Hollow pellets and soaking method

Abstract

The present disclosure provides a pellet. In one embodiment, the pellet includes a body having a first end and an opposing second end. The body is composed of a polymeric material. The body has a length and a diameter (body diameter). A channel having a diameter (channel diameter) extends through the body from the first end to the second end. The pellet has a channel diameter to body diameter ratio of 0.05 to 0.45. The present disclosure also provides a process for forming a filled pellet by immersing the pellet in a liquid additive to form the filled pellet.

Description

[Background technology]

[0001] It is known to soak pellets of polymer resins in liquid additives in order to infuse or otherwise combine the additives with the polymer pellets prior to further processing. For example, in the manufacture of plastic coatings for power cables, olefin-based polymer pellets are often soaked in liquid peroxide before being melt mixed or melt extruded with other components.

[0002] Unfortunately, additive soaking of olefin-based polymer pellets has several drawbacks. Many olefin-based polymer pellets require long soaking times (10 hours or more) to incorporate sufficient amounts of additive into the pellets. Such long soaking times add capital costs for soaking equipment and reduce production throughput rates. Summary of the Invention [Problem to be solved by the invention]

[0003] The use of porous pellets is known as a method to shorten the soaking time of olefin-based polymer pellets. However, porous olefin-based polymer pellets are expensive to manufacture, limiting their practical use in industry. Porous olefin-based polymer pellets also exhibit non-uniformity problems during melt mixing or extrusion. As a result, the art recognizes the need for polymer resin pellets that can shorten the soaking time of additives without adversely affecting downstream manufacturing processes.

[0004] The art further recognizes the need for pellets with increased surface area.

[0005] The present disclosure provides a pellet. In one embodiment, the pellet includes a body having a first end and an opposing second end. The body is constructed from a polymeric material. The body has a length and a diameter (body diameter). A channel having a diameter (channel diameter) extends through the body from the first end to the second end. The pellet has a channel diameter to body diameter ratio of 0.05 to 0.45.

[0006] The present disclosure provides a process. In one embodiment, the process includes providing a pellet having a body, the body having a first end and an opposing second end, the body being constructed from a polymeric material, the pellet having a channel extending through the body from the first end to the second end. The process includes soaking the pellet in an additive. The additive is in a liquid state. The additive has a material selected from the group consisting of silanes, organic peroxides, isocyanurates, and combinations thereof. The process includes forming a loaded pellet having the material within the body. [Brief description of the drawings]

[0007] [Figure 1A] FIG. 1A is a perspective view of a pellet having a channel extending through the pellet body according to one embodiment of the present disclosure. [Figure 1B] FIG. 1B is a perspective view of a hollow pellet according to an embodiment of the present disclosure. [Figure 2A] FIG. 2A is a cross-sectional view of the pellet taken along line 2A-2A in FIG. 1B. [Figure 2B] FIG. 2B is a cross-sectional view of the pellet taken along line 2B-2B in FIG. 1B. [Diagram 3] FIG. 3 is an exploded view of the pellet of FIG. 1B. [Figure 4A] FIG. 4A is a perspective view of a closed pellet according to an embodiment of the present disclosure. [Figure 4B] FIG. 4B is a cross-sectional view of the closed pellet taken along line 4B-4B of FIG. 4A. [Diagram 5]FIG. 5 is a plot of additive capacity percentage versus soak time. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] definition For purposes of United States patent practice, the contents of any referenced patent, patent application, or publication are incorporated by reference in their entirety (or the equivalent United States version is so incorporated by reference), particularly with respect to the disclosure of definitions (to the extent not inconsistent with any definitions specifically provided in this disclosure) and general knowledge in the art.

[0009] Numerical ranges disclosed herein include all values ​​from and including the lower and upper limit values, and for ranges including explicit values ​​(e.g., 1, or 2, or 3 to 5, or 6, or 7), also include all subranges between any two explicit values ​​(e.g., 1 to 2, 2 to 6, 5 to 7, 3 to 7, 5 to 6), etc.

[0010] The terms "comprising," "including," "having," and their derivatives are not intended to exclude the presence of any additional components, steps, or procedures, whether or not they are specifically disclosed herein. For the avoidance of doubt, all compositions claimed through the use of the term "comprising" may include any additional additives, adjuvants, or compounds (whether polymeric or non-polymeric), unless stated to the contrary. In contrast, the term "consisting essentially of" excludes from the scope of any succeeding recitation any other component, step, or procedure, except those that are not essential to operability. The term "consisting of" excludes any component, step, or procedure not expressly delineated or listed. The term "or" refers to the recited components individually as well as in any combination, unless otherwise stated. The use of the singular includes the use of the plural, and vice versa.

[0011] Unless stated to the contrary, implicit from the context, or customary in the art, all parts and percentages are by weight and all testing methods are current as of the filing date of this disclosure.

[0012] "Blend", "polymer blend" and similar terms refer to a combination of two or more polymers. Such blends may or may not be miscible. Such combinations may or may not phase separate. Such combinations may or may not include one or more domain configurations as determined from transmission electron spectroscopy, light scattering, x-ray scattering, and any other method known in the art.

