Polyvinyl alcohol manufacturing method and manufacturing apparatus

Abstract

The present invention relates to a method for producing plasticized homopolymer polyvinyl alcohol, comprising introducing a polyvinyl alcohol polymer, including polyvinyl alcohol or a blend thereof, having a degree of hydrolysis ranging from 93% to 98% by weight, into a mixing reactor; reacting the polymer with a processing aid, a predetermined plasticizer, and the polymer in a reaction zone to form a plasticized polymer; and passing the plasticized polymer through a first outlet of the mixing reactor. The mixing reactor includes a blending chamber having at least two interengaging parts and a second inlet located downstream of the first inlet for introducing reactants, including the processing aid, the predetermined plasticizer, and a predetermined reaction stabilizer, into the chamber, and applying a shear force to the polymer while conveyed by the parts. The blending chamber includes a heating zone that increases the temperature toward the outlet and a second outlet located between the reaction zone and the first outlet to allow removal of the processing aid.

Description

[Technical Field]

[0001] The present invention relates to a method for producing polyhydric polymers, particularly polyvinyl alcohol. The present invention also relates to an apparatus for use in carrying out the method. The present invention further relates to a method for producing polyvinyl alcohol in a physical form suitable for processing into films or other extruded products, particularly, but not exclusively. The present invention further relates to novel processable polyvinyl alcohol compositions that may be produced using this method. [Background technology]

[0002] Polyvinyl alcohol is generally produced by the hydrolysis of polyvinyl acetate. The degree of hydrolysis affects the properties of the polymer. Polyvinyl alcohol with a low degree of hydrolysis (LD) of less than 84% is widely used industrially. For example, vinyl acetate copolymers with ethylene acetate have been used to produce vinyl alcohol copolymers that are easier to process. However, these copolymers lack the advantageous physical properties of homopolymer polyvinyl alcohol, especially highly hydrolyzed polyvinyl alcohol homopolymers. The present invention particularly relates to polyvinyl alcohol produced by the hydrolysis of homopolymer polyvinyl acetate.

[0003] Highly hydrolyzed polyvinyl acetate, having a degree of hydrolysis greater than 93, e.g., 98% or greater, is a polymer essentially consisting of homopolyvinyl alcohol. This polymer, like many carbohydrates, decomposes before reaching a melting point of about 250°C. This makes melt processing difficult, and for this reason, highly hydrolyzed polyvinyl alcohol polymers are processed as aqueous solutions. Partially hydrolyzed polyvinyl acetate is easily melt-processed. For example, 80% hydrolyzed polyvinyl acetate can be easily converted into film by extrusion or blow molding.

[0004] The most significant difference between highly hydrolyzed (HD) and partially hydrolyzed (LD) polyvinyl alcohol is the degree and quality of crystalline order due to differences in chain structure. Polyvinyl alcohol with less than 2% unhydrolyzed acetate groups can readily crystallize to form strongly hydrogen-bonded crystalline domains. These crystalline domains have essentially the same structure as those found in polyethylene. This is likely due to the smaller size of the hydroxyl groups. However, the melting point of highly hydrolyzed polyvinyl alcohol is approximately 150°C higher than that of polyethylene due to hydrogen bonding. Polyols have been used as plasticizers, but efficient production of highly hydrolyzed plasticized polyvinyl alcohol has been difficult to achieve.

[0005] WO 2017 / 046361 discloses a method for producing plasticized polyvinyl alcohol having a degree of hydrolysis of 98% by weight or more. Summary of the Invention

