PVC compositions containing mineral fillers and vinyl-functional polydiorganosiloxanes, polymer composite articles formed therewith, and methods for preparing same

Abstract

A polyvinyl chloride (PVC) composition and method for preparing a polymer composite article. The composition includes (A) a mineral filler in an amount of 7.5 to 75 weight percent. The composition also includes (B) a polyvinyl chloride polymer in an amount of 20 to 92 weight percent. The composition further includes (C) a polydiorganosiloxane in an amount greater than 0 to 5 weight percent, the polydiorganosiloxane having the unit formula: (R2R'SiO2) 1 / 2 ) a (R3SiO 1 / 2 )b(R2SiO 2 / 2 )c(RR'SiO 2 / 2 ) d wherein each R is an independently selected monovalent hydrocarbon radical of 1 to 18 carbon atoms free of aliphatic unsaturation; 、 each R' is an independently selected alkenyl group of 2 to 18 carbon atoms, subscript a is 0 to 2, subscript b is 0 to 2, the quantity (a+b)=2, subscript c≧0, subscript d≧0, the quantity (a+d)≧1, and the quantity (a+b+c+d) is sufficient to impart to the polydiorganosiloxane a viscosity of 2,000 mPa·s to 60,000 mPa·s at 25°C as measured at 0.1 to 50 RPM on a Brookfield DV-III cone and plate viscometer with a #CP-52 spindle. The ranges for components (A) through (C) are based on the total weight of components (A), (B), and (C) in the composition.

Description

[Technical Field]

[0001] The present invention relates generally to polyvinyl chloride (PVC) compositions, and more particularly to PVC compositions for preparing polymer composite articles, methods for preparing PVC compositions and polymer composite articles using the same, and polymer composite articles formed thereby. [Background technology]

[0002] Polymer composite articles are known in the art and are utilized in a variety of end-use applications. Polymer composite articles are becoming increasingly popular with consumers due to the cost and desirable properties associated with polymer composite articles, including physical and mechanical properties.

[0003] In the PVC industry, it is common to include fillers in composite articles. Fillers are relatively inexpensive and are often used to reduce costs. Such composite articles are typically produced by thoroughly blending the filler with PVC to obtain a blend. However, high levels of filler can adversely affect the properties of the composite article. For example, large amounts of filler can affect important properties such as density, percent elongation, impact strength, surface finish, melt flow, melt viscosity, melt strength, and processability.

[0004] Due to its nature, PVC cannot be processed alone. Other additives, such as stabilizers, processing aids, and lubricants, are required for the polymer's processability and performance. Typically, these additives are mixed in a high-speed mixer / blender to create a dry blend. High filler levels make it difficult to form a uniform dry blend. The system often becomes very dusty and difficult to handle. Fillers also tend to adhere to the mixer walls and blades, resulting in less than the desired amount of filler in the blend. Filler adhesion also increases equipment cleaning times and can increase contamination of the next batch.

[0005] Conventional, low-cost organic processing aids generally suffer from the drawback of requiring high loadings to achieve faster production rates, thereby impacting cost and / or performance characteristics. Furthermore, many conventional processing aids can adversely affect the physical properties of composite articles, reducing their mechanical properties (e.g., impact resistance, flexural strength, flexural modulus), especially when used at elevated temperatures. Conventional processing aids can also migrate out of polymer composite articles, adversely affecting one or more properties of the polymer composite article over time, such as its physical properties, appearance, feel, ability to be overmolded, ability to be coextruded, ability to adhere to the surface of the polymer composite article, ability to print on the surface, and ability to paint on the surface. Furthermore, some organic processing aids volatilize at higher application temperatures, which can lead to the formation of bubbles and cracks in the polymer composite article and potentially impair the long-term performance of these articles.

[0006] High filler levels also tend to increase the density of the polymer system. Higher density increases the weight of the final composite article, which in turn can increase the associated shipping costs. Upon foaming, high filler levels also restrict the expansion of the polymer.

[0007] High filler levels typically make polymer systems shear sensitive: these systems exhibit higher shear thinning behavior.

[0008] The use of inorganic fillers can increase the char content and improve smoke and flame properties, but often results in a decrease in mechanical properties such as % elongation and impact strength.

[0009] Current PVC compositions must sacrifice at least one property for another benefit: for example, a PVC composition may be formulated to improve impact strength but reduce percent elongation, or to improve surface finish but reduce throughput, or to provide a desired density but affect other physical properties.

[0010] It would be desirable to provide a polymer system with a high filler content that addresses one or more of the above problems. Summary of the Invention

[0011] The present invention provides a polyvinyl chloride composition for preparing a polymer composite article. The composition includes (A) a filler in an amount of 10 to 90% by weight. The composition also includes (B) a polyvinyl chloride polymer in an amount of 10 to 90% by weight. The composition further includes (C) a polydiorganosiloxane in an amount of greater than 0 to 5% by weight, the polydiorganosiloxane having the unit formula: (R2R'SiO2) 1 / 2 ) a (R3SiO 1 / 2 ) b (R2SiO 2 / 2 ) c (RR'SiO 2 / 2 ) d wherein each R is an independently selected monovalent hydrocarbon radical of 1 to 18 carbon atoms free of aliphatic unsaturation; 、 each R' is an independently selected alkenyl group of 2 to 18 carbon atoms, subscript a is 0 to 2, subscript b is 0 to 2, the quantity (a+b)=2, subscript c≧0, subscript d≧0, the quantity (a+d)≧1, and the quantity (a+b+c+d) is sufficient to impart to the polydiorganosiloxane a viscosity of 2,000 mPa·s to 60,000 mPa·s at 25°C as measured at 0.1 to 50 RPM on a Brookfield DV-III cone and plate viscometer with a #CP-52 spindle. The ranges for components (A) through (C) are based on the total weight of components (A), (B), and (C) in the composition.

[0012] Also provided is a method of preparing the composition, comprising combining (A) a mineral filler, (B) a polymer, and (C) a polydiorganosiloxane, thereby preparing the composition.

[0013] Further provided by the present invention is a method for preparing a polymer composite article, the method comprising preparing the polymer composite article from the composition. Additionally, a polymer composite article formed according to the method is also provided. DETAILED DESCRIPTION OF THE INVENTION

[0014] The present invention provides compositions for preparing polymer composite articles. The polymer composite articles, as described below, have excellent physical properties and are suitable for a myriad of end-use applications. Methods for preparing the polymer composite articles, and the polymer composite articles formed thereby, are also provided and described below.

[0015] A composition for preparing a polymer composite article includes (A) a filler in an amount of 10 to 90 weight percent, (B) a polymer in an amount of 10 to 90 weight percent, and (C) a polydiorganosiloxane in an amount of greater than 0 to 10 weight percent, each based on the total weight of components (A), (B), and (C) in the composition.

