Note: Descriptions are shown in the official language in which they were submitted.
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CRAZE-RESISTANT TRANSPARENT RESINOUS COPO~YMERS
~ield of the Invention
The invention pertains to resinous copolymers. In one aspect,
the invention pertains to resinous copolymers which are craze-resistant
and transparent with minimal coloration. In a further aspect, the
invention pertains to methods of sequential block copolymerization for
the preparation of craze-resistant, low-color resinous copolymers. In
another aspect, the invention pertains to methods of producing block
copolymer resins which are transparent, possess good mechanical
properties, particularly impact resistance, are not susceptible to
flexural stress clouding, and yet are transparent with minimal
coloration.
Background of the Invention
Resinous block copolymers have been produced by methods
employing various sequential polymerization steps. Among the pioneer
inventions in the field of resinous block copolymers are such patents as
U.S. 3,639,517 to Kitchen and Szalla, U.S. 4,080,407 to Eodor, and U.S.
4,091,053 to Kitchen.
Much effort has been directed to the preparation of
substantially transparent block copolymer resins with a variety of block
structures produced by a variety of monomer addition sequences.
However, products frequently have had residual coloration
tinges, or the impact strength has been low, or importantly for many
~S
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purposes there has been a high incidence of crazing (flexural stress
clouding).
One of the more important applications for transparent resinous
copolymers has been in blister packaging of bandages, syringes, and the
like for contained product protection and maintenance of sterile
conditions during shipping. Unfortunately, all too frequently, crazing
of the blister packs has occurred because of squeezing during shipping.
The crazed packs, plus their valuable contents, then must be discarded by
the recipients, such as hospitals or physicians, since it is presumed
that air has leaked into the pack and that the contents have lost their
sterility due to contamination.
Other usages of the transparent resinous polymers have been for
blending with general purpose polystyrene. The transparent resinous
polymers have been used for various molding purposes. However, many of
the so-formed products have had a bluish tinge, or lacked clarity because
of haze, frequently leading to customer objection and reluctance to
purchase.
Needed, still, are resinous copolymers, readily made, impact
resistant, exhibiting a high resistance to crazing, transparent with good
~0 clarity, substantially no color, and substantially haze-free.
Brief Summary of the Invention
I have discovered resinous block copolymers which are highly
craze-resistant, transparent, and substantially color-free. I have also
discovered methods of producing these highly desirable craze-resistant
non-blue, non-hazy, transparent block copolymers.
A haze of less than 3 is considered good, and of about 2 or
less very good, per ASTM 1003 on a 50 mil thick sample (see my Table VI
herein). Substantial freedom from craze is desired (see my Table VI
herein).
It is an object of my invention to provide resinous block
copolymers which in use are substantially craze-resistant and exhibit
minimal coloration, retaining a haze-free character, particularly in thin
sheet products. It is another object of my invention to provide methods
for producing these highly desirable resinous copolymers.
IZ5~17 31383CA
The polymers are characterized as resinous, polymodal,
copolymers of at least one conjugated diene with at least one
monovinylarene, and are prepared so that at least a portion of the final
product is of a coupled character, linear or radial or both. The
copolymers contain about 55 to 95, preferably 60 to 87, more preferably
70 to 80, percent by weight of copolymerized monovinyl aromatic compound
(monovinylarene), and correspondingly about 45 to 5, 40 to 13, or 30 to
27, percent by weight of copolymerized conjugated diene. The coupled
portions of the resinous, polymodal copolymers have terminal
polymonovinylarene blocks on the extending arms of each linear or radial
copolymer molecule, and further contain a central internal block of
polyconjugated diene, ignoring any interruption of the internal block by
a coupling agent residue. The resinous copolymeric polymodal products
also contain portions of linear uncoupled block copolymers of
poly(monovinylarene)-poly(conjugated diene), which content is considered
to be an important portion of the resinous product, important that is in
its overall properties.
The copolymers are prepared by a process of sequential charge
copolymerization comprising the solution polymerization of at least two
charges each of a conjugated diene monomer, a monovinylarene monomer, and
a monoalkali metal initiator, at least one charge of conjugated diene
monomer precedes the last charge of alkali metal initiator, at least one
charge each of monovinylarene and of conjugated diene follow the last
charge of monoalkali metal initiator, and the last charge of monomer is a
charge of conjugated diene, such that the number of charges of each of
the three components is not more than three, and the total of the charges
of the three components is 8 or 9. Each monomer charge is allowed to
polymerize to substantial completion prior to the next monomer charge (if
any).
The resinous, polymodal block copolymers can be prepared by
various modifications (modes) of the above general procedure. Table I
following shows the preferred sequences, compared with prior art
sequences and control modes. In Table I, the indicated Runs refer to
exemplary Runs in my Examples included herein in my specification. The
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differences in result are significant, my inventive products being more
craze-resistant and having less coloration than the comparative products.
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T~BLE I
Invention Comparisons
Mode A Mode B Mode C Runs
Charge Runs Runs Runs 9-10-11- Runs Example
Order 1-2-3 4-5-6 7-8 12-13-14 15-16-17 VII
1/2 L/S~ L/S-~' L/S-~ L/S* L/S-~ L/S*
3 B B
4/5 L/S* S L/S-~ S S S
6 B B B - B
7/8 L/S* L/S* L/S* L/S~; L/S* S
9 B B B B B B
(Total additions) (9) (8) (8) (6) (7) (5)
10 C C C C C C
either L or S are charged first, then the other, or effectively
substantially at the same time; presently preferred is charge of
initiator prior to monomer.
where L = monoalkali metal initiator.
S = monovinylarene monomer and the resultant polymer block.
B = conjugated diene monomer and the resultant polymer block.
C = coupling agent.
In Table I, "L" refers to any monoalkali metal initiator useful
in solution polymerization systems; "S" refers to a monovinylarene
monomer and to the resultant polymonovinylarene block formed by the
substantially complete polymerization of the monovinylarene monomer added
at the indicated stage; "B" indicates a conjugated diene monomer and the
resultant polyconjugated diene block formed from the substantially
complete polymerization of the conjugated diene monomer added at that
stage; and "C" indicates a coupling agent.
Table II following indicates further the relationship of my
inventive sequences compared to the other methods as to the number of
additions of alkali metal initiator, conjugated diene, and monovinylarene
prior to coupling:
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TABLE II
Number of Additions of Each Component
Invention Comparisons
Mode A Mode B Mode C Runs Runs
Runs Runs Runs 9-10-11 15-16-
1-2-3 4-5-6 7-8 12-13-14-19 17-18 Example VII
L 3 2 3 2 2
S 3 3 3 3 3 3
B 3 3 2 1 2
10 Total Additions 9 8 8 6 7 5
As can be seen from Table II above, comparisons employ three
additions of monovinylarene tsuch as styrene), only a single or two
additions of conjugated diene monomer (such as butadiene), and, only one
or two additions of monoalkali metal initiator. Thus, my products and
processes are distinguished therefrom, and are improved thereover, by
using at least two additions of conjugated diene monomer as well as at
least two, and preferably three, additions of monoalkali metal initiator,
in a prescribed sequence as disclosed hereinabove, and as exemplified by
my Examples hereinafter set forth.
In accordance with one aspect (mode) of my invention, the
following copolymeric species are considered to be formed prior to
coupling in accordance with the sequence of addition of monomers and
initiator:
Mode A:
Sl-B1-S2-B2-S3-B3-L
S2-B2-S3-B3-L
S3-B3-L.
Each of "Sl", "S2", and "S3" indicates a block of substantially
homopolymeric polymonovinylarene, formed in appropriate sequence by
addition of the monovinylarene monomer and polymerization thereof under
solution polymerization conditions such that substantially complete
polymerization of the monomer charge is obtained before the next step of
monomer or initiator addition, if any. Each of "Bl", "B2", and "B3"
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similarly represents a block oE substantially homopolymeric
poly(conjugated diene) similarly formed in appropriate sequence by
polymerization of the charge to substantial completion prior to the next
step or charge. The subscript numbers indicate which step evolved the
block or blocks. Each "L" indicates a residue from a monoalkali metal
initiator remaining on the end of the polymerization chain prior to
termination. The "L" subsequently is removed o} displaced during
coupling and/or termination when the above species groups form various
combinations of coupled copolymeric species. My methods thus effectively
provide broad polymodal benefits.