[0006] According to a first aspect of the present invention, there is provided a method for producing a plasticized polyvinyl alcohol polymer, the method comprising the steps of: introducing into a mixing reactor a polyvinyl alcohol polymer comprising a homopolymer polyvinyl alcohol or a blend thereof having a degree of hydrolysis in the range of 93% to 98% by weight or greater; Here, the mixing reactor is a blending chamber having a first inlet, a first outlet, and at least two interengaging components extending between the first inlet and the first outlet, the components being positioned to apply a shear force to the polymer as it is conveyed by the components from the inlet through a reaction zone to the outlet; one or more second inlets located downstream of the first inlet for introducing reactants, including processing aids, plasticizers, and reaction stabilizers, into the chamber to form a reaction mixture; the plasticizer is selected from the group consisting of sugar alcohols, diols, triols, polyols, and mixtures thereof; the reaction stabilizer is selected from the group consisting of sodium stearate, potassium oleate, sodium benzoate, calcium stearate, stearic acid, dimethylpropionic acid, and mixtures thereof; Additionally, the blending chamber may include: a plurality of heating zones arranged to expose the mixture to a temperature profile that increases in temperature from the inlet to the outlet; a second outlet disposed between the reaction region and the first outlet to allow removal of a processing aid from the chamber; reacting a processing aid, a plasticizer, and the polymer in the reaction zone to form a plasticized polymer; and Passing the plasticized polymer through a first outlet.

[0007] The use of a reactive mixing device, typically an extruder according to the present invention, allows the processing aids and plasticizers to react with the polyvinyl alcohol or blends thereof without polymer degradation, followed by removal of all or most of the processing aids through a second outlet to obtain the plasticized polyvinyl alcohol or blends thereof.

[0008] The use of reactive stabilizers can advantageously reduce the degree of degradation during melt processing, allowing homopolymer polyvinyl alcohols having a high degree of hydrolysis, e.g., 93% by weight or greater, to be processed to form pellets, films, and fibers.

[0009] The reaction stabilizer may be used in an amount of about 0.2% by weight to about 5% by weight, for example, about 0.5% by weight to about 3% by weight, for example, 0.5% by weight to about 2% by weight, for example, about 0.5% by weight to about 1.5% by weight, for example, about 1% by weight.

[0010] The reactive stabilizers of the present invention can reduce the degree of polymer degradation during processing. Homopolymer polyvinyl alcohol has been difficult to process due to its decomposition at the high temperatures required. This degradation burden has led to the use of polyvinyl alcohol copolymers, resulting in a loss of engineering properties. This can be seen by UV spectroscopy of the amount of bond present in the polymer. Sodium benzoate has been found to be particularly effective.

[0011] In exemplary embodiments, thin films of the melt-processed polyvinyl alcohol formulations of the present invention remain transparent and do not exhibit a whitening effect after exposure to humidity. The use of an appropriate reactive stabilizer can provide films with improved visual appearance. A preferred reactive stabilizer is sodium benzoate. Although less advantageous, the formation of an opaque, cloudy, or white film after 24 hours of humidity testing can indicate that phase separation has occurred.

[0012] The polyvinyl alcohol polymer may comprise polyvinyl alcohol or a blend thereof, the polyvinyl alcohol polymer having a degree of hydrolysis of from 93% to less than 98% by weight, preferably 93% to 97% by weight, or alternatively 93% to 95% by weight.

[0013] The use of homopolymer polyvinyl alcohol is particularly advantageous. Homopolymer polyvinyl alcohol is produced by hydrolysis of homopolymer polyvinyl acetate, and the degree of hydrolysis is 93% by weight or more in an embodiment of the present invention. Polyvinyl alcohol copolymers produced by hydrolysis of polyvinyl acetate copolymers have inferior properties compared to homopolymer polyvinyl alcohol. Homopolymer polyvinyl alcohol can exhibit the following advantageous properties:

[0014] The polyvinyl alcohol polymers of the present invention can have excellent film-forming, emulsifying, and adhesive properties. The polymers exhibit excellent barrier properties, including resistance to oil, grease, and solvents. The polymers can also have high tensile strength and flexibility, as well as high oxygen and odor barrier properties. [Brief explanation of the drawings]

[0015] [Figure 1] DSC data showing the relationship between reactive stabilizer and crystallinity. [Figure 2] 4 shows torque test results for the examples. DETAILED DESCRIPTION OF THE INVENTION

[0016] Polyvinyl alcohol can be produced by hydrolysis of the homopolymer polyvinyl acetate, the degree of hydrolysis being in the range of 93% up to 98% by weight, such as 93% to less than 98% by weight, for example 93% to 97% by weight, for example 93% to 95% by weight.

