OLEFIN-MALEIC ANHYDRIDE COPOLYMER COMPOSITIONS AND USES THEREOF
Described herein are concentrate compositions (e.g. master batches) comprising olefin-maleic anhydride copolymers and other additives dispersed in various carrier resins and methods for their preparation and use.
1 . A master batch composition for use in preparing a polyamide formulation from a polyamide, comprising an olefin-maleic anhydride copolymer and one or more carrier resins.
2 . The master batch composition of claim 1 wherein the carrier resin is selected from the group consisting of ethylene-ester copolymers; polyamides wherein amine end groups of the polyamide are capped, or the end groups of the polyamide are carboxylic acid groups and not amines; polysulfonylamides, where the end groups of the polysulfonylamides are not amines; polycarbonates, where the end groups of the polycarbonate are carboxylic acid groups; and polyesters, where the end groups of the polyester are carboxylic acid groups; or combinations thereof.
3 . The master batch composition of claim 1 wherein the carrier resin is an ethylene-n-butyl acrylate copolymer, an ethylene-ethyl acrylate copolymer, an ethylene-methyl acrylate copolymer, or a combination thereof.
4 . The master batch composition of claim 1 wherein the carrier resin is an ethylene-methyl acrylate copolymer.
5 . The master batch composition of claim 1 further comprising one or more additives independently selected in each instance from the group consisting of anti-oxidants, nucleating agents, colorants, plasticizers, lubricants, rheology modifiers, friction modifiers, other processing aids, and heat stabilizers for polyamides.
6 . The master batch composition of claim 5 wherein the one or more additives are independently selected in each instance from the group consisting of anti-oxidants and heat stabilizers for polyamides.
7 . The master batch composition of claim 5 wherein the additives are cuprous iodide, potassium iodide, N,N-hexane-1,6-diylbis[3-(3,5-di-tert-butyl-4-hydroxyphenylpropionamide)], and tris(2,4-di-tert-butylphenyl)phosphite.
8 . The master batch composition of claim 1 wherein the polyamide is a prime polyamide or a recycled polyamide.
9 . The master batch composition of claim 1 wherein the polyamide is a prime polyamide.
10 . The master batch composition of claim 1 wherein the polyamide is a recycled polyamide-6 or polyamide-6,6.
11 . The master batch composition of claim 1 wherein the polyamide is a recycled polyamide-6.
12 . The master batch composition of claim 1 wherein the polyamide is a recycled polyamide-6,6.
13 . The master batch composition of claim 1 wherein the olefin-maleic anhydride copolymer is a 1:1 olefin-maleic anhydride copolymer.
14 . The master batch composition of claim 1 wherein the olefin-maleic anhydride copolymer is a 1:1 ethylene-maleic anhydride copolymer.
15 . The master batch composition of claim 1 wherein the olefin-maleic anhydride copolymer is a 1:1 alternating copolymer.
16 . The master batch composition of claim 1 wherein the olefin-maleic anhydride copolymer is a 1:1 alternating ethylene-maleic anhydride copolymer has a weight average molecular weight (MW w ) of 1,000 to 800,000 Daltons.
17 . The master batch composition of claim 1 wherein the olefin-maleic anhydride copolymer is 1:1 alternating ethylene-maleic anhydride copolymer has a weight average molecular weight (MW w ) of 50,000 to 500,000 Daltons.
18 . The master batch composition of claim 1 wherein the olefin-maleic anhydride copolymer is a 1:1 alternating ethylene-maleic anhydride copolymer has a weight average molecular weight (MW w ) of 60,000 Daltons.
19 . The master batch composition of claim 1 wherein the concentration of olefin-maleic anhydride copolymer in the master batch is from about 5% to about 50%, or from about 10% to about 40%, or from about 10% to about 35%, or from about 10% to about 30%, or from about 15% to about 25%.
20 . A process for preparing the master batch composition of claim 1 , the process comprising the step of mixing an olefin-maleic anhydride copolymer with a carrier resin.
21 . The process of claim 20 wherein the carrier resin is selected from the group consisting of ethylene-ester copolymers; polyamides wherein amine end groups of the polyamide are capped, or the end groups of the polyamide are carboxylic acid groups; polysulfonylamides, where the end groups of the polysulfonylamides are not amines; polycarbonates, where the end groups of the polycarbonate are carboxylic acid groups; and polyesters, where the end groups of the polyester are carboxylic acid groups; or combinations thereof.