[0016] The composition comprises: (A) a filler in an amount of 10 to 90 weight percent; (B) a polyvinyl chloride polymer in an amount of 10 to 90 weight percent; and (C) a polydiorganosiloxane in an amount of greater than 0 to 5 weight percent, wherein the polydiorganosiloxane has the unit formula: (R2R'SiO2) 1 / 2 ) a (R3SiO 1 / 2 ) b (R2SiO 2 / 2 ) c (RR'SiO 2 / 2 ) dwherein each R is an independently selected monovalent hydrocarbon radical of 1 to 18 carbon atoms free of aliphatic unsaturation; each R' is an independently selected alkenyl radical of 2 to 18 carbon atoms; subscript a is 0 to 2; subscript b is 0 to 2; the quantity (a+b)=2; subscript c≧0; subscript d≧0; the quantity (a+d)≧1; and the quantity (a+b+c+d) is sufficient to impart to the polydiorganosiloxane a viscosity of 2,000 mPa s to 60,000 mPa s at 25° C. as measured at 0.1 to 50 RPM on a Brookfield DV-III cone and plate viscometer with a #CP-52 spindle. The range of components (A) through (C) is based on the total weight of components (A), (B), and (C) in the composition.

[0017] Component (A) Mineral Filler The composition includes (A) a mineral filler, which is capable of forming a discontinuous phase in compositions for preparing polymer composite articles and in the composite articles so prepared.

[0018] The (A) mineral filler may be untreated, pretreated with any filler treating agent, or added in combination therewith; if so added, the (A) mineral filler may be treated in situ or prior to incorporation into the composition. If treated, the (A) mineral filler may be treated with any conventional filler treating agent known in the art. The (A) mineral filler may be a single filler or a combination of two or more fillers that differ in at least one property, such as filler type, preparation method, treatment or surface chemistry, filler composition, filler shape, filler surface area, average particle size, and / or particle size distribution.

[0019] Preferably, the (A) mineral filler comprises at least 90 wt. % of the total weight of fillers in the PVC composition, i.e., the PVC composition may contain up to 10 wt. % of non-mineral fillers. More preferably, the (A) mineral filler comprises at least 95 wt. % of the total weight of fillers in the PVC composition. Even more preferably, the filler in the PVC composition consists essentially of or consists of at least one mineral filler. As used herein, "consisting essentially of" means that any filler other than the mineral filler present in the PVC composition does not adversely affect either the physical properties of the PVC composition and / or the processability of the PVC composition. Preferably, the PVC composition contains less than 5 wt. % of lignocellulosic or organic fillers. More preferably, the PVC composition does not contain lignocellulosic or organic fillers.

[0020] The shape and size of the (A) mineral filler are also not particularly limited. For example, the (A) mineral filler may be spherical, oblong, oval, irregular, and may be in the form of, for example, powder, fiber, particles, and combinations thereof. The size and shape are typically selected based on the type of (A) mineral filler utilized, the selection of other components included within the composition, and the end-use application of the polymer composite article formed therewith.

[0021] Non-limiting examples of mineral fillers that may function as extending or reinforcing fillers include quartz and / or crushed quartz, aluminum oxide, magnesium oxide, silica (e.g., fumed, crushed, precipitated), hydrated magnesium silicate, magnesium carbonate, dolomite, silicone resin, wollastonite, soapstone, kaolinite, kaolin, mica muscovite, phlogopite, halloysite (hydrated aluminum silicate), aluminum silicate, sodium aluminosilicate, glass (including fibers, beads, or particles, e.g., recycled glass from wind turbines or other sources), clay, magnetite, hematite, calcium carbonate, e.g., precipitated, fumed, and / or crushed calcium carbonate, calcium sulfate, barium sulfate, calcium metasilicate, zinc oxide, talc, diatomaceous earth, iron oxide, clay, mica, chalk, titanium dioxide (titania), zirconia, Examples of fillers include graphite, anthracite, lignite, magnesium oxide, magnesium hydroxide, magnesium oxysulfate fiber, aluminum trihydrate, aluminum oxyhydrate, pigments (e.g., titanium dioxide, non-hydrated, partially hydrated, or hydrated fluorides, chlorides, bromides, iodides, chromates, carbonates, hydroxides, phosphates, hydrogen phosphates, nitrates, oxides, and sulfates of sodium, potassium, magnesium, calcium, and barium), antimony pentoxide, antimony trioxide, beryllium oxide, chromium oxide, lithopone, borates such as zinc borate, barium metaborate, or aluminum borate, mixed metal oxides such as vermiculite, bentonite, pumice, perlite, fly ash, clay, and silica gel, pyrophyllite, sepiolite, zinc stannate, zinc sulfide, and combinations thereof. Alternatively, the extending or reinforcing filler may be selected from the group consisting of calcium carbonate, talc, and combinations thereof.

[0022] Extending fillers are known in the art and are commercially available, for example, ground silica sold under the name MIN-U-SIL by US Silica of Berkeley Springs, WV. Suitable precipitated calcium carbonates include Solvay's Winnofil™ SPM, and SMI's Ultra-pflex™ and Ultra-pflex™ 100.

[0023] The (A) mineral filler may be treated or untreated. If treated, the (A) mineral filler may be treated with any conventional filler treating agent known in the art.

[0024] The (A) mineral filler is present in the composition in an amount of 7.5 to 75, alternatively 10 to 65, alternatively 20 to 60, alternatively 49.5 to 60 weight percent, based on the total weight of (A), (B), and (C) in the composition. All endpoints and subranges between 7.5 and 75 weight percent are included and disclosed herein. For example, the (A) mineral filler may be present in an amount of at least 7.5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, or at least 50 weight percent, based on the total weight of (A), (B), and (C) in the composition. The (A) mineral filler may be present in an amount of 75 weight percent or less, 70 weight percent or less, 65 weight percent or less, or 60 weight percent or less, based on the total weight of (A), (B), and (C) in the composition. Alternatively, in certain applications, it may be desirable to maximize the relative amount of (A) mineral filler in the composition, thereby reducing the overall cost of the polymer composite article formed therewith, while maintaining or achieving the desired properties thereof. Those skilled in the art will understand that the amount of (A) mineral filler may be varied for this purpose, including balancing cost and resulting properties, as well as the presence or absence of other optional ingredients, as described below.

[0025] (B) PVC polymer The composition further includes a (B) PVC polymer. The PVC polymer can form all or part of the continuous phase in the composition for preparing a polymer composite article and in the composite article prepared therefrom. The choice of the (B) PVC polymer typically depends on the desired end-use application of the polymer composite article formed with the composition, as various polymers have different melting point temperatures (and / or glass transition temperatures) and physical / mechanical properties, as well as suitable or acceptable continuous-use application temperatures. In certain embodiments, the (B) PVC polymer has a softening point temperature that is lower than the decomposition temperatures of the other components in the composition. In these embodiments, the (B) PVC polymer has a softening point temperature of less than 250°C, alternatively less than 225°C, or alternatively less than 200°C. The softening point temperature is sometimes referred to as the processing temperature. In at least one embodiment, the (B) PVC polymer has a softening point temperature in the range of 150-250°C, e.g., 160-220°C or 170-210°C. Preferably, the (B) PVC polymer is a powder.