In another aspect (mode~ of my invention, the following
copolymeric species are considered to be formed prior to coupling:
Mode B:
Sl-Bl-S2-B2-S3-B3-L
S3-B3-L.
In the third aspect of my invention, presently more preferred
than Modes A and B, the following species are expected to be formed prior
to coupling:
Mode C:
S1-S2-B1-S3-B2-L
S2-Bl-S3-B2-L
S3-B2-L.
The final resinous polymodal product resulting from the
polymerization procedure of the prescribed series of steps of additions
of monomer/initiator/coupling also result in proportions of terminated
uncoupled species which escape coupling.
Of course, in addition to the sequence of addition of the
monomers and of the initiator, it is important to control the amount of
each monomer and initiator addition under each sequence above at each
increment so that a suitable proportion of block sizes and proportion of
polymodality is obtained in each mode. It is feasible to stretch out
over an interval of time the addition of one or more of the increments of
initiator and/or the input of the appropriate monovinylarene monomer
8 31383CA
charge, thus spreading (increasing) further the polymodality of the
resulting product upon coupling.
Tables III following describe broad and preferred increments of
monomers and of monoalkali metal initiator, using L to symbolize the
monoalkali metal indicator, S for monovinylarene, and B for conjugated
diene.
TABLES III
Ranges of Monomers and of Initiator Additions at each Increment
Node A - TABLE III-A
Broad Preferred
Step IA L-l (phm)l)2) 0.02-0.035 0.022-0.03
L-1 (mhm)3 4 0.3-0.55 0.34-0.47
S-1 (phm) 30-45 35-41
Step IB B-1 (phm) 0.6-9 2-4
15Step IIA L-2 (phm) 0.02-0.035 0.022-0.03
L-2 (mhm) 0.3-0.55 0.34-0-47
S-2 (phm) 10-20 12-18
Step IIB B-2 (phm) 0.6-9 2-4
Step III L-3 (phm) 0.07-0.18 0.1-0.15
L-3 (mhm) 1.1-2.8 1.56-2.34
S-3 (phm) 15-30 18-26
Step IV B-3 (phm) 3.8-27 16-23
Totals S (phm) 55-95 70-80
B (phm) 45-5 30-20
L (phm) 0.1-0.25 0.13-0.2
L (mhm) 1.7-3.9 2.2-3.3
l)phm = parts by weight per 100 parts by weight of total monomers.
2)phm for L is based only on n-butyllithium molecular weight.
3)mhm = gram-millimoles per 100 grams of total monomers.
4)mhm for L is applicable for any monoalkali metal initiator. The
levels suggested are exclusive of requirements for any poisons in
the solvent streams, such as traces of alcohols.
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Mode B - TABLE III-B
Broad Preferred
Step IA L-1 (phm) 0.025-0.05 0.03-0.04
L-1 (mhm) 0.39-0.78 0.47-0.63
S-1 (phm) 30-45 35~40
Step IIB B-l (phm) 0.6-9 2-4
Step IIA S-2 (phm) 10-20 13-18
Step IIB B-2 (phm) 0.6-9 2-4
Step III L-2 (phm) 0.1-0.25 0.12-0.17
L-2 (mhm) 1.56-3.9 1.88-2.66
S-3 (phm) 15-30 18-25
Step IV B-3 (phm) 3.8-27 15-23
Totals S (phm) 55-95 70-80
B (phm) 45-5 30-20
L (phm) 0.13-0.25 0.15-0.22
L (mhm) 2.-4.7 2.3-3.'f
MODE C - TABLE III-C
Broad Preferred
Step IA L-1 (phm) 0.02-0.04 0.024-0.035
L-1 (mhm) 0.3-0.63 0.38-0.55
S-1 (phm) 30-45 35-40
Step IIA L-2 (phm) 0.02-0.04 0.025-0.035
L-2 (mhm) 0.3-0.63 0.38-0.55
S-2 (phm) 10-20 12-18
25 Step IIB B-1 (phm) 1.2-18 4-8
Step III L-3 (phm) 0.06-0.18 0.08-0.014
L-3 (mhm) 0.94-2.8 1.25-2.19
S-3 (phm) 15-30 20-25
Step IV B-2 (phm) 3.8-27 15-22
30 Totals S (phm) 55-95 70-80
B (phm) 45-5 30-20
L (phm) 0.1-0.26 0.13-0.2
L (mhm) 1.5-4 2-3.3
Based on the above monomer additions, assuming substantially
complete tco)polymerization of each monomer increment added at each step
before proceeding to the next step, and assuming equivalent rates of
initiation and propagation, the following relative Block Sizes Prior to
lZ54 317 31383CA
Coupling can be calculated (in which phm - weight percent) as shown below
in Tables IV:
TABLES IV
Calculated Relative Block Sizes Before Coupling
5Calculated from Ranges of Monomer Additions
Mode A - TABIE-IVA
Broad Preferred
(1)Sl-Bl-s2-B2-s3-B3:
S1 (phm) 30-45 35-41
B1 (phm) 0.6-9 2-4
S2 (phm) 5-lO 6-9
B2 (phm) 0.3-4.5 1-2
S3 (phm) 2.6-4.2 2.7-3.7
B3 (phm) 0.7-3.8 2.4-3.3
(2)S2-B2-s3-B3:
S2 (phm~ 5-10 6-9
B2 (phm) 0.3-4.5 1-2
S3 (phm) 2.6-4.2 2.7-3.7
B3 (phm) 0.7-3.8 2.4-3.3
(3)
S3 (phm) 9.7-21.6 12.5-18.5
B3 (phm) 2.4-19.4 11.1-16.4
After Couplin~: )
M xlO 1 80-300 150-200
MnWx10 3 1) 50-200 90-120
1)NW = weight average molecular weight.
2)Nn = number average molecular weight.
Mode B - TABLE IV-B
Broad Preferred
(1)Sl-Bl-s2-B2-s3-B3:
S1 ~phm) 30-45 35-40
B1 (phm) 0.6-9 2-4
S2 (phm) 10-20 13-18
B2 (phm) 0.6-9 2-4
S3 (phm) 3-5 3.6-4.8
B3 (phm) 0.8-4.5 3-4.4
(2) S3-B3:
S3 (phm) 12-25 14.4-20.2
B3 (phm) 3-22.5 12-18.6
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After Coupling:
M xlO 80-300 140-200
MWnxlO 3 50-200 90-120
Mode C - TAB~E IV-C
Broad Preferred
(1) S1-S2-B1-S3-B2:
S1 (phm) 30-45 35-40
S2 (phm) 5-10 6-9
B1 (phm) 0.6-9 2-4
S3 (phm) 3-4.6 3.8-4.2
B2 (phm) 0.7-4.2 2.8-3.7
(2) S2-B1-S3-B2:
S2 (phm) 5-10 6-9
B1 (ph~) 0.6-9 2-4
S3 (phm) 3-4.6 3.8-4.2
B2 (phm) 0.7-4.2 2.8-3.7
(3) ~ 2:
S3 (phm) 9-20.7 12.4-16.6
B2 (phm) 2.4-18.6 9.3-14.6
After Coupling:
M x10 3 80-300 150-200
MWnx10 3 50-200 90-120
Monomers
The conjugated dienes employed ordinarily are those of 4 to 6
carbon atoms per molecule, including the presently preferred
1,3-butadiene, as well as isoprene, 2-ethyl-1,3-butadiene,
2,3-dimethyl-1,3-butadiene, and piperylene, alone or in admixture.
The monovinylarenes employed alone or in admixture, ordinarily
contain 8 to 10 carbon atoms per molecule, including the presently
preferred styrene, as well as ~-methylstyrene, p-vinyltoluene,
m-vinyltoluene, o-vinyltoluene, 4-ethylstyrene, 3-ethylstyrene,
2-ethylstyrene, 4-tert-butylstyrene, and 2,4-dimethylstyrene.
