Process for the manufacture of polybutylene terephthalate copolymers from polyethylene terephthalate, and compositions and articles thereof

1. A process comprising:

depolymerizing, with 1,4-butane diol,

a first polymer comprising a polyethylene terephthalate component selected from the group consisting of polyethylene terephthalate homopolymers, polyethylene terephthalate copolymers, and combinations thereof, in the presence of

at least one second polymer selected from the group consisting of polyvinyl chlorides, polyvinylidene chlorides, polyamides, polylactic acid, and combinations thereof,

in a reactor at a first temperature and a first pressure that is at least atmospheric pressure, for a time and under conditions effective to produce a molten mixture comprising

a first component selected from the group consisting of oligomers containing ethylene terephthalate groups, oligomers containing ethylene isophthalate groups, oligomers containing diethylene terephthalate groups, oligomers containing diethylene isophthalate groups, oligomers containing butylene terephthalate groups, oligomers containing butylene isophthalate groups, covalently bonded oligomeric moieties containing at least two of the foregoing groups, 1,4-butane diol, ethylene glycol, and combinations thereof; and

a second component selected from the group consisting of

(i) the at least one second polymer selected from the group consisting of polyvinyl chlorides, polyvinylidene chlorides, polyamides, polylactic acid, and combinations thereof;

(ii) at least one residue derived from the at least one second polymer selected from the group consisting of polyvinyl chlorides, polyvinylidene chlorides, polyamides, polylactic acid, and combinations thereof; and

(iii) combinations thereof; and

polymerizing the molten mixture at a second temperature that is higher than the first temperature, a second pressure that is lower than the first pressure and that is subatmospheric pressure, with agitation under an inert atmosphere, for a time and under conditions sufficient to form a modified polybutylene terephthalate copolymer having a melting temperature of more than 200° C. and an intrinsic viscosity ranging from 0.5 to 1.4 dL/g, comprising

(a) at least one polyethylene terephthalate component residue, and

(b) a member selected from the group consisting of

(i) the at least one second polymer selected from the group consisting of polyvinyl chlorides, polyvinylidene chlorides, polyamides, polylactic acid, and combinations thereof;

(ii) the at least one residue derived from the second polymer; and

(iii) combinations thereof.

2. The process of claim 1 , wherein depolymerizing is conducted with agitation under an inert atmosphere.

3. The process of claim 1 , wherein the at least one polyethylene terephthalate component residue is selected from the group consisting of ethylene glycol groups, diethylene glycol groups, isophthalic acid groups, antimony-containing compounds, germanium-containing compounds, titanium-containing compounds, cobalt-containing compounds, tin-containing compounds, aluminum, aluminum salts, 1,3-cyclohexane dimethanol isomers, 1,4-cyclohexane dimethanol isomers, alkali salts, alkaline earth metal salts, phosphorous-containing compounds and anions, sulfur-containing compounds and anions, naphthalene dicarboxylic acids, 1,3-propanediol groups, and combinations thereof.

4. The process of claim 1 , wherein the at least one polyethylene terephthalate component residue is selected from the group consisting of ethylene glycol, diethylene glycol, isophthalic acid, cobalt-containing compounds, antimony-containing compounds, isophthalic acid groups, and combinations thereof.

5. The process of claim 1 , wherein the at least one polyethylene terephthalate component residue is selected from the group consisting of cis isomer of 1,3-cyclohexane dimethanol, cis isomer of 1,4-cyclohexane dimethanol, trans isomer of 1,3-cyclohexane dimethanol, trans isomer of 1,4-cyclohexane dimethanol and combinations thereof.

6. The process of claim 1 , wherein the at least one polyethylene terephthalate component residue is selected from the group consisting of ethylene glycol groups, diethylene glycol groups, and cyclohexane dimethanol groups; and the polyethylene terephthalate component residue is in an amount ranging from 0.1 to 10 mole %, based on 100 mole % of glycol in the modified polybutylene terephthalate copolymer.

7. The process of claim 6 , wherein the at least one polyethylene terephthalate component residue further comprises isophthalic acid groups in an amount ranging from more than 0 to 10 mole %, based on 100 mole % of acid functionality in the modified polybutylene terephthalate random copolymer.