[0026] Elastomers and / or rubbers may be added to or compounded with the (B) PVC polymer to modify or improve properties such as impact strength. Preferably, the (B) PVC polymer includes at least one acrylic processing additive. The additives may include those known in the art, such as those disclosed by Stevenson et al., Journal of Vinyl Technology, December 1993, Vol. 15, No. 4, pages 244-251, which is incorporated herein by reference.

[0027] In certain embodiments, the polymer in the PVC composition consists essentially of PVC polymer. By consisting essentially of, it is meant that the (B) PVC polymer can include one or more additional polymers other than polyvinyl, provided that such additional polymers can be processed with the (B) PVC polymer to form a polymer composite article. When the (B) PVC polymer does not consist of PVC polymer, it typically comprises at least 50, alternatively at least 60, alternatively at least 65, alternatively at least 70, alternatively at least 75, alternatively at least 80, alternatively at least 85, alternatively at least 90, alternatively at least 95, alternatively at least 96, alternatively at least 97, alternatively at least 98, alternatively at least 99 weight percent of PVC polymer, based on the total weight of the (B) PVC polymer utilized in the composition.

[0028] (B) The PVC polymer may further comprise an elastomer. Non-limiting examples of elastomers include styrene-butadiene rubber, polyether urethane rubber, polyester urethane rubber, butyl rubber, nitrile rubber, chloroprene rubber (neoprene), polyacrylate rubber, ethylene acrylate rubber, ethylene-propylene rubber, ethylene-propylene-diene rubber, ethylene propylene diene monomer (EPDM), ethylene propylene rubber (EPR), fluorosilicone rubber, fluorocarbon rubber, perfluorinated elastomer, styrene butadiene rubber, chlorosulfonated polyethylene, polyisoprene rubber, polysulfide rubber, ethylene acrylate rubber, epichlorohydrin rubber, perfluorinated elastomer (e.g., Kalrez™), polysulfide rubber, chlorinated polyethylene (e.g., chlorinated polyethylene containing up to 40 weight percent chlorine), and combinations thereof.

[0029] When the (B) PVC polymer contains polymers other than and in addition to PVC, the (B) PVC polymer may further contain at least one polymer that is fully or partially thermodynamically miscible with PVC. Such polymers include, but are not limited to, poly(methyl methacrylate) (PMMA), polyethylene oxide (PEO), thermoplastic polyurethane (TPU), polycaprolactone (CPL), and styrene-acrylonitrile resin (SAN). Other thermodynamically miscible polymers are known in the art and are disclosed, for example, in Robeson, L.M. (1990), "Miscible polymer blends containing poly(vinyl chloride)." J. Vinyl Addit. Technol., 12:89-94, incorporated herein by reference.

[0030] Regardless of the (B)PVC polymer utilized, the (B)PVC polymer can include virgin polymer and / or recycled polymer. Recycled polymer, if utilized, can be sourced from industrial production streams as well as from post-industrial and / or post-consumer sources. The selection of the (B)PVC polymer, and any ratio of virgin to recycled polymer, if utilized in concert, typically varies depending on the cost and desired properties of the polymer composite article formed therewith.

[0031] The amount of (A) mineral filler is greater than the amount of (B) PVC polymer in the PVC composition, i.e., the ratio of (A) mineral filler to (B) PVC polymer is greater than 1.

[0032] The (B) PVC polymer may be present in the composition in an amount of 20 to 92, alternatively 35 to 90, alternatively 40 to 49.5 weight percent, based on the total weight of (A), (B), and (C) in the composition. For example, the (B) PVC polymer may be present in the composition in an amount of at least 20, at least 25, at least 30, at least 35, or at least 40 weight percent, based on the total weight of (A), (B), and (C). The (B) PVC polymer may be present in the composition in an amount of 92 weight percent or less, 90 weight percent or less, 85 weight percent or less, 80 weight percent or less, 75 weight percent or less, 70 weight percent or less, 65 weight percent or less, 60 weight percent or less, or 55 weight percent or less, based on the total weight of (A), (B), and (C) in the composition. In certain embodiments, it is desirable to minimize the relative amount of the (B) PVC polymer in the composition, thereby reducing the overall cost of the polymer composite article formed therewith, as appropriate, while maintaining or obtaining desirable properties. Those skilled in the art will understand that the amount of (B) PVC polymer can be varied for this purpose, including balancing cost and resulting properties, as well as the presence or absence of other optional ingredients, as described below.

[0033] (C) Polydiorganosiloxane The composition further comprises (C) a polydiorganosiloxane having at least one silicon-bonded alkenyl group per molecule. The (C) polydiorganosiloxane has the unit formula: (R2R'SiO2) 1 / 2 ) a (R3SiO 1 / 2 ) b (R2SiO 2 / 2 ) c (RR'SiO 2 / 2 ) dwherein each R is an independently selected monovalent hydrocarbon radical of 1 to 18 carbon atoms free of aliphatic unsaturation; each R' is an independently selected alkenyl radical of 2 to 18 carbon atoms; subscript a is 0 to 2; subscript b is 0 to 2; the quantity (a+b)=2; subscript c≧0; subscript d≧0; the quantity (a+d)≧1; and the quantities (a+b+c+d) are sufficient to impart to the polydiorganosiloxane a viscosity of 2,000 mPa·s to 60,000 mPa·s at 25° C. as measured at 0.1 to 50 RPM on a Brookfield DV-III cone and plate viscometer with a #CP-52 spindle. Those skilled in the art will recognize that as viscosity increases, the rotational speed decreases and will be able to select an appropriate rotational speed when measuring viscosity using this test method. Alternatively, the viscosity may be from 2,000 mPa·s to 10,000 mPa·s, alternatively from 2,000 mPa·s to 5,000 mPa·s, as measured according to the test method above at 5 RPM. Alternatively, the subscript d may be from 0 to 4, alternatively from 1 to 4, alternatively from 1 to 3, alternatively from 2. Alternatively, the quantity (a+d) may be sufficient to provide an amount of alkenyl groups R' of from 0.05% to 7%, alternatively from 0.09% to 6.5%, based on the weight of the polydiorganosiloxane. The vinyl content may be measured by 29Si NMR and 13C NMR spectroscopy.

[0034] Alternatively, in the above polydiorganosiloxane unit formula, each R can be an alkyl group of 1 to 18 carbon atoms, alternatively 1 to 12 carbon atoms, alternatively 1 to 6 carbon atoms, or alternatively 1 to 4 carbon atoms. Suitable alkyl groups include methyl, ethyl, propyl (including n-propyl and iso-propyl), and butyl (including n-butyl, tert-butyl, sec-butyl, and iso-butyl). Alternatively, each R can be methyl.