[0017] A blend of two or more polyvinyl alcohol polymers can be used, for example, a blend of two polyvinyl alcohol polymers having relatively high and relatively low molecular weights, respectively.

[0018] Blends of polyvinyl alcohols with different hydrolysis levels can be combined. Blending different polyvinyl grades together can enhance the properties of the resulting polymer, such as viscosity, solubility, and melt strength.

[0019] Blends of two polyvinyl alcohol polymers with the same degree of hydrolysis but different viscosities can be used. For example, to provide a polymer with a specific desired viscosity, one polymer can have a viscosity of 5 cp and the other can have a viscosity of 28 cp. Viscosity can be adjusted by varying the ratio of the lower viscosity polymer to the higher viscosity polymer. In one embodiment, a blend of a higher viscosity and a lower viscosity polyvinyl alcohol in a ratio of 80:20 wt% can result in a higher polymer viscosity than a blend with a 40:60 wt% ratio. This allows for control of the polymer's properties for use in specific applications. By controlling the combination and relative weight ratio of polymers with different degrees of hydrolysis, the solubility of the resulting polymer can be controlled. For example, for two polymers with the same plasticizer, a blend of polyvinyl alcohol with a degree of hydrolysis greater than 98% can have a dissolution temperature in water of 70°C, while a blend of polyvinyl alcohol with a degree of hydrolysis between 87 and 96% can have a dissolution temperature in water of 40°C. The same polyvinyl alcohol blend in an 80:20 wt% ratio may be water soluble at 40° C., while in a 60:40 wt% ratio the dissolution temperature may be 30° C. This is illustrated in the table below.

[0020] [Table 1]

[0021] Melt strength can be improved by increasing the ratio of high molecular weight polyvinyl alcohol to low molecular weight polyvinyl alcohol in the blend.

[0022] For example, the blend may include a low viscosity grade having a molecular weight in the range of 13,000 to 27,000 and a degree of polymerization of 300 to 600, and a medium to high viscosity grade having a molecular weight in the range of 107,000 to 120,000 and a degree of polymerization of 2,400 to 2,600.

[0023] In embodiments, the polyvinyl alcohol comprises a blend of two or more polyvinyl alcohol polymers, each having a degree of hydrolysis of 93% to 98%, preferably one high molecular weight and at least one low molecular weight polyvinyl alcohol. In a preferred embodiment, the polymer comprises 80% high molecular weight polyvinyl alcohol and 20% low molecular weight polyvinyl alcohol. The ratio of high molecular weight polyvinyl alcohol to low molecular weight polyvinyl alcohol can be from about 2:1 to about 10:1, alternatively from about 3:1 to 7:1, alternatively from about 6:1 to 4:1, alternatively about 5:1.

[0024] The high molecular weight polymer can have a molecular weight of 60,000 to 120,000.

[0025] The low molecular weight polymer can have a molecular weight of 5,000 to 30,000.

[0026] The blend of different molecular weight polymers used is selected according to the physical properties required for the final product. This may require the use of different molecular weight materials. The use of more than two different molecular weight polymers may be advantageous. The use of a single molecular weight polymer is not excluded.

[0027] The use of a blend can allow for control of the viscosity of the polymer. The selection of a stabilizer according to the present invention allows for the use of a blend with a desired viscosity without losing other properties. Alternatively, the use of a blend can allow for the use of polyvinyl alcohol containing one or more stabilizers while maintaining viscosity or other properties to allow for the production of pellets or films. The processing aid is preferably water. Alternatively, the processing aid may comprise a mixture of water and one or more hydroxyl compounds having a boiling point below the boiling point or melting point of the plasticizer. For cost and environmental reasons, the use of water is preferred.

[0028] When a mixture of plasticizers is used, a binary mixture may be preferred.