8. The process of claim 1 , wherein

prior to depolymerizing the polyethylene terephthalate component, the second polymer comprises more than 0 to less than 290 ppm of polyvinyl chloride, based on the total parts by weight of the polyethylene terephthalate component; and

a sample molded from the modified polybutylene terephthalate copolymer has an unnotched Izod strength of 1500 to 2500 J/m, measured in accordance with ASTM D256, and a tensile elongation at break of at least 100%, measured in accordance with ASTM D638.

9. The process of claim 1 , wherein

prior to depolymerizing the polyethylene terephthalate component, the second polymer comprises more than 0 to less than 5.7 wt. % of a polyamide as the second polymer, based on the total weight of the polyethylene terephthalate component, wherein the polyamide is Nylon 6; and

a molded sample of the modified polybutylene terephthalate copolymer has a tensile elongation at break of at least 100%, measured in accordance with ASTM D638.

10. The process of claim 1 , wherein

prior to depolymerizing the polyethylene terephthalate component, the second polymer comprises more than 0 to less than 1.45 wt. % of a polyamide as the second polymer, based on the total weight of the polyethylene terephthalate component;

the polyamide is Nylon 6; and

a molded sample of the modified polybutylene terephthalate copolymer has a heat deflection temperature at 0.455 MPa of at least 90° C., measured in accordance with ASTM D648.

11. The process of claim 1 , wherein

prior to depolymerizing the polyethylene terephthalate component, the second polymer comprises more than 0 to less than 5.7 wt. % of a polyamide as the second polymer, based on the total weight of the polyethylene terephthalate component;

the polyamide is Nylon 6,6; and

a molded sample of the modified polybutylene terephthalate copolymer has a tensile elongation at break that is at least 100%, measured in accordance with ASTM D638.

12. The process of claim 1 , wherein

prior to depolymerizing the polyethylene terephthalate component, the second polymer comprises more than 0 to less than 4.6 wt. % of a polyamide as the second polymer, based on the total weight of the polyethylene terephthalate component;

the polyamide is Nylon 6,6; and

a molded sample of the modified polybutylene terephthalate copolymer has a heat deflection temperature at 0.455 MPa that is at least 70° C., measured in accordance with ASTM D648.

13. The process of claim 1 , wherein depolymerizing the polyethylene terephthalate is carried out at a temperature from 180° C. to 230° C.

14. The process of claim 1 , wherein depolymerizing the polyethylene terephthalate component is carried out at a pressure from 100 kPa to 500 kPa absolute.

15. The process of claim 1 , wherein depolymerizing the polyethylene terephthalate component is carried out for at least 30 minutes.

16. The process of claim 1 , wherein the second temperature is from 230° C. to 260° C.

17. The process of claim 1 , wherein the second pressure is less than 0.3 kPa absolute.

18. The process of claim 1 , wherein the polymerization of the molten mixture is carried out for at least 60 minutes.

19. The process of claim 1 , wherein a catalyst is present during a step selected from the group consisting of (i) depolymerizing the polyethylene terephthalate component, (ii) polymerization of the molten mixture, and (iii) combinations thereof.

20. The process of claim 1 , wherein a basic compound is present during a step selected from the group consisting of (i) depolymerizing the polyethylene terephthalate component, (ii) polymerization of the molten mixture, and (iii) a combination thereof.

21. The process of claim 1 , wherein the process is carried out in at least two reactors.

22. A composition comprising a modified polybutylene terephthalate copolymer having a melting temperature of more than 200° C. and an intrinsic viscosity ranging from 0.5 to 1.4 dL/g, and comprising

(a) at least one residue derived from a polyethylene terephthalate component; and

(b) a member selected from the group consisting of

(i) at least one polymer selected from the group consisting of polyvinyl chlorides, polyvinylidene chlorides, polyamides, polylactic acid, and combinations thereof;

(ii) at least one residue derived from a polymer selected from the group consisting of polyvinyl chlorides, polyvinylidene chlorides, polyamides, polylactic acid, and combinations thereof; and

(iii) combinations thereof.

23. The composition of claim 22 , wherein

the at least one polymer comprises polyvinyl chloride as the second polymer, present in an amount of more than 0 and less than 220 ppm of, based on the total parts by weight of the polyethylene terephthalate component; and

a molded sample of the composition has an unnotched Izod strength of 1500 to 2500 J/m, measured in accordance with ASTM D256, and a tensile elongation at break that is at least 100%, measured in accordance with ASTM D638.