[0035] Alternatively, in the above polydiorganosiloxane unit formula, each R' can be an alkenyl group of 2 to 12 carbon atoms, alternatively 2 to 6 carbon atoms, or alternatively 2 to 4 carbon atoms. Suitable alkenyl groups include vinyl, allyl, butenyl, and hexenyl. Alternatively, each R' can be vinyl or hexenyl. Alternatively, each R' can be vinyl.

[0036]

[0002] Polydiorganosiloxanes can have terminal alkenyl groups, pendant alkenyl groups, or both terminal and pendant alkenyl groups. Alternatively, in the above polydiorganosiloxane unit formula, subscript a can be 0 and subscript d can be 1 or greater, i.e., the polydiorganosiloxane can have pendant alkenyl groups but no terminal alkenyl groups. Alternatively, subscript a can be 2, subscript b can be 0, and subscript d can be 0, i.e., the polydiorganosiloxane can be a bis-alkenyl-terminated polydiorganosiloxane.

[0037] The bis-alkenyl terminated polydiorganosiloxane has the formula (I): [ka] where each R and R' is as defined above and the subscript x has a value sufficient to impart to the polydiorganosiloxane a viscosity of 2,000 mPa·s to 60,000 mPa·s, as measured above. Those skilled in the art will recognize that the rotational speed decreases as the viscosity increases and will be able to select an appropriate rotational speed when measuring viscosity using this test method. Alternatively, the viscosity may be 2,000 mPa·s to 10,000 mPa·s, or 2,000 mPa·s to 5,000 mPa·s, as measured according to the test method above at 5 RPM.

[0038] Alternatively, each R can be an alkyl group of 1 to 18 carbon atoms, alternatively 1 to 12 carbon atoms, alternatively 1 to 6 carbon atoms, alternatively 1 to 4 carbon atoms. Suitable alkyl groups include methyl, ethyl, propyl (including n-propyl and iso-propyl), and butyl (including n-butyl, tert-butyl, sec-butyl, and iso-butyl). Alternatively, each R can be methyl.

[0039] Alternatively, in the polydiorganosiloxane formula above, each R' can be an alkenyl group of 2 to 12 carbon atoms, alternatively 2 to 6 carbon atoms, or alternatively 2 to 4 carbon atoms. Suitable alkenyl groups include vinyl, allyl, butenyl, and hexenyl. Alternatively, each R' can be vinyl or hexenyl. Alternatively, each R' can be vinyl.

[0040] (C) The organopolysiloxane is selected from the group consisting of the following: c-1) α,ω-dimethylvinylsiloxy-terminated polydimethylsiloxane, c-2) α,ω-dimethylvinylsiloxy-terminated poly(dimethylsiloxane / methylphenylsiloxane), c-3) α,ω-dimethylvinylsiloxy-terminated poly(dimethylsiloxane / diphenylsiloxane), c-4) α,ω-phenyl, methyl, vinyl-siloxy terminated polydimethylsiloxane, c-5) α,ω-dimethylhexenylsiloxy-terminated polydimethylsiloxane, c-6) α,ω-dimethylhexenylsiloxy-terminated poly(dimethylsiloxane / methylphenylsiloxane), c-7) α,ω-dimethylhexenylsiloxy-terminated poly(dimethylsiloxane / diphenylsiloxane), c-8) α,ω-phenyl, methyl, hexenyl-siloxy terminated polydimethylsiloxane, c-9) α,ω-dimethylvinylsiloxy-terminated poly(dimethylsiloxane / methylvinylsiloxane), c-10) α,ω-dimethylvinylsiloxy-terminated poly(dimethylsiloxane / methylphenylsiloxane / methylvinylsiloxane), c-11) α,ω-dimethylvinylsiloxy-terminated poly(dimethylsiloxane / diphenylsiloxane / methylvinylsiloxane), c-12) α,ω-phenyl, methyl, vinyl-siloxy terminated poly(dimethylsiloxane / methylvinylsiloxane), c-13) α,ω-dimethylhexenylsiloxy-terminated poly(dimethylsiloxane / methylhexenylsiloxane), c-14) α,ω-dimethylhexenylsiloxy-terminated poly(dimethylsiloxane / methylphenylsiloxane / methylhexenylsiloxane), c-15) α,ω-dimethylhexenylsiloxy-terminated poly(dimethylsiloxane / diphenylsiloxane / methylhexenylsiloxane), c-16) α,ω-phenyl, methyl, hexenyl-siloxy terminated poly(dimethylsiloxane / methylhexenylsiloxane), c-17) Trimethylsiloxy-terminated poly(dimethylsiloxane / methylvinylsiloxane), c-18) trimethylsiloxy-terminated poly(dimethylsiloxane / methylphenylsiloxane / methylvinylsiloxane), c-19) Trimethylsiloxy-terminated poly(dimethylsiloxane / diphenylsiloxane / methylvinylsiloxane), C-20) Trimethylsiloxy-terminated poly(dimethylsiloxane / methylhexenylsiloxane), c-21) Trimethylsiloxy-terminated poly(dimethylsiloxane / methylphenylsiloxane / methylhexenylsiloxane), c-22) Trimethylsiloxy-terminated poly(dimethylsiloxane / diphenylsiloxane / methylhexenylsiloxane), c-23) Polydiorganosiloxanes such as combinations of two or more of c-1) to c-22) may be included.

[0041] Alternatively, the polydiorganosiloxane may be selected from the group consisting of c-1), c-5), c-9), c-13), c-17), c-20), and combinations of two or more thereof. Alternatively, the polydiorganosiloxane may be selected from the group consisting of c-1), c-5), c-9), c-13), and combinations of two or more thereof. Alternatively, the polydiorganosiloxane may be a bis-vinyldimethylsiloxy-terminated polydimethylsiloxane. The above polydiorganosiloxanes are commercially available. Bis-vinyldimethylsiloxy-terminated polydimethylsiloxanes are commercially available from Dow Silicones Corporation (Midland, Michigan, USA). Examples include bis-vinyldimethylsiloxy-terminated polydimethylsiloxanes with viscosities of 60,000 mPa·s, 10,000 mPa·s, 5,000 mPa·s, and 2,000 mPa·s. Viscosity was measured at 25°C using a Brookfield DV-III cone and plate viscometer equipped with a #CP-52 spindle at 0.1-50 RPM. Suitable polydiorganosiloxanes may be prepared by methods known in the art, such as the hydrolysis and condensation of suitable organohalosilane monomers and / or the equilibration of linear and cyclic polyorganosiloxanes, optionally with end-capping.

[0042] The (C) organopolysiloxane may comprise two or more different organopolysiloxanes that may be independently selected. Typically, the (C) organopolysiloxane functions as a processing aid for the composition and polymer composite article. Without wishing to be bound by theory, the (C) organopolysiloxane may be an internal and / or external processing aid. However, the (C) organopolysiloxane may serve other purposes in addition to, or instead of, its function as a processing aid to improve the physical or mechanical properties of the composition and polymer composite article, for example.