[0013] An "ethylene-based polymer" is a polymer that contains greater than 50 weight percent polymerized ethylene monomer (based on the total amount of polymerizable monomers) and may optionally contain at least one comonomer. Ethylene-based polymers include ethylene homopolymers and ethylene copolymers (meaning units derived from ethylene and one or more comonomers). The terms "ethylene-based polymer" and "polyethylene" may be used interchangeably. Non-limiting examples of ethylene-based polymers (polyethylenes) include low density polyethylene (LDPE) and linear polyethylene. Non-limiting examples of linear polyethylenes include linear low density polyethylene (LLDPE), very low density polyethylene (ULDPE), very low density polyethylene (VLDPE), multicomponent ethylene-based copolymers (EPE), ethylene / α-olefin multiblock copolymers (also known as olefin block copolymers (OBC)), single-site catalyzed linear low density polyethylene (m-LLDPE), substantially linear or linear plastomers / elastomers, medium density polyethylene (MDPE), and high density polyethylene (HDPE). In general, polyethylene can be produced in gas phase, fluidized bed reactors, liquid phase slurry process reactors, or liquid phase solution process reactors using heterogeneous catalyst systems such as Ziegler-Natta catalysts, homogeneous catalyst systems including group 4 transition metals and ligand structures such as metallocenes, nonmetallocene metal centers, heteroaryls, heterovalent aryloxy ethers, phosphinimines, and others. A combination of heterogeneous and / or homogeneous catalysts can also be used in either a single reactor or dual reactor configuration. In one embodiment, the ethylene-based polymer does not contain an aromatic comonomer polymerized therein.

[0014] "Ethylene plastomer / elastomer" refers to a polymer that contains units derived from ethylene and at least one C3-C 10A substantially linear, or linear, ethylene / α-olefin copolymer containing a uniform short chain branching distribution comprising units derived from an α-olefin comonomer, or at least one C4-C8 α-olefin comonomer, or at least one C6-C8 α-olefin comonomer. The ethylene plastomer / elastomer has a density of 0.870 g / cc, or 0.880 g / cc, or 0.890 g / cc to 0.900 g / cc, or 0.902 g / cc, or 0.904 g / cc, or 0.909 g / cc, or 0.910 g / cc, or 0.917 g / cc. Non-limiting examples of ethylene plastomers / elastomers include AFFINITY™ plastomers and elastomers (available from The Dow Chemical Company), EXACT™ plastomers (available from ExxonMobil Chemical), Tafmer™ (available from Mitsui), Nexlene™ (available from SK Chemicals Co.), and Lucene™ (available from LG Chem Ltd.).

[0015] "High density polyethylene" (or "HDPE") is a polyethylene that is a mixture of at least one C4 to C 10 An ethylene homopolymer or ethylene / α-olefin copolymer having an α-olefin comonomer, or a C4-C8 α-olefin comonomer, and a density greater than 0.94 g / cc, or 0.945 g / cc, or 0.95 g / cc, or 0.955 g / cc to 0.96 g / cc, or 0.97 g / cc, or 0.98 g / cc. HDPE may be a unimodal or multimodal copolymer. A "unimodal ethylene copolymer" is an ethylene / C4-C8 copolymer having one distinct peak in gel permeation chromatography (GPC) showing the molecular weight distribution. 10 It is an α-olefin copolymer. A "multimodal ethylene copolymer" is an ethylene / C4-C copolymer that has at least two distinct peaks in the GPC showing the molecular weight distribution. 10It is an α-olefin copolymer. Multimodality includes copolymers with two peaks (bimodal) as well as copolymers with three or more peaks. Non-limiting examples of HDPE include DOW™ high density polyethylene (HDPE) resins, ELITE™ reinforced polyethylene resins, and CONTINUUM™ bimodal polyethylene resins, each available from The Dow Chemical Company, LUPOLEN™ available from LyondellBasell, and HDPE products from Borealis, Ineos, and ExxonMobil.

[0016] An "interpolymer" (or copolymer) is a polymer prepared by the polymerization of at least two different monomers. This generic term includes copolymers, which are commonly used to refer to polymers prepared from two different monomers, and polymers prepared from three or more different monomers, such as terpolymers, tetrapolymers, etc.

[0017] "Low density polyethylene" (or "LDPE") is defined as any ethylene homopolymer or copolymer having a density between 0.915 g / cc and 0.940 g / cc and containing at least one C3-C4 long chain branch having a broad MWD. 10 It consists of ethylene / α-olefin copolymers containing α-olefins, preferably C3-C4. LDPE is typically produced by high pressure free radical polymerization (tubular reactor or autoclave using free radical initiators). Non-limiting examples of LDPE include MarFlex™ (Chevron Phillips), LUPOLEN™ (LyondellBasell), as well as LDPE products from Borealis, Ineos, ExxonMobil, etc.

[0018] "Linear low density polyethylene" (or "LLDPE") is a type of polyethylene that contains units derived from ethylene and at least one C3-C 10A linear ethylene / α-olefin copolymer containing a heterogeneous short chain branching distribution, including units derived from an α-olefin comonomer, or at least one C4-C8 α-olefin comonomer, or at least one C6-C8 α-olefin comonomer. LLDPE is characterized by little, if any, long chain branching, in contrast to conventional LDPE. LLDPE has a density of 0.910 g / cc, or 0.915 g / cc, or 0.920 g / cc, or 0.925 g / cc to 0.930 g / cc, or 0.935 g / cc, or 0.940 g / cc. Non-limiting examples of LLDPE include TUFLIN™ linear low density polyethylene resins and DOWLEX™ polyethylene resins, each available from the Dow Chemical Company, and MARLEX™ polyethylene (available from Chevron Phillips).