[0029] The plasticizer can be selected from the following group: (a) sugar alcohols selected from the group consisting of diglycerol, triglycerol, fructose, ribose, xylose, D-mannitol, triacetin, and mixtures thereof; polyols selected from the group consisting of pentaerythritol, dipentaerythritol, and mixtures thereof; (b) diols selected from the group consisting of methylpentanediol, 1,2-propanediol, 1,4-butanediol, 2-hydroxy-1,3-propanediol, 3-methyl-1,3-butanediol, 3,3-dimethyl-1,2-butanediol, and mixtures thereof; (c) glycols selected from the group consisting of polyethylene glycol 300, polyethylene glycol 400, alkoxylated polyethylene glycol, and mixtures thereof; (d) Caprolactam, tricyclic trimethylolpropane formal, rosin ester, euricamide, and mixtures thereof.

[0030] In a first embodiment, the following plasticizers can be used in combination: Dipentaerythritol, methylpentanediol, triacetin, 2-hydroxy-1,3-propanediol, 3,3-dimethyl-1,2-butanediol, tricyclic trimethylolpropane formal, D-mannitol, triglycerol, and xylose.

[0031] Preferably, a two-component composition of the plasticizer of the first embodiment is used.

[0032] In a second embodiment, the following plasticizers are used alone or in combination with one another, or in combination with one or more plasticizers of the first embodiment: caprolactam, alkoxylated polyethylene glycol.

[0033] Amounts of plasticizers between 2 and 15% by weight can be used, where the total amount of plasticizer in the formulation is between about 15% and about 30% by weight.

[0034] In a second embodiment, the following plasticizers are used alone or in combination with one another, or together with one or more plasticizers of the first embodiment: caprolactam, alkoxylated polyethylene glycol.

[0035] A suitable grade of dipentaerythritol is Di-Penta-93 (Perstorp).

[0036] A suitable grade of caprolactam is Caprolactam 3031 (Ingevity).

[0037] Suitable grades of alkoxylated polyethylene glycol are Alkoxylate 4528 or Alkoxylate 3380 (Perstorp).

[0038] In an exemplary embodiment, thin films of the melt-processed polyvinyl alcohol formulations of the present invention remain transparent and do not exhibit a whitening effect after exposure to humidity. The use of an appropriate lubricant can provide films with improved visual appearance. An exemplary lubricant is euricamide. Although less favorable, the formation of an opaque, cloudy, or white film after 24 hours of humidity testing can indicate phase separation.

[0039] Preferred solid plasticizers or reactive stabilizers are also volatile under processing conditions at processing temperatures. Preferred plasticizers or reactive stabilizers have a melting point of about 150°C to about 300°C, typically about 150°C to about 275°C.

[0040] An aqueous solution of a plasticizer or stabilizer can be injected through a single second inlet.

[0041] The solid plasticizer or stabilizer may be provided independently or together with one or more of the polymeric materials of the formulation.

[0042] Polymers containing the stabilizers and / or plasticizers of the present invention provide films that can exhibit complete clarity after a 24 hour humidity test.

[0043] One or more processing aids may be used. Euric amide may be used as a slip additive. Amounts of 0 to 5% by weight may be used.

[0044] Additional additives may be used, including antioxidants, lubricants, dyes and pigments.

[0045] The water content of the polymers of the present invention can range from about 0.1% to about 5% by weight, for example, from about 1% to about 4% by weight.

[0046] Processing temperatures can be up to about 260°C, depending on residence time in the higher temperature zones of the extruder.

[0047] In an exemplary embodiment, the mixing reactor comprises a twin-screw extruder. Alternatively, the mixing reactor may comprise a batch reactor for smaller scale processing. The mixing reactor should have a high internal surface area to allow for efficient heat dissipation.

[0048] The extruder reactor chamber may consist of 5 to 20 heating zones, typically 10 to 15, and more preferably about 12. The temperature profile may increase from ambient temperature in the first zone to 200°C near the exit. The reaction zone may have a temperature up to 260°C.

[0049] The location of the reaction zone can be controlled by selecting and adjusting one or more of the screw configuration, formulation, temperature profile, rotational speed of one or more screws (depending on the type of reactor), and feed rate of the reaction mixture to the apparatus. The location of the reaction zone may be determined by temperature measured by one or more thermocouples or other temperature sensors positioned along the length of the chamber. In a preferred embodiment, the reaction zone is controlled to be located before the second outlet and upstream of the first outlet. The location of the reaction zone may be adjusted to allow the reaction to be completed before venting.

