Polyester composition and article thereof

Abstract

The invention provides a polyester composition and a product thereof. The polyester composition includes a resin (A), a fiber reinforcing material (B), an inorganic reinforcing material (C), a nucleating agent (D), and a toughening agent (E). The resin (A) has an intrinsic viscosity of 0.6 dL / g to 0.85 dL / g.

Description

TECHNICAL FIELD

[0001] The present application relates to a polyester composition, and in particular to a polyester composition capable of being processed at low temperature and an article thereof. BACKGROUND

[0002] Currently, most of the tableware is made of melamine. However, when the melamine tableware is damaged or scratched, it will release toxins when heated, which will then enter the human body and cause organ damage. The polyester tableware commonly used at present is made of polyethylene terephthalate (PET) containing nucleating agents. However, the polyethylene terephthalate containing nucleating agents needs to be injection molded at a high mold temperature (e.g. 130°C) or needs to be post-crystallized after being injection molded at a low mold temperature, and the heat-resistant temperature of the tableware made thereof is only 150°C. Therefore, how to improve the production efficiency and heat resistance of non-toxic products is the goal that those skilled in the art desire to develop. SUMMARY

[0003] The present application provides a polyester composition having good mechanical properties, heat resistance and processability and an article thereof.

[0004] The polyester composition of the present application comprises resin (A), fiber reinforcing material (B), inorganic reinforcing material (C), nucleating agent (D) and toughening agent (E). The intrinsic viscosity (IV) of resin (A) is 0.6 dL / g to 0.85 dL / g.

[0005] In an embodiment of the present application, the resin (A) comprises polyethylene terephthalate (PET) virgin resin, recycled polyethylene terephthalate (RPET) or a combination thereof.

[0006] In an embodiment of the present application, the fiber reinforcing material (B) comprises glass fiber, carbon fiber, titanium fiber, boron fiber or a combination thereof.

[0007] In an embodiment of the present application, based on the total amount of the polyester composition being 100 parts by weight, the amount of fiber reinforcing material (B) used is 5 parts by weight to 20 parts by weight.

[0008] In an embodiment of the present application, the inorganic reinforcing material (C) comprises talc, titanium dioxide, silicon dioxide, calcium carbonate or a combination thereof.

[0009] In one embodiment of the present application, the inorganic reinforcing material (C) is used in an amount of 5 to 20 parts by weight, based on 100 parts by weight of the total amount of the polyester composition.

[0010] In one embodiment of the present application, the nucleating agent (D) includes at least one organic nucleating agent.

[0011] In one embodiment of the present application, the toughening agent (E) includes ethylene-methyl acrylate-glycidyl methacrylate terpolymer (EMA-g-GMA), polyethylene octene grafted glycidyl methacrylate (POE-g-GMA), styrene-ethylene / butylene-styrene copolymer (SEBS), styrene-ethylene / butylene-styrene block copolymer grafted maleic anhydride (SEBS-g-MAH), methyl methacrylate-butadiene-styrene (MBS), or a combination thereof.

[0012] In one embodiment of the present application, the polyester composition further includes a slip agent (F). The slip agent (F) includes a stearate salt, a polyethylene wax, a silicone modifier, a fluorine-based resin, or a combination thereof.

[0013] In one embodiment of the present application, the polyester composition further includes an antioxidant (G). The antioxidant (G) includes a hindered phenol antioxidant, a phenol antioxidant, a phosphite antioxidant, a complex antioxidant, or a combination thereof.

[0014] In one embodiment of the present application, the polyester composition further includes a slip agent (F), an antioxidant (G), or a combination thereof. The slip agent (F) is used in an amount of 0.1 to 2 parts by weight, and the antioxidant (G) is used in an amount of 0.2 to 2 parts by weight, based on 100 parts by weight of the total amount of the polyester composition.

[0015] In one embodiment of the present application, the resin (A) is used in an amount of 60 to 80 parts by weight, the nucleating agent (D) is used in an amount of 2.5 to 10 parts by weight, and the toughening agent (E) is used in an amount of 0.3 to 2 parts by weight, based on 100 parts by weight of the total amount of the polyester composition.