[0019] “Multicomponent ethylene-based copolymers” (or “EPEs”) are copolymers that contain units derived from ethylene and at least one C3-C6 unit, as described in patent references U.S. Pat. No. 6,111,023, U.S. Pat. No. 5,677,383, and U.S. Pat. No. 6,984,695. 10 and at least one C4-C8 α-olefin comonomer, or at least one C6-C8 α-olefin comonomer derived units. The EPE resin has a density of 0.905 g / cc, or 0.908 g / cc, or 0.912 g / cc, or 0.920 g / cc to 0.926 g / cc, or 0.929 g / cc, or 0.940 g / cc, or 0.962 g / cc. Non-limiting examples of EPE resins include ELITE™ reinforced polyethylene and ELITE AT™ advanced technology resins (each available from Dow Chemical Company), SURPASS™ polyethylene (PE) resins (available from Nova Chemicals), and SMART™ (available from SK Chemicals Co.).

[0020] An "olefin-based polymer" or "polyolefin" is a polymer that contains greater than 50 weight percent polymerized olefin monomer (based on the total amount of polymerizable monomers) and may optionally contain at least one comonomer. Non-limiting examples of olefin-based polymers include ethylene-based polymers and propylene-based polymers. "Olefin" and similar terms refer to a hydrocarbon composed of hydrogen and carbon, whose molecules contain a pair of carbon atoms joined together by a double bond.

[0021] A "polymer" is a compound prepared by polymerizing monomers, whether of the same or different types, which, in polymerized form, provide a plurality and / or repeating "units" or "structural units" that make up the polymer. Thus, the generic term polymer encompasses the term homopolymer, which is commonly used to refer to a polymer prepared from only one type of monomer, and the term copolymer, which is commonly used to refer to a polymer prepared from at least two types of monomer. It also encompasses all forms of copolymers, e.g., random, block, etc. The terms "ethylene / α-olefin polymer" and "propylene / α-olefin polymer" refer to copolymers as described above, prepared by polymerizing ethylene or propylene, respectively, with one or more additional polymerizable α-olefin monomers. It should be noted that while polymers are often referred to as "made from" one or more specified monomers, such as "based on" the specified monomers or types of monomers, "containing" the specified monomer content, etc., in this context, the term "monomer" is understood to refer to the polymerized residue of the specified monomer and not to the non-polymerized species. Generally, polymers are referred to herein in terms of "units" that are the polymerized form of the corresponding monomers.

[0022] "Single-site catalyzed linear low density polyethylene" (or "m-LLDPE") is a type of polyethylene that contains units derived from ethylene and at least one C3-C 10m-LLDPE is a linear ethylene / α-olefin copolymer containing a uniform short chain branching distribution with units derived from an α-olefin comonomer, or at least one C4-C8 α-olefin comonomer, or at least one C6-C8 α-olefin comonomer. The m-LLDPE has a density of 0.913 g / cc, or 0.918 g / cc, or 0.920 g / cc to 0.925 g / cc, or 0.940 g / cc. Non-limiting examples of m-LLDPE include EXCEED™ Metallocene PE (available from ExxonMobil Chemical), LUFLEXEN™ m-LLDPE (available from LyondellBasell), and ELTEX™ PF m-LLDPE (available from Ineos Olefins & Polymers).

[0023] "Ultra-low density polyethylene" (or "ULDPE") and "very low density polyethylene" (or "VLDPE") are polyethylenes that each contain units derived from ethylene and at least one C3-C 10 A linear ethylene / α-olefin copolymer containing a heterogeneous short chain branching distribution, including units derived from an α-olefin comonomer, or at least one C4-C8 α-olefin comonomer, or at least one C6-C8 α-olefin comonomer. The ULDPE and VLDPE have a density of 0.885 g / cc, or 0.90 g / cc to 0.915 g / cc, respectively. Non-limiting examples of ULDPE and VLDPE include ATTANE™ ULDPE resins and FLEXOMER™ VLDPE resins, each available from The Dow Chemical Company.

[0024] "Melt mixing" is a process in which at least two components are combined or otherwise mixed together, with at least one of the components being in a molten state. Melt mixing can be accomplished by one or more of a variety of known processes, such as, for example, batch mixing, extrusion mixing, extrusion molding, etc. A "melt mixed" composition is a composition formed through the process of melt mixing.

[0025] "Thermoplastic polymer" and like terms refer to a linear or branched polymer that can be repeatedly softened and made flowable when heated and then returned to a hardened state when cooled to room temperature. Thermoplastic polymers typically have a modulus of elasticity greater than 10,000 psi as measured in accordance with ASTM D638-72. Furthermore, when heated to a softened state, thermoplastic polymers can be molded or extruded into articles of any given shape.

[0026] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT The present disclosure provides a pellet. In one embodiment, the pellet includes a body constructed from a polymeric material. The body has a first end and a second end opposite the body. The body includes a length and a diameter. The body has a channel having a channel diameter. The channel extends through the body from the first end to the second end. The pellet has a channel diameter to body diameter ratio of 0.05 to 0.45.

