TREATED MINERAL FILLER PRODUCTS, PROCESS FOR THE PREPARATION THEREOF AND USES OF SAME
The present invention relates to treated mineral filler products comprising a) at least one mineral filler, b) a treatment layer located on the surface of said mineral filler(s), said treatment layer comprising at least one saturated C 8 to C 24 aliphatic carboxylic acid; and at least one di and/or trivalent cation salt of one or more saturated C 8 to C 24 aliphatic carboxylic acid, wherein the weight ratio of all of said aliphatic carboxylic acid salt(s):all of said aliphatic carboxylic acid(s) is from 51:49 to 75:25; and said treatment layer is present in an amount of at least 2.5 mg/m 2 of said mineral filler. Furthermore the present invention relates to processes to prepare such treated mineral filler products, and to their uses, notably in plastic applications, and especially in polypropylene (PP)- or polyethylene (PE)-based breathable or extrusion coating film applications.
1 . A process for mixing and/or extruding and/or compounding and/or blow molding a plastic material comprising contacting the plastic material during mixing and/or extruding and/or compounding and/or blow molding with a treated mineral filler product, wherein the treated mineral filler product comprises:
a) at least one mineral filler;
b) a treatment layer located on the surface of the mineral filler, the treatment layer comprising:
at least one saturated C 8 to C 24 aliphatic carboxylic acid(s); and
at least one di and/or trivalent cation salt of one or more saturated C 8 to C 24 aliphatic carboxylic acid(s);
wherein:
the weight ratio of the aliphatic carboxylic acid salt(s):the aliphatic carboxylic acid(s) is from 51:49 to 75:25; and
the treatment layer is present in an amount of at least 2.5 mg/m 2 of the mineral filler.
2 . The process according to claim 1 , wherein the plastic material comprises polyolefin.
3 . The process according to claim 1 , wherein the plastic material comprises a thermoplastic.
4 . The process according to claim 1 , wherein the thermoplastic is selected from polyethylenes (PE), polypropylenes (PP), polyurethanes (PU), and mixtures thereof.
5 . The process according to claim 1 , wherein the mineral filler in the treated mineral filler product is a calcium carbonate-comprising mineral filler, a plate-like mineral-comprising mineral filler, a quartz-comprising mineral filler, a clay-comprising mineral filler, or any mixture thereof.
6 . The process according to claim 1 , wherein the mineral filler in the treated mineral filler product is a calcium carbonate-comprising mineral filler.
7 . The process according to claim 6 , wherein the calcium carbonate-comprising mineral filler is precipitated calcium carbonate (PCC) and/or natural ground calcium carbonate (NGCC).
8 . The process according to claim 6 , wherein the calcium carbonate-comprising mineral filler is precipitated calcium carbonate (PCC) comprising one or more of the aragonitic, vateritic and calcitic mineralogical crystal forms.
9 . The process according to claim 6 , wherein the calcium carbonate-comprising mineral filler is natural ground calcium carbonate (NGCC) comprising marble, limestone, or chalk, and/or dolomite.
10 . The process according to claim 6 , wherein the calcium carbonate-comprising mineral filler comprises marble and/or dolomite.
11 . The process according to claim 1 , wherein the mineral filler in the treated mineral filler product is a plate-like mineral-comprising mineral filler.
12 . The process according to claim 11 , wherein the plate-like mineral-comprising mineral filler is talc.
13 . The process according to claim 1 , wherein the at least one C 8 to C 24 aliphatic carboxylic acid(s) is a C 10 to C 18 aliphatic carboxylic acid(s).
14 . The process according to claim 1 , wherein the least one C 8 to C 24 aliphatic carboxylic acid(s) is a C 12 to C 18 aliphatic carboxylic acid(s).
15 . The process according to claim 1 , wherein the at least one C 8 to C 24 aliphatic carboxylic acid(s) is one or more fatty acids.
16 . The process according to claim 1 , wherein the at least one C 8 to C 24 aliphatic carboxylic acid(s) is stearic, palmitic, myristic, or lauric acid, or any mixture thereof.
17 . The process according to claim 1 , wherein the at least one C 8 to C 24 aliphatic carboxylic acid(s) is stearic and/or palmitic acid.
18 . The process according to claim 1 , wherein the di and/or trivalent cation salt of one or more C 8 to C 24 aliphatic carboxylic acid(s) is a calcium, magnesium, strontium, or aluminium salt, or any mixture thereof.
19 . The process according to claim 1 , wherein the di and/or trivalent cation salt of one or more C 8 to C 24 aliphatic carboxylic acid(s) is a calcium or magnesium salt, or mixture thereof.
20 . The process according to claim 1 , wherein the di and/or trivalent cation salt of one or more C 8 to C 24 aliphatic carboxylic acid(s) is a di and/or trivalent cation salt of one or more C 10 to C 18 aliphatic carboxylic acid(s).
21 . The process according to claim 1 , wherein the di and/or trivalent cation salt of one or more C 8 to C 24 aliphatic carboxylic acid(s) is a di and/or trivalent cation salt of one or more C 12 to C 18 aliphatic carboxylic acid(s).