[0016] An article of the present application is manufactured using the polyester composition described above as an engineering plastic pellet.

[0017] Based on the above, the polyester composition of the present application includes resin (A), fiber reinforcing material (B), inorganic reinforcing material (C), crystal nucleus agent (D), and toughening agent (E), and the inherent viscosity of resin (A) is 0.6 dL / g to 0.85 dL / g. Thereby, the polyester composition can have good mechanical properties, heat resistance, and processability. In addition, the polyester composition of the present application can be processed as engineering plastic pellets, and can be processed at low mold temperature, making the process simple and easy to implement, and having industrial production value.

[0018] In order to make the above features and advantages of the present application more obvious and easy to understand, the following specific examples are described in detail as follows. DETAILED DESCRIPTION

[0019] The following are examples of detailed description of the content of the present application. The implementation details presented in the examples are for illustrative purposes and do not limit the scope of the content of the present application. Those skilled in the art can modify or change the implementation details according to the actual implementation needs. In addition, the description of well-known devices, methods and materials can be omitted to avoid obscuring the description of various principles of the present application.

[0020] The range can be expressed herein as from "about" one particular value to "about" another particular value, which also can be expressed as a particular value and / or to another particular value. In expressing a range, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when a value is expressed as an approximation by use of the antecedent "about," it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each range are explicitly associated with another endpoint or are not associated with another endpoint.

[0021] In this document, non-limiting terms such as "may", "can", "for example", or other similar phrases are optional or alternative implementations, inclusions, additions, or existences.

[0022] Unless otherwise defined, all terms used herein, including technical and scientific terms, have the same meaning as commonly understood by those skilled in the art to which the present application belongs. It will also be understood that terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant art and should not be interpreted in an idealized or overly formal sense, unless expressly defined herein.

[0023] <polyester composition>

[0024] The present application provides a polyester composition including resin (A), fiber reinforcing material (B), inorganic reinforcing material (C), nucleating agent (D), and toughening agent (E). In addition, the polyester composition of the present application can further include slip agent (F), antioxidant (G), or other suitable additives as needed. Hereinafter, the above-mentioned various components will be described in detail.

[0025] Resin (A)

[0026] The inherent viscosity of resin (A) is 0.6 dL / g to 0.85 dL / g, preferably 0.6 dL / g to 0.76 dL / g. When the inherent viscosity of resin (A) is less than 0.6 dL / g, the impact resistance of the polyester composition can be reduced, and thus the polyester composition or its product can have the problem of insufficient strength and / or cracking. When the inherent viscosity of resin (A) is greater than 0.85 dL / g, the melt flow index (MI) of the polyester composition can be increased, and thus the flowability of the polyester composition can be poor and not easy to apply to subsequent processing processes.

[0027] The structure / composition of resin (A) is not particularly limited, and an appropriate resin can be selected as needed. For example, resin (A) can include polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or other suitable resins. Polyethylene terephthalate can include polyethylene terephthalate virgin pellets, recycled polyethylene terephthalate, or a combination thereof. The source of recycled polyethylene terephthalate includes packaging material recycled pellets, film material recycled pellets, fabric recycled pellets, industrial recycled environmentally friendly recycled polyester pellets, or other suitable polyethylene terephthalate products to meet the needs of introducing recycled materials, but is not limited thereto. Packaging material recycled pellets can include bottle recycled pellets (e.g., PET bottle recycled pellets), tray recycled pellets, or other suitable packaging material products.

[0028] Based on the total amount of the polyester composition used is 100 parts by weight, the amount of resin (A) used is 60 parts by weight to 80 parts by weight, preferably 65 parts by weight to 72 parts by weight.

[0029] Fiber reinforcing material (B)

[0030] The fiber reinforcing material (B) is not particularly limited, and an appropriate fiber reinforcing material can be selected as needed. In the present embodiment, the fiber reinforcing material (B) can include glass fiber, carbon fiber, titanium fiber, boron fiber, a combination thereof, or other suitable fiber reinforcing material, preferably glass fiber or carbon fiber. When the polyester composition includes fiber reinforcing material (B), the polyester composition can have better impact resistance, bending strength, rigidity, and heat resistance, i.e., better mechanical properties and heat resistance.