[0027] pellet Referring now to the drawings and initially to FIG. 1A, a plurality of pellets of the present disclosure are shown. FIG. 1B shows an individual pellet 10, the pellet 10 including a body 20. The body 20 includes a first end 15 and a second end 25. The pellet 10 includes a channel 30. The channel 30 extends through the body 20 from the first end 15 to the second end 25. A pellet 10 having a body 20 and a channel 30 extending therethrough is hereinafter referred to interchangeably as a "hollow pellet."

[0028] In one embodiment, the body 20 has a cylindrical shape. The body 20 includes a first end 15 and a second end 25, which have a circular or substantially circular shape. The first end 15 and the second end 25 are located on opposite sides of the body 20. An axis of symmetry A is located at the center of the circle formed by the ends 15 and 25. The pellet 10 includes a channel 30 parallel to the axis of symmetry A. The channel 30 has a cylindrical or substantially cylindrical shape and is located at the center of the body 20. The channel 30 runs the entire length of the body 20. The channel 30 extends from the first end 15 to the second end 25.

[0029] The body 20 has a circular or substantially circular cross-sectional shape. The body 20 also has a cylindrical or substantially cylindrical shape. It is understood that the circular cross-sectional shape of the body 20 may change (i.e., squeeze, press, or pack) due to forces applied to the pellets 10 during industrial scale production and / or handling of the pellets while they are still in a molten state. As a result, the cross-sectional shape of the body 20 may be more elliptical than circular in shape, thus the definition of "substantially circular in cross-sectional shape."

[0030] The body 20 and channel 30 each have a respective diameter (body diameter 40 and channel diameter 45). As used herein, the term "diameter" is the maximum length between two points on the body / channel surface extending through the center along the axis of symmetry A of the body / channel. In other words, if the pellet 10 is elliptical (rather than circular), the diameter is the major axis of the ellipse. In one embodiment, the shape of the body 20 resembles an ice hockey puck.

[0031] FIG. 2A shows the body diameter 40 and channel diameter 45 of the pellet 10. In one embodiment, the body diameter 40 is 0.7 millimeters (mm), or 0.8 mm, or 0.9 mm, or 1.0 mm, or 1.5 mm to 3.7 mm, or 4.0 mm, or 4.2 mm, or 4.6 mm, or 5.0 mm. In further embodiments, the body diameter 40 is 0.7 to 5.0 mm, or 0.8 to 4.2 mm, or 1.0 to 4.0 mm. In one embodiment, the channel diameter 45 is 0.10 mm, or 0.13 mm, or 0.15 mm, or 0.18 mm to 0.3 mm, or 0.4 mm, or 0.5 mm, or 0.6 mm, or 0.8 mm, or 1 mm, or 1.6 mm, or 1.8 mm. In further embodiments, the channel diameter 45 is between 0.10 and 1.8 mm, or between 0.15 and 1.6 mm, or between 0.18 and 1 mm, or between 0.18 and 0.8 mm, or between 0.18 and 0.6 mm.

[0032] The pellet 10 has a channel diameter to body diameter (CBD) ratio. As used herein, the term "channel diameter to body diameter (or "CBD") ratio" refers to the result obtained by dividing the channel diameter by the body diameter (i.e., CBD is the quotient of the channel diameter and the body diameter). For example, if the channel diameter is 2.0 mm and the body diameter is 7.0 mm, the CBD ratio is 0.29. In one embodiment, the CBD ratio is 0.03, or 0.05, or 0.07, or 0.11-0.13, or 0.15, or 0.2, or 0.25, or 0.3, or 0.35, or 0.4, or 0.45, or 0.5. In further embodiments, the CBD ratio is 0.03-0.5, or 0.05-0.45, or 0.05-0.25, or 0.05-0.15, or 0.11-0.15.

[0033] 2B shows the length 35 of the body 20. In one embodiment, the length 35 is 0.4 mm, or 0.8 mm, or 1 mm, or 1.2 mm, or 1.4 mm, or 1.5 mm, or 1.6 mm, or 1.7 mm to 1.9 mm, or 2 mm, or 2.2 mm, or 2.5 mm, or 3 mm, or 3.3 mm, or 3.5 mm, or 4 mm. In further embodiments, the length 35 is 0.4 to 4 mm, or 0.8 to 3.5 mm, or 1 to 3.5 mm, or 1.4 to 2.5 mm, or 1.5 to 1.9 mm.