[0050] The energy provided by the application of shear and control of the temperature of the polymer mixture allows for control of the chemical energy of the exothermic reaction between the processing aid and the hydrogen-bonded crystalline domains of the polymer after the exothermic reaction has begun. Failure to exercise proper temperature control can result in decomposition and even charring of the polymer mixture.

[0051] In a preferred embodiment, the screw configuration, typically the co-rotating, closely intermeshing twin screws of a twin screw extruder, may be as follows:

[0052] The conveying section may be located at the throat or inlet of the extruder. The feed rate should be adjusted to avoid overfeeding the throat. The conveying section is followed by an intensive mixing zone, which in turn is followed by another conveying section, forming a reaction zone. The reaction is essentially complete in the reaction zone. This is followed by an intensive mixing section, where the reaction is carried out to full completion. Following the intensive mixing section is a low-pressure zone where venting is permitted. A compression zone then feeds the mixture into a die, pump, or simple screw extruder.

[0053] The temperatures that can be used for blown film formulations are as follows:

[0054] [Table 2]

[0055] The temperatures that can be used for extrusion coating formulations are as follows:

[0056] [Table 3]

[0057] The temperature of the reaction mixture may not be the same as the set point due to mechanical heating caused by the mixing process, shear heating effects, reaction exotherm, and insufficient heat transfer to the coolant in the steel reaction vessel. Those skilled in the art can determine appropriate process conditions.

[0058] To ensure complete reaction of the processing aid with the polymer, an intensive mixing zone can be provided downstream of the reaction zone. In a preferred embodiment, the intensive mixing zone can include a paddle mixer disposed between the reaction zone and the second outlet. The mixing zone can also be a kneading zone including pairs of intermeshing rotors or paddles.

[0059] The preferred mixing reactor is self-cleaning during use. Co-rotating intermeshing screws such as those used in twin-screw extruders can be used. The operating conditions described can be employed with appropriate start-up and shutdown procedures.

[0060] For start-up, a completely empty and clean extruder barrel can be used. The water or processing aid feed is started, followed simultaneously or continuously by the polymer powder and plasticizer. The initial feed rate and screw rotation are lower than the steady-state speed. If a die is directly connected to the twin-screw extruder, once a consistent strand is produced, the feed rate and screw speed are increased to steady-state conditions. The installation of a dry surface cutter or strand pelletizer is carried out in the usual manner known to those skilled in the art. If a single screw is used, it must be empty and connected to the twin-screw extruder before start-up.

[0061] When using the method of the present invention, pre-flushing with standard flushing agents such as low density polyethylene, high density polyethylene or polypropylene, whether filled or unfilled, is neither necessary nor desirable. When the die is attached to a single screw extruder pelletizer, the filling is as described above.

[0062] To provide a clean extruder for subsequent startup, the shutdown procedure can include stripping all feeds and reducing all screw speeds, and then continuing operation until as much material as possible has been delivered. If the twin-screw extruder is coupled to a single-screw extruder or other type of melt pump, the twin screws can be decoupled from the single screw, and the die can also be decoupled. The die can be placed in a furnace at 300-450°C to burn off any remaining polymer, or immersed in hot water until the polymer melts or swells, allowing for easy mechanical removal. The temperature of the isolated twin-screw extruder can then be lowered to a uniform 100-110°C with the screws rotating, and the residual polymer can be discharged as crumbs until the barrel is empty. The barrel can then be polished by feeding a portion of dry powdered polymer. After the polishing stage, the final residual material is discharged.

[0063] In single-screw extruders, an optimum processing temperature of around 200°C is maintained. If a closed-barrel extruder is used, the screw can be slowly separated and removed without cooling. The polymer is withdrawn from the screw as it leaves the barrel. This results in a clean screw. If a clamshell single-screw extruder is used, the casing can be opened and the polymer can be quickly removed while hot before removing the heated screw. The barrel can be cleaned with a wire brush while it cools. Cleaning the extruder barrel with purged material is neither necessary nor effective.

