 . Use of a compacted material according to claim 10 in a process for producing a polymer product, the process preferably being selected from melt processing techniques, and more preferably being selected from profile extrusion, cable extrusion, film extrusion, moulding, fibre spinning, co-kneading, or pultrusion.

15 . Use of a compacted material according to claim 10 in a polymer product, wherein the product is a fibre, preferably a carpet fibre, a filament, a thread, a woven material, a nonwoven material, a film, preferably a blown-film or a breathable film, a profile, a cable, or a moulded product.

16 . Use of a compacted material according to claim 10 in an article, wherein the article is selected from the group consisting of healthcare products, geotextile products, agriculture products, horticulture products, clothing, footwear products, baggage products, household products, industrial products, packaging products, building products, upholstery products, industrial apparel, medical products, home furnishings, protective products, cosmetic products, hygiene products, filtration materials, carpets and construction products.

17 . A polymer composition comprising a compacted material according to claim 10 , said polymer composition preferably being a thermoplastic polymer composition.

18 . Use of a polymer composition according to claim 17 in a process for producing a polymer product, the process preferably being selected from melt processing techniques, and more preferably being selected from profile extrusion, cable extrusion, film extrusion, moulding, fibre spinning, co-kneading, or pultrusion.

19 . A polymer product comprising a compacted material according to claim 10 or a polymer composition comprising said compacted material wherein the product is a fibre, preferably a carpet fibre, a filament, a thread, a woven material, a nonwoven material, a film, preferably a blown-film or a breathable film, a profile, a cable, or a moulded product.

20 . An article comprising a polymer product according to claim 19 , wherein the article is selected from the group consisting of healthcare products, geotextile products, agriculture products, horticulture products, clothing, footwear products, baggage products, household products, industrial products, packaging products, building products, upholstery products, industrial apparel, medical products, home furnishings, protective products, cosmetic products, hygiene products, filtration materials, carpets and construction products.

Assignees

• Omya Int Ag

Inventors

• Brunner Martin
• Knerr Michael
• Hirsiger Christoph
• Riesen Roland
• Schirosi Giuseppe
• Tinkl Michael
• Schulz Karsten Udo
• Muratore Antonio

Classifications

• C01P2004/61

  Micrometer sized, i.e. from 1-100 micrometer · CPC title

• C08K2003/265

  Calcium, strontium or barium carbonate · CPC title

• B29B7/007

  for continuous mixing · CPC title

• B29B7/90 Primary

  Fillers or reinforcements {, e.g. fibres} · CPC title

• C09C1/021

  Calcium carbonates · CPC title