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Stabilization of polymer blends

Imported: 23 Feb '17 | Published: 22 Oct '02

Navjot Singh, Farid Fouad Khouri

USPTO - Utility Patents

Abstract

Disclosed are stabilized polymeric blends wherein two components having different viscosities are stabilized by the use of a filler material. Also disclosed are methods for the formation of such stabilized blends.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a graphical representation of viscosity as measured by capillary rheometry of unmodified silicone gum and silicone gum with additional fumed silica.

FIG. 2 is a picture obtained by acoustic microscopy of Example 3 molded at injection speeds of 2 inches per second and 6 inches per second.

FIG. 3 is a picture obtained from scanning electron microscopy of Example 4 showing coalescence and delamination near the surface.

FIG. 4 is a picture obtained from scanning electron microscopy of Example 3 showing the lack of coalescence and delamination near the surface.

FIG. 5 is a graphical representation of viscosity as measured by capillary rheometry of polybutylene terephthalate with unmodified silicone gum, and with silicone gum modified with fumed silica.

FIG. 6 is a graphical representation of viscosity as measured by capillary rheometry of polyphenylene oxide with unmodified silicone gum, and with silicone gum modified with fumed silica.

FIG. 7 is a graphical representation of viscosity as measured by capillary rheometry of high impact polystyrene with different levels of unmodified silicone gum.

FIG. 8 is a picture obtained from scanning electron microscopy of Examples 11 and 12 showing silica filler confined in the silicone dispersed phase.

FIG. 9 is an illustration of differences in Processes A and B as compared with Process C as described in the present invention.

Claims

1. A polymer blend composition which comprises:

2. The composition of claim 1, wherein the matrix phase polymer is a thermoplastic polymer.

3. The composition of claim 2, wherein the thermoplastic polymer is selected from the group consisting of polyesters, polycarbonates, polystyrenes, polymethylmethacrylates, polyketones, polyamides, aromatic polyethers, polyether sulfones, polyether imides, polyether ketones, polyetherether ketones, polyphenylene ethers, polyphenylene sulfides, and combinations thereof.

4. The composition of claim 1, wherein the dispersed phase polymer is a rubbery polymer.

5. The composition of claim 4, wherein the rubbery polymer is selected from the group consisting of natural rubber, silicone rubber, ethylenepropylene rubber, ethylene/(alpha)olefin/nonconjugated polyene (EPDM) rubber, styrene/butadiene rubber, acrylonitrile/butadiene (NBR) rubber, polychloroprenes, sulfur modified polychloroprene, polybutadiene rubber, and combinations thereof.

6. The composition of claim 1, wherein the viscosity ratio of the matrix phase polymer to the modified dispersed phase polymer is in a range between about 1 and about 1.5 at a shear rate of about 400 s

−1 at a temperature the blend is conventionally processed.

7. The composition of claim 1, wherein the matrix phase polymer is present in a range between about 65% by weight and about 100% by weight of total polymer.

8. The composition of claim 1, wherein the ratio of the filler to the dispersed phase polymer is in a range between about 3% by weight and about 90% by weight of the dispersed phase polymer.

9. A method for the formation of a blend of a matrix phase polymer and a dispersed phase polymer initially having a lower viscosity than the matrix phase polymer, said method comprising:

10. The method of claim 9, wherein the matrix phase polymer is a thermoplastic polymer.

11. The method of claim 10, wherein the thermoplastic polymer is selected from the group consisting of polyesters, polycarbonates, polystyrenes, polymethylmethacrylates, polyketones, polyamides, aromatic polyethers, polyether sulfones, polyether imides, polyether ketones, polyetherether ketones, polyphenylene ethers, polyphenylene sulfides, and combinations thereof.

12. The method of claim 9, wherein the dispersed phase polymer is a rubbery polymer.

13. The method of claim 12, wherein the rubbery polymer is selected from the group consisting of natural rubber, silicone rubber, ethylenepropylene rubber, ethylene/(alpha)olefin/nonconjugated polyene (EPDM) rubber, styrene/butadiene rubber, acrylonitrile/butadiene (NBR) rubber, polychloroprenes, sulfur modified polychloroprene, polybutadiene rubber, and combinations thereof.

14. The method of claim 9, wherein the viscosity ratio of the matrix phase polymer to the modified dispersed phase polymer is in a range between about 1 and about 1.5 at a shear rate of about 400 s

−1 at a temperature the blend is conventionally processed.

15. The method of claim 9, wherein the matrix phase polymer is present in a range between about 65% by weight and about 99% by weight of total polymer.

16. The method of claim 9, wherein the ratio of the filler to the dispersed phase polymer is in a range between about 3% by weight and about 90% by weight of the dispersed phase polymer.

