FUNCTIONALIZED PROCESSING AID MIXTURES FOR CELLULAR PVC

Abstract

A method for reducing foam density that results in a foamed polyvinyl chloride (PVC) component exhibiting reduced density. The foamed PVC component contains at least one PVC resin and a processing aid mixture. The processing aid mixture contains from 1 wt% to 60 wt% (based on the weight of the mixture) of a functionalized processing aid, and from 99 wt% to 40 wt% (based on the weight of the mixture) of a non-functionalized processing aid. The functionalized processing aid includes at least one base polymer functionalized with a reactive epoxy, hydroxyl, β-ketoester, β-ketoamide, or carboxylic acid functional group.The foamed PVC component containing the process aid mixture has a lower density than a reference foamed PVC component manufactured under the same process conditions and additives, but containing only the non-functionalized process aid and not the functionalized process aid.

Description

FUNCTIONALIZED PROCESSING AID MIXTURES FOR CELLULAR PVC FIELD OF INVENTION This disclosure relates to processing aids used in polyvinyl chloride (PVC) and other thermoplastic polymer formulations. More specifically, this disclosure relates to processing aids capable of reducing the density of foamed PVC components and other foamed thermoplastic polymer components. BACKGROUND OF THE INVENTION Foamed polyvinyl chloride (PVC) resins are generally chemically inert, resistant to water and environmental corrosion, provide good electrical and thermal insulation, and can maintain performance over a wide temperature range. Commercial polymerization processes and post-polymerization processing techniques (e.g., extrusion, injection molding, blow molding, etc.) used with polyvinyl chloride (PVC or vinyl, as it is commonly called) have matured. This manufacturing base, along with the inherent properties of PVC, has led to a proliferation of products containing foamed PVC. For example, PVC foam components are used as structural and decorative building materials. Vinyl products are durable, recyclable, and easy to maintain.They are resistant to mold and mildew growth and are unaffected by rot, corrosion, cracking, peeling, or insect infestation. Vinyl products exhibit excellent fire-resistance properties, meeting most building codes for ignition, flammability, heat release, rate of combustion, flame spread, and smoke generation. Because vinyl products are typically the same color throughout, minor scratches do not require painting or repair, and the aesthetics are easily maintained by washing with soap and water. In addition, foamed PVC building products can be painted. When properly installed and maintained, vinyl products provide lasting aesthetics, reliable performance, and ongoing energy savings. The dispersion of pigments in the PVC formulation can provide color, while the incorporation of mattifying agents in the formulation can modify the surface gloss of a final PVC product. PVC can be used alone as a base resin in a formulation. PVC can also be blended with other thermoplastic resins, such as acrylics, including polymethyl methacrylate, acrylonitrile styrene acrylate copolymers, and polycarbonate. ML / t / ¿U¿¿ / UOOO4U copolymers of acrylonitrile butadiene styrene and polyvinylidene difluoride to form an alloy. These PVC alloys can be further formulated with various additives, including pigments and matting agents, to achieve the desired appearance in a manner similar to PVC formulation. These PVC alloys can also be used in a capacity similar to PVC resins using similar downstream polymerization processes to produce the final articles. Other thermoplastic resins with similar properties to PVC resins or PVC alloys can also be used, employing similar post-polymerization processes, to produce the final foamed articles. These resins include acrylic polymers, styrenics, polyolefins, PVC blends, PVC alloys, polycarbonates, polyurethanes, fluoropolymers, and blends thereof. US patent n.e3,301,919 describes process aids for polyvinyl chloride comprising substantially linear copolymers obtained by polymerizing a mixture of 20 to 98.5 wt percent methyl methacrylate, 0.5 to 40 wt percent ethyl acrylate and 1 to 40 wt percent glycidyl methacrylate, such that the oxirane ring is intact in at least 85 wt percent of the glycidyl methacrylate units. Korean Patent No. 101030513 describes a method for manufacturing a methacrylate copolymer used as a processing aid for a vinyl chloride resin. The method comprises the steps of polymerizing a mixture of monomers in the presence of a water-soluble initiator and an emulsifier to prepare a polymeric latex and solidifying the polymeric latex. The monomer mixture comprises 60 to 85 wt% methyl methacrylate, 15 to 30 wt% an alkyl acrylate-based compound, and 1 to 10 wt% an epoxide-based compound. This application incorporates by reference the U.S. document serial number 16 / 081,055 in its entirety, filed on March 23, 2017, which claims priority from U.S. documents 62 / 313,187, filed on March 25, 2016, and PCT / US2018 / 052624, filed on September 25, 2018, which claims priority from U.S. document 62 / 563,841, filed on September 27, 2017. BRIEF DESCRIPTION OF THE INVENTION The present invention generally provides foamed polyvinyl chloride (PVC) and other thermoplastic polymers and resins comprising a processing aid mixture. The processing aid mixture comprises from about 1% by weight to about 60% by weight (based on the weight of the processing aid mixture) of a functionalized processing aid, and from about 99% by weight to about 40% by weight (based on the weight of the processing aid mixture) of MA / t / ¿U¿¿ / UOOO4U process) of a non-functionalized processing aid. The functionalized processing aid comprises at least one base polymer that is functionalized with a reactive epoxy, reactive hydroxyl, reactive β-ketoester, reactive β-ketoamide, or reactive carboxylic acid functional group in an amount of 0.5 wt% to 35 wt% based on the total weight of the functionalized processing aid. In another embodiment, the processing aid mixture comprises from about 1 to about 24%, preferably about 10%, more preferably about 1 to about 20%, by weight (based on the weight of the processing aid mixture) of a functionalized processing aid, and from about 99 to about 76%, preferably about 90%, and more preferably about 80 to 99% by weight of a non-functionalized processing aid. The functionalized processing aid comprises at least one base polymer that is functionalized with a reactive epoxy, hydroxyl, β-ketoester, β-ketoamide, or carboxylic acid functional group in an amount of 0.1% to 35% by weight based on the total weight of the functionalized processing aid. The foamed PVC or PVC alloy comprising the processing aid mixture of the invention has a reduced density compared to a foamed PVC or similar PVC alloy comprising only the non-functionalized processing aid. The present invention also provides a method for reducing this density compared to materials that do not comprise the processing aid mixture. Foamed PVC or other thermoplastic polymer or mixture or alloy thereof, comprising a blend of processing aids, also exhibits an improved cellular structure compared to similar materials that do not include such a blend