[0031] Based on a total usage of 100 parts by weight of the polyester composition, the usage of fiber reinforcing material (B) is 5 to 20 parts by weight, preferably 8 to 15 parts by weight. When the usage of fiber reinforcing material (B) is within the above range, the resin composition can possess good mechanical properties, heat resistance, and processability. When the usage of fiber reinforcing material (B) is less than 5 parts by weight, the heat resistance of the polyester composition may be poor. When the usage of fiber reinforcing material (B) is greater than 20 parts by weight, the melt index of the polyester composition may increase, thereby resulting in poor flowability of the polyester composition and making it difficult to apply to subsequent processing processes.

[0032] Inorganic reinforcing materials (C)

[0033] There are no particular limitations on the inorganic reinforcing material (C), and appropriate inorganic reinforcing materials can be selected according to requirements. In this embodiment, the inorganic reinforcing material (C) includes talc, titanium dioxide, silica, calcium carbonate, combinations thereof, or other suitable inorganic reinforcing materials, preferably talc or calcium carbonate. When the polyester composition includes the inorganic reinforcing material (C), the polyester composition can have better flexural strength, rigidity, heat resistance, and formability.

[0034] Based on a total usage of 100 parts by weight of the polyester composition, the usage of the inorganic reinforcing material (C) is 5 to 20 parts by weight, preferably 8 to 18 parts by weight. When the usage of the inorganic reinforcing material (C) is within the above range, the resin composition can possess good mechanical properties, heat resistance, and processability. When the usage of the inorganic reinforcing material (C) is less than 5 parts by weight, the heat resistance of the polyester composition may be poor and it may be difficult to demold during molding. When the usage of the inorganic reinforcing material (C) is greater than 20 parts by weight, the impact resistance of the polyester composition may be reduced, thereby causing the polyester composition or its products to fail drop tests.

[0035] Nucleating agent (D)

[0036] The nucleating agent (D) is not particularly limited and can be selected as needed. In this embodiment, the nucleating agent (D) may include at least one organic nucleating agent. The organic nucleating agent may include an organosodium salt or other suitable organic nucleating agent. The organosodium salt may include sodium benzoate, sodium lignite, surlyn resin (e.g., EMAA (trade name), manufactured by DuPont) or other suitable organosodium salts, preferably sodium benzoate, surlyn resin, or a combination thereof, more preferably a combination of sodium benzoate and surlyn resin. The mixing weight ratio of sodium benzoate to surlyn resin may be 1:10 to 1:20, preferably 1:12 to 1:16. When the polyester composition includes the nucleating agent (D), the heat resistance of the polyester composition can be improved.

[0037] Based on the total amount of polyester composition used being 100 parts by weight, the amount of nucleating agent (D) used is 2.5 parts by weight to 10 parts by weight, preferably 3 parts by weight to 5 parts by weight.

[0038] Toughening agent (E)

[0039] There are no particular limitations on the toughening agent (E), and an appropriate toughening agent can be selected according to requirements. In this embodiment, the toughening agent (E) may include ethylene-methyl acrylate-glycidyl methacrylate terpolymer, polyethylene octene grafted with glycidyl methacrylate, styrene-ethylene / butene-styrene copolymer, styrene-ethylene / butene-styrene block copolymer grafted with maleic anhydride, methyl methacrylate-butadiene-styrene, combinations thereof, or other suitable toughening agents, preferably ethylene-methyl acrylate-glycidyl methacrylate terpolymer (EMA-g-GMA). When the polyester composition includes the toughening agent (E), it can improve the interfacial compatibility and impact resistance between the components in the polyester composition.

[0040] Based on the total amount of polyester composition used being 100 parts by weight, the amount of toughening agent (E) used is from 0.3 parts by weight to 2 parts by weight, preferably from 0.5 parts by weight to 1 part by weight.