17. A method for the formation of a blend of a thermoplastic polymer and a rubber polymer initially having a lower viscosity than the thermoplastic polymer, said method comprising:

18. The method of claim 17, wherein the thermoplastic polymer is selected from the group consisting of polyesters, polycarbonates, polystyrenes, polymethylmethacrylates, polyketones, polyamides, aromatic polyethers, polyether sulfones, polyether imides, polyether ketones, polyetherether ketones, polyphenylene ethers, polyphenylene sulfides, and combinations thereof.

19. The method of claim 17, wherein the rubbery polymer is selected from the group consisting of natural rubber, silicone rubber, ethylenepropylene rubber, ethylene/(alpha)olefin/nonconjugated polyene (EPDM) rubber, styrene/butadiene rubber, acrylonitrile/butadiene (NBR) rubber, polychloroprenes, sulfur modified polychloroprene, polybutadiene rubber, and combinations thereof.

20. The method of claim 17, wherein the viscosity ratio of the thermoplastic polymer to the modified rubbery polymer is in a range between about 1 and about 1.5 at a shear rate of about 400 s

−1 at a temperature the blend is conventionally processed.

21. The method of claim 17, wherein the thermoplastic polymer is present in a range between about 65% by weight and about 99% by weight of total polymer.

22. The method of claim 17, wherein the ratio of the filler to the rubbery polymer is in a range between about 3% by weight and about 90% by weight of a rubbery polymer.

23. A method for the formation of a blend of a matrix phase polymer and a dispersed phase polymer, said method comprising at least one of the following steps

24. The method of claim 23, wherein the matrix phase polymer is a thermoplastic polymer.

25. The method of claim 24, wherein the thermoplastic polymer is selected from the group consisting of polyesters, polycarbonates, polystyrenes, polymethylmethacrylates, polyketones, polyamides, aromatic polyethers, polyether sulfones, polyether imides, polyether ketones, polyetherether ketones, polyphenylene ethers, polyphenylene sulfides, and combinations thereof.

26. The method of claim 23, wherein the dispersed phase polymer is a rubbery polymer.

27. The method of claim 26, wherein the rubbery polymer is selected from the group consisting of natural rubber, silicone rubber, ethylenepropylene rubber, ethylene/(alpha)olefin/nonconjugated polyene (EPDM) rubber, styrene/butadiene rubber, acrylonitrile/butadiene (NBR) rubber, polychloroprenes, sulfur modified polychloroprene, polybutadiene rubber, and combinations thereof.

28. The method of claim 23, wherein the viscosity ratio of the matrix phase polymeric component to the modified dispersed phase polymeric component is in a range between about 1 and about 1.5 at a shear rate of about 400 s

−1 at a temperature the blend is conventionally processed.

29. The method of claim 23, wherein the matrix phase polymeric component is present in a range between about 65% by weight and about 99% by weight of total polymer.

30. The method of claim 23, wherein the ratio of the filler to the dispersed phase polymeric component is in a range between about 3% by weight and about 90% by weight of the dispersed phase polymeric component.

31. A method for the formation of a blend of a thermoplastic polymer and a rubbery polymer, said method comprising at least one of the following steps:

32. The method of claim 31, wherein the thermoplastic polymer is selected from the group consisting of polyesters, polycarbonates, polystyrenes, polymethylmethacrylates, polyketones, polyamides, aromatic polyethers, polyether sulfones, polyether imides, polyether ketones, polyetherether ketones, polyphenylene ethers, polyphenylene sulfides, and combinations thereof.

33. The method of claim 31, wherein the rubbery polymer is selected from the group consisting of natural rubber, silicone rubber, ethylenepropylene rubber, ethylene/(alpha)olefin/nonconjugated polyene (EPDM) rubber, styrene/butadiene rubber, acrylonitrile/butadiene (NBR) rubber, polychloroprenes, sulfur modified polychloroprene, polybutadiene rubber, and combinations thereof.

34. The method of claim 31, wherein the viscosity ratio of the thermoplastic polymer to the modified rubbery polymer is in a range between about 1 and about 1.5 at a shear rate of about 400 s

−1 at a temperature the blend is conventionally processed.

35. The method of claim 31, wherein the thermoplastic polymer is present in a range between about 65% by weight and about 99% by weight of total polymer.

36. The method of claim 31, wherein the ratio of the filler to the rubbery polymer is in a range between about 3% by weight and about 90% by weight of rubbery polymer.

37. A polymer blend made by the method of claim 9.

38. A polymer blend made by the method of claim 17.

39. A polymer blend made by the method of claim 23.

40. A polymer blend made by the method of claim 31.