[0043] Generally speaking, various advantages can be realized by combining (A) mineral filler, (B) PVC polymer, and (C) organopolysiloxane. For example, when the composition is mixed in an extruder, the combination of (A) mineral filler, (B) PVC polymer, and (C) organopolysiloxane generally reduces the melting temperature of the composition in the extruder. The reduced melting temperature refers to the temperature of the composition in the extruder and Brabender, as opposed to the melting point temperature of any one individual component in the composition (and in the extruder). Importantly, this allows the composition to be processed at lower temperatures, providing numerous benefits, including cost and aesthetics. For example, certain fillers, such as lignocellulosic fillers, may carbonize or decompose at certain high processing temperatures, which are typically required to make the composition flowable. The use of a combination of (A) mineral filler, (B) PVC polymer, and (C) organopolysiloxane allows for the preparation of polymer composite articles at low temperatures without decomposing, charring, or otherwise adversely affecting the (A) mineral filler and other aspects of the polymer composite article. Furthermore, when the composition is mixed in an extruder, the combination of (A) mineral filler, (B) PVC polymer, and (C) organopolysiloxane generally reduces the torque of the extruder. The reduced torque allows for greater output, which is particularly important from the standpoint of production throughput.

[0044] In certain embodiments, (i) the extrusion temperature is reduced compared to the extrusion temperature of a mixture of (A) mineral filler and (B) PVC polymer without the (C) polydiorganosiloxane, and / or (ii) the extruder torque when mixing the composition is reduced compared to the extruder torque when extruding a mixture of (A) mineral filler and (B) PVC polymer without the (C) polydiorganosiloxane. The extrusion temperature is the temperature at which the composition is generally processable in an extruder, e.g., melting the (B) PVC polymer and other components in the composition. The extrusion temperature is distinct from the melting point temperature of any one component in the composition.

[0045] The (C) polydiorganosiloxane may be present in an amount of greater than 0 to 5, alternatively from 0.1 to 2.5, alternatively from 0.5 to 1 weight percent, based on the total weight of (A), (B), and (C) in the composition. For example, the (C) polydiorganosiloxane may be present in an amount of at least 0.1, at least 0.25, or at least 0.5 weight percent, based on the total weight of (A), (B), and (C) in the composition. The (C) polydiorganosiloxane may be present in an amount of 5 weight percent or less, 4 weight percent or less, 3 weight percent or less, or 2.5 weight percent or less, based on the total weight of (A), (B), and (C) in the composition.

[0046] The (C) polydiorganosiloxane can be utilized in neat (pure) form, or can be provided in any other suitable form, such as in a diluted liquid form combined with a carrier vehicle, or alternatively in a solid form. In certain embodiments, the (C) polydiorganosiloxane is a liquid at 25° C.

[0047] In certain embodiments, in addition to components (A) mineral filler, (B) polymer, and (C) polydiorganosiloxane, the composition for preparing the polymer composite article described above further comprises one or more additives selected from colorants (e.g., pigments and / or dyes), blowing agents (e.g., chemical and / or physical), UV and / or light stabilizers, processing aids, preservatives, biocides (e.g., fungicides, herbicides, insecticides, antimicrobial agents), flame retardants and / or smoke suppressants, impact modifiers, heat stabilizers, and lubricants. These components are known in the art and may be used in accordance with conventional practices. Each additive, if utilized, may be present in the composition in an amount greater than 0 to 30 weight percent, based on the total weight of the composition. The composition may also include other optional additives, as known in the art. Such additives are described, for example, in Walker, Benjamin M., and Charles P. Rader, eds. Handbook of thermoplastic elastomers. New York: Van Nostrand Reinhold, 1979; Murphy, John, ed. Additives for plastics handbook. Elsevier, 2001, which are incorporated herein by reference.

[0048] Also provided is a method for preparing a polymer composite article. The method includes preparing the polymer composite article from the composition. In certain embodiments, the method further includes forming the composition. The composition is formed by combining at least components (A) a mineral filler, (B) a PVC polymer, and (C) a polydiorganosiloxane, along with any optional components present in the composition.

[0049] The components of the composition can be combined in any order and in any suitable manner. In certain embodiments, for example, the (B) PVC polymer can be melted before, during, and / or after forming the composition. For example, the (B) PVC polymer can be heated before and / or during the combination of the components so that the (A) mineral filler and (C) polydiorganosiloxane are combined with the molten form of the (B) PVC polymer. The (A) mineral filler and (C) polydiorganosiloxane can be combined with the molten form of the (B) PVC polymer in any order, for example, individually, sequentially, together, or simultaneously. However, alternatively, the (B) PVC polymer can be combined with the (A) mineral filler and (C) polydiorganosiloxane before heating or melting the (B) PVC polymer so that the (B) PVC polymer is in a solid, unmelted or unsoftened form when the composition is prepared. Alternatively, (A) the mineral filler and (C) the polydiorganosiloxane may be combined and heated and then added to (B) the PVC polymer in solid or liquid form when preparing the composition.

[0050] Preferably, (A) the mineral filler and (B) the PVC polymer are combined together to form a powder masterbatch, and then (C) the polydiorganosiloxane can be combined with the powder masterbatch to be absorbed into the powder, followed by further blending to ensure uniform distribution of the (C) polydiorganosiloxane.

[0051] The melting point temperature (or glass transition temperature) of the (B) PVC polymer typically varies depending on the (B) PVC polymer utilized. For example, certain types of polymers have different melting point temperatures than other types of polymers. In certain embodiments, the (B) PVC polymer is heated to a temperature above the melting point temperature of the (B) polymer, e.g., 10 to 90°C, or 10 to 40°C, above the melting point temperature of the (B) polymer, before, during, and / or after forming the composition. This ensures that the (B) polymer melts, rather than simply softens. Alternatively, a lower temperature in combination with shear or mixing can be utilized to ensure softening and / or melting of the (B) polymer.

[0052] Compositions for preparing polymer composite articles can be formed under mixing or shear using, for example, suitable mixing equipment. For example, the compositions can be formed in a vessel equipped with an agitator and / or mixing blade. The vessel can be, for example, an internal mixer such as a Banbury, Sigma (Z) blade, or cavity transfer-style mixer. Alternatively or additionally, the compositions can be formed in or processed by any extruder, such as a single-screw extruder equipped with rotating and / or reciprocating (co-kneader) screws, and a multi-screw device equipped with two or more screws that can be aligned tangentially or partially / fully intermeshing and rotate in the same or counter-rotating direction. Alternatively, a conical extruder can be used to form the compositions described herein.