[0064] The second outlet may be a vent port that allows volatile processing aids, such as water vapor, to be completely or partially removed from the polymer mixture.

[0065] When water is the processing aid, the water content of the plasticized polymer may be less than 5% by weight, preferably less than 2% by weight, and more preferably 0.5% by weight or less.

[0066] In an alternative embodiment, the processing aid inlet is placed upstream of the plasticizer inlet. This allows the polymer to mix with the processing aid before the plasticizer is introduced. Without wishing to be bound by theory, it is believed that plasticizer molecules, such as neopentyl glycol, may be slow to decompose into the crystalline domains of polyvinyl alcohol. The energy provided by the application of shear force and control of the temperature of the polymer mixture allows for control of the chemical energy of the exothermic reaction between the processing aid and the hydrogen-bonded crystalline domains of the polymer after the exothermic reaction has begun. Failure to exercise proper control can result in polymer degradation and even charring.

[0067] The rotational speed of the twin screws may be adjusted to control the specific energy per unit length of the reactive mixing chamber, such that the screws act as an energy input device.

[0068] In a typical embodiment, 30% to 70% of the mixing reactor chamber may be filled with the polymer mixture, with the remaining volume either empty or serving as a lower pressure zone to facilitate devolatilization. As a result, the output rate of polymer from the first outlet may be inconsistent and pulsed. A compression zone may be used to provide a continuous output.

[0069] In a preferred embodiment, the mixer reactor is a twin-screw extruder having a preferred length to diameter ratio in the range of 25:1 to 50:1, preferably in the range of about 25:1 to 45:1, more preferably about 40:1. For example, a typical mixer reactor may have two 95 mm diameter screws with a length of 4.8 m.

[0070] The first outlet may include a die, for example a multi-strand die.

[0071] Alternatively, in an advantageous embodiment of the present invention, a pump can be provided downstream of the first outlet. The pump can comprise a single-screw extruder unit. The configuration and rotational speed of the single screw can be selected so that the pump is filled with plasticized polymer during use. In this way, the screw functions as a controllable variable pump to provide a constant flow of polymer to a die located downstream of the reaction mixer.

[0072] By mixing a temperature-controlled mixture of polyvinyl alcohol and water or other processing aids and applying shear, an exothermic reaction occurs which, if properly controlled, serves to reduce or destroy the crystallinity of the highly hydrolyzed polyvinyl alcohol. Without wishing to be bound by theory, it is believed that the lattice energy of the crystalline polyvinyl alcohol is released by the introduction of hydrogen bonds through the incorporation of water or other processing aids into the polymer mixture.

[0073] The onset of the exothermic reaction can be controlled by selecting the temperature profile and shear rate applied to the twin screw. The extent of the exothermic reaction can be controlled by adjusting the rate of heat removal from the mixer, the composition and feed rate of the reaction mixture, and the amount of shear energy input and the location of the reaction zone. The location of the reaction zone where the exothermic reaction occurs can be controlled by appropriate control of the temperature profile and rotation speed.

[0074] The boiling point of the processing aid is preferably selected to be below the temperature of the reaction and mixing zones, allowing excess processing aid to be released from the polymer mixture.

[0075] The average residence time in the mixer can be about 2 to 10 minutes, preferably about 5 minutes. The residence time in the reactor is preferably sufficient to allow the reaction to go to completion so that a viscoelastic melt is obtained with a minimal amount of unreacted polyvinyl alcohol.

[0076] A cooling chamber may be located downstream of the die, which may include a system of moving rollers located in a controlled atmosphere to ensure that the polymer strands emerging from the die are maintained under proper tension as they cool and solidify prior to pelletization.

[0077] Percentages referred to herein may be selected from any range that adds up to 100%. Percentages or other amounts used herein are by weight unless otherwise specified.