Polymerization
The solution process polymerization is carried out as is known
in the art in a hydrocarbon diluent at any suitable temperature such as
in the range of about -100 to 150C, more usually about 0 to 110C, at
a pressure sufficient to maintain the reaction mixture substantially as a
liquid. Preferred are cycloparaffins, alone or in admixture with such as
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pentane or isooctane. Presently preferred is cyclohexan~. As is known,
small amounts of polar compounds, such as tetrahydrofuran, can be
included in the diluent for vinyl control of the diene polymer blocks,
and/or to improve effectiveness of some initiators such as the primary
alkyllithium initiators for monovinylarene polymerizations.
The initiators can be any of the organomonoalkali metal
compounds known for such purposes. Preferably employed are the
hydrocarbylmonoalkali metal compounds which correspond to the formula RM
in which R is a hydrocarbyl aliphatic, cycloaliphatic, or aromatic
radical, preferably alkyl, and M is an alkali metal, preferably lithium.
Presently preferred are alkylmonolithium initiators such as sec- and
n-butyllithium. The amounts of monoalkali metal-based initiator employed
depends upon the desired polymer or incremental block molecular weight as
is known in the art, and are readily determinable from my ranges given
above, making due allowance for traces of poisons in the feed streams.
The polymerization is ccnducted in the substantial absence of
air or moisture, preferably under an inert atmosphere. The resulting
polymers contain a very high percentage of molecules in which an alkali
metal atom is positioned at an end of the polymer chains. Of course,
traces of impurities present in the feeds, such as water or alcohol, tend
to reduce the amount of monoalkali metal-terminated polymer formed.
Thereafter, a coupling step is performed.
Coupling Reaction
In my use of the term "coupling" as herein employed, the term
means the bringing together and joining, by means of one or more central
coupling atoms or coupling moieties, two or more of the living monoalkali
metal-terminated polymer chains. A wide variety of compounds for such
purposes can be employed.
Among the suitable coupling agents are the di- or
multivinylaromatic compounds, di- or multiepoxides, di- or
multiisocyanates, di- or multiimines, di- or multialdehydes, di- or
multiketones, di- or multihalides, particularly silicon halides and
halosilanes, mono-, di-, or multianhydrides, mono-, di-, or multiesters,
preferably the esters of monoalcohols with polycarboxylic acids, diesters
which are esters of monohydric alcohols with dicarboxylic acids,
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lactones, and the like, including combination type compounds containing
two or more groups, and mixtures.
Examples of suitable vinylaromatic coupling agents include
divinylbenzene, 1,2,4-trivinylbenzene, 1,3-divinylnaphthalene,
1,3,5-trivinylnaphthalene, 2,4-divinylbiphenyl, and the like. Of these,
the divinylaromatic hydrocarbons are preferred, particularly
divinylbenzene in either its ortho, meta, or para isomer. Commercial
divinylbenzene which is a mixture of the three isomers and other
compounds is satisfactory.
While any di- or multiepoxide can be used, those which are
liquid are convenient since they are more readily handled and form a
relatively small nucleus for a radial polymer. Epoxidized hydrocarbon
polymers such as epoxidized liquid polybutadiene and the epoxidized
vegetable oils such as epoxidized soybean oil and epoxidized linseed oil,
and epoxy compounds such as 1,2; 5,6; 9,10-triepoxydecane, and the like,
can be used.
Examples of suitable multiisocyanates include
benzene-1,2,4-triisocyanate, naphthalene-1,2,5,7-tetraisocyanate, and the
like. Commercially available products known as PAPI-l~, a
polyarylpolyisocyanate having an average of 3 isocyanate groups per
molecule and an average molecular weight of about 380 are suitable.
The multiimines, also known as multiaziridinyl compounds, such
as those containing 3 or more aziridine rings per molecule, are useful.
Examples include the triaziridinyl phosphine oxides or sulfides such as
tri(l-aziridinyl)phosphine oxide, tri(2-methyl-1-aziridinyl)phosphine
oxide, tri(2-ethyl-3-decyl-1-aziridinyl)phosphine sulfide, and the like.
The multialdehydes are represented by compounds such as
1,4,7-naphthalenetricarboxyaldehyde, 1,7,9-anthracenetricarboxaldehyde,
1,1,5-pentanetricarboxyaldehyde, and similar multialdehyde-containing
aliphatic and aromatic compounds. The multiketones are represented by
compounds such as 1,4,9,10-anthracenetetrone,
2,3-diacetonylcyclohexanone, and the like. Examples of the
multianhydrides include pyromellitic dianhydride, styrene-maleic
anhydride copolymers, and the like. Examples of the multiesters include
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diethyladipate, triethylcitrate, 1,3,5-tricarbethoxybenzene, and the
like.
Among the multihalides are the silicon tetrahalides such as
silicon tetrachloride, silicon tetrabromide, and silicon tetraiodide; the
trihalosilanes such as trifluorosilane, trichlorosilane,
trichloroethylsilane, tribromobenzylsilane, and the like; and the
multihalogen-substituted hydrocarbons, such as
1,3,5-tri(bromomethyl)benzene, 2,5,6,9~tetrachloro-3,7-decadiene, and the
like, in which the halogen is attached to a carbon atom which is alpha to
an activating group such as an ether linkage, a carbonyl group, or a
carbon-to-carbon double bond. Substituents inert with respect to lithium
atoms in the terminally reactive polymer can also be present in the
active halogen-containing compounds. Alternatively, other suitable
reactive groups different from the halogen as described above can be
present.
Examples of compounds cGntaining more than one type of
functional group include 1,3-dichloro-2-propanone,
2,2-dibromo-3-decanone, 3,5,5-trifluoro-4-octanone,
2,4-dibromo-3-pentanone, 1,2,4,5-diepoxy-3-pentanone, 1,2;
4,5-diepoxy-3-hexanone, 1,2; 11,12-diepoxy-8-pentadecanone, 1,3;
18,19-diepoxy-7,14-eicosanedione, and the like.
Other metal multihalides, particularly those of tin, lead, or
germanium, can be employed as coupling and branching agents. Silicon or
other metal multialkoxides, such as silicon tetraethoxide, are also
suitable coupling agents.
Any effective amount of the coupling agent can be employed.
While the amount is not believed to be particularly critical, a
stoichiometric amount relative to the active polymer-alkali metal tends
to promote maximum coupling as a generality. However, less than
stoichiometric amounts can be used for lesser degrees of coupling where
desired for particular products of broadened molecular weight.
Typically, the total amount of coupling agent is in the range
of about 0.1 to 20 mhm (gram millimoles per 100 grams of total monomers
employed in the polymerization), presently preferably about 0.1 to 1 mhm
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(or about 0.1 to 1 phm). Preferred at present is an epoxidized soybean
oil.
Polymer Recovery
Following completion of the coupling reaction, the coupled
polymer, which may still contain bound alkali metal atoms depending on
the type of coupling agent employed, is treated to remove any remaining
alkali metal from the copolymer and to recover the copolymer.
The polymer cement (polymer in polymerization solvent) from
polymerization usually contains about 10 to 40, more usually 20 to 30,
weight percent solids, the balance solvent. Preferably, but not
necessarily, the polymer cement is flashed to remove by evaporation a
portion of the solvent so as to reduce the solvent content to a
concentration of about 10 to 50, more usually about 30 to 40, weight
percent (corresponding to a solids content of about 90 to 50, more
usually about 70 to 60, weight percent).
The polymer cement from polymerizstion, optionally concentrated
by flashing, then is treated by various means, as is known in the art,
such as by carbon dioxide and water, or treated with an aliphatic linear
~,w-dibasic acid, such as disclosed in U.S. 4,403,Q74, and recovered such
as by separation and drying.
The resinous copolymeric products can be, and normally are,
compounded with anti-oxidants, anti-blocking agents, release agents, and
the like, as known in the compounding arts.
The resinous polymodal in situ made copolymer products can be
blended with general purpose polystyrene. Broad ranges include such as
about 5-90 weight percent polystyrene, more usually 10-40 weight percent
polystyrene, the balance one or more of my polymodal resinous impact
resistant copolymer products.
Examples
Examples following are intended to $urther illustrate my
invention. Particular species employed, relationships, ratios,
conditions, should be considered as a part of my overall disclosure
without being limiting of the reasonable scope of my invention.