of processing aids. The foamed PVC or other thermoplastic polymer / resin component comprises: a polymer or resin such as PVC; and a blend of processing aids. A foamed component made of PVC or another thermoplastic polymer / resin and the blend of processing aids has a lower density compared to a similar foamed component where the blend of processing aids is not used. A component made of PVC or another thermoplastic polymer / resin can be used in an automotive product, a building material, a household or kitchen item, flooring, a medical or office product, an electronic product, clothing or personal care packaging, or other consumer products. PVC or PVC alloys comprising a mixture of functionalized and non-functionalized processing aids may exhibit higher viscosity and melt strength, contributing to lower density and improved cellular structure. ML / t / ZUZZ / U3OO4U the foams produced from the same compared to said foams manufactured only with the non-functionalized processing aid (but not with the functionalized processing aid). Functionalized processing aids comprise at least one base polymer functionalized with approximately 0.1 wt% to approximately 35 wt% of a reactive functional group such as epoxy, hydroxyl, β-ketoester, β-ketoamide, or carboxylic acid, based on the total weight of the functionalized processing aid. The blend of processing aids may be present in an amount of approximately 0.1 to approximately 25 wt% or approximately 0.1 to approximately 12 wt% in PVC formulations, or 0.1 to approximately 20 wt% in other thermoplastic resin components (i.e., non-PVC). When desired, the functionalized processing aids may be further functionalized with at least 0.1 wt%, or preferably at least 1 wt%, of the reactive functional group, based on the total weight of the processing aids.The reactive functional groups epoxy, hydroxyl, β-ketoester, β-ketoamide or carboxylic acid in the functionalized processing aids may be derived from hydroxyl-substituted (meth)acrylic acid alkyl esters; vinyl esters of linear or branched carboxylic acids; unsaturated C3-C6 monocarboxylic acids and unsaturated C4-C6 dicarboxylic acids; monomers containing epoxy groups; β-ketoesters of (meth)acrylic acids; β-ketoamides of (meth)acrylic acids; or a mixture thereof. The method for reducing the density of polyvinyl chloride (PVC) or another thermoplastic resin component comprises combining a base PVC or other thermoplastic resin, a processing aid mixture, a blowing agent (BA), and other additives, including, for example, stabilizers and lubricants. The blowing agent may be a chemical blowing agent (CBA), a physical blowing agent, or a combination thereof. The PVC resin, processing aid mixture, and BA are then combined to form a foamable PVC composition. The foamable PVC composition may then be extruded or otherwise processed in polymer processing equipment, as known in the art, to form the foamed PVC component.A person experienced in the technique can easily appreciate that the blending and forming steps can be combined, for example, in a process where PVC, a blend of processing aids, and CBA are placed together in an extruder hopper and then blended and formed through the extrusion process. The resulting foamed PVC component exhibits a reduced density compared to a similar foamed PVC component where only the non-functionalized processing aid is used (but not the functionalized processing aid). The density reduction method may also include that the mixtures of ML / t / ¿U¿¿ / UOOO4U Processing aids are present in an amount of about 0.1 to about 15 parts per hundred (phr) by weight of the PVC resin in PVC formulations or from 0.1 to about 25 phr in other thermoplastic resin formulations. When desired, the functionalized processing aid in the processing aid mixture may be functionalized with at least 0.1 wt% of the reactive functional group(s) based on the total weight of the functionalized processing aid.The reactive functional group epoxy, hydroxyl, β-ketoester, β-ketoamide or carboxylic acid of the functionalized processing aid in processing aid mixtures may be derived from hydroxyl-substituted (meth)acrylic acid alkyl esters; vinyl esters of linear or branched carboxylic acids; unsaturated C3-C6 monocarboxylic acids and unsaturated C4-C6 dicarboxylic acids; monomers containing epoxy groups; β-ketoesters of (meth)acrylic acids; β-ketoamides of (meth)acrylic acids; or a mixture thereof. The reactive functionalized processing aid may contain more than one type of functional group, such as if the functionalized processing aid is derived from glycidyl methacrylate (GMA) and / or hydroxyethyl methacrylate (HEMA), or from a mixture of either of these compounds. The base polymer of the functionalized processing aid may be composed of an acrylic polymer or copolymer.The base polymer of the non-functionalized processing aid may also be composed of an acrylic polymer or copolymer. This acrylic polymer or copolymer may be derived from vinyl- or (meth)acrylic-containing monomers; styrene or styrene derivatives; olefins; dienes; or mixtures thereof. Functionalized processing aids may have a weight-average molecular weight (WM) of approximately 50,000 g / mol or higher. Other areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are for illustrative purposes only and are not intended to limit the scope of this disclosure. BRIEF DESCRIPTION OF THE DRAWINGS The drawings described in this document are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way. Figure 1 is a graph of the effect of various process aid mixtures according to certain embodiments of the present disclosure and the effect of comparative process aids on the melt strength and extensibility of PVC compositions. Figure 2 is a graph of the density of foamed PVC components manufactured using a mixture of process aids according to an embodiment of the present disclosure and a comparative process aid. ML / t / ¿U¿¿ / UOOO4U Figure 3 shows representative optical microscopy images of foamed PVC components manufactured using a mixture of process aids according to an embodiment of the present disclosure and a comparative process aid. Figure 4 shows an optical microscopy image of a void in the cell structure that forms when the melt strength of PVC is too low. DETAILED DESCRIPTION OF THE INVENTION The following description is merely illustrative and in no way intends to limit this disclosure or its application or uses. For example, polyvinyl chloride (PVC) formulations manufactured and used in accordance with the teachings contained herein may be described throughout this disclosure along with “PVC” or “vinyl” trim, molding, windows, and doors to more fully illustrate their composition and use. The incorporation and use of such a PVC formulation in other applications or products is contemplated to be within the scope of this disclosure. Formulations made using other thermoplastic polymers / resins in other applications or products are also contemplated within the scope of this disclosure.These applications may include, but are not limited to, automotive products, construction materials, flooring, household or kitchen items, medical or office products, apparel, personal care packaging, or other consumer products. It should be understood that, throughout