[0034] In one embodiment, (i) length 35 is 0.4 mm, or 0.8 mm, or 1 mm, or 1.2 mm, or 1.4 mm, or 1.5 mm, or 1.6 mm, or 1.7 mm to 1.9 mm, or 2 mm, or 2.2 mm, or 2.5 mm, or 3 mm, or 3.3 mm, or 3.5 mm, or 4 mm; (ii) body diameter 40 is 0.7 millimeters (mm), or 0.8 mm, or 0. .9mm, or 1.0mm, or 1.5mm to 3.7mm, or 4.0mm, or 4.2mm, or 4.6mm, or 5.0mm, and (iii) the channel diameter 45 is 0.10mm, or 0.13mm, or 0.15mm, or 0.18mm to 0.3mm, or 0.4mm, or 0.5mm, or 0.6mm, or 0.8mm or 1mm, or 1.6mm, or 1.8mm. In further embodiments, (i) length 35 is 0.4 to 4 mm, or 0.8 to 3.5 mm, or 1 to 3.5 mm, or 1.4 to 2.5 mm, or 1.5 to 1.9 mm, (ii) body diameter 40 is 0.7 to 5.0 mm, or 0.8 to 4.2 mm, or 1.0 to 4.0 mm, and (iii) channel diameter 45 is 0.10 to 1.8 mm, or 0.15 to 1.6 mm, or 0.18 to 1 mm, or 0.18 to 0.8 mm, or 0.18 to 0.6 mm.

[0035] Returning to FIG. 1B, a first face 55 of the pellet 10 is shown. The first face 55 is located at the first end 15. The first orifice 50 is located at the center of the first face 55. The first orifice 50 is circular or nearly circular in shape and opens into the channel 30. The first orifice 50 has an area that is a function of the channel diameter 45. It is understood that the area of ​​the first orifice 50 is a void and that the first orifice 50 has no surface. The first face 55 and the first orifice 50 form concentric circles bisected by the axis of symmetry A. The first face 55 has a surface that does not include the first orifice 50. In other words, the first face 55 has the shape of a flat ring.

[0036] The second orifice 60 is located at the center of the second face 65. The second orifice 60 is circular or nearly circular in shape and opens into the channel 30. The second orifice 60 has an area that is a function of the channel diameter 45. It is understood that the area of ​​the second orifice 60 is a void and that the second orifice 60 has no surface. The second face 65 and the second orifice 60 form concentric circles bisected by the axis of symmetry A. The second face 65 has a surface that does not include the second orifice 60. In other words, the second face 65 has the shape of a flat ring.

[0037] The first surface 55 is given by the formula (0.25×π×[(body diameter 40) 2 -(Channel diameter 45) 2 ]). The second face 65 has a "first surface area" which is the product of (0.25×π×[(body diameter 40) 2 -(Channel diameter 45) 2 ]). The surface area of ​​first face 55 is equal to or substantially equal to the surface area of ​​second face 65.

[0038] The body 20 has a body surface that includes an "exterior surface." The exterior surface includes a first face 55 and a second face 65. The exterior surface has an "exterior surface area" that is the sum of the surface area of ​​the first face 55 and the surface area of ​​the second face 65. The exterior surface area is calculated according to the formula 2×(0.25×π×[(body diameter 40)2 -(Channel diameter 45) 2 ]).

[0039] FIG. 3 shows a shell 70. The shell 70 is the outer surface of the body 20 parallel to the axis of symmetry A. The shell 70 has a cylindrical or approximately cylindrical shape. The shell 70 includes a "shell surface" and a "shell surface area", the latter being a product of the formula (π x body diameter 40 x length 35). The body 20 has a "body surface" that includes the shell surface and the outer surface. The body surface has a "body surface area" that is the sum of the shell surface area and the outer surface area. In one embodiment, the body surface area is 25 square millimeters (mm 2 ), or 30mm 2 , or 32mm 2 , or 34mm 2 , or 35mm 2 ~40mm 2 , or 45mm 2 In a further embodiment, the body surface area is 25 to 50 mm 2 , or 30-45mm 2 , or 35-40mm 2 It is.

[0040] The channel 30 has a channel surface 75 that includes a "channel surface area." The channel surface area is a product of the formula (π × channel diameter 45 × length 35). In one embodiment, the channel surface area is 0.5 mm 2 , or 1 mm 2 , or 2 mm 2 , or 3 mm 2 ~6mm 2 , 7mm 2 , or 8mm 2 , or 9mm 2 , or 10mm 2 , or 11mm 2 In a further embodiment, the channel surface area is between 0.5 and 11 mm 2 , or 1 to 9 mm 2 , or 1 to 8 mm 2 , or 2 to 8 mm 2 It is.

[0041] The pellet 10 has a surface area that is the sum of the body surface area and the channel surface area. In one embodiment, the pellet has a surface area of ​​4 mm 2 , or 15mm 2 , or 25mm 2 , or 30mm 2 , or 35mm 2 ~40mm 2 , or 45mm 2 , or 50mm 2 , or 60mm 2 , or 70mm 2 , or 80mm 2 In a further embodiment, the pellet surface area is between 15 and 80 mm 2 , or 30 to 60 mm 2 , or 35-50mm 2 It is.