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Example I
These data describe the preparation of inventive coupled,
resinous, polymodal butadiene-styrene copolymers employing three
n-butyllithiu~ (NBL) initiator charges, three styrene charges, and three
1,3-butadiene charges, total 9, prior to coupling. Butadiene, styrene,
and NBL were employed as representative of the conjugated dienes,
monovinylarenes, and monoalkali metal initiators, respectively.
Polymerization runs were carried out under nitrogen in a
stirred, jacketed, stainless steel reactor of two gallons capacity
employing essentially anhydrous reactants and conditions. Recipes 1, 2,
and 3 were used for the preparation of ten representative, inventive,
resinous copolymer samples:
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Recipe 1
Run lA Run lB Run lC Run lD
Step IA
Cyclohexane diluent, phm1) 150 150 150 150
Tetrahydrofuran, phm 0.025 0.025 0.025 0.025
Styrene, phm 37 37 37 37
n-Butyllithium, phm 0.025 0.025 0.025 0.025
Polymerization Time, m~n. 12 12 13 12
Polymerization, Temp.2 , F 139~167126~156148~167 140~154
Reactor Pressure, psig21~ 3025~ 30 26~ 30 25> 30
Step IB
Cyclohexane3), phm 6.7 6.7 6.7 6.7
1,3-Butadiene, phm 3 3 3 3
Polymerization Time, min. 15 15 21 17
Polymerization Temp.,F 161 151 160 159
Reactor Pressure, psig 30 30 30 30
Step IIA
Cyclohexane, phm 13.3 13.3 13.3 13.3
n-Butyllithium, phm 0.025 0.025 0.025 0.025
Styrene, phm 16 16 16 16
Polymerization Time, min. 10 10 9 10
Polymerization Temp., F148~165150~163155~161156~151
Reactor Pressure, psig30~ 3531~ 35 30~ 31 30~ 35
Step IIB
Cyclohexane, phm 6.7 6.7 6.7 6.7
1,3-Butadiene, phm 3 3 3 3
Polymerization Time, min. 15 16 22 18
Polymerization Temp., F165 163 161 165
Reactor Pressure, psig 35 35 31 35
Step III
Cyclohexane, phm 13.3 13.3 13.3 13.3
n-Butyllithium, phm 0.11 0.11 0.11 0.11
Styrene, phm 23 23 23 23
Polymerization Time, min. 10 11 16 10
Polymerization Temp., F150)174144~165144~161145)179
Reactor Pressure, psig30~ 5030~ 50 30~ 50 20~ 50
31383CA
18 12S4:~17
Step IV
Cyclohexane, phm 6.7 6.7 6.7 6.7
1,3-Butadiene, phm 18 18 18 18
Polymerization Time, min. 20 14 19 20
Polymerization Temp., F174)218164~216161~215179)218
Reactor pressure, psig 50 50 50 50
Step V (Coupling)
CyclohexaneJ, phm 6.7 6.7 6.7 6.7
Admex 7114 , phm 0.4 0.4 0.4 0.4
10 Coupling Time, min. 20 20 20 20
Coupling Temp., F 218 216 215 218
Reactor Pressure, psig 50 50 50 50
Step VI (Recovery)
Water, phm 0.22 0.22 0.22 0.22
15 CO2, psiS 120 120 120 120
Termination Time, psig 13 15 - -
Termination Temp., F 218 218 219 220
Reactor Pressure, psig 100 100 50 50
Recovered Resin
20 Flow Rate6), g/10 ~in. 5.9 9.0 7.9 7.0
Added AntiQxidant7 , wt. % 1.25 1.25 1.25 1.25
Added Wax8J, wt. % 0.25 0.25 0.25 0.25
Butadiene:Styrene Wt. Ratio 24:7624:76 24:76 24:76
1)Parts by weight per 100 parts by weight of total monomer.
2)The temperatures listed for Steps IA, IB, IIA, IIB, III, and IV are
the recorded initial and final polymerization temperatures; the
higher peak temperatures were not recorded.
3)Small amounts of cyclohexane were used in each step (except Step VI) to
flush the feed lines.
30 4)Epoxidized soybean oil; molecular weight: 980-1000; density: 1.03 g/cc;
marketed by Sherex Co., Dublin, Ohio.
5)The amount of CO2 employed was that amount from a 350 ml container
pressurized to 120 psig; about 1.4 grams, or about 0.1 phm.
6)Determined at 200C according to ASTM D-1238, Condition G, employing
a total weight of 5.0 kg.
7)Tris(nonylphenyl)phosphite (TNPP), 1 wt. %; Irganox~ 1076, 0.25 wt. %.
8)"Be Square~" microcrystalline wax 195 marketed by Bareco, a Div. of
Petrolite Corp., Tulsa, Oklahoma; used as an antioblocking agent.
31383CA
19 lZS~3~ 7
Recipe 2
Run 2A Run 2B Run 2C
Step IA
Cyclohexane, phm 150 150 150
Tetrahydrofuran, phm 0.025 0.025 0.025
Styrene, phm 40 40 40
n-Butyllithium, phm 0.027 0.027 0.027
Polymerization Time, min. 12 12 11
Polymerization, Temp., F 130~161132~167 134~167
10 Reactor Pressure, psig28~ 3025~ 32 25~ 30
Step IB
Cyclohexane, phm 6.7 6.7 6.7
1,3-Butadiene, phm 3 3 3
Polymerization Time, min. 15 19 17
15 Polymerization Temp.,F 156 162 161
Reactor Pressure, psig 30 32 30
Step IIA
Cyclohexane, phm 13.3 13.3 13.3
n-Butyllithium, phm 0.025 0.025 0.025
20 Styrene, phm 13 13 13
Polymerization Time, min. 11 10 10
Polymerization Temp., F147>161152~160150~164
Reactor Pressure, psig30~ 3230~ 32 30) 32
Step IIB
25 Cyclohexane, phm 6.7 6.7 6.7
1,3-Butadiene, phm 3 3 3
Polymerization Time, min. 17 15 15
Polymerization Temp., F161 160 164
Reactor Pressure, psig 32 32 32
Step III
Cyclohexane, phm 13.3 13.3 13.3
n-Butyllithium, phm 0.12 0.12 0.12
Styrene, phm 23 23 23
Polymerization Time, min. 10 14 10
35 Polymerization Temp., F141>171148~164145~176
Reactor Pressure, psig30~ 5030~ 50 30~ 50
--- 31383CA
1 Z S 4 3
Step IV
Cyclohexane, phm 6.7 6.7 6.7
1,3-Butadiene, phm 18 18 18
Polymerization Time, min.15 22 20
Polymerization Temp., F171i213 164~219 176~217
Reactor pressure, psig 50 50 50
Step V (Coupling)
Cyclohexane, phm 6.7 6.7 6.7
Admex 711, phm 0.4 0.4 0.4
Coupling Time, min. 20 20 20
Coupling Temp., F 213 219 217
Reactor Pressure, psig 50 50 50
Step VI (Recovery)
Water, phm 0.22 0.22 0.22
CO2, psi 120 120 120
Termination Time, psig 13 14 15
Termiuation Temp., F 217 219 219
Reactor Pressure, psig 100 100 100
Recovered Resin
Flow Rate, g/10 min. 6.4 6.6 6.8
Added Antioxidant, wt. %1.25 1.25 1.25
Added Wax, wt. X 0.25 0.25 0.25
Butadiene:Styrene Wt. Ratio 24:76 24:76 24:76
Footnotes to Recipe 1 also apply to Recipe 2.