the description, the corresponding reference numbers indicate similar or equivalent parts and features. This disclosure generally provides a foamed polyvinyl chloride (PVC), foamed PVC alloy, or other foamed thermoplastic resin component comprising a mixture of functionalized and non-functionalized processing aids and exhibiting reduced density compared to a similar foamed component made using only the non-functionalized processing aid, but not the functionalized processing aid. More specifically, the foamed PVC, foamed PVC alloy, or other thermoplastic resin component comprises polyvinyl chloride (PVC) or another thermoplastic resin and a processing aid mixture. The processing aid mixture comprises, essentially consists of, or consists of 1 wt% to 60 wt%, based on weight Q, of a functionalized processing aid, and 99 wt% to 40 wt%, based on weight Q, of a non-functionalized processing aid.The functionalized processing aid comprises, essentially consists of, or consists of at least one base polymer that is functionalized with from 0.1 wt% to 35 wt% of a reactive epoxy, hydroxyl, β-ketoester, β-ketoamide, or carboxylic acid functional group based on the total weight of the functionalized processing aid. The non-functionalized processing aid is not particularly restricted but does not contain any reactive epoxy, hydroxyl, β-ketoester, β-ketoamide, or carboxylic acid functional group.The foamed PVC component comprising the process aid mixture has a lower density than a reference foamed PVC component comprising 100% by weight, based on weight Q, of the non-functionalized process aid, wherein the foamed PVC component comprising weight Q of the process aid mixture and the reference foamed PVC component comprising 100% by weight Q of the non-functionalized process aid were prepared using the same process conditions and additives. The mixture of the functionalized processing aid (f-PA) and the non-functionalized processing aid (PA) significantly reduces density, improves cell structure, morphology, and appearance of the resulting foam, and maintains or even improves the mechanical properties of the foamed PVC or other thermoplastic resin component, compared to a foamed component made using the same processing conditions, blowing agent, etc., but comprising only the non-functionalized processing aid and no functionalized processing aid. Furthermore, the cell structure, morphology, and appearance of foams manufactured with the combination of functionalized and non-functionalized processing aids are significantly better than those of similar foams manufactured using an identical process but comprising only the functionalized processing aid and no non-functionalized processing aid.Therefore, the combination of functionalized and non-functionalized processing aids, as described herein, surprisingly produces a superior foamed PVC component with at least one improvement in density, cell structure, cell morphology, and cell appearance compared to using either processing aid alone. Furthermore, the PVC or PVC alloys comprising the mixture of functionalized and non-functionalized processing aids exhibit improved viscosity and melt strength, which contribute to the lower density and improved cell structure of the foams produced from them compared to foams manufactured using only the non-functionalized processing aid. Mechanical properties and melt rheology that are not substantially affected or are improved by the addition of the processing aid mixture include, but are not limited to, impact properties and density, as well as parameters associated with processability (e.g., extrusion) of foamable PVC or other thermoplastic resin formulations. According to another aspect of this disclosure, the reduction in density ML / t / ¿U¿¿ / UOOO4U of a foamed PVC component comprising the mixture of functionalized and non-functionalized processing aids compared to a similar foamed PVC component with only non-functionalized processing aids and comprising no functionalized processing aids may alternatively be characterized by having a density that is at least 2 percent lower (e.g., 0.1 g / cc based on a product of 0.5 g / cc density) for the composition comprising the processing aid mixture. Mixture of process help me Without wishing to limit ourselves to theory, it may be that the functionalized process aids in the process aid mixture to be used in the foamed polyvinyl chloride processing defined herein have different effects on the polyvinyl chloride matrix compared to the conventional non-functionalized process aids that are also included in the process aid mixture. The functionalized processing aids in the processing aid mixture comprise acrylic polymers or copolymers synthesized with reactive epoxy, hydroxyl, β-ketoester, β-ketoamide, or carboxylic acid functional groups. An example of a method capable of forming foamed PVC or another thermoplastic resin component includes, but is not limited to, an extrusion process. The PVC or PVC alloys comprising the functionalized and non-functionalized processing aid mixture may therefore exhibit substantially equal or even greater melt viscosity and higher melt strength, which can contribute to the lower density and improved cell structure of the foams produced from them compared to such foams manufactured solely with the non-functionalized processing aid. Non-functionalized processing aids used in processing aid mixtures that are foamed or foamable polyvinyl chloride (PVC) formulations are typically composed of acrylate and methacrylate monomers, which are non-reactive during such processing. Non-functionalized processing aids in processing aid mixtures may also include conventional processing aids such as those known and used in PVC and foamed PVC processing techniques. Non-limiting examples include chlorinated polyethylene (PE-C), polyolefin-based processing aids (e.g., oxidized polyethylene), EVA-based polymers, polyester-based polymers (e.g., Elvaloy® (Dow Chemical), which is an ethylene ketone ester), ABS, and / or styrenic polymers. The functionalized process aids of the process aid mixture of the present disclosure can be prepared according to any method known in the art, including, but not limited to, emulsion polymerization. ML / t / ¿U¿¿ / UOOO4U Furthermore, the non-functionalized process aids of the process aid mixture of the present disclosure can be prepared according to any method known in the art, including, but not limited to, emulsion polymerization. Functionalized or non-functionalized processing aids can be composed of acrylic polymers or copolymers as their base polymer, with a variety of compositions and molecular weights. They can have a higher molecular weight than PVC resin or other thermoplastic resins. Specifically in PVC resin, because they are highly compatible with it, these processing aids (functionalized or non-functionalized) can assist with the mixing of PVC particles in the initial melting stages—that is, the melting of the polymer granules or particles at the beginning of the forming process, for example, in the feed section of an extruder. The functionalized processing aids in the processing aid mixture of this disclosure may have a weight average molecular weight (also called molar mass (MW)) that is greater than about 50,000 g / mol; alternatively, the weight average molecular weight of the processing aids is greater than about 100,000 g / mol; alternatively, the molecular weight (MW) of the processing aids is about 250,000 g / mol or greater; alternatively, the soluble fraction (MW) of the processing aids is between about 50,000 g / mol and about 15 million g / mol, or alternatively between about 750,000 g / mol and about 12 million g / mol.The weight average molecular weight of the functionalized process coadjuvants can be 60,000 g / mol, 70,000 g / mol, 80,000 g / mol, 90,000 g / mol, 100,000 g / mol, 150,000 g / mol, 200,000 g / mol, g / mol, 300,000 g / mol, 350,000 g / mol, 400,000 g / mol, 450,000 g / mol, 500,000 g / mol, 550,000 g / mol, 600,000 g / mol, 650,000 g / mol, 70,000 g / mol 750,000 g / mol, 800,000 g / mol, 850,000 g / mol, 900,000 g / mol, 950,000 g / mol, 1,000,000 g / mol, 1,500,000 g / mol, 2,000,000 g / mol, 200,000 g / mol 3,000,000 g / mol, 3,500,000 g / mol, 4,000,000 g / mol, 4,500,000 g / mol, 5,000,000 g / mol, 5,500,000 g / mol, 6,000,000 g / mol, 6,000,000 g / mol 7,000,000 g / mol, 7,500,000 g / mol, 8,000,000 g / mol, 8,500,000 g / mol, 9,000,000 g / mol, 9,500,000 g / mol, 10,000,000 g / mol, 10,000,000 g / mol 11,000,000 g / mol, 11,500,000 g / mol or 12,000,000 g / mol. The weight average molecular weight can be measured by any known method, including, but not limited to, gel permeation chromatography (GPC). The upper end of the molecular weight measurement may be affected by the occurrence of crosslinking between the polymeric process aids. The molecular weight of the soluble portion of the processing aids can be determined using gel permeation chromatography (GPC) by several methods and ML / t / ¿U¿¿ / UOOO4U known procedures. One of these methods uses a differential refractometer equipped with two mixed PL gel columns and a pre-column. An injection volume of 150 microliters of the soluble portion of the processing aid, in the form of a THF solution with a concentration of 0.5 mg / ml, is injected into the column at a temperature of 35 °C. Elution of the processing aids through the column is performed using a flow rate of 1.0 ml / min of THF solvent (HPLC grade). Each sample of the processing aids is tested in an unfiltered state. Chromatograms for each sample are obtained and analyzed, and molar mass values ​​are calculated relative to a poly(methyl methacrylate), PMMA, calibration curve. More information on the GPC methodology is available in ASTM D4001 - 13 (ASTM International, West Conshohocken, PA). A total of three injections were averaged for each sample to obtain the average molecular weight (Pm). The average molecular weight (Pm) of the analyzed samples ranged from approximately 50,000 g / mol to approximately 5 million g / mol. The polydispersity, defined as the ratio of the average weight molecular weight to the average number molecular weight (μ / μ), was measured for each analyzed sample to be between approximately 10 and approximately 20. In one embodiment, the functionalized processing aids of the invention exhibit surprising insolubility in organic solvents. In other words, the functionalized processing aids of the invention may have both soluble and insoluble fractions. In this case, the molecular weight of the insoluble fraction is considered infinite and cannot be measured by GPC. However, the molecular weight of the soluble fraction can be measured. The molecular weight ranges for the soluble fraction can vary from 500 g / mol to approximately 10 million g / mol, from 0.5 million to approximately 7 million g / mol, from 0.5 million to approximately 6 million g / mol, or from 0.5 million to approximately 5 million g / mol. The soluble and insoluble fractions of the processing aids can be determined using a solvent extraction technique, such as with acetone, tetrahydrofuran (THF), or methyl ethyl ketone (MEK).The insoluble fraction of the processing aids ranges from 1% to 95% (by weight), from 10% to 90%, from 40% to 90%, from 50% to 90%, from 60% to 90%, or from 60% to about 85%. Alternatively, the insoluble fraction ranges from about 2% to about 70%; or from about 4% to about 55%, preferably from about 10% to 50%, more preferably from about 20% to 45%, and even more preferably from about 25% to 40%. Functionalized process aids have a glass transition temperature (Tg) that is greater than or equal to 0 °C and up to around 150 °C; Alternatively, the Tg of the process aids is within the range of about 60 °C to about 125 °C, preferably from about 60 °C to about 85 °C. The Tg of the process aids can be measured as powders or pressed bars formed from such powders using any known method, including differential scanning calorimetry (DSC). Each DSC measurement is obtained in the temperature range of -75 °C to 160 °C using a heating rate of 20 °C / minute and a cooling rate of 10 °C / minute. The glass transition temperature (Tg) is determined as an average of at least two measurements obtained for each sample formulation. A more detailed description of the DSC methodology is available in ASTM E1356-08 (2014) (ASTM International, West Conshohocken, PA). The glass transition temperature (Tg) of process aids can be determined as a powder or as a bar formed from powder. The powder can be pressed into a bar by subjecting it to an elevated temperature (e.g., 215 °C) and high pressure (e.g., 25 tons). Functionalized processing aids comprise a base polymer or copolymer derived from ethylenically unsaturated monomers, including, but not limited to, vinyl- and (meth)acrylic-containing monomers, such as linear or branched alkyl esters of acrylic or methacrylic acid; styrene and styrene derivatives; olefins, such as ethylene; dienes, such as butadiene; and mixtures thereof, with preference given to linear or branched alkyl esters of acrylic or methacrylic acid. Specific examples of vinyl- and (meth)acrylic-containing monomers include, but are not limited to, methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl (meth)acrylate (BMA), 2-ethylhexyl (meth)acrylate, and mixtures thereof, with preference given to methyl (meth)acrylate and ethyl (meth)acrylate.Alternatively, the base polymer or copolymer of the functionalized processing aids may be poly(methyl methacrylate), poly(butyl acrylate), poly(ethyl acrylate), a poly(methyl methacrylate-styrene copolymer, or a mixture thereof. Alternatively, the base polymer of the functionalized processing aids comprises poly(methyl methacrylate), which is preferred due to its compatibility with the PVC matrix. When desired, other acrylates, such as poly(butyl acrylate) or poly(ethyl acrylate), may be added at a level of 10 to 30 wt% to control the glass transition temperature (Tg) and melting properties of the functionalized processing aid. In one embodiment, the base polymer is functionalized with glycidyl (meth)acrylate. In another embodiment, the base polymer is functionalized with a reactive epoxy functional group derived from glycidyl methacrylate, or glycidyl acrylate, or mixtures thereof. The functionalized processing aid used in the processing aid mixture of ML / t / ¿U¿¿ / UOOO4U process added to the formulation of PVC or other thermoplastic resin to form a foamed PVC component or other foamed thermoplastic resin