1,5-pentanediol-based polyester compositions with enhanced crystallization rates and methods of manufacture
A fast crystallizing polymer composition comprising (1) a 1,5-pentanediol-based polyester material comprising at least one aliphatic acid and/or aromatic diacid, and (2) a nucleating agent, such as a poly(ethylene-co-methacrylic acid) ionomer and/or a poly(ethylene-co-acrylic acid) ionomer, and a method of making such wherein the polymer composition crystallizes within a period of about 30 seconds or less.
1 . A method of forming a polymer composition, comprising:
(1) providing a 1,5-pentanediol-based polyester material comprising 1,5-pentanediol (PDO) and a mixture of at least one aliphatic acid and at least one aromatic diacid;
(2) heating the PDO-based polyester material to a temperature sufficient to form melted 1,5-pentanediol-based polyester material;
(3) providing at least one nucleating agent (NA) selected from the group consisting of a poly(ethylene-co-methacrylic acid) ionomer and a poly(ethylene-co-acrylic acid) ionomer; and
(4) combining the at least one NA with the melted PDO-based polyester material to form a mixture, and further comprising combining a coupling agent with the mixture, and wherein the mixture forms a crystallized PDO-based polyester material.
2 . The method of claim 1 , wherein the at least one NA is partially or fully neutralized with a metal cation selected from Zn 2+ , Li + , Nat, K + , Ca 2+ , Mg 2+ , and Fe 3+ , and combinations thereof.
3 . The method of claim 1 , wherein the at least one NA is selected from zinc-neutralized, sodium-neutralized, lithium-neutralized, and magnesium-neutralized ionomers of poly(ethylene-co-methacrylic acid), and zinc-neutralized, sodium-neutralized, lithium-neutralized, and magnesium-neutralized ionomers of poly(ethylene-co-acrylic acid).
4 . The method of claim 1 , wherein the at least one NA is selected from unneutralized ionomers of poly(ethylene-co-methacrylic acid), and unneutralized ionomers of poly(ethylene-co-acrylic acid).
5 . The method of claim 1 , wherein the at least one NA comprises an amount in a range of 0.1 wt % to about 2.5 wt % of the PDO-based polyester material.
6 . The method of claim 1 , wherein the at least one NA comprises an amount in a range of 0.4 wt % to about 0.6 wt % of the PDO-based polyester material.
7 . The method of claim 1 , wherein the coupling agent is selected from the group consisting of methylene diphenyl 4,4′-diisocyanate (MDI), maleic anhydride (MA), hexamethylene diamine (HMDA), 2,2′-bis(2-oxazoline) (BOZ), epoxidic multifunctional oligomers, polycarbodiimides (PCDI), glycerol, and hexane-1,2,5,6-tetrol (HTeO).
8 . The method of claim 1 , wherein the at least one aliphatic acid and the at least one aromatic diacid make up the PDO-based polyester material in an aliphatic acid mole % to aromatic diacid mole % ratio in a range of about 25 mole %: 75 mole % to about 40 mole %: 60 mole %.
9 . The method of claim 8 , wherein the at least one aliphatic acid is adipic acid.
10 . The method of claim 8 , wherein the at least one aromatic diacid is terephthalic acid.
11 . The method of claim 1 , wherein the at least one aliphatic acid comprises adipic acid and the at least one aromatic diacid comprises terephthalic acid.
12 . The method of claim 1 , wherein the crystallized PDO-based polyester material is a blown film.
13 . A method of forming a polymer composition, comprising:
(1) providing a 1,5-pentanediol-based polyester material comprising 1,5-pentanediol (PDO) and a mixture of at least one aliphatic acid and at least one aromatic diacid;
(2) heating the PDO-based polyester material to a temperature sufficient to form melted PDO-based polyester material;
(3) providing at least one nucleating agent (NA); and
(4) combining the at least one NA with the melted PDO-based polyester material to form a mixture, and further comprising combining a coupling agent with the mixture, and wherein the mixture forms a crystallized PDO-based polyester material.
14 . The method of claim 13 , wherein the at least one NA is selected from the group consisting of dialkyl sulfoisophthalates, sodium dimethyl 5-sulfoisophthalate (SSIPA)), potassium dimethyl 5-sulfoisophthalate (LAK-301), terephthalates, monosodium terephthalate, dialkyl terephthalates, dimethyl terephthalates, naphthalene dicarboxylates, monosodium naphthalene dicarboxylate, isophthalates, monosodium isophthalate, N ′1 , N ′6 -dibenzoyladipohydrazide (TMC-306), N 1 , N 1′ -(ethane-1,2-diyl)bis(N 2 -phenyloxalamide, sulfoisophthalic acids and salts thereof, sulfoterephthalic acids and salts thereof, dialkyl sulfoterephthalic acids and salts thereof, sulfonaphthalene dicarboxylic acids and salts thereof, phenylphosphonic acid, metal salts of phenylphosphonic acid, zinc phenylphosphonate, p-toluene sulfonate, dodecylbenzenesulfonic acid, and 3-sulfobenzoic acid, and combinations of the above.
15 . The method of claim 13 , wherein the at least one NA is partially or fully neutralized with a metal cation selected from Zn 2+ , Li + , Nat, K + , Ca 2+ , Mg 2+ , and Fe 3+ , and combinations thereof.
16 . The method of claim 13 , wherein the at least one NA is unneutralized.
17 . The method of claim 13 , wherein the at least one NA comprises an amount in a range of 0.1 wt % to about 2.5 wt % of the PDO-based polyester material.
18 . The method of claim 13 , wherein the at least one NA comprises an amount in a range of 0.4 wt % to about 0.6 wt % of the PDO-based polyester material.
19 . The method of claim 13 , wherein the coupling agent is selected from the group consisting of methylene diphenyl 4,4′-diisocyanate (MDI), maleic anhydride (MA), hexamethylene diamine (HMDA), 2,2′-bis(2-oxazoline) (BOZ), epoxidic multifunctional oligomers, polycarbodiimides (PCDI), glycerol, and hexane-1,2,5,6-tetrol (HTeO).
20 . The method of claim 13 , wherein the at least one aliphatic acid and the at least one aromatic diacid make up the PDO-based polyester material in an aliphatic acid mole % to aromatic diacid mole % ratio in a range of about 25 mole %: 75 mole % to about 40 mole %: 60 mole %.
21 . The method of claim 20 , wherein the at least one aliphatic acid is adipic acid.
22 . The method of claim 20 , wherein the at least one aromatic diacid is terephthalic acid.
23 . The method of claim 13 , wherein the at least one aliphatic acid comprises adipic acid and the at least one aromatic diacid comprises terephthalic acid.
24 . The method of claim 13 , wherein the crystallized PDO-based polyester material is a blown film.