Recipe 3
Run 3A Run 3B Run 3C
Step IA
Cyclohexane, phm 150 150 150
Tetrahydrofuran, phm 0.025 0.025 0.025
Styrene, phm 40 40 40
n-Butyllithium, phm 0.027 0.027 0.027
Polymerization Time, min.12 12 12
Polymerization, Temp., F136~165156~166 136~165
Reactor Pressure, psig 293 30 25~ 30 25~ 30
31383CA
21 12S4317
Step IB
Cyclohexane, phm 6.7 6.7 6.7
1,3-Butadiene, phm 3 3 3
Polymerization Time, min. 15 15 15
Polymerization Temp.,F 158 162 161
Reactor Pressure, psig 30 30 30
Step IIA
Cyclohexane, phm 13.3 13.3 13.3
n-Butyllithium, phm 0.025 0.025 0.025
10 Styrene, phm 13 13 13
Polymerization Time, min. 10 10 10
Polymerization Temp., F151~166 151~162 153~164
Reactor Pressure, psig30~ 4130~ 3530~ 31
Step IIB
15 Cyclohexane, phm 6.7 6.7 6.7
1,3-Butadiene, phm 3 3 3
Polymerization Time, min. 14 16 15
Polymerization Temp., F166 162 164
Reactor Pressure, psig 41 35 31
Step III
Cyclohexane, phm 13.3 13.3 13.3
n-Butyllithium, phm 0.13 0.13 0.13
Styrene, phm 21 21 21
Polymerization Time, min. 15 14 10
25 Polymerization Temp., F154~161 152~171 147~169
Reactor Pressure, psig30) 5130~ 5030~ 50
Step IV
Cyclohexane, phm 6.7 6.7 6.7
1,3-Butadiene, phm 20 20 20
30 Polymerization Time, min. 19 20 20
Polymerization Temp., F161~218 171~219 169~215
Reactor pressure, psig 50 50 50
Step V (Coupling)
Cyclohexane, phm 6.7 6.7 6.7
35 Admex 711, phm 0.4 0.4 0.4
Coupling Time, min. 20 20 19
Coupling Temp., F 218 219 215
Reactor Pressure, psig 50 50 50
- ` ~ZS4317 31383CA
22
Step VI (Recovery)
Water, phm 0.22 0.22 0.22
C02, psi 120 120 120
Termination Time, psig 30 18 22
Termination Temp., F 220 220 218
Reactor Pressure, psig 100 100 100
Recovered Resin
Flow Rate, g/10 min. 7.2 7.0 7.2
Added Antioxidant, wt. % 1.25 1.25 1.25
Added Wax, wt. % 0.25 0.25 0.25
Butadiene:Styrene Wt. Ratio 24:74 24:74 24:74
Footnotes to Recipe 1 also apply to Recipe 3.
Example II
These data describe the preparation of coupled, resinous,
polymodal butadiene-styrene copolymers employing two n-butyllithium
initiator charges, three styrene charges, and three 1,3-butadiene
charges, total 8, prior to coupling. Recipes 4, 5, and 6 were used for
the preparation of seven representative, inventive resinous copolymers
similarly as described in Example I.
Recipe 4
Run 4A Run 4B Run 4C
Step IA
Cyclohexane, phm 157 157 157
Tetrahydrofuran, phm 0.025 0.025 0.025
Styrene, phm 37 37 37
n-Butyllithium, phm 0.032 0.032 0.032
Polymerization Time, min. 13 13 11
Polymerization, Temp., F 140~159 143~162 130~158
Reactor Pressure, psig28) 3029~ 30 25~ 30
Step IB
Cyclohexane, phm 6.7 6.7 6.7
1,3-Butadiene, phm 3 3 3
Polymerization Time, min. 15 15 15
Polymerization Temp.,F 154 159 154
Reactor Pressure, psig 30 30 30
31383CA
--` 23 lZS~
Step IIA
Cyclohexane, phm 6.7 6.7 6.7
n-Butyllithium, phm none none none
Styrene, phm 16 16 16
Polymerization Time, min. 11 12 10
Polymerization Temp., F153 156 149
Reactor Pressure, psig 30 32 30
Step IIB
Cyclohexane, phm 6.7 6.7 6.7
1,3-Butadiene, phm 3 3 3
Polymerization Time, min. 22 15 22
Polymerization Temp., F168 167 166
Reactor Pressure, psig 35 39 35
Step III
Cyclohexane, phm 13.3 13.3 13.3
n-Butyllithium, phm 0.15 0.15 0.15
Styrene, phm 23 23 23
Polymerization Time, min. 17 13 15
Polymerization Temp., F148il70 153)173 146~162
Reactor Pressure, psig30) 5030~ 50 30~ 50
Step IV
Cyclohexane, phm 6.7 6.7 6.7
1,3-Butadiene, phm 18 18 18
Polymerization Time, min. 18 20 20
Polymerization Temp., F170~219 173i219 162)216
Reactor pressure, psig 50 50 50
Step V (Coupling)
Cyclohexane, phm 6.7 6.7 6.7
Admex 711, phm 0.4 0.4 0.4
Coupling Time, min. 20 20 17
Coupling Temp., F 219 219 216
Reactor Pressure, psig 50 50 50
Step VI (Recovery)
Water, phm 0.22 0.22 0.22
CO2, psi 120 120 120
Termination Time, psig 24 15 22
Termination Temp., F 221 220 219
Reactor Pressure, psig 100 100 100
31383CA
~4 12S~
Recovered Resin
Flow Rate, g/10 min. 4.9 3.9 5.2
Added Antioxidant, wt. % 1.25 1.25 1.25
Added Wax, wt. % 0.25 0.25 0.25
Butadiene:Styrene Wt. Ratio 24:76 24:76 24:76
Footnotes to Recipe 1 also apply to Recipe 4.
Recipe 5 Recipe 6
Run 5A Run 5B Run 6A Run 6B
Step IA
10 Cyclohexane, phm 157 157 157 157
Tetrahydrofuran, phm 0.025 0.025 0.025 0.025
Styrene, phm 37 37 37 37
n-Butyllithium, phm 0.035 0.035 0.030 0.032
Polymerization Time, min. 20 28 16 18
15 Polymerization, Temp., F 134~151128~154125~150 129~154
Reactor Pressure, psig29~ 30 29~ 30 25~ 31 25~ 30
Step IB
Cyclohexane, phm 6.7 6.7 6.7 6.7
1,3-Butadiene, phm 3 3 3 3
20 Polymerization Time, min. 15 15 15 20
Polymerization Temp.,F 142 145 146 152
Reactor Pressure, psig 32 30 31 30
Step IIA
Cyclohexane, phm 13.3 13.3 13.3 13.3
25 n-Butyllithium, phm none none none none
Styrene, phm 16 16 16 16
Polymerization Time, min. 15 15 18 15
Polymerization Temp., F 142~159141)160145~157 150~161
Reactor Pressure, psig 32~ 35 31-> 40 35 30~ 32
Step IIB
Cyclohexane, phm 6.7 6.7 6.7 6.7
1,3-Butadiene, phm 3 3 3 3
Polymerization Time, min. 14 15 15 15
Polymerization Temp., F 159 160 157 161
35 Reactor Pressure, psig 35 40 35 32
31383CA
,. ~
~2S4317
Step III
Cyclohexane, phm 13.3 13.3 13.3 13.3
n-Butyllithium, phm 0.12 0.14 0.15 0.14
Styrene, phm 21 21 21 21
Polymerization Time, min. 15 17 17 16
Polymerization Temp., F146~162145~163145~161147~162
Reactor Pressure, psig30~ 5030~ 50 30i 50 31~ 50
Step IV
Cyclohexane, phm 6.7 6.7 6.7 6.7
1,3-Butadiene, phm 20 20 20 20
Polymerization Time, min. 20 20 15 20
Polymerization Temp., F162~218163i217161~215162~218
Reactor pressure, psig 50 50 50 50
Step V (Coupling)
Cyclohexane, phm 6.7 6.7 6.7 6.7
Admex 711, phm 0.4 0.4 0.4 0.4
Coupling Time, min. 20 20 20 20
Coupling Temp., F 218 217 215 218
Reactor Pressure, psig 50 50 50 50
Step VI (Recovery)
Water, phm 0.22 0.22 0.22 0.22
C02, psi 120 120 120 120
Termination Time, psig 26 18 l9 20
Termination Temp., F 221 222 219 220
Reactor Pressure, psig70~10070~100 100 100
Recovered Resin
Flow Rate, g/10 min. 7.6 10.2 6.2 6.5
Added Antioxidant, wt. % 1.25 1.25 1.25 1.25
Added Wax, wt. % 0.25 0.25 0.25 0.25
Butadiene:Styrene Wt. Ratio 26:74 26:74 26:74 26:74
Footnotes to Recipe 1 also apply to Recipes 5 and 6.