[0042] In one embodiment, (i) the length 35 is 0.4 mm, or 0.8 mm, or 1 mm, or 1.2 mm, or 1.4 mm, or 1.5 mm, or 1.6 mm, or 1.7 mm to 1.9 mm, or 2 mm, or 2.2 mm, or 2.5 mm, or 3 mm, or 3.3 mm, or 3.5 mm, or 4 mm; (ii) the body diameter 40 is 0.7 mm, or 0.8 mm, or 0.9 mm, or 1.0 mm, or 1.5 mm to 3.7 mm, or 4.0 mm, or 4.2 mm, or 4.6 mm, or 5.0 mm; and (iii) the surface area of ​​the pellet is 4 mm. 2 , or 15mm 2 , or 25mm 2 , or 30mm 2 , or 35mm 2 ~40mm 2 , 45mm 2 , or 50mm 2 , or 60mm 2 , or 70mm 2 , or 80mm 2and (iv) the CBD ratio is 0.03, or 0.05, or 0.07, or 0.11-0.13, or 0.15, or 0.2, or 0.25, or 0.3, or 0.35, or 0.4, or 0.45, or 0.5. In further embodiments, (i) the length 35 is 0.4-4 mm, or 0.8-3.5 mm, or 1-3.5 mm, or 1.4-2.5 mm, or 1.5-1.9 mm, (ii) the body diameter 40 is 0.7-5.0 mm, or 0.8-4.2 mm, or 1.0-4.0 mm, and (iii) the surface area of ​​the pellet is 15-80 mm. 2 , or 30 to 60 mm 2 , or 35-50mm 2 and (iv) the CBD ratio is 0.03 to 0.5, or 0.05 to 0.45, or 0.05 to 0.25, or 0.05 to 0.15, or 0.11 to 0.15.

[0043] The term "standard pellet" as used herein refers to a pellet without channels (i.e., a "solid pellet") that is otherwise identical to the pellet 10 of the present disclosure, i.e., the standard pellet has the same body diameter 40 and the same body length 35 as the pellet 10, and the standard pellet is made of the same polymeric material as the body 20 of the pellet 10. In one embodiment, the surface area of ​​the pellet 10 is greater than that of the standard pellet due to the presence of the channels 20 in the pellet 10. The ratio of the pellet surface area to the standard pellet surface area is referred to as the "PSP ratio." In one embodiment, the PSP ratio is 1.02, or 1.03, or 1.05, or 1.07 to 1.09, or 1.1, or 1.11, or 1.12, or 1.15, or 1.2, or 1.4. In further embodiments, the PSP ratio is 1.02 to 1.4, or 1.05 to 1.15, or 1.05 to 1.11.

[0044] The pellet 10 has a channel surface area to body surface area (CSBS) ratio. As used herein, the term "channel surface area to body surface area ratio" (or "CSBS") refers to the result obtained by dividing the channel surface area by the body surface area (i.e., CSBS is the quotient of the channel surface area divided by the body surface area). For example, if the channel surface area is 2.0 mm 2 and the body surface area is 7.0 mm 2 In the case of, the CSBS ratio is 0.29. In one embodiment, the CBD ratio is 0.02, or 0.03, or 0.06, or 0.10, or 0.13-0.15, or 0.18, or 0.21, or 0.23, or 0.25, or 0.3. In a further embodiment, the CSBS ratio is 0.02-0.3, or 0.03-0.25, or 0.03-0.23, or 0.03-0.21, or 0.03-0.18.

[0045] In one embodiment, (i) length 35 is 0.4 mm, or 0.8 mm, or 1 mm, or 1.2 mm, or 1.4 mm, or 1.5 mm, or 1.6 mm, or 1.7 mm to 1.9 mm, or 2 mm, or 2.2 mm, or 2.5 mm, or 3 mm, or 3.3 mm, or 3.5 mm, or 4 mm, (ii) body diameter 40 is 0.7 mm, or 0.8 mm, or 0.9 mm, or 1.0 mm, or 1.5 mm to 3.7 mm, or 4.0 mm, or 4.2 mm, or 4.6 mm, or 5.0 mm, and (iii) pellet area is 4 mm. 2 , or 15mm 2 , or 25mm 2 , or 30mm 2 , or 35mm 2 ~40mm 2 , 45mm 2 , or 50mm 2 , or 60mm 2 , or 70mm 2 , or 80mm 2and (iv) the CSBS ratio is 0.02, or 0.03, or 0.06, or 0.10, or 0.13 to 0.15, or 0.18, or 0.21, or 0.23, or 0.25, or 0.3. In further embodiments, (i) the length 35 is 0.4 to 4 mm, or 0.8 to 3.5 mm, or 1 to 3.5 mm, or 1.4 to 2.5 mm, or 1.5 to 1.9 mm, (ii) the body diameter 40 is 0.7 to 5.0 mm, or 0.8 to 4.2 mm, or 1.0 to 4.0 mm, and (iii) the surface area of ​​the pellet is 15 to 80 mm. 2 , or 30 to 60 mm 2 , or 35-50mm 2 and (iv) the CSBS ratio is 0.02 to 0.3, or 0.03 to 0.25, or 0.03 to 0.23, or 0.03 to 0.21, or 0.03 to 0.18.

[0046] FIG. 1B shows that first end 15 and second end 25 are open ended.

[0047] 4A-4B show a closed pellet 80. The closed pellet 80 includes a first closed end 82, a second closed end 84, and a channel 30. The remaining features of the closed pellet 80 are identical to the features of pellet 10, as described herein.

[0048] The body 20 is constructed from a polymeric material. In one embodiment, the polymeric material is selected from the following materials: polyolefins, crosslinkable polyolefins, polyamides, polyimides, polyesters, polycarbonates, polysulfides, polysulfones, polyurethanes, polyethers, polythioethers, waxes, hot melt adhesives, thermoplastic elastomers, rubbers, aromatic vinyl polymers, aliphatic vinyl polymers, aromatic alkenyl polymers, and any combination thereof. In further embodiments, the polymeric material is selected from ethylene-based polymers, olefin-based polymers (i.e., polyolefins), organic polymers, propylene-based polymers, thermoplastic polymers, thermoset polymers, polymer melt blends, polymer blends thereof, and combinations thereof.