[0053] As introduced above, the present method also includes preparing a polymer composite article from the composition for preparing the polymer composite article. The composition can be formed, for example, in a container, then removed from the container and formed in a separate device to form the polymer composite article. Alternatively, the same device can be used to prepare the composition and then form the polymer composite article. For example, the composition can be prepared and / or mixed in an extruder, and the extruder can be used to prepare the polymer composite article using the composition. Alternatively, the polymer composite article can be formed by molding, for example, using an injection molding or transfer molding process. The composition can be formed in situ in a mold or formed independently and then placed in a mold. Alternatively, the polymer composite article can be a film. In such an embodiment, the composition can be formed or placed in a container, optionally with mixing at an elevated temperature, and then placed in or on equipment for preparing a film from the composition. Such equipment and techniques for preparing films from compositions, particularly those containing a thermoplastic material such as (B) a PVC polymer, are well known in the art.

[0054] In certain embodiments, preparing a polymer composite article from the composition further comprises forming the composition into a desired shape. The desired shape depends on the end use application of the polymer composite article. Those skilled in the art will understand how extrusion dies and molding molds can be selected and constructed based on the desired shape of the polymer composite article.

[0055] In certain embodiments, the process is carried out continuously or semi-continuously in an extruder such as a twin-screw extruder (screws that co-rotate with partial or full intermeshing, or counter-rotate with tangential, partially or fully intermeshing alignment). In one embodiment, the (C) polydiorganosiloxane is placed in the extruder simultaneously with the (A) mineral filler and (B) PVC polymer. Alternatively, the (C) polydiorganosiloxane can be placed in the extruder after the (B) PVC polymer has been melted and before the (A) mineral filler is added. Alternatively, the (C) polydiorganosiloxane can be placed in the extruder after the (A) mineral filler and (B) PVC polymer have exited the extruder and before the polymer composite article has exited the extruder. Alternatively, (A) the mineral filler can be placed in the extruder simultaneously with (C) the polydiorganosiloxane, where they are heated to effect surface treatment of (A) the mineral filler with (C) the polydiorganosiloxane, and then (B) the PVC polymer is placed in the extruder to obtain a mixture, and the temperature is increased to a temperature suitable for compounding the mixture and forming the polymer composite article. The extruder can have one or more zones, for example, 1 to 3, or 3 to 8, or 1 to 12 zones, into which starting materials can be added. The zones can be heated at different temperatures.

[0056] The polymer composite articles of the present invention are not limited and can be customized for a myriad of end-use applications and industries. By way of example only, the polymer composite articles can be utilized in or as pipes, piping, hoses, insulating (e.g., thermal and / or electrical insulating) articles, interior components, including floor mats, automotive components and applications, consumer products and applications, industrial or commercial products and applications, aerospace products and applications, transportation products and applications, aircraft products and applications, electronic products and applications, residential or commercial building and construction products and applications, such as decks, railings, siding, fences, window frames, flooring, etc.

[0057] While the present invention has been described in an illustrative manner, it is to be understood that the terminology used is intended to be in the nature of words of description rather than of limitation. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. The present invention may be practiced otherwise than as specifically described.

[0058] Industrial Applicability Without wishing to be bound by theory, it is believed that (C) the polydiorganosiloxane may provide one or more benefits to the polymer composites described herein and / or the processes for making them. These include the following: A reduction in the density of the foamed polymer composition, resulting in lower costs; Higher expansion of foamed polymer compositions resulting in thicker products at the same blowing agent and processing aid loading levels, efficient and cost-effective formulation; Better mixing with lower levels of dusting and / or filler adhesion to the blender and blades, easier cleaning of the blender, Improved melt strength resulting in robust processing, maximum expansion, and maximum gas containment; Increased char content resulting in better flame retardancy and smoke suppression; Improved tribological properties, better wear resistance, Lower shear thinning resulting in a wider processing window, Improved cell structure of foamed articles; Lower torque during compounding may result in lower power consumption for processing, allowing for higher throughput and improving production yields; increased compounding throughput and / or lower energy consumption, Better filler dispersion and reduced glass fiber breakage during compounding and molding (if glass fiber is used); Improved melt flow, resulting in the ability to mold thinner walls; the ability to include high filler loadings resulting in cost savings; Lower reject rates during demolding, Better surface quality and / or finish, which can be a challenge at higher filler levels; Improved elongation regardless of higher filler loading, Improved impact strength regardless of higher filler loadings, Improved fusion characteristics, Maintain or improve key properties even at higher filler loadings, resulting in better performance and processing while reducing formulation costs; Improved melt rheology resulting in compounds that are less sensitive to shear and provide robust processing; Improved hydrophobicity, the ability to utilize a greater proportion of recycled polymer or different grades of polymer; and / or This includes enabling additives that improve strength and other properties. [Example]

[0059] Examples A1 to A14 Table 1 below shows the types and amounts of ingredients utilized to prepare the compositions of Examples A1-A14 and Comparative Examples C1 and C2. Exemplary polyvinyl chloride formulations were prepared by sequentially adding the materials in Table 1. Masterbatches were prepared in approximately 20 minutes by adding the PVC polymer to a Gunther Papenmeier / Welex blender at room temperature, increasing the power to 15 A, adding the heat stabilizer at 125°F, adding the lubricant package at 150°F, adding the impact modifier at 170°F, adding TiO2 at 190°F, and adding CaCO3 at 195°F. The siloxane was post-mixed at room temperature using a small blender. [Table 1-1] [Table 1-2]

[0060] The compositions in Table 1 were milled on an electric Collin Roll mill with a 0.3 mm gap at 185°C for 3 minutes to obtain milled sheets from each composition, which were then compression molded to form 3.2 mm thick plaques at 190°C. The color performance of the plaques was measured using a Lab Scan (HunterLab), and notched Izod impact strength (measured according to ASTM D256) was evaluated. These physical properties are listed in Table 2 below. [Table 2]

[0061] As shown in Table 2 above, the examples containing bis-vinyl terminated polydimethylsiloxane exhibited improved color stability during processing and potentially a wider processing window. The examples containing bis-vinyl terminated polydimethylsiloxane also exhibited higher impact strength.

[0062] Additional physical properties of the composites made in Examples A1-A14 and Comparative Examples C1 and C2 were measured and are listed in Tables 3 and 4 below. The physical properties listed in Table 3 were measured according to ASTM D638 using a Type 5 tensile bar and a speed of 0.5 inches / minute. The physical properties listed in Table 4 related to Brabender rheological impact and fusion time, torque were measured using a Brabender mixer commercially available from Brabender GmbH & Co. KG (Duisburg, Germany) with operating conditions maintained at 60 RPM, 185°C, and 65 grams of resin. [Table 3] [Table 4]