Example III
These data describe the preparation of coupled, resinous,
polymodal butadiene-styrene copolymers employing three n-butyllithium
charges, three styrene charges, and two 1,3-butadiene charges, total 8,
prior to coupling. Recipes 7 and 8 were used for the preparation of
seven representative, inventive, resinous copolymer samples similarly as
described in Example I.
~2S4317 31383CA
26
Recipe 7
Run 7A Run 7B Run 7_ Run 7D
Step IA
Cyclohexane, phm 157 157 157 157
Tetrahydrofuran, phm 0.025 0.025 0.025 0.025
Styrene, phm 37 37 37 37
n-Butyllithium, phm 0.030 0.030 0.030 0.030
Polymerization Time, min. 14 14 15 14
Polymerization, Temp., F 134i152 126~151132~152 126~147
10 Reactor Pressure, psig29~ 3029> 30 253 30 25~ 30
Step IB
Cyclohexane, phm
1,3-Butadiene, phm none none none none
Polymerization Time, min. - - - -
Polymerization Temp.,F
Reactor Pressure, psig
Step IIA
Cyclohexane, phm 13.3 13.3 13.3 13.3
n-Butyllithium, phm 0.030 0.030 0.030 0.030
20 Styrene, phm 16 16 16 16
Polymerization Time, min. 12 12 12 12
Polymerization Temp., F172~159 159~162159~164 156
Reactor Pressure, psig303 32303 35 30) 35 30~ 32
Step IIB
25 Cyclohexane, phm 6.7 6.7 6.7 6.7
1,3-Butadiene, phm 6 6 6 6
Polymerization Time, min. 24 12 15 25
Polymerization Temp., F159 162 164 156
Reactor Pressure, psig 32 35 35 32
Step III
Cyclohexane, phm 13.3 13.3 13.3 13.3
n-Butyllithium, phm 0.11 0.10 0.10 0.10
Styrene, phm 23 23 23 23
Polymerization Time, min. 12 12 12 12
35 Polymerization Temp., F147il64 153)18314~169 143~171
Reactor Pressure, psig30~ 5030i 50 30) 50 20) 50
lZ543~7 31383CA
27
Step IV
Cyclohexane, phm 6.7 6.7 6.7 6.7
1,3-Butadiene, phm 18 18 18 18
Polymerization Time, min. 20 20 20 20
Polymerization Temp., F164~217183~217169~217171)217
Reactor pressure, psig 50 50 50 50
Step V (Coupling)
Cyclohexane, phm 6.7 6.7 6.7 6.7
Admex 711, phm 0.4 0.4 0.4 0.4
10 Coupling Time, min. 15 15 15 15
Coupling Temp., F 217 217 217 217
Reactor Pressure, psig 50 50 50 50
Step VI (Recovery)
Water, phm 0.22 0.22 0.22 0.22
15 C02, psi 120 120 120 120
Termination Time, psig 18 15 8 18
Termination Temp., F 219 219 219 219
Reactor Pressure, psig 100 100 100 100
Recovered Resin
20 Flow Rate, g/10 min. 8.4 6.9 7.3 7.1
Added Antioxidant, wt. % 1.25 1.25 1.25 1.25
Added Wax, wt. % 0.25 0.25 0.25 0.25
Butadiene:Styrene Wt. Ratio 24:7624:76 24:76 24:76
Footnotes to Recipe I also apply to Recipe 7.
Recipe 8
Run 8A Run 8B un 8C
Step IA
Cyclohexane, phm 157 157 157
Tetrahydrofuran, phm 0.025 0.0250.025
30 Styrene, phm 37 37 37
n-Butyllithium, phm 0.030 0.0300.030
Polymerization Time, min. 13 15 17
Polymerization, Temp., F 136)155156)157131~152
Reactor Pressure, psig26~ 3029-~ 3229~ 30
lZS4~17 31383CA
28
Step IB
Cyclohexane, phm - - -
1,3-Butadiene, phm none none none
Polymerization Timet min. - - -
Polymerization Temp.,F
Reactor Pressure, psig
Step IIA
Cyclohexane, phm 13.3 13.3 13.3
n-Butyllithium, phm 0.030 0.030 0.030
10 Styrene, phm 16 16 16
Polymerization Time, min. 12 15 12
Polymerization Temp., F 167~159167~156 164~154
Reactor Pressure, psig30~ 3130~ 31 30
Step IIB
15 Cyclohexane, phm 6.7 6.7 6.7
1,3-Butadiene, phm 6 6 6
Polymerization Time, min. 10 15 17
Polymerization Temp., F 159 156 159
Reactor Pressure, psig30 31 30
Step III
Cyclohexane, phm 13.3 13.3 13.3
n-Butyllithium, phm 0.12 0.11 0.11
Styrene, phm 22 22 22
Polymerization Time, min. lS 15 12
25 Polymerization Temp., F 160~164147~165 143~175
Reactor Pressure, psig30~ 5030> 5030~ 50
Step TV
Cyclohexane, phm 6.7 6.7 6.7
1,3-Butadiene, phm 19 19 19
30 Polymerization Time, min. 17 20 20
Polymerization Temp., F 164~218165~219 175~218
Reactor pressure, psig50 50 50
Step V (Coupling)
Cyclohexane, phm 6.7 6.7 6.7
35 Admex 711, phm 0.4 0.4 0.4
Coupling Time, min. 15 15 15
Coupling Temp., F 218 219 218
Reactor Pressure, psig50 50 50
31383CA
29 ~25431~;'
Step VI (Recovery)
Water, phm 0.22 0.22 0.22
C02, psi 120 120 120
Termination Time, psig 20 23 14
Termination Temp., F 220 220 220
Reactor Pressure, psig 100 100 105
Recovered Resin
-
~low Rate, g/10 min. 9.0 7.5 7.6
Added Antioxidant, wt. % 1.25 1.25 1.25
10 Added Wax, wt. /O 0.25 0.25 0.25
Butadiene:Styrene Wt. Ratio 25:75 25:75 25:75
Footnotes to Recipe 1 also apply to Recipe 8.
Example IV
In this example, typical recipes for preparing coupled,
resinous, polymodal, butadiene-styrene control resins, essentially in
accordance with the procedure given in Example I of U.S. Patent
3,639,517, are described. Recipes 9, 10, and 11 list average
polymerization parameters of numerous representative control runs:
Control Recipes 9, 10, and 11
Run 9 Run 10 Run 11
Step IA
Cyclohexane, phm 167 167 167
Tetrahydrofuran, phm 0.025 0.025 0.025
Styrene, phm -33 33 33
25 n-Butyllithium, phm 0.030-0.034 0.030-0.034 0.030
Polymerization Time, min. 15-20 15-20 17-20
Polymerization, Temp., F 110-170 110-170 110-170
Reactor Pressure, psig 30 30 30
Step IB
Cyclohexane, phm
1,3-Butadiene, phm none none none
Polymerization Time, min.
Polymerization Temp.,F
Reactor Pressure, psig
31383CA
~ ~2543~'7
Step IIA
Cyclohexane, phm 6.7 6.7 6.7
n-Butyllithium, phm none none none
Styrene, phm 20 20 15
Polymerization Time, min. 15-20 15-20 15-20
Polymerization Temp., F 140-180 140-180 140-180
Reactor Pressure, psig30- 40 30- 40 30- 40
Step IIB
Cyclohexane, phm
10 1,3-Butadiene, phm none none none
Polymerization Time, min.