is functionalized with about 0.1 wt% to about 35 wt% of a reactive functional group epoxy, hydroxyl, β-ketoester, β-ketoamide or carboxylic acid, or a mixture thereof, based on the total weight of the functionalized process aid.Alternatively, the functionalization load of the reactive group in the functionalized processing aid is between about 1 wt% and about 25 wt%; alternatively, the functionalized processing aid includes at least between about 1 wt% and about 20 wt% or preferably between 2 wt% and about 20%, or preferably at least between about 3 wt% and about 20 wt% and more preferably about 5 wt% to about 10 wt% of the reactive functional groups based on the total weight of the functionalized processing aid. The functionalized processing aid may include at least approximately 0.1% by weight, or approximately 0.2% by weight, or approximately 0.3% by weight, or approximately 0.4% by weight, or approximately 0.5% by weight, or approximately 0.6% by weight, or approximately 0.7% by weight, or approximately 0.8% by weight, or approximately 0.9% by weight, or approximately 1.0% by weight, or approximately 1.5% by weight, or approximately 2.0% by weight, or approximately 2.5% by weight, or approximately 3.0% by weight, or approximately 3.5% by weight, or approximately 4.0% by weight, or approximately 4.5% by weight, or approximately 5.0% by weight, or approximately 6.0% by weight, or approximately 7.0% by weight, or approximately 8.0% by weight, or approximately of 9.0% by weight, or about 10.0% by weight, or about 11.0% by weight, or about 12.0% by weight, or about 13.0% by weight, or about 14.0% by weight, or about 15.0% by weight, or about 16%, or about 17%, or about 18% by weight, or about 19% by weight, or about 20.0% by weight, or about 21.0% by weight, or about 22.0% by weight, or about 23.0% by weight, or about 24.0% by weight, or about 25.0% by weight, or about 26.0% by weight, or about 27.0% by weight, or about 28.0% by weight, or about 29.0% by weight, or about 30.0% by weight, or about 31.0% by weight, or about 32.0% by weight, or about 33.0% by weight, or about 34.0% by weight, or about 35% by weight of the reactive functional groups (or mixture of such groups) on a weight basis total of the functionalized process aid. The ratio of the weights of the functionalized processing aid to the non-functionalized processing aid with respect to the total amount of processing aid mixture used in the composition may range from 1:99 to approximately 60:40; alternatively, approximately 2:98; or approximately 3:97; or approximately 4:96; or approximately 5:95; or approximately 6:94; or approximately 7:93; or approximately 8:92; or approximately 9:99; or approximately 10:90; or ML / t / ¿U¿¿ / UOOO4U around 11:89; or around 12:88; or around 13:87; or around 15:85; or around 16:84; or around 17:83; or around 19:81; or around 20:80; or around 21:79; or around 23:77; or around 24:76; or around 25:75; or around 27:73; around 28:72; around 29:71; around 31:69; around 62:78; around 63:67; around 35:65:; around 36:64; around 37:63; around 39:61; around 40:60; around 41:59; around 43:57; or around 44:56; or around 45:55; around 47:53; around 48:52; or around 49:51 around 51:49 around 52:48; or around 53:47; around 55:45; around 56:44 or around; 57:43; around 14:86; or around 18:82; or around 22:78; or around 26:74; or around 30:70; or around 34:66; or around 38:62; or around 42:58; or around 46:54; or around 50:50; or around 54:46; or around 58:42; or ML / t / ¿U¿¿ / UOOO4U around 59:41 or around 60:40. Functionalized and non-functionalized processing aids in the processing aid mixture may be used in powder, particle, or granular form, or combinations thereof. Process aid mixtures may be spray-dried blends of functionalized and non-functionalized processing aids. The processing aid mixture may be a molten and pelletized or powdered blend of each of the functionalized and non-functionalized processing aids in the relative proportions described herein. The process mixture may also be a dry blend of granules, particles, or powders of each of the functionalized and non-functionalized processing aids in the relative proportions described herein.In one embodiment, the process aid mixture as described herein can be provided as a standalone product that can be mixed with PVC or another thermoplastic resin, for example in the hopper of an extruder. The powder or particles comprising the functionalized processing aid may be solid particles comprising a base polymer that is substantially functionalized with reactive groups, or the functionalized processing aid may comprise core-shell pseudoparticles. Functionalized processing aids (f-PAs) may be prepared in a multi-step polymerization process, such that the functionalized processing aids resemble core-shell pseudoparticles comprising a core made of non-functionalized base polymer, with at least part of said core being encapsulated with a shell that includes reactive epoxy, hydroxyl, or carboxylic acid functional groups, which would also be in the form of a processing aid mixture. The reactive epoxy, hydroxyl, or carboxylic acid groups of the functionalized processing aid can be derived from the addition of monomers containing epoxy, hydroxyl, β-ketoester, β-ketoamide, or carboxylic acid, or a mixture of such monomers, to the base polymer. Examples of such monomers include, but are not limited to, hydroxyl-substituted alkyl esters of (meth)acrylic acid, such as 2-hydroxyethyl (meth)acrylate; β-ketoesters of (meth)acrylic acids; and β-ketoamides of (meth)acrylic acids. vinyl esters of linear or branched carboxylic acids, such as vinyl valerate, unsaturated carboxylic acids, including unsaturated C3-C6 monocarboxylic acids, such as acrylic acid (AA), and unsaturated C4-C6 dicarboxylic acids, such as maleic acid and yllaconic acid; and monomers containing epoxy groups, such as glycidyl acrylate or glycidyl methacrylate (GMA). unsaturated C3-C6 monocarboxylic acids,such as acrylic acid (AA), and unsaturated C4-C6 dicarboxylic acids, such as maleic acid and itaconic acid; and monomers containing epoxy groups, such as glycidyl acrylate or glycidyl methacrylate (GMA), are preferred, with acrylic acid, glycidyl acrylate, and glycidyl methacrylate (GMA) being the most preferred. Alternatively, the functional groups can be incorporated into the base polymer of the processing aids by the addition of acrylic acid (AA), glycidyl methacrylate (GMA), which are the most preferred, or a mixture thereof. The functionalized processing aid can also be prepared by a method comprising a polymerization step of at least one functionalized monomer comprising at least one functional group selected from the group consisting of hydroxyl functional groups, epoxy functional groups, β-ketoester functional groups, β-ketoamide functional groups, and carboxylic acid functional groups.optionally together with one or more non-functionalized monomers. The functionalized processing aid can also be prepared by a method comprising polymerizing at least one monomer composed of at least one functional group that is a precursor to a functional group selected from the group consisting of hydroxyl functional groups, epoxy functional groups, β-ketoester functional groups, β-ketoamide functional