[0063] Examples A15 and A16 and Comparative Example C3 Table 5 below shows the types and amounts of ingredients utilized to prepare the compositions of Examples A15 and A16 and Comparative Example C3. Examples A15 and A16 and Comparative Example C3 have the same compositions as Examples A9 and A14 and Comparative Example C2, respectively. Exemplary polyvinyl chloride formulations were prepared by sequentially adding the ingredients in Table 5. Masterbatches were prepared in approximately 20 minutes by adding the PVC polymer to a Gunther Papenmeier / Welex blender at room temperature, increasing the power to 15 A, adding the heat stabilizer at 125°F, the lubricant package at 150°F, the impact modifier at 170°F, the TiO2 at 190°F, and the CaCO3 at 195°F. The masterbatch powder was then cooled to room temperature. The siloxane was then added to the masterbatch powder. After the siloxane was absorbed into the masterbatch powder, the mixture was placed in a laboratory Waring blender and blended for several minutes to achieve a uniform siloxane dispersion. [Table 5]

[0064] The compounded PVC listed in the table was ground on an electric Collin Roll mill with a 0.3 mm gap at 185°C for 3 minutes, and the ground sheets were then compression molded into 3.2 mm thick plaques at 190°C. Notched Izod impact strength (measured according to ASTM D256) was evaluated. These physical properties are listed in Table 6 below. [Table 6]

[0065] Examples A17 to A22 Table 7 below shows the types and amounts of ingredients utilized to prepare the compositions of Examples A17-A22 and Comparative Example C4. Exemplary PVC formulations were prepared by sequentially adding the materials in Table 7. Masterbatches were prepared in approximately 20 minutes by adding the PVC polymer to a Gunther Papenmeier / Welex blender at room temperature, increasing the power to 15 A, adding the heat stabilizer at 125°F, adding the lubricant package at 150°F, adding the impact modifier at 170°F, adding TiO2 at 190°F, and adding CaCO3 at 195°F. The siloxane was post-added at room temperature before fusing in a Brabender. [Table 7]

[0066] The compositions in Table 7 were mixed in a Brabender at 185°C for 7 minutes at 60 RPM, and then the molten polymer was compression molded into 3.2 mm thick plaques at room temperature (20°C). The fusion rheology is shown in Table 8, which shows a significant reduction in compression and fusion torque for the samples containing siloxane. [Table 8]

[0067] Notched Izod impact strength (ASTM D256) and tensile properties according to ASTM D638 were measured using a crosshead speed of 0.2 in / min, as shown below in Table 9. The siloxane-containing examples exhibit comparable yield stress, similar or higher stress at break, and similar or higher modulus of elasticity. [Table 9]

[0068] A second set of examples was formulated, similar to Examples A17-A22, substituting up to all of the original calcium carbonate filler with talc, as shown in Table 10 below. The same process and testing protocols were used as described above for Examples A17-A22. The talc-containing formulations showed no significant differences in rheology compared to formulations containing corresponding levels of calcium carbonate. The effects of talc and siloxane on the mechanical properties of PVC formulations were intertwined, with some combinations having significantly higher impact strength and ductility performance. Overall, higher modulus was achieved with only 4 phr of talc compared to 12 phr of calcium carbonate. [Table 10-1] [Table 10-2] [Table 11] [Table 12]

[0069] Examples B1 to B8 (PVC foam deck) Table 13 below shows the types and amounts of ingredients utilized to prepare the compositions of Examples B1-B8 and Comparative Examples C8 and C9. Exemplary PVC formulations were prepared by sequentially adding the materials in Table 13. Masterbatches were prepared in approximately 20 minutes by adding the PVC polymer to a Gunther Papenmeier / Welex blender at room temperature, increasing the power to 15 A, adding the heat stabilizer at 125°F, adding the lubricant package at 150°F, adding the impact modifier at 170°F, adding TiO2 at 190°F, and adding CaCO3 at 195°F. The siloxane was post-added at room temperature before fusing in a Brabender. [Table 13-1] [Table 13-2]

[0070] The compositions in Table 13 were milled on an electric Collin Roll mill with a 0.3 mm gap at 185°C for 3 minutes to obtain milled sheets from each composition, which were then compression molded to form 3.2 mm thick plaques at 190°C. The color performance of the plaques was measured using a Lab Scan (HunterLab), and notched Izod impact strength (measured according to ASTM D256) was evaluated. These physical properties are listed in Table 14 below. [Table 14] [Table 15] [Table 16]

[0071] As shown in Table 16, at the same filler loading level, the examples containing siloxane exhibited lower foam density and improved surface appearance. [Table 17]

[0072] Examples D1 to D4 (PVC LVT rigid foam layer) Table 18 below shows the types and amounts of ingredients utilized to prepare the compositions of Examples D1-D4 and Comparative Examples C10 and C11. Exemplary PVC formulations were prepared by sequentially adding the materials in Table 18. Dry blends were prepared by adding PVC to a Gunther Papenmeier / Welex blender at room temperature, increasing the power to 15 A, adding the heat stabilizer at 125°F, adding a lubricant package containing siloxane at 150°F, adding the acrylic processing aid at 170°F, adding TiO2 at 190°F, and adding CaCO3 at 195°F. After the powders were blended, they were cooled to room temperature. [Table 18-1] [Table 18-2]

[0073] Compounded PVC samples were ground on an electric Collin Roll mill with a 0.3 mm gap at 170°C for 5 minutes, and the ground sheets were then compression molded into 3.2 mm thick plaques at 175°C. Samples were cut for Izod impact (unnotched) strength (measured according to ASTM D256), tensile strength (ASTM D638), and heat distortion temperature (HDT) (ASTM D648). For density, expansion, and processing condition testing, foam rods were extruded using a Polylab RS 5000 laboratory twin-screw extruder with a 4.78 mm rod die. The extrusion temperature settings were 170°C / 175°C / 185°C / 180°C (die) with a screw speed of 60 RPM. The time to bed was reported as the time it took for the melt / rod to reach the bed from the die. Fusion testing was performed on a Brabender Intelli Torque 7150 at 190°C, 60 rpm, for 7 minutes at 74 grams for 100 PHR CaCO3 and 78 grams for 140 PHR CaCO3. The material from the Brabender was pressed into flat plaques, which were cut into pieces and fed into the capillary of the rheometer for melt viscosity measurements at 190°C. [Table 19]

[0074] Definitions and Usage of Terms Unless otherwise indicated by the context of the specification, all amounts, ratios, and percentages are by weight, and all test methods are current as of the filing date of this disclosure. The articles "a," "an," and "the" each refer to one or more. It is understood that the scope of the appended claims is not limited to the language in the "Description of Embodiments" and the specific compounds, compositions, or methods described therein, which may vary among specific embodiments within the scope of the appended claims. With respect to any Markush group relied upon herein to describe particular features or aspects of various embodiments, different, special, and / or unexpected results may be obtained from each member of the respective Markush group independent of all other Markush members. Each member of a Markush group may be relied upon individually and / or in combination to provide adequate support for specific embodiments within the scope of the appended claims.