Polymerization Temp., F
Reactor Pressure, psig
Step III
15 Cyclohexane, phm 13.3 13.3 13.3
n-Butyllithium, phm 0.12-0.14 0.12-0.14 0.14
Styrene, phm 23 23 26
Polymerization Time, min. 15-20 15-20 15-20
Polymerization Temp., F 140-180 140-180 140-180
20 Reactor Pressure, psig30- 40 30- 40 30- 40
Step IV
Cyclohexane, phm 6.7 6.7 6.7
1,3-Butadiene, phm 24 24 26
Polymerization Time, min. 15-20 15-20 15-20
25 Polymerization Temp., F 100-225 100-225 150-225
Reactor pressure, psig30- 50 30- 50 30- 50
Step V (Coupling)
Cyclohexane, phm 6.7 6.7 6.7
Admex 711, phm 0.40 0.40 0.40
30 Coupling Time, min. 10-15 10-15 10-15
Coupling Temp., F 215-225 215-225 215-225
Reactor Pressure, psig40- 50 40- 50 40- 50
Step VI (Recovery)
Water, phm 0.22 0.22 0.22
35 CO2, psi 120 120 120
Termination Time, psig10-15 10-15 10-15
Termination Temp., F210-220 210-220 210-220
Reactor Pressure, psig50-100 50-100 50-100
lZS4317 31383CA
31
Recovered Resin
Flow Rate, g/10 min. - ~ ~
Added Antioxidant, wt. % 1.25 1.25 1.25Added Wax, wt. % 0.25 0.25 0.25Butadiene:Styrene Wt. Ratio 24:76 24:76 26:74
~ootnotes to Recipe 1 also apply to Recipes 9, 10, and 11.
Example V
In this Example, physical properties of the coupled, polymodal,
butadiene-styrene resins prepared in accordance with Recipes 1 through 11
inclusive are described. Approximately equal amounts of resins prepared
in equivalent runs (about 3 lb per run) were blended by first manually
shaking the portions of resins together in a carton drum for about l
minute and then feeding the mixture through a grinder to produce the
blend. Prepared blends are listed in Table V:
32 31383CA
TABLE V
Resin Runs for Preparing Bd.:Styr. Flow M 3) M 3)
Blend Blend Components Wt. Ratio Rate xWlO 3 xn10 3
Resin 1 Runs lA, lB, lC, lD 24:76 7.4 158 93
Resin 2 Runs 2A, 2B, 2C 24:76 7.3 189 114
Resin 3 Runs 3A, 3B, 3C 26:74 6.7 188 112
Resin 4 Runs 4A, 4B, 4C 24:76 4.1 186 99
Resin 5 Runs 5A, 5B 26:74 8.3 157 96
Resin 6 Runs 6A, 6B 26:74 6.2 177 100
10 Resin 7 Runs 7A, 7B, 7C, 7D 24:76 7.5 174 115
Resin 8 Runs 8A, 8B, 8C 24:76 8.2 173 109
Resin 9 Seven Run 9 resins 24:76 6.3 _1)
Resin 10 Eight Run 10 resins24:76 7.3
Resin 11 Three Run 11 resins26:74 7.4
15 Resin 12 Control Resin2) 24:76 7.7 170-200 90-120
Resin 13 Control Resin2) 24:76 8.4 170-200 90-120
Resin 14 Control Resin2) 24:76 7.7 170-200 90-120
l)a dash indicates not determined.
2)commercially available, coupled, resinous butadiene-styrene copolymer,
prepared essentially in accordance with Recipes 9 a~d 10; marketed by
Phillips Chemical Co., Bartlesville, OK, as K-Resin resin KR03.
3)weight average molecular weight (M ) and number average molecular
weight (M ), as determined from ge~ permeation chromatography
curves acncording to the procedure described by G. Kraus and C. Stacy
in J. Poly. Sci. A-2, 10, 657 (1972) and J. Poly. Sci. Symposium No. 43,
329 (1973); actual molecular weights are in thousands, e.g., resin has
Mw of 158,000.
The dry-mixed blends were molded in an Arburg 221 E/150, 1
ounce molding machine at a barrel temperature of about 210C, a mold
30 temperature of about 50C, a screw speed setting of about 200, an
injection pressure ranging from about 54 to 57 KP/cm2, and a total cycle
~2S4317 31383CA
33
time of 35 seconds. Physical properties of molded specimens are listed
in Table VI:
~ZS~317 31383CA
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31383CA
, .
~Z5~31'7
Data in Table VI clearly show at least two significant
improvements in properties of my Inventive Resins Runs 1-8 inclusive vs.
control resins Runs 9-12: less blue color (lower negative Hunter "b"
value), and no crazing and opaqueness upon impact. Tensile strength and
hardness were comparable for inventive and control resins, whereas
flexural modulus tended to be somewhat lower for inventive polymers,
though not undesirably so. The Vicat deflection temperatures seemed to
trend slightly lower for the inventive resins. Gardner impact of disks
is comparable for inventive and control resins; bowl impact is generally
higher for inventive resins, while sheet impact is lower for inventive
resins. Based on bowl impact data, Resins 7 and 8 prepared with three
n-butyllithium initiator charges, three styrene charges, and two
butadiene charges, total 9 before coupling,presently are most preferred.
Example VI
In this example the polymerization and properties of control
resins Runs 15-19 inclusive are described.
Control Resins 15-18 inclusive which were prepared with two
n-butyllithium (NBL) initiator charges, three styrene charges, and two
butadiene charges. The recipes for Control Runs 15-18 were essentially
the same as the recipes for Control Runs 9-11 except that in Control Runs
15-18 a portion of butadiene was added after the second styrene charges
and before the second and final NBL charge, i.e., recipes of Control Runs
15-18 contained Step IIB (absent in recipes of Control Runs 9-11)
employing 5-12 phm butadiene. The time for polymerizing the first
butadiene charge in Step IIB was about 15 minutes. Temperature and
pressure were about the same as listed for Step IIA (see recipes of
Control Runs 9-11). It is expected that the following polymeric species
before coupling were formed: S-S-B-S-B-Li and S-B-Li.
Control Run 19 was essentially the same as Control Runs 9-11
(Recipe in Example IV).
Monomer charges in polymerization Control Runs 9, 10, and
Control Runs 15-19 inclusive, plus some key physical properties of formed
resins are summarized in Table VII. NBL (n-butyllithium) charges (in
phm) are designated Ll, L2, L3; styrene charges (in phm) are designated
Sl, S2, S3; and butadiene charges (in phm) are designated Bl, B2.
- ` i2S43~7
36
TABLE VII
Run Char~e 15 16 17 9 10 18 19
Sl 26.4 26.4 26.4 33 33 22 25.5
Ll 0.04 0.04 0.04 0.03 0.03 0.03 0.035
S2 26.6 26.6 26.6 20 20 22 25.5
Bl 12 5 5 0 0 8 0
L2 0.13 0.13 0.13 0.13 0.13 0.13 0.145
S3 23 23 23 23 23 29 22
B2 12 19 19 24 24 19 27
Wt-% Butadiene 24 24 24 24 24 27 27
Wt-% Styrene 76 76 76 76 76 73 73
Flow Rate 4.0 12.5 3.6 - - 4.2 7.7
Haze (%) 15.4 20.7 28.0 1.9 1.728.8 6.4
Dart Impact1) _2) >81 >81 - - >81 >80
Tensile Strength3) 2.42 - 2.98 4.72 4.57 2.26 2.53
l)determined in accordance with ASTM D 1709-75; given in inch-lb.
2)a dash indicates not determined.
3)at yield; given in Kpsi
Data in Table VII show that the control resins of Runs 15-18
inclusive employing two butadiene charges did not exhibit strength and
impact advantages versus the control resins of Runs 9, 10, and 19
prepared with only one butadiene charge. In addition, the resins
produced in Control Runs 15-18 inclusive possessed unacceptable high
haze.
The control resin of Run 19 showed tensile similar to Runs 15,
17, 18; a somewhat better but still unsatisfactory haze as compared to
Runs 15-19, though not as good as, Control Runs 9-10. None of these
control copolymers were acceptable for clear copolymer usages requiring
excellent mechanical properties.
lZ54317 31383CA
37
Example VII
Comparative resinous 76:24 weight ratio styrene:butadiene
copolymers were employing a charge sequence of a single initiator charge,
three incremental monovinylarene charges, and a single (final) conjugated
diene charge ~charge order ~/S, S, S, B), followed by coupling.
Anticipated species formed would be: S-B-~ prior to coupling. Otherwise,
the conditions employed were essentially similar to Recipe 1 above
The so-prepared coupled resinous copolymers employing a single
initiator charge do not exhibit any significant polymodality, despite
multiple monomer additions.
These copolymers, while resinous, fairly transparent, with
satisfactory flexural modulus and tensile, thus suitable for many
purposes (importantly) shatter at only about 10-inch-lbs. Satisfactory
craze resistant copolymers pass the test at about 60 inch-lbs and above,
using the test shown in my Table VI footnote 3.