[0078] According to a second aspect of the present invention, a homopolymer polyvinyl alcohol polymer composition comprises a homopolymer polyvinyl alcohol having a degree of hydrolysis of 93% or greater, a plasticizer, and a reactive stabilizer: wherein the plasticizer is selected from the group consisting of sugar alcohols, diols, triols, polyols, and mixtures thereof; the reaction stabilizer is selected from the group consisting of sodium stearate, potassium oleate, sodium benzoate, calcium stearate, stearic acid, dimethylpropionic acid, and mixtures thereof; The polymer is a viscoelastic thermoplastic material.

[0079] According to a third aspect of the present invention, a method for reducing degradation of homopolymer polyvinyl alcohol during processing comprises the steps of the method of the first aspect of the present invention.

[0080] The polyvinyl alcohol compositions of the present invention offer many advantages over previously used compositions. Exemplary compositions are extrudable and can be used to make pellets, films, and fibers. [Example]

[0081] The invention will now be further illustrated by way of examples, but not in a limiting sense.

[0082] Example 1: Use of sodium benzoate Sodium benzoate was used as a reaction stabilizer along with various plasticizers and plasticizer combinations as listed below. Trimethylolethane (TME) and trimethylolpropane (TMP), ratio 1:2 Trimethylolethane (TME) and trimethylolpropane (TMP), 1:1 ratio Trimethylolethane (TME) and trimethylolpropane (TMP), ratio 2:1 Neopentyl glycol (NPG) and trimethylolpropane (TMP), 1:1 ratio Neopentyl glycol (NPG) and trimethylolpropane (TMP), ratio 2:1 Neopentyl glycol (NPG) and trimethylolpropane (TMP), ratio 3:1 Tripentaerythritol (TPE) and trimethylolpropane (TMP), ratio 1:4 Diethyl pentanediol dineopentanoate (DEPD) and trimethylolpropane (TMP), ratio 1:3 Diethyl pentanediol dineopentanoate (DEPD) and trimethylolpropane (TMP), ratio 1:2 Diethyl pentanediol dineopentanoate (DEPD) and trimethylolpropane (TMP), 1:1 ratio

[0083] Sodium benzoate was used as a reaction stabilizer, and the combination and ratio of plasticizers was varied.

[0084] The results show that polymer degradation can be controlled when sodium benzoate is used as a reactive stabilizer and the plasticizer combination and plasticizer ratio are varied. For example, in the case of the NPG:TMP plasticizer combination, increasing the ratio of NPG to TMP results in greater polymer degradation. When using the same plasticizer ratio of 3:1 but different plasticizers, specifically pentaerythritol, TME, and NPG, the TME:TMP combination was found to be superior, exhibiting the least degradation. From the degradation data, the preferred plasticizer combinations are TME:TMP and DEPD:TMP.

[0085] The crystallinity of a polymer is important because it can affect the secondary and tertiary processing required to produce the final product. For example, if a film is too crystalline, it will be very brittle, hindering the ability to process the film into a finished product. The crystallinity of polymers in the form of pellets, films, or prepared films (i.e., films exposed to moisture) was compared. The results are shown below.

[0086] The addition of the reactive stabilizer according to the present invention can reduce the crystallinity of the film. In general, the crystallinity values ​​of the pellets were slightly higher or similar to those of the films. However, there was no significant change in crystallinity before and after the wet treatment.

[0087] When alternative plasticizers were used in the formulations, Tg values ​​could be observed by DSC analysis. The obtained Tg values ​​ranged from 44 to 65°C. The melting peaks (Tm) for all of the reactive stabilizer and plasticizer combinations were in the range of 200 to 215°C. Thus, from a thermal standpoint, the combinations of plasticizer and reactive stabilizer were shown to be suitable for processing. However, the preferred combination is sodium stearate and the plasticizer combination TMP and pentaerythritol.

[0088] The results are shown in the following table.

[0089] [Table 4]

[0090] Phase separation of films without reactive stabilizers was observed after 24 hours. The films became milky. When sodium benzoate was used as a stabilizer in combination with various plasticizers and plasticizer combinations, clear films were obtained after preparation.