[0049] In one embodiment, the body is composed of an ethylene-based polymer. Non-limiting examples of suitable ethylene-based polymers include ethylene / alpha-olefin interpolymers and ethylene / alpha-olefin copolymers. In one embodiment, the alpha-olefins include C3-C 20 In a further embodiment, the alpha-olefins include, but are not limited to, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, and 1-octene.

[0050] In one embodiment, the polymeric material of the body 20 is aromatic polyester, phenol-formaldehyde resin, polyamide, polyacrylonitrile, polyethylene terephthalate, polyimide, polystyrene, polytetrafluoroethylene, polyvinyl chloride, thermoplastic polyurethane, and combinations thereof.

[0051] The polymeric material may comprise two or more embodiments disclosed herein.

[0052] In one embodiment, the body 20 includes an additive. The additive is absorbed into the body 20. In one embodiment, the additive is adsorbed onto a body surface. In a further embodiment, the additive is absorbed into the body 20 and adsorbed onto a body surface. As used herein, the term "absorption" and its derivatives (i.e., "absorbed") refers to the assimilation of the additive molecular species throughout (i.e., within) the bulk of the body 20. As used herein, the term "adsorption" and its derivatives (i.e., "adsorbed") refers to the accumulation of the additive molecular species at the body surface, rather than within the bulk of the body 20.

[0053] In one embodiment, the channel 30 contains an additive. The additive in the channel is in a liquid state. The liquid additive is disposed in the channel 30, and the liquid additive is in direct contact with the channel surface 75. The liquid additive is adsorbed onto the channel surface 75. In one embodiment, the liquid additive is absorbed into the body 20 through the channel surface 75.

[0054] In one embodiment, the additive is a liquid and includes silanes, peroxides, isocyanurates, catalysts, antioxidants, UV stabilizers, processing aids, and combinations thereof. In a further embodiment, the additive is a liquid and is a mixture of silanes and peroxides, a mixture of silanes and catalysts, a mixture of peroxides and antioxidants, and combinations thereof. In a further embodiment, the peroxide is an organic peroxide. In another embodiment, the additive is dicumyl peroxide, tert-butylperoxy-2-ethylhexyl carbonate, triallyl isocyanurate, methacryloylpropyltrimethoxysilane, and combinations thereof.

[0055] The additive may comprise two or more embodiments disclosed herein.

[0056] In one embodiment, pellets 10 are manufactured as disclosed in co-pending application __________, filed on ________ (Attorney Docket No. 82430-WO-PCT), the entire contents of which are incorporated herein by reference.

[0057] process The present disclosure provides a process. In one embodiment, the process includes providing a pellet including a body comprised of a polymeric material. The body includes a first end and an opposing second end. The body includes a channel extending through the body from the first end to the second end. The process includes soaking the pellet with an additive. The additive has a material selected from a silane, an organic peroxide, an isocyanurate, and combinations thereof. The process includes forming a loaded pellet having the material within the body.

[0058] The process includes providing a pellet 10, as shown in FIG. 1B. The pellet 10 includes a body 20. The body 20 includes a first end 15 and a second end 25. The pellet 10 includes a channel 30. The channel 30 extends through the body 20 from the first end 15 to the second end 25. The process includes immersing the pellet 10 in the additive in a liquid state. In one embodiment, the immersing includes contacting the pellet 10 with the liquid additive, optionally with agitation. In a further embodiment, the immersing includes floating the pellet 10 on the floating liquid additive. In another embodiment, the immersing includes completely immersing the pellet 10 in the liquid additive.

[0059] The additives include materials selected from silanes, peroxides, isocyanurates, catalysts, antioxidants, UV stabilizers, processing aids, and combinations thereof. In further embodiments, the additives are mixtures of silanes and peroxides, mixtures of silanes and catalysts, mixtures of peroxides and antioxidants, and combinations thereof. In further embodiments, the peroxides are organic peroxides. In another embodiment, the additives are dicumyl peroxide, tert-butylperoxy-2-ethylhexyl carbonate, triallyl isocyanurate, methacryloylpropyltrimethoxysilane, and combinations thereof.

[0060] In one embodiment, the soaking step is carried out at ambient temperature (15° C.-25° C.), with or without agitation. In a further embodiment, the soaking step is carried out at elevated temperature (26° C. or above), with or without agitation.

[0061] The additive may comprise two or more embodiments disclosed herein.

[0062] The process includes forming a loaded pellet. The term "loaded pellet" as used herein refers to a pellet (hollow pellet) having an amount of additive absorbed within the body of the loaded pellet. It is understood that the loaded pellet may also include an amount of additive located in the channel 30. The loaded pellet includes an additive capacity. The term "additive capacity" as used herein is the maximum amount of additive that the hollow pellet can absorb and adsorb. The additive capacity is determined by immersing the pellet in excess additive (liquid state) for 24 hours. For example, if the loaded pellet has a mass of 25g and the initial pellet mass is 20g after immersion in excess liquid additive for 24 hours, the additive capacity is 5g.