groups, and carboxylic acid functional groups to obtain a polymeric processing aid precursor comprising at least one functional group that is a precursor to a functional group selected from the group consisting of hydroxyl functional groups, epoxy functional groups, β-ketoester functional groups, β-ketoamide functional groups, and carboxylic acid functional groups, and converting at least a portion of the at least one functional group that is a precursor into a functional group selected from the group consisting of hydroxyl functional groups,epoxy functional groups, β-ketoester functional groups, β-ketoamide functional groups, and carboxylic acid functional groups in the polymer process as a precursor of at least one functional group selected from the group consisting of, ML / t / ¿U¿¿ / UOOO4U hydroxyl functional groups, epoxy functional groups, β-ketoester functional groups, β-ketoamide functional groups and carboxylic acid functional groups to obtain a functionalized process aid. The amount of process aid blend present in the foamed or foamable PVC formulation may range from about 0.1 phr to about 15 phr in PVC formulations or from 0.1 to about 25 phr in other thermoplastic resin components; alternatively, from about 0.1 phr to about 10 phr in PVC formulations or from 0.1 to about 10 phr in other thermoplastic resin components; alternatively, greater than or equal to 1 phr. For the purposes of this disclosure, the term phr means parts per hundred parts of the total resin blend, excluding the plastic additive polymer (e.g., PVC plus non-PVC polymer, where the PVC / non-PVC blend equals 100 phr). The amount of process aid blend present in the PVC or other thermoplastic resin formulation may also be expressed as a weight percentage based on the total weight of the PVC or other thermoplastic resin formulation.The usage level of the process aid blend in PVC formulations can vary depending on the type of PVC formulation selected and the specifications established for the application in which the foamed PVC or other foamed thermoplastic resin component will be used. In other words, the amount of process aid blend in the formulation can be predetermined based on the usage level required to meet the density and cell morphology requirements for a given application using a foam component (e.g., siding, window profile, pipe, or foamed sheet, among others). Without wishing to be limited to any single theory, the process aid blend can promote PVC resin melting by altering the melt rheology of the PVC formulation during extrusion or other processing operations in which heat is applied. The process aid blend can also help control melt viscosity, improving the mixing of components as the PVC resin melts, enhancing the strength and extensibility of the molten polymer blend, and controlling the volume increase or expansion that occurs immediately after the molten polymer blend exits the die opening (including, but not limited to, die expansion as the extruded part foams). It also reduces plate appearance and crystallinity, and improves long-term impact strength and weather resistance. The blend of processing aids, comprising functionalized and non-functionalized processing aids, can increase the melt elongation / extensibility and elasticity of the molten polymer blend. The processing aid blend of The ML / t / ¿U¿¿ / UOOO4U process can also increase the initial melt strength of the molten polymer blend. It is known that these two properties together (i.e., a combination of high melt strength and high elongation before break) contribute to improving the characteristics, such as cell structure, cell appearance, and cell morphology, of a foamed component. These characteristics of the polymer foam contribute to reducing the foam density, as well as improving the mechanical properties and the composition's ability to accept high levels of filler. In general, the blend of processing aids described herein, comprising a functionalized processing aid with a higher weight-average molecular weight, may tend to lead to a higher level of matrix expansion. A higher level of matrix expansion can be beneficial when manufacturing a foamed PVC component.Cell morphology, that is, the size and range of cell sizes comprising the foam in the foamed component, is affected by the relative amounts of functionalized and non-functionalized processing aids in the processing aid mixture. In other thermoplastic resins, as well as in PVC, the amount of functionalized processing aid can reduce gloss. Polyvinyl chloride (PVC) resin The PVC resin used to produce the foamed component, which is combined with the processing aid mixture described herein, can be produced with various molecular weights using any method known in the art, including, but not limited to, solution, suspension, or emulsion polymerization. The PVC resin may include, but is not limited to, rigid PVC resins, flexible PVC resins, PVC plastisols, as well as mixtures or combinations of PVC formed with one or more thermoplastic and / or thermoset resins. PVC resin can be characterized by its molecular weight, which is commonly expressed as the inherent viscosity (IV) or K-value. In general, the higher the IV or K-value of the PVC resin, the greater the impact strength of the PVC or other thermoplastic resin component manufactured from it.However, in PVC resins with a high molecular weight, it is also more difficult to achieve polymer melting and flow without the use of excessive heat or shear. The molecular weight of the PVC resin used in the formulation from which a PVC component is manufactured can be predetermined based on the desired mechanical properties and economic factors for the final product. Typically, resins within the K-value range of approximately 56 to approximately 72; alternatively, approximately 63 to approximately 67; or alternatively, approximately 65 are used to form PVC components with a rigid profile. Lower molecular weights are used for foam applications. The molecular weight of PVC resin is generally lower than... ML / t / ¿U¿¿ / UOOO4U the molecular weight of the processing aids used with it. The amount of PVC resin used in the formulation to form the foamed PVC or other thermoplastic resin component can range from 20% by weight to 90% by weight, 30% by weight to 85% by weight, 40% by weight to about 85% by weight, or from about 50% by weight to about 80% by weight, of the entire PVC formulation. Other thermoplastics Other thermoplastics useful for blending with PVC to form a PVC blend or alloy to form the foamed PVC component of the present invention include, but are not limited to, acrylic polymers, styrenic polymers, polyolefins, polycarbonate (PC), polyurethane (PU), polyvinylidene fluoride (PVDF) polymers, polylactic acid (PLA), and the like, and blends thereof. Such other thermoplastics as described herein may be combined with PVC, or used in any combination thereof with or without PVC, and further include the processing aid blends of the invention to form a foamed component with reduced density and improved cellular structure, appearance, and morphology compared to that of such a component which includes only the non-functionalized processing aid in the processing aid blend, but not the functionalized processing aid.These other