22 . The process of claim 20 wherein the carrier resin is an ethylene-n-butyl acrylate copolymer, an ethylene-ethyl acrylate copolymer, an ethylene-methyl acrylate copolymer, or a combination thereof.
23 . The process of claim 20 wherein the carrier resin is an ethylene-methyl acrylate copolymer.
24 . The process of claim 20 further comprising the step of adding one or more additives independently selected in each instance from the group consisting of anti-oxidants, nucleating agents, colorants, plasticizers, lubricants, rheology modifiers, friction modifiers, other processing aids, and heat stabilizers for polyamides.
25 . The process of claim 24 wherein one or more of the additives is independently selected in each instance from the group consisting of anti-oxidants and heat stabilizers for polyamides.
26 . The process of claim 24 wherein the additives are cuprous iodide, potassium iodide, N,N′-hexane-1,6-diylbis[3-(3,5-di-tert-butyl-4-hydroxyphenylpropionamide)], and tris(2,4-di-tert-butylphenyl)phosphite.
27 . The process of claim 20 wherein the polyamide is a prime polyamide or a recycled polyamide.
28 . The process of claim 20 wherein is a prime polyamide.
29 . The process of claim 20 wherein the polyamide is a recycled polyamide-6 or polyamide-6,6.
30 . The process claim 20 wherein the olefin-maleic anhydride copolymer is a 1:1 olefin-maleic anhydride copolymer.
31 . The process of claim 20 wherein the olefin-maleic anhydride copolymer is a 1:1 ethylene-maleic anhydride copolymer.
32 . The process of a claim 20 wherein the olefin-maleic anhydride copolymer is a 1:1 alternating copolymer.
33 . The process of claim 32 wherein the 1:1 alternating ethylene-maleic anhydride copolymer has a weight average molecular weight (MW w ) of 1,000 to 800,000 Daltons.
34 . The process of claim 32 wherein the 1:1 alternating ethylene-maleic anhydride copolymer has a weight average molecular weight (MW w ) of 50,000 to 500,000 Daltons.
35 . The process of claim 32 wherein the 1:1 alternating ethylene-maleic anhydride copolymer has a weight average molecular weight (MW w ) of 60,000 Daltons.
36 . A polyamide formulation comprising a recycled polyamide or a virgin polyamide compounded with the master batch composition of claim 1 .
37 . The polyamide formulation of claim 36 wherein the polyamide is a virgin polyamide.
38 . The polyamide formulation of claim 36 wherein the polyamide is a recycled polyamide-6 or polyamide-6,6.
39 . The polyamide formulation of claim 36 wherein the polyamide is a recycled polyamide-6.
40 . The polyamide formulation of claim 36 wherein the polyamide is a recycled polyamide-6,6.
41 . The polyamide formulation of claim 36 wherein the average molecule weight of the compounded polyamide is increased.
42 . The polyamide formulation of a claim 36 wherein the polyamide formulation has increased tensile strength, improved stretch performance, increased impact strength, increased flex modulus, increased heat deflection temperature, or a combination thereof compared to the recycled polyamide
43 . The polyamide formulation of claim 36 wherein each of the tensile strength, tensile elongation, flexural strength and flexural modulus of the polyamide formulation increases.
44 . A process for preparing a polyamide formulation, the process comprising the step of reaction compounding a polyamide with the master batch composition of claim 1 .
45 . The process of claim 44 wherein the polyamide is a virgin polyamide or a recycled polyamide.
46 . The process of claim 44 wherein the polyamide is virgin polyamide.
47 . The process of claim 44 wherein the polyamide is a recycled polyamide.
48 . The process of claim 44 wherein the temperature of the compounding step is from about 230° C. to about 280° C.
49 . The process of claim 44 wherein the compounding step in performed in a twin-screw extruder, a single-screw extruder, an oscillating screw extruder, a continuous mixer, a Banbury mixer, or a planetary extruder.
50 . The process of claim 44 wherein the concentration of the master batch composition in the polyamide formulation is from about 0.5% to about 10%, or about 1%, or about 2%, or about 3% or about 4% or about 5%.