[0063] In one embodiment, the process involves obtaining at least 95% of the additive capacity of the pellets by soaking in a period of 6 hours (h) or less at ambient temperature. In further embodiments, the process involves obtaining 95% of the additive capacity of the pellets by soaking in a period of 1 hour, or 2 hours, or 3 hours, or 4 to 5 hours, or less than 6 hours at ambient temperature.

[0064] The process of soaking involves absorbing a portion of the liquid additive into the body 20 through the channels 30. In one embodiment, the liquid additive passes through the channels 30 and then enters the body 20. In a further embodiment, the additive passes through the channels 30 and then is absorbed into the body 20. In another embodiment, the additive passes through the channels 30 and then is absorbed into the body 20 and simultaneously adsorbs onto the body 20.

[0065] The invention is more fully illustrated by the following examples in which all parts and percentages are by weight unless otherwise stated. EXAMPLES

[0066] The raw materials used to formulate the inventive examples ("IE") are shown in Table 1 below. [Table 1]

[0067] 1. Hollow pellets Examples 1 to 8 (IE-1 to IE-8) of the present invention are hollow pellets imaged by optical microscopy. The dimensions obtained by analyzing the optical microscopy images are shown in Table 2. [Table 2]

[0068] 2. Immersion test A hollow pellet made of XUS38660 and having the structure shown in Figures 1B, 2A, 2B and the dimensions of Example 1 (IE-1) of the present invention in Table 2 is immersed in a liquid additive made of dicumyl peroxide, vinyltrimethoxysilane, curing coagent, and UV agent. A solid pellet made of XUS38660 and having the same body diameter and pellet length (without channels) as IE-1 is immersed in the same liquid additive. The pellet is immersed in the liquid additive at room temperature and agitated on a roller with a rotation speed of 70 rpm. The pellet has an additive capacity of 1.92 g of liquid additive. The hollow pellet of IE-1 absorbs 95% of the additive capacity (1.82 g) in 5.5 hours. The solid pellet reaches 95% of the additive capacity in 17.5 hours.

[0069] FIG. 5 shows the percentage of additive capacity plotted against soak time for IE-1 (hollow pellets) of the present invention versus the comparative solid pellets.

[0070] The present disclosure is not limited to the embodiments and figures contained herein, but is specifically intended to include modifications of these embodiments, including portions of the embodiments and combinations of elements of different embodiments that fall within the scope of the following claims.

Claims

1. A pellet, a body having a first end and an opposing second end, the body being constructed from a polymeric material and having a length and a diameter (body diameter), the length being between 1.0 millimeters (mm) and 1.8 mm; a channel having a diameter (channel diameter) extending through the body from the first end to the second end, the channel diameter being between 0.1 mm and 0.6 mm; the pellet has a channel diameter to body diameter ratio of 0.05 to 0.25; Each end has a respective orifice and a respective face; the body having a body surface including a shell and an exterior surface, the body surface having a body surface area including a shell surface area and an exterior surface area; the channel having a channel surface including a channel surface area; The pellet has a channel surface area to body surface area ratio of 0.03 to 0.

15.

2. 2. The pellet of claim 1, wherein the body diameter is between 1.0 mm and 4.0 mm.

3. A pellet according to any one of claims 1 to 2, wherein the channel diameter is between 0.15 mm and 0.55 mm.

4. The pellet according to any one of claims 1 to 3, comprising an additive in the body.

5. 5. The pellet of claim 4 containing the additive within the channels, the additive being in a liquid state and absorbed into the body through the channel surfaces.

6. 6. The pellet of any one of claims 1 to 5, wherein the body is comprised of a polymeric material selected from the group consisting of polyolefins, crosslinkable polyolefins, polyamides, polyimides, polyesters, polycarbonates, polysulfides, polysulfones, polyurethanes, polyethers, polythioethers, waxes, hot melt adhesives, thermoplastic elastomers, rubbers, aromatic vinyl polymers, aliphatic vinyl polymers, aromatic alkenyl polymers, and combinations thereof.

7. A process comprising: providing a pellet having a body, the body having a first end and an opposing second end, the body being constructed from a polymeric material, the body having a length between 1.0 millimeters (mm) and 1.8 mm, the pellet having a channel extending through the body from the first end to the second end, the channel having a diameter between 0.1 mm and 0.6 mm, each end having a respective orifice and a respective face, the body having a body surface including a shell and an exterior surface, the body surface having a body surface area including a shell surface area and an exterior surface area, the channel having a channel surface including a channel surface area, the pellet having a channel surface area to body surface area ratio of 0.03 to 0.15, the body having a length and a diameter (body diameter), the channel having a channel diameter, and the pellet having a channel diameter to body diameter ratio of 0.05 to 0.25; immersing the pellets in an additive, the additive being in a liquid state, the additive having a material selected from the group consisting of silanes, organic peroxides, isocyanurates, and combinations thereof; forming a charged pellet comprising said material within said body.

8. 8. The process of claim 7, wherein the loaded pellets have an additive capacity, and the process comprises obtaining at least 95% of the additive capacity by immersion at ambient temperature for a period of 6 hours or less.

9. 9. The process of claim 7 or 8, wherein the soaking comprises absorbing a portion of the additive into the body through the channel surfaces.

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