thermoplastics can be included in the PVC composition at a weight percentage of 50% less than the total resin (not a processing aid) in the mixture. Styrenic polymers, as used herein, include, but are not limited to, polystyrene, high-impact polystyrene (HIPS), acrylonitrile-butadiene-styrene copolymers (ABS), acrylonitrile-styrene-acrylate copolymers (ASA), styrene-acrylonitrile copolymers (SAN), methacrylate-acrylonitrile-butadiene-styrene copolymers (MABS), styrene-butadiene copolymers (SB), styrene-butadiene-styrene block copolymers (SBS) and their partially or fully hydrogenated derivatives, styrene-isoprene copolymers, styrene-isoprene-styrene block copolymers (SIS) and their partially or fully hydrogenated derivatives, styrene-(meth)acrylate copolymers such as styrene-methyl methacrylate (S / MMA) copolymers and mixtures thereof. A preferred styrenic polymer is ASA.The styrenic copolymers of the invention have a styrene monomer content of at least 10 percent by weight, preferably at least 25 percent by weight. Styrenic polymers can also be blended with other polymers to form compatible blends. Examples include ASA blended with PVC and SAN blended with PMMA. Acrylic polymers, as used herein, include, but are not limited to, homopolymers, copolymers, and terpolymers comprising alkyl (meth)acrylates. The alkyl (meth)acrylate monomer is preferably methyl methacrylate, which can ML / t / ¿U¿¿ / UOOO4U may constitute 60 to 100 percent by weight of the monomer mixture. It may also be present in the monomer mixture at zero to 40 percent by weight of other acrylate, methacrylate and / or other vinyl monomers. Other methacrylates, acrylates, and other vinyl monomers useful in monomer blending include, but are not limited to, methyl acrylate, ethyl acrylate and ethyl methacrylate, butyl acrylate and butyl methacrylate, iso-octyl methacrylate and iso-octyl acrylate, lauryl acrylate and lauryl methacrylate, stearyl acrylate and stearyl methacrylate, isobornyl acrylate and isobornyl methacrylate, methoxyethyl acrylate and methacrylate, 2-ethoxyethyl acrylate and 2-ethoxyethyl methacrylate, acrylate monomers and dimethylaminoethyl methacrylate, styrene, and their derivatives. Alkyl(meth)acrylic acids such as (meth)acrylic acid and acrylic acid may be useful for monomer blending.Small levels of multifunctional monomers can also be used as crosslinking agents. A preferred acrylic polymer is a copolymer of methyl methacrylate and 2 to 16 wt percent of one or more C1-4 acrylates. The thermoplastic polymers of the invention can be manufactured by any means known in the art, including emulsion polymerization, solution polymerization, and suspension polymerization. In one embodiment, the matrix-free thermoplastic has a weight-average molecular weight of between 50,000 and 500,000 g / mol, and preferably between 75,000 and 150,000 g / mol, as measured by gel permeation chromatography (GPC). The molecular weight distribution of the thermoplastic matrix can be monomodal or multimodal with a polydispersity index greater than 1.5. The thermoplastics especially preferred for the matrix polymer are styrenic polymers (including SAN, ABS, MABS, ASA, HIPS), acrylic polymers, and PVDF. Impact modifiers When desirable, the PVC formulation used to form the foamed PVC or other thermoplastic resin component may optionally include at least one impact modifier. Impact modifiers improve the toughness and resistance of the final foamed product against cracking or rupture during any subsequent manufacturing operations performed on the foamed PVC or other thermoplastic resin component, such as cutting or drilling holes in the foamed component's profile. Impact modifiers typically function by absorbing and / or dissipating the energy of a propagating crack. Impact modifiers may include any compatible polymeric particle, including block copolymers and core-shell particle polymers that have either a soft rubber core (Tg < 0 °C) or a hard core (Tg > 0 °C) with limited compatibility with the PVC resin and a grafted, compatible outer polymer shell.The polymeric particles or the compatible outer polymeric coating may comprise methacrylate / butadiene / styrene (MBS), acrylic polymers (e.g., known). ML / t / ZUZZ / U3OO4U as acrylic impact modifiers (AIM), or acrylate / butadiene / methacrylate and acrylonitrile / butadiene / styrene (ABS); semi-compatible polymers, such as chlorinated polyethylene (CPE) polymers and acrylic-grafted CPE, and ethylene-vinyl acetate (EVA); and other polymers, such as ethylene / vinyl acetate / carbon monoxide terpolymers, ethylene / propylene / carbon monoxide terpolymers, olefin polymers with acrylates, various butadiene copolymers with acrylonitrile, methacrylates or other rubbers, and even materials enhanced with polysiloxanes. Preferred covers comprise polymethyl methacrylate (PMMA). Fillings The formulation of PVC or other thermoplastic resin used to form the foamed PVC component may also optionally or preferably comprise one or more inorganic fillers or particles, pigments, lubricants, stabilizers, or other desired additives. The inclusion of a processing aid in the mixture can improve the ability of the PVC composition to accept higher filler loading levels. For example, ultrafine CaCO₃ particles can be used as a filler to improve low-temperature impact strength and increase UV stability in rigid foamed PVC products. Synthetic amorphous silica particles can be incorporated into a PVC formulation to also improve impact strength and provide enhanced flow properties.Other solid fillers, including but not limited to kaolin clay, talc, mica, wollastonite, and calcium metasilicate, may also be incorporated into the formulation simply to reduce formulation costs without substantially affecting the properties exhibited by the foamed PVC or other foamed thermoplastic resin component. The filler range in the foam can be from approximately 5 phr to approximately 150 phr. Other additives Various pigments can be included to provide color to the foamed PVC component or other foamed thermoplastic resin component. These pigments generally exhibit stability at elevated temperatures and in the presence of hydrogen chloride. These pigments may include, but are not limited to, various organic pigments or ceramic pigments, such as titanium dioxide and other metal oxides, with or without a silica or alumina surface treatment. Several lubricants can be included in a PVC formulation in relatively small quantities to reduce the flow resistance of the polymer chains and other ingredients present. These lubricants can act as an external lubricant or a metal release (slip) agent that improves the flow of the hot material through the polymer processing equipment, or as an internal lubricant that reduces the ML / t / U / UOOO4U melt viscosity of the material being processed. Lubricants are the main additive that can be added to the formulation to help facilitate or accelerate the melting of PVC resin. Examples of lubricants include, but are not limited to, paraffin waxes and long-chain carboxylic acids or their esters, amides, and salts. The amount of lubricant used is typically below the level that will cause platelet stripping. Platelet stripping occurs when the lubricants present in the formulation are squeezed