[0041] Lubricant (F)

[0042] There are no particular limitations on the lubricant (F), and an appropriate lubricant can be selected according to requirements. In this embodiment, the lubricant (F) may include stearates, polyethylene waxes, siloxane modifiers, fluoropolymers, combinations thereof, or other suitable lubricants, preferably polyethylene waxes. When the polyester composition includes lubricant (F), the flowability of the polyester composition can be improved. This helps to improve the flow and release properties of subsequent processing (e.g., injection molding).

[0043] Based on the total amount of polyester composition used being 100 parts by weight, the amount of lubricant (F) used is from 0.1 parts by weight to 2 parts by weight, preferably from 0.3 parts by weight to 1 part by weight.

[0044] Antioxidants (G)

[0045] There are no particular limitations on the antioxidant (G), and appropriate antioxidants can be selected according to requirements. In this embodiment, the antioxidant (G) may include hindered phenolic antioxidants, phenolic antioxidants, phosphite antioxidants, complex antioxidants, combinations thereof, or other suitable antioxidants, preferably complex antioxidants. For example, a complex antioxidant may include a combination of hindered phenolic antioxidants and phosphite antioxidants, or other suitable combinations of antioxidants. The mixing weight ratio of hindered phenolic antioxidants to phosphite antioxidants may be 2:1 to 1:2, preferably 1:1 to 1:1.5. When the polyester composition includes antioxidant (G), the heat resistance and processability of the polyester composition can be improved.

[0046] Based on the total amount of polyester composition used being 100 parts by weight, the amount of antioxidant (G) used is from 0.2 parts by weight to 2 parts by weight, preferably from 0.3 parts by weight to 1 part by weight.

[0047] <Preparation Method of Polyester Composition>

[0048] There are no particular limitations on the preparation method of the polyester composition. For example, resin (A), fiber reinforcing material (B), inorganic reinforcing material (C), nucleating agent (D) and toughening agent (E) are placed in a stirrer and stirred until they are uniformly mixed into a solution. If necessary, lubricant (F) and antioxidant (G) can also be added. After mixing them evenly, a liquid polyester composition can be obtained.

[0049] <Products>

[0050] An exemplary embodiment of the present invention provides an article made using the above-described polyester composition as engineering plastic pellets.

[0051] For example, polyester compositions, as engineering plastic granules, can be processed into articles. There are no particular limitations on the processing methods; appropriate methods can be selected based on requirements. Processing methods may include extrusion molding, injection molding, sheet processing, or other suitable methods.

[0052] The temperature of the forming mold in the processing technology can be below 80°C, preferably between 60°C and 80°C. This allows the product formed by the mold to proceed directly to subsequent processes without prior cooling, thus improving production efficiency and reducing energy consumption.

[0053] The invention will be described in detail below with reference to examples. The following examples are provided to illustrate the invention, and the scope of the invention includes the scope set forth in the following claims, as well as their substitutions and modifications, but is not limited to the scope of the examples.

[0054] Example

[0055] To demonstrate that the polyester composition proposed in this invention has good mechanical properties, heat resistance, and processability, the following experimental example is specifically presented.

[0056] The types of components and their amounts used in the polyester compositions of Example 1 and Comparative Examples 1 to 6 are listed in Tables 1 and 2 below. The obtained polyester compositions were analyzed using the following test methods, and the results are shown in Tables 1 and 2.

[0057] [Table 1]

[0058]

[0059] *The fiber reinforcement material (B) uses HP 3786 glass fiber (trade name, manufactured by PFG FIBER GLASS CORPORATION), which is a short fiber with a diameter of 10 micrometers and a length of 4.5 millimeters.

[0060] *The salyn resin used in nucleating agent (D) is Surlyn 8920 (trade name, manufactured by DuPont).

[0061] *The antioxidant (G) selected is B225 (trade name, manufactured by Double Bond Chemical Co., Ltd.), which is a mixture of hindered phenolic antioxidants and phosphite antioxidants in a 1:1 weight ratio.

[0062] [Table 2]

[0063]

[0064] <Testing Method>

[0065] Impact strength: Tested according to ASTM D256 standard. The obtained value (kg-cm / cm) is the total energy that the polyester composition can withstand upon breaking. The higher the value, the higher the impact strength (or resistance strength) that the polyester composition can withstand.