[0075] Furthermore, any ranges and subranges relied upon in describing various embodiments of the present invention are understood to be individually and collectively included in the appended claims, describing and contemplated ranges including their whole and / or fractional values, even if such values ​​are not expressly written herein. Those skilled in the art will readily recognize that the recited ranges and subranges fully describe and enable various embodiments of the present invention, and that such ranges and subranges may be further elaborated into related halves, thirds, quarters, fifths, etc. As merely an example, a range "from 0.1 to 0.9" may be further elaborated into a lower third, i.e., 0.1 to 0.3, a middle third, i.e., 0.4 to 0.6, and an upper third, i.e., 0.7 to 0.9, which are individually and collectively within the appended claims and may be relied upon individually and / or collectively to provide appropriate support for specific embodiments of the appended claims. Additionally, with respect to terms defining or modifying ranges, such as "at least," "greater than," "less than," "less than or equal to," etc., it is understood that such terms include subranges and / or upper or lower limits. As another example, the range "at least 10" inherently includes subranges of at least 10 to 35, at least 10 to 25, 25 to 35, etc., each of which may be relied upon individually and / or collectively to provide appropriate support for specific embodiments of the appended claims. Finally, individual numbers within disclosed ranges may be relied upon to provide appropriate support for specific embodiments of the appended claims. For example, the range "1 to 9" includes various individual integers, such as 3, as well as individual numbers containing decimal points (or fractions), such as 4.1, which may be relied upon to provide appropriate support for specific embodiments of the appended claims.

[0076] As used herein, the term "composition" includes the materials which comprise the composition, as well as reaction products and decomposition products formed from the materials of the composition.

[0077] The term "comprising" and its derivatives are not intended to exclude the presence of any additional components, steps, or procedures, whether or not they are disclosed herein. For the avoidance of doubt, all compositions claimed herein through the use of the term "comprising" may include any additional additives, adjuvants, or compounds, whether polymeric or otherwise, unless stated to the contrary. In contrast, the term "consisting essentially of" excludes from the scope of any succeeding description any other component, step, or procedure, except those that are not essential to operability. The term "consisting of" also excludes any component, step, or procedure not specifically defined or listed.

[0078] As used herein, the term "polymer" refers to a polymeric compound prepared by polymerizing monomers, whether of the same type or different types. Thus, the generic term polymer encompasses the term homopolymer (used to refer to a polymer prepared from only one type of monomer, with the understanding that minor amounts of impurities may be incorporated into the polymer structure), and the term interpolymer, as defined herein below. Minor amounts of impurities may be incorporated into and / or within the polymer.

[0079] "Blend," "polymer blend," and like terms refer to a composition of two or more polymers. Such blends may or may not be miscible. Such blends may or may not be phase separated. Such blends may or may not contain one or more domain configurations as determined from transmission electron spectroscopy, light scattering, X-ray scattering, and any other method known in the art. Blends are not laminates, although one or more layers of a laminate may contain a blend.

Claims

1. 1. A polyvinyl chloride (PVC) composition for preparing a polymer composite article, said composition comprising: (A) a mineral filler in an amount of 49.5 to 75 wt. %; (B) polyvinyl chloride in an amount of 20 to 49.5 wt. %; (C) a polydiorganosiloxane in an amount of greater than 0 to 5 weight percent, said (C) polydiorganosiloxane having the unit formula: (R ２ R'SiO １／２ ) ａ (R ３ SiO １／２ ) ｂ (R ２ SiO ２／２ ) ｃ (RR'SiO ２／２ ) ｄ wherein each R is an independently selected monovalent hydrocarbon radical of 1 to 18 carbon atoms free of aliphatic unsaturation, each R' is an independently selected alkenyl radical of 2 to 18 carbon atoms, subscript a is 0 to 2, subscript b is 0 to 2, the quantity (a+b)=2, subscript c≧0, subscript d≧0, the quantity (a+d)≧1, and the quantity (a+b+c+d) is sufficient to impart to said polydiorganosiloxane a viscosity of from 2,000 mPa·s to 60,000 mPa·s at 25° C. as measured at 0.1 to 50 RPM on a Brookfield DV-III cone and plate viscometer with a #CP-52 spindle; (D) one or more additives selected from colorants, blowing agents, UV and / or light stabilizers, processing aids, preservatives, biocides, flame retardants and / or smoke suppressants, impact modifiers, heat stabilizers, and lubricants in an amount of from greater than 0 to 30 weight percent based on the total weight of the composition; a polyvinyl chloride (PVC) composition, wherein the amounts of (A), (B), and (C) are each based on the total weight of components (A), (B), and (C) in the composition;

2. The polydiorganosiloxane (C) is represented by the formula (I): 【Chemistry 1】 10. The composition of claim 1, which is a bis-alkenyl terminated polydiorganosiloxane of the formula: wherein each R is an independently selected monovalent hydrocarbon radical of 1 to 18 carbon atoms free of aliphatic unsaturation, each R' is an independently selected alkenyl radical of 2 to 18 carbon atoms, and subscript x has a value sufficient to impart to said polydiorganosiloxane a viscosity of from 2,000 mPa·s to 60,000 mPa·s as measured at 25° C. and 0.1 to 50 RPM on a Brookfield DV-III cone and plate viscometer with a #CP-52 spindle.

3. 3. The composition of claim 2, wherein each R is an alkyl group of 1 to 12 carbon atoms and each R' is an alkenyl group of 1 to 12 carbon atoms, subscript x has a value sufficient to impart a viscosity of from 2,000 mPa·s to 10,000 mPa·s to said polydiorganosiloxane, and said (C) polydiorganosiloxane is present in an amount of from 1% to 4% by weight.

4. 4. The composition according to claim 3, wherein in said (C) polydiorganosiloxane, each R is an alkyl group of 1 to 6 carbon atoms and each R' is an alkenyl group of 1 to 6 carbon atoms.

5. 3. The composition of claim 2, wherein in the (C) polydiorganosiloxane, each R is selected from the group consisting of methyl, ethyl, propyl, and butyl, and each R′ is selected from the group consisting of vinyl, allyl, butenyl, and hexenyl.

6. 6. The composition of any one of claims 1 to 5, wherein (i) the (A) mineral filler is present in an amount of 50 to 60 weight percent, (ii) the (B) polyvinyl chloride is present in an amount of 35 to 49.5 weight percent, and (iii) the (C) polydiorganosiloxane is present in an amount of 0.5 to 5 weight percent.

7. The composition of any one of claims 1 to 6, wherein the mineral filler is selected from calcium carbonate, talc, and combinations thereof.

8. A method for preparing a composition according to any one of claims 1 to 7, said method comprising: (A) said mineral filler, (B) said polyvinyl chloride, (C) said polydiorganosiloxane, and (D) said additive, thereby preparing said composition.

9. 1. A method for preparing a polymer composite article, said method comprising: A method comprising preparing said polymer composite article from the composition of any one of claims 1 to 7.

10. 10. The method of claim 9, wherein (i) preparing the polymer composite article from the composition further comprises forming the composition into a desired shape; (ii) preparing the polymer composite article from the composition comprises extruding the composition; (iii) preparing the polymer composite article from the composition comprises molding the composition; or (iv) any combination of (i)-(iii).

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