[0091] Torque analysis of polyvinyl alcohol homopolymer stabilized with various reactive stabilizers was performed in a batch mixer. Processing was performed at 190°C, 60 rpm for 8 minutes on 40g total batches. All stabilizers reduced torque. The combination of calcium stearate and stearic acid gave the greatest reduction. The results are shown below and in the accompanying figures.

[0092] [Table 5]

[0093] DSC Data [Table 6]

Claims

1. 1. A method for producing a plasticized homopolymer polyvinyl alcohol, comprising the steps of: introducing a polyvinyl alcohol polymer comprising polyvinyl alcohol having a degree of hydrolysis ranging from 93% to 98% by weight or a blend thereof into a mixing reactor; Here, the mixing reactor is a blending chamber having a first inlet, a first outlet, and at least two interengaging components extending between the first inlet and the first outlet, the components being positioned to apply a shear force to the polymer as it is conveyed by the components from the first inlet through a reaction zone to the first outlet; one or more second inlets located downstream of the first inlet for introducing reactants, including water as a processing aid, a plasticizer, and a reaction stabilizer, into the chamber to form a reaction mixture; the plasticizer is selected from the group consisting of diglycerol, triglycerol, fructose, ribose, xylose, D-mannitol, triacetin, pentaerythritol, dipentaerythritol, methylpentanediol, 1,2-propanediol, 1,4-butanediol, 2-hydroxy-1,3-propanediol, 3-methyl-1,3-butanediol, 3,3-dimethyl-1,2-butanediol, polyethylene glycol 300, polyethylene glycol 400, alkoxylated polyethylene glycol, caprolactam, tricyclic trimethylolpropane formal, rosin esters, and mixtures thereof; the reaction stabilizer is selected from the group consisting of sodium stearate, potassium oleate, sodium benzoate, calcium stearate, dimethylpropionate, and mixtures thereof; Additionally, the blending chamber may include: a plurality of heating zones arranged to expose the mixture to a temperature profile that increases in temperature from the first inlet toward the first outlet; a second outlet disposed between the reaction region and the first outlet to allow removal of water from the chamber; reacting water, a plasticizer, and the polymer in the reaction zone to form a plasticized polymer; and Passing the plasticized polymer through a first outlet.

2. 10. The method of claim 1, wherein the reaction stabilizer is sodium benzoate.

3. 3. The method according to claim 1, wherein the amount of the reaction stabilizer is from 0.2% to 5% by weight.

4. 4. The method of claim 3, wherein the amount of the reaction stabilizer is 0.5% to 3% by weight.

5. 5. The method of claim 4, wherein the amount of the reaction stabilizer is 0.5% to 2% by weight.

6. 6. The method of claim 5, wherein the amount of the reaction stabilizer is 0.5% to 1.5% by weight.

7. 7. The method of any one of claims 1 to 6, wherein the polyvinyl alcohol polymer comprises polyvinyl alcohol or a blend thereof, and the polyvinyl alcohol has a degree of hydrolysis of from 93% to less than 98% by weight.

8. 8. The method of claim 7, wherein the degree of hydrolysis is from 93% to 97% by weight.

9. 9. The method of claim 8, wherein the degree of hydrolysis is from 93% to 95% by weight.

10. The method of any one of claims 1 to 9, wherein the polyvinyl alcohol polymer is a blend of two or more polyvinyl alcohol polymers.

11. 11. The method of claim 10, wherein the blend comprises a polymer having a molecular weight in the range of 13,000 to 27,000 and a degree of polymerization of 300 to 600, and a polymer having a molecular weight in the range of 107,000 to 120,000 and a degree of polymerization of 2,400 to 2,600.

12. The method according to any one of claims 1 to 11, wherein two or more of the following plasticizers are used in combination: dipentaerythritol, methylpentanediol, triacetin, 2-hydroxy-1,3-propanediol, 3,3-dimethyl-1,2-butanediol, tricyclic trimethylolpropane formal, D-mannitol, triglycerol, and xylose.

13. 13. The method according to any one of claims 1 to 12, wherein caprolactam and alkoxylated polyethylene glycol plasticizers are used alone or in combination with each other.

Images