24. The composition of claim 22 , wherein

the at least one polymer comprises Nylon 6 as the second polymer, present in an amount of more than 0 and less than 5.7 wt. % of, based on the total weight of the polyethylene terephthalate component, and

a molded sample of the composition has a tensile elongation at break that is at least 100%, measured in accordance with ASTM D638.

25. The composition of claim 22 , wherein

the at least one polymer comprises Nylon 6 as the second polymer, present in an amount of more than 0 and less than 1.45 wt. %, based on the total weight of the polyethylene terephthalate component; and

a molded sample of the modified polybutylene terephthalate copolymer has a heat deflection temperature at 0.455 MPa that is at least 90° C., measured in accordance with ASTM D648.

26. The composition of claim 22 , wherein

the at least one polymer comprises Nylon 6,6 as the second polymer, present in an amount of more than 0 and less than 5.7 wt. %, based on the total weight of the polyethylene terephthalate component; and

a molded sample of the modified polybutylene terephthalate copolymer has a tensile elongation at break that is at least 100%, measured in accordance with ASTM D638.

27. The composition of claim 22 , wherein

the at least one polymer comprises Nylon 6,6 as the second polymer, present more than 0 and less than 4.6 wt. %, based on the total weight of the polyethylene terephthalate component, and

a molded sample of the modified polybutylene terephthalate copolymer has a heat deflection temperature at 0.455 MPa that is at least 70° C., measured in accordance with ASTM D648.

28. The composition of claim 22 , wherein the residue derived from the polyethylene terephthalate component is selected from the group consisting of ethylene glycol groups, diethylene glycol groups, isophthalic acid groups, antimony-containing compounds, germanium-containing compounds, titanium-containing compounds, cobalt-containing compounds, tin-containing compounds, aluminum, aluminum salts, 1,3-cyclohexane dimethanol isomers, 1,4-cyclohexane dimethanol isomers, alkali salts, alkaline earth metal salts, phosphorous-containing compounds and anions, sulfur-containing compounds and anions, naphthalene dicarboxylic acids, 1,3-propanediol groups, and combinations thereof.

29. The composition of claim 22 , wherein the at least one residue derived from the polyethylene terephthalate component comprises mixtures of ethylene glycol and diethylene glycol.

30. An article comprising the composition of claim 22 .

31. A composition comprising a modified polybutylene terephthalate copolymer having a melting temperature of more than 200° C. and an intrinsic viscosity ranging from 0.5 to 1.4 dL/g, and comprising

(a) at least one residue derived from a polyethylene terephthalate component; and

(b) a member selected from the group consisting of

(i) at least one polymer selected from the group consisting of polyvinyl chlorides, polyvinylidene chlorides, polyamides, polylactic acid, and combinations thereof;

(ii) at least one residue derived from a polymer selected from the group consisting of polyvinyl chlorides, polyvinylidene chlorides, polyamides, polylactic acid; and combinations thereof; and

(iii) combinations thereof;

wherein

the modified polybutylene terephthalate copolymer is derived from a polyethylene terephthalate mixture comprising a second polymer selected from the group consisting of

more than 0 to less than 290 ppm polyvinyl chloride,

more than 0 to less than 5.7 wt. % Nylon 6;

more than 0 to less than 5.7 wt. % Nylon 6,6; and

optionally, more than 0 to less than 8 wt. % polylactic acid, each based on the parts by weight or weight of the polyethylene terephthalate component; and

the residue derived from the polyethylene terephthalate component is selected from the group consisting of ethylene glycol groups, diethylene glycol groups, isophthalic acid groups, antimony-containing compounds, germanium-containing compounds, titanium-containing compounds, cobalt-containing compounds, tin containing compounds, aluminum, aluminum salts, 1,3-cyclohexane dimethanol isomers, 1,4-cyclohexane dimethanol isomers, alkali salts, alkaline earth metal salts, phosphorous-containing compounds and anions, sulfur-containing compounds and anions, naphthalene dicarboxylic acids, 1,3-propanediol groups, and combinations thereof.

32. The composition of claim 31 , wherein the at least one residue derived from the polyethylene terephthalate component comprises mixtures of ethylene glycol and diethylene glycol.

33. An article comprising the composition of claim 31 .