22 . The process according to claim 1 , wherein the di and/or trivalent cation salt of one or more C 8 to C 24 aliphatic carboxylic acid(s) is a di and/or trivalent cation salt of one or more aliphatic monocarboxylic acid(s).
23 . The process according to claim 1 , wherein the di and/or trivalent cation salt of one or more C 8 to C 24 aliphatic carboxylic acid(s) is a salt of one or more fatty acids.
24 . The process according to claim 1 , wherein the di and/or trivalent cation salt of one or more C 8 to C 24 aliphatic carboxylic acid(s) is a salt of stearic, palmitic, myristic, or lauric acid, or any mixture thereof.
25 . The process according to claim 1 , wherein the di and/or trivalent cation salt of one or more C 8 to C 24 aliphatic carboxylic acid(s) is a salt of stearic and/or palmitic acid.
26 . The process according to claim 1 , wherein the di and/or trivalent cation salt of one or more C 8 to C 24 aliphatic carboxylic acid(s) has an equivalent isolated viscosity of more than 100,000 mPa·s, at 180° C. when measured in a PHYSICA MCR 300 equipped with a CP50-1 instrumentation at a shear rate of 5 s −1 and scanning temperatures from 200 to 130° C.
27 . The process according to claim 1 , wherein the di and/or trivalent cation salt of one or more C 8 to C 24 aliphatic carboxylic acid(s) has an equivalent isolated viscosity of more than 1,000,000 mPa·s, at 180° C. when measured in a PHYSICA MCR 300 equipped with a CP50-1 instrumentation at a shear rate of 5 s −1 and scanning temperatures from 200 to 130° C.
28 . The process according to claim 1 , wherein the weight ratio of the aliphatic carboxylic acid salt(s):the aliphatic carboxylic acid(s) is from 55:45 to 75:25.
29 . The process according to claim 1 , wherein the weight ratio of the aliphatic carboxylic acid salt(s):the aliphatic carboxylic acid(s) is from 60:40 to 70:30.
30 . The process according to claim 1 , wherein the weight ratio of the aliphatic carboxylic acid salt(s):the aliphatic carboxylic acid(s) is from 64:36 to 67:33.
31 . The process according to claim 1 , wherein the treated mineral filler product comprises greater than 2.7 mg of total aliphatic carboxylic acid(s) and aliphatic carboxylic acid salt(s)/m 2 of mineral filler.
32 . The process according to claim 1 , wherein the treated mineral filler product comprises at least 3 mg of total aliphatic carboxylic acid(s) and aliphatic carboxylic acid salt(s)/m 2 of mineral filler.
33 . The process according to claim 1 , wherein the treated mineral filler product comprises at least 3.2 mg of total aliphatic carboxylic acid(s) and aliphatic carboxylic acid salt(s)/m 2 of mineral filler.
34 . The process according to claim 1 , wherein an equivalent isolated mixture of the aliphatic carboxylic acid salts(s) and the aliphatic carboxylic acid(s) has a viscosity of less than 10,000 mPa·s at 180° C.
35 . The process according to claim 1 , wherein an equivalent isolated mixture of the aliphatic carboxylic acid salts(s) and the aliphatic carboxylic acid(s) has a viscosity of less than 1000 mPa·s at 180° C.
36 . The process according to claim 1 , wherein an equivalent isolated mixture of the aliphatic carboxylic acid salts(s) and the aliphatic carboxylic acid(s) has a viscosity of less than 500 mPa·s at 180° C.
37 . The process according to claim 1 , wherein the aliphatic carboxylic acid is a 1:1 stearic acid:palmitic acid mixture, and the aliphatic carboxylic acid salt(s) is a magnesium or calcium stearate.
38 . The process according to claim 1 , wherein the mineral matter comprises calcium carbonate, the aliphatic carboxylic acid(s) comprises a mixture of stearic acid and palmitic acid, and the salt of the aliphatic carboxylic acid(s) is calcium stearate.
39 . The process according to claim 1 , wherein the mineral matter comprises calcium carbonate, the aliphatic carboxylic acid(s) comprises a mixture of stearic acid and palmitic acid, and the salt of the aliphatic carboxylic acid(s) is magnesium laurate.
40 . The process according to claim 1 , wherein the mineral matter comprises dolomite, the aliphatic carboxylic acid(s) is lauric acid, and the salt of the aliphatic carboxylic acid(s) is aluminium stearate.
41 . The process according to claim 1 , wherein the treated mineral product has a total volatiles between 25 and 280° C. of less than 0.25% by mass.
42 . The process according to claim 1 , wherein the treated mineral filler product has a volatile onset temperature of greater than or equal to 270° C.
43 . The process according to claim 1 , wherein the treated mineral filler product has a volatile onset temperature of greater than or equal to 290° C.
44 . The process according to claim 1 , wherein the treated mineral filler product has a volatile onset temperature of greater than or equal to 300° C.