[0066] Tensile strength: Tested according to ASTM D638 standard. The obtained value is the total energy that the polyester composition can withstand under tensile deformation. The higher the value, the higher the tensile strength that the polyester composition can withstand.

[0067] Flexural strength: Tested according to ASTM D790 standard. The obtained value represents the polyester composition's resistance to bending deformation. The higher the value, the higher the flexural strength that the polyester composition can withstand.

[0068] Flexural modulus: Tested according to ASTM D790 standard. The obtained value is the total energy of the polyester composition against flexural deformation. The higher the value, the higher the rigidity of the polyester composition.

[0069] Heat deflection temperature (HDT): Tested according to ASTM D648 standard at a pressure of 0.45 MPa. The obtained value represents the polyester composition's resistance to heat distortion. The higher the value, the higher the heat resistance of the polyester composition.

[0070] Melt Flow Index: Based on ASTM D1238 standard, the amount of flow during a 10-minute test at 275°C with a hammer weight of 2.16 kg is measured. The resulting value represents the flowability of the polyester composition. A higher value indicates a higher viscosity of the polyester composition.

[0071] Molding properties: The polyester composition is injection molded into an article at a mold temperature of 80°C. Observe whether the article can be formed normally, cannot be formed, or cannot be ejected from the mold (i.e., sticking to the mold). The better the molding properties of the polyester composition, the better the molding properties of the article.

[0072] Drop test: Products made of the polyester composition are dropped freely from a height of 1.8 meters, and it is observed whether the products break. Products that do not break indicate that the products made of the polyester composition have better toughness.

[0073] <Test Results>

[0074] As shown in Table 1, when the polyester composition includes resin (A), fiber reinforcement (B), inorganic reinforcement (C), nucleating agent (D), and toughening agent (E), and the intrinsic viscosity of resin (A) is between 0.6 dL / g and 0.85 dL / g (Example 1), the polyester composition simultaneously possesses good impact resistance, flexural strength, rigidity, heat resistance (e.g., up to 170°C), flowability, moldability, and toughness; that is, good mechanical properties, moldability, and the ability to produce crack-free articles. In contrast, when the intrinsic viscosity of resin (A) in the polyester composition is not in the range of 0.6 dL / g to 0.85 dL / g (Comparative Examples 1-2), the impact resistance, flexural strength, rigidity, heat resistance, flowability, moldability, and / or toughness of the polyester composition are poor. When the intrinsic viscosity of resin (A) in the polyester composition is less than 0.6 dL / g (Comparative Example 1), the article made from the polyester composition will crack after a drop test. When the intrinsic viscosity of the resin (A) in the polyester composition is greater than 0.85 dL / g (Comparative Example 2), the polyester composition cannot be molded under high pressure (high pressure) during the manufacturing process.

[0075] Furthermore, as shown in Table 2, compared to polyester compositions that do not include fiber reinforcement (B) or whose total amount of polyester composition is 100 parts by weight and whose amount of fiber reinforcement (B) is less than 5 parts by weight (Comparative Example 3), polyester compositions that include fiber reinforcement (B) and whose amount of fiber reinforcement (B) is between 5 and 20 parts by weight (Example 1) have better impact resistance, flexural strength, rigidity and heat resistance, and also have good formability and toughness.

[0076] Furthermore, compared to polyester compositions where the total amount of fiber reinforcing material (B) is 100 parts by weight and the amount of fiber reinforcing material (B) is greater than 20 parts by weight (Comparative Example 4), polyester compositions where the amount of fiber reinforcing material (B) is 5 to 20 parts by weight (Example 1) have better formability and also have good impact resistance, flexural strength, rigidity and heat resistance.

[0077] Furthermore, compared to polyester compositions that do not include inorganic reinforcing material (C) or whose total amount of polyester composition is 100 parts by weight and whose amount of inorganic reinforcing material (C) is less than 5 parts by weight (Comparative Example 5), polyester compositions that include inorganic reinforcing material (C) and whose amount of inorganic reinforcing material (C) is from 5 to 20 parts by weight (Example 1) have better flexural strength, rigidity, heat resistance and formability, while also having good impact resistance and toughness.

