Method for dewatering a polymer and the polymer made therefrom

1. A method of dewatering a wet polymer composition comprising:

introducing the wet polymer composition comprising an interfacial polycarbonate powder via a polymer feed location to a powder conveying section of an extruder; wherein the wet polymer composition comprises greater than or equal to 1 wt % of water based on the total weight of the wet polymer composition;

venting the water through a conveying section vent to form a dry polymer composition;

adding an additive; wherein the adding comprises adding an optionally liquid additive composition comprising the additive in the powder conveying section to the dry polymer composition, wherein the adding is optionally performed under nitrogen;

melt kneading the dry polymer composition in a melt kneading section of the extruder to form a polymer melt;

introducing the polymer melt from the melt kneading section directly into a melt seal section located in a melt conveying section; and then

conveying the polymer melt in through the remaining melt conveying section of the extruder.

2. A method of dewatering a wet polymer composition comprising:

introducing the wet polymer composition via a polymer feed location to a powder conveying section of an extruder; wherein the wet polymer composition comprises greater than or equal to 1 wt % of water based on the total weight of the wet polymer composition;

venting the water through a conveying section vent to form a dry polymer composition;

melt kneading the dry polymer composition in a melt kneading section of the extruder to form a polymer melt, wherein the melt kneading section comprises a melt kneading block; and

introducing the polymer melt from the melt kneading section directly into a melt seal section located in a melt conveying section; wherein the melt seal section comprises a reverse flighted conveying element, a dam ring, a kneading block, and a low shear element; wherein the kneading block comprises a forward kneading block, a neutral kneading block, a reverse kneading block, or a combination comprising at least one of the foregoing; wherein the low shear element imparts a lower shear to the polymer melt than that which is imparted by the melt-kneading block;

conveying the polymer melt through the remaining melt conveying section of the extruder; wherein the conveying introduces a shear to the polymer melt;

venting the polymer melt in the melt conveying section downstream of the melt seal section; and

optionally adding an additive.

3. The method of claim 2 , wherein the low shear element comprises a screw mixing element, a turbine mixing element, a zahnmisch element, or a combination comprising at least one of the foregoing.

4. The method of claim 1 , wherein the additive comprises 0.01 to 1 wt % of a heat stabilizer, 0.01 to 1 wt % of a release agent, 0.01 to 1 wt % of a UV stabilizer, 0 to 1 wt % of a colorant, or a combination comprising at least one of the foregoing, all based on the total weight of the polymer and additive.

5. A method of dewatering a wet polymer composition comprising:

introducing the wet polymer composition via a polymer feed location to a powder conveying section of an extruder; wherein the wet polymer composition comprises greater than or equal to 1 wt % of water based on the total weight of the wet polymer composition;

venting the water through a conveying section vent to form a dry polymer composition;

melt kneading the dry polymer composition in a melt kneading section of the extruder to form a polymer melt;

conveying the polymer melt in a melt conveying section of the extruder; and

adding an additive in the powder conveying section, wherein the additive comprises 0.01 to 1 wt % of a heat stabilizer, 0.01 to 1 wt % of a release agent, 0.01 to 1 wt % of a UV stabilizer, 0 to 1 wt % of a colorant, or a combination comprising at least one of the foregoing, all based on the total weight of the polymer and additive.

6. The method of claim 1 , wherein the adding comprises adding the liquid additive composition comprising the additive in the powder conveying section to the dry polymer composition.

7. The method of claim 1 , wherein the melt kneading section comprises a melt kneading block, and wherein the melt seal comprises a reverse flighted conveying element, a dam ring, a kneading block, and a low shear element; wherein the kneading block comprises a forward kneading block, a neutral kneading block, a reverse kneading block, or a combination comprising at least one of the foregoing; wherein the low shear element imparts a lower shear to the polymer melt than that which is imparted by the melt-kneading block.

8. The method of claim 1 , wherein the conveying comprises conveying the polymer melt using a two lobe mixing element.

9. The method of claim 1 , further comprising melt filtering the polymer melt after the melt conveying section.

10. The method of claim 1 , wherein the extruder has a length to inner diameter ratio of greater than 40.

11. The method of claim 1 , wherein the dry polymer composition comprises less than or equal to 0.4 wt % of water and/or wherein the wet polymer composition comprises greater than or equal to 5 wt % of water.

12. The method of claim 1 , wherein the adding comprises adding the additive in the melt conveying section and/or wherein the venting occurs at a vacuum pressure of less than or equal to 120 kPa.

13. The method of claim 1 , wherein the additive comprises tris(2,4-di-tert-butylphenyl)phosphite, octadecyl-3-(3,5-di-tert.butyl-4-hydroxyphenyl)-propionate, pentaerythritol tetrastearate, stearyl stearate, glycerol monostearate, glycerol tristearate, 2-(2-Hydroxy-5-tert-octylphenyl) benzotriazole, ultramarine blue, or a combination comprising at least one of the foregoing, or the additive comprises tris(2,4-di-tert-butylphenyl)phosphite.

14. The method of claim 1 , wherein the wet polymer composition comprises greater than 0 to less than or equal to 5 wt % of halogenated solvent based on the total weight of the wet polymer composition and/or wherein the dry polymer composition comprises less than or equal to 1 ppm of a residual halogenated solvent based on the total weight of the dry polymer composition.

15. The method of claim 1 , wherein the wet polymer composition comprises greater than or equal to 5 wt % of water based on the total weight of the wet polymer composition and the dry polymer composition comprises less than 5 wt % of water based on the total weight of the wet polymer composition.

16. The method of claim 1 , further comprising introducing the melt polymer to a pressure buildup zone at a distal end of the melt conveying section away from the powder conveying section.

17. A dry polymer composition prepared by the method of claim 1 , wherein the dry polymer composition has one or more of a sulfur content of less than or equal to 10 mg sulfur per kilogram of the dry polymer composition, and an ionic chloride level of less than or equal to 1 mg per kilogram of the dry polymer composition.

18. The method of claim 1 , further comprising pelletizing the melt and then forming an article from the pellets; wherein the article is a lens; or wherein the article is a consumer electronic screen.

19. The method of claim 1 , further comprising introducing the dry polymer composition to a powder seal section located in the powder conveying section directly upstream of the melt kneading section.

20. The method of claim 1 , wherein the wherein the conveying the polymer melt through the remaining melt conveying section further comprises introducing the polymer melt to a second melt kneading section in the melt conveying section.