~xample VIII
The size and makeup of the polymeric species considered to be
present in some of the above-described resinous, polymodal,
butadiene-styrene copolymers are depicted below.
Sl, S2, S3, each represents a block of polymonovinylarene
formed after addition of and substantial completion of polymerization of
a charge of monomeric monovinylarene. The subscripts indicate the order
of formation.
B1, B2, B3, each represents a block of polyconjugated diene
formed after addition of and substantial completion of polymerization of
a charge of monomeric conjugated diene. The subscripts indicate the
order of formation.
B represents the initiator residue on the end of a
polymer-chain prior to any termination or coupling of the chain.
Mode A, Inventive Resins 1, 2, and 3, prepared with three initiator
charges, three styrene charges, and three butadiene charges, form an in
situ mixture of the following three primary species before coupling since
each NBL addition initiates a new polymer chain:
38 31383CA
Sl-Bl-S2-B2-S3-B3-I.
S2-B2-S3-B3-L
S3-B3-L.
Mode B, Inventive Resins 4, 5, and 6, prepared with two initiator
charges, three butadiene charges, and three styrene charges, form an in
situ the following two primary species before coupling:
Sl-Bl-S2-B2-S3-B3-L
S3-B3-L.
Mode C, Inventive Resins 7 and 8, prepared with three initiator charges,
two butadiene charges, and three styrene charges, form the following
three primary species before coupling:
Sl-S2-Bl-S3-B2-L
S2-Bl-S3-B2-L
S3-B2-L -
Control Resins 9-14, prepared with two initiator charges, three
styrene charges, and one butadiene charge, form the following two primary
species before coupling:
S 1 -S2-S3-B-L
S3-B-L.
Control resins prepared with two initiator charges, three
styrene charges, and two butadiene charges, form the following primary
species before coupling:
Sl-S2-Bl-S3-B2-L
S3-B2-L
Of course, in any sequence of solution polymerization stages,
traces of initiator poisons, when present or introduced with feed
streams, can cause termination of a few growing chains. For example,
after the first stage, a small amount of S block polymer likely is
present.
The sizes of the various S and B blocks, as well as B/S ratios
and molecular weights of the different polymer species can be estimated.
The method of calculation for these estimates is exemplified for
Inventive Resin 1 (Recipe 1)(all calculations are based on assumption
that no initiator poisons were present, and that initiation rates and
propagation rates were equal).
31383CA
-` ~ZS4317
39
Initiator charges (NBL):
L1 (Steps IA/IB): 0.025 phm = 0.39 mhm
L2 (Steps IIA/IIB): 0.025 phm = 0.39 mhm
L3 (Steps III/IV): 0.11 phm = 1.72 mhm
NBL Total = 2.50 mhm
(g-millimoles per 100 g monomers)
Steps IA/IB:
37 phm styrene and 3 phm butadiene polymerize to form
(S1~B1)X-Li polymer chains where Li = lithium.
Steps IIA/IIB:
A portion of added 16 phm styrene and of 3 phm butadiene
polymerizes onto the existing (S1-B1) -Li polymer chains; this portion is
L~
Ll+L2 .
Thus 8.0 phm styrene and 1.5 phm butadiene form S2 and B2
blocks attached to S1-B1 to form (S1-B1)x-(S2-B2)y~Li. The other
portion,
L2
L1+L2, of styrene and butadiene forms new polymer chains initiated
with L2. Thus, 8 phm styrene and 1.5 phm butadiene form new polymer
chains (S2-B2)y~Li. It is assumed that the propagation rate of both
chains is the same.
Steps III/IV:
The portion of 23 phm styrene and 18 phm butadiene polymerized
onto (S1-B1)X-(s2-B2)y~Li chains is
Ll
I.l+L2+I~3 -
Thus 0.39 x 23 = 3.6 phm S3 and 0.39 x 18 = 2.8 phm B3 are polymerized
2.50 2.50
30 to form (S1-B1)X-(S2-B2)y-(s3-B3)z-Li chains-
The portion of styrene and butadiene polymerized onto (B2-S2)y~Li chains
is L2 . Thus 3.6 phm S3 and 2.8 phm B3 are polymerized to
L1+L2+L3
form (S2-B2)y~(S3~B2)z~Li chains. The portion of styrene and butadiene
31383CA
-` lZ54317
that forms newly initiated (S3-B3)z-Li polymer chains is L3
Ll+L2+L3
Thus 1.72 x 23 = 15.8 phm S3 and 1.72 x 18 = 12.4 phm B3 are polymerized
to form ~S3-B3) -Li polymer chains. It is assumed that the propagation
rate of each chain is the same.
The molecular weights (Mn) of the species before coupling can
be estimated by dividing the number of phms of monomers in each chain
(species) by the number of moles of Li associated with each chain:
37.0 3.0 8.0 1.5 3.6 2.8
S1 - B1 - S2 - B2 ~ S3 - B3 Mn = 55 9 = 143,000
0.39xlO
8.0 1.5 3.6 2.8
S2 - B2 ~ S3 - B3 Mn = 15.9 = 41,000
0.39xlO 3
15.8 12.4
S3 - B3 Mn = 28.2 = 16,000
1.72xlO 3
The described calculations were also carried out for Inventive
Resins 2-8 and for control Resins 12-14. Results are summarized in Table
VIII:
31383CA
41 lZ54317
TABLE VIII
Bd:Styr. M Before
Resin Block Sequence, phm Wt. Ratio Conupling
1 37.0 3.0 8.0 1.5 3.6 2.8 13:87 143,000
S1 - B1 - S2 - B2 - S3 - B3
8.0 1.5 3.6 2.8
S2 - B2 ~ S3 - B3 27:7341,000
15.8 12.4
S3 - B3 44:5616,000
2 40.0 3.0 6.7 1.6 3.6 2.8
S1 - B1 - S2 - B2 ~ S3 - B3 14:86137,000
6.3 1.4 3.3 2.6
S2 ~ B2 - S3 - B3 29:7135,000
16.1 12.6
S3 - B3 44:5615,000
3 40.0 3.0 6.7 1.6 3.1 ~.0
S1 - B1 - S2 - B2 - S3 - B3 13:87136,000
6.3 1.4 2.9 2.7
S2 ~ B2 - S3 - B3 31:6934,000
15.0 14.3
S3 - B3 49:5113,000
4 37.0 3.0 16.0 3.0 4.0 3.2
S1 - B1 - S2 - B2 ~ S3 - B3 14:86132,000
19.0 14.8
S3 - B3 44:5614,000
37.0 3.0 16.0 3.0 4.5 4.3
S1 - B1 - S2 - B2 ~ S3 - B3 15:85123,000
16.5 15.7
S3 - B3 49:5116,000
6 37.0 3.0 16.0 3.0 3.7 3.5
S1 - B1 - S2 - B2 ~ S3 - B3 14:86138,000
17.3 16.5
S3 - B3 49:5115,000
31383CA
-~ ~254317
42
7 37.0 8.0 3.0 4.3 3.4
Sl - S2 - Bl - S3 - B2 11:89 119,000
8.0 3.0 4.3 3.4
S2 ~ Bl - S3 - B2 34:66 40,000
14.4 11.2
S3 - B2 44:56 16,000
8 37.0 8.0 3.0 3.8 3.3
Sl - S2 - Bl - S3 - B2 11:89 117,000
8.0 3.0 3.8 3.3
S2 - Bl - S3 - B2 35:65 39,000
14.0 12.4
S3 - B2 46:54 15,000
12-14 37.0 16.0 4.8 4.g
Sl - S2 - S3 - B 8:92 101,000-
120,000
18.2 19.0
S3 - B 51:49 18,000-
20,000
The disclosure, including data, illustrate the value and
effectiveness of my invention.
The resinous polymodal copolymer products of my invention are
particularly useful as a blending component for general purpose
polystyrene to improve greatly the scope of use of the polystyrene.
The Examples, the knowledge and background of the field of the
invention, and the general principles of chemistry and of other
applicable sciences, form the bases from which the broad descriptions of
my invention including the ranges of conditions and the generic groups of
operant components have been developed, and form the bases for my claims
here appended.