[0078] Furthermore, compared to polyester compositions where the total amount of the polyester composition used is 100 parts by weight and the amount of inorganic reinforcing material (C) used is greater than 20 parts by weight (Comparative Example 6), polyester compositions where the amount of inorganic reinforcing material (C) used is 5 to 20 parts by weight (Example 1) have better impact resistance, flexural strength and toughness, while also having good rigidity and heat resistance.

[0079] In summary, the polyester composition of the present invention comprises resin (A), fiber reinforcing material (B), inorganic reinforcing material (C), nucleating agent (D), and toughening agent (E). When the intrinsic viscosity of resin (A) is between 0.6 dL / g and 0.85 dL / g, the polyester composition possesses good mechanical properties and moldability, making it suitable for subsequent processing into articles, particularly allowing for article molding (e.g., injection molding) under low mold temperatures (e.g., below 80°C). Furthermore, articles made from the polyester composition of the present invention exhibit good toughness, show no breakage after drop testing, and can incorporate environmentally friendly recycled materials, thus reducing carbon emissions. Therefore, it can be applied to products such as tableware requiring good heat resistance, while also possessing microwaveability and non-toxic properties, resulting in excellent applicability.

[0080] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A polyester composition comprising: Resin (A) has an intrinsic viscosity of 0.6 dL / g to 0.85 dL / g; Fiber reinforcement (B); Inorganic reinforcing material (C); Nucleating agent (D); and Toughening agent (E).

2. The polyester composition according to claim 1, wherein the resin (A) comprises virgin polyethylene terephthalate particles, recycled polyethylene terephthalate, or a combination thereof.

3. The polyester composition according to claim 1, wherein the fiber reinforcement (B) comprises glass fiber, carbon fiber, titanium fiber, boron fiber, or a combination thereof.

4. The polyester composition according to claim 1, wherein the fiber reinforcing material (B) is used in an amount of 5 to 20 parts by weight, based on a total amount of 100 parts by weight of the polyester composition.

5. The polyester composition according to claim 1, wherein the inorganic reinforcing material (C) comprises talc, titanium dioxide, silicon dioxide, calcium carbonate, or a combination thereof.

6. The polyester composition according to claim 1, wherein the inorganic reinforcing material (C) is used in an amount of 5 to 20 parts by weight, based on a total amount of 100 parts by weight of the polyester composition.

7. The polyester composition according to claim 1, wherein the nucleating agent (D) comprises at least one organic nucleating agent.

8. The polyester composition according to claim 1, wherein the toughening agent (E) comprises ethylene-methyl acrylate-glycidyl methacrylate terpolymer, polyethylene octene grafted with glycidyl methacrylate, styrene-ethylene / butene-styrene copolymer, styrene-ethylene / butene-styrene block copolymer grafted with maleic anhydride, methyl methacrylate-butadiene-styrene, or combinations thereof.

9. The polyester composition according to claim 1, further comprising a lubricant (F), wherein the lubricant (F) comprises stearates, polyethylene waxes, siloxane modifiers, fluoropolymers, or combinations thereof.

10. The polyester composition according to claim 1, further comprising an antioxidant (G), wherein the antioxidant (G) comprises hindered phenolic antioxidants, phenolic antioxidants, phosphite antioxidants, complex antioxidants, or combinations thereof.

11. The polyester composition according to claim 1, further comprising a lubricant (F), an antioxidant (G), or a combination thereof. The total amount of the polyester composition used is 100 parts by weight, the amount of the lubricant (F) used is 0.1 to 2 parts by weight, and the amount of the antioxidant (G) used is 0.2 to 2 parts by weight.

12. The polyester composition according to claim 1, wherein, based on a total amount of 100 parts by weight of the polyester composition, the amount of resin (A) is 60 to 80 parts by weight, the amount of nucleating agent (D) is 2.5 to 10 parts by weight, and the amount of toughening agent (E) is 0.3 to 2 parts by weight.

13. An article made using the polyester composition of any one of claims 1 to 12 as engineering plastic pellets.

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