out of the hot bulk material as the extrudate exits the die or passes through a vacuum calibrator, resulting in a plug or deposit of material. Various stabilizers can be included in a PVC or other thermoplastic formulation to improve the resistance of the foamed component to heat or ultraviolet light, among other applications. Thermal stabilizers may include, but are not limited to, organotin or lead-based compounds, mixed metal stabilizers, or organic stabilizers such as epoxides. UV stabilizers may include, but are not limited to, hindered amines or phenols. The non-limiting aspects of the invention can be summarized as follows: Aspect 1: A foamed polyvinyl chloride (PVC) component comprising: a) a PVC resin; b) a weight Q in parts per hundred (phr) of PVC resin from a processing aid mixture, wherein the processing aid mixture comprises from 1 wt% to 60 wt%, based on weight Q, of a functionalized processing aid and from 99 wt% to 40 wt% with respect to weight Q, of a non-functionalized processing aid, wherein the functionalized processing aid comprises at least one base polymer that is functionalized with from 0.1 wt% to 35 wt% of a reactive epoxy, hydroxyl, β-ketoester, β-ketoamide or carboxylic acid functional group or mixture thereof based on the total weight of the functionalized processing aid; and the foamed PVC component comprising the process aid mixture has a lower density than a reference foamed PVC component comprising 100% by weight, based on weight Q, of the non-functionalized process aid, and wherein the foamed PVC component comprising weight Q of the process aid mixture and the reference foamed PVC component comprising 100% by weight Q of the non-functionalized process aid are manufactured using the same process conditions and additives. Aspect 2: The foamed PVC component according to Aspect 1, where ML / t / ¿U¿¿ / UOOO4U the process aid mixture comprises from 1% by weight to 25% by weight, based on weight Q, of the functionalized process aid, and from 99% by weight to 75% by weight, based on weight Q, of the non-functionalized process aid. Aspect 3: The foamed PVC component according to Aspect 1 or Aspect 2, wherein the functionalized processing aid comprises at least 1% by weight of the reactive functional group. Aspect 4: The foamed PVC component in accordance with any of Aspects 1 to 3, wherein the functionalized processing aid comprises at most 25% by weight of the reactive functional group. Aspect 5: The foamed PVC component in accordance with any of Aspects 1 to 4, wherein the weight Q is from 0.1 to 15 parts per hundred (phr) by weight of PVC resin. Aspect 6: The foamed PVC component according to any of Aspects 1 to 5, wherein the foamed PVC component comprising the process aid mixture has a density that is at least 2 percent less than the density of the reference foamed PVC component. Aspect 7: The foamed PVC component according to any of Aspects 1 to 6, wherein the base polymer of the functionalized processing aid is derived from one or more monomers comprising monomers containing (meth)acrylic. Aspect 8: The foamed PVC component according to any of Aspects 1 to 7, wherein the functionalized process aid base polymer is derived from i) one or more monomers comprising a monomer containing (meth)acrylic and i) at least one monomer selected from the group consisting of monomers containing vinyl, styrene and styrene derivatives, olefins, dienes and mixtures thereof. Aspect 9: The foamed PVC component according to any of Aspects 1 to 8, wherein the reactive functional group epoxy, hydroxyl, β-ketoester, β-ketoamide, or carboxylic acid is derived from hydroxyl-substituted alkyl esters of (meth)acrylic acid; vinyl esters of linear or branched carboxylic acids; unsaturated C3-C6 monocarboxylic acids and unsaturated C4-C6 dicarboxylic acids; β-ketoesters of (meth)acrylic acids; β-ketoamides of (meth)acrylic acids; monomers containing epoxy groups, or mixtures thereof. Aspect 10: The foamed PVC component according to any of Aspects 1 to 9, wherein the base polymer is functionalized with a reactive epoxy functional group derived from glycidyl methacrylate, or glycidyl acrylate, or mixtures thereof. Aspect 11: The foamed PVC component according to any of Aspects 1 to 10, wherein the non-functionalized processing aid comprises a ΜΛ / t / ZUZZ / UOOO4U acrylic polymer or an acrylic copolymer. Aspect 12: The foamed PVC component according to any of Aspects 1 to 11, wherein the functionalized processing aid has a weight average molecular weight of at least 50,000 g / mol. Aspect 13: The foamed PVC component according to any of Aspects 1 to 12, wherein the non-functionalized processing aid comprises a polymer. Aspect 14: The foamed PVC component according to any of Aspects 1 to 13, wherein the non-functionalized processing aid comprises chlorinated polyethylene (PE-C). Aspect 15: The foamed PVC component in accordance with any of Aspects 1 to 14, wherein the foamed PVC component is a building or flooring material. Aspect 16: A method for manufacturing a foamed polyvinyl chloride (PVC) component, wherein the method comprises combining: a) a polyvinyl chloride (PVC) resin; b) a weight Q in parts per hundred (phr) of PVC resin from a mixture of processing aids, wherein the mixture of processing aids comprises from 1% by weight to 60% by weight, based on weight Q, of a functionalized processing aid, and from 99% by weight to 40% by weight, based on weight Q, of a non-functionalized processing aid and c) an expansion agent (BA); to form a foamable PVC composition; and to process the foamable PVC composition to form the foamed PVC component; wherein the functionalized processing aid comprises at least one base polymer that is functionalized with from 0.1 wt% to 35 wt% of a reactive epoxy, hydroxyl, β-ketoester, β-ketoamide or carboxylic acid functional group, or a mixture thereof, based on the total weight of the functionalized processing aid; and the foamed PVC component comprising the process aid mixture has a lower density than a reference foamed PVC component comprising 100% by weight Q of the non-functionalized process aid, wherein the foamed PVC component comprises weight Q of the process aid mixture and the reference foamed PVC component comprising 100% by weight, based on weight Q of the non-functionalized process aid, is manufactured using the same process conditions and additives. Aspect 17: The method in accordance with Aspect 16, wherein the process aid mixture comprises from 1% by weight to 24% by weight, based on weight Q, of the functionalized process aid, and from 99% by weight to 76% by weight, based on weight Q, of the non-functionalized process aid. Aspect 18: The method for manufacturing a foamed polyvinyl chloride (PVC) component according to either Aspect 16 or 17, wherein the functionalized processing aid comprises at least 1% by weight of the reactive functional group. Aspect 19: The method for manufacturing a foamed PVC component according to any of Aspects 16 to 18, wherein the functionalized processing aid comprises at most 25% by weight of the reactive functional group. Aspect 20: The method for manufacturing a foamed PVC component according to any of Aspects 16 to 19, wherein the weight Q is from 0.1 to 15 parts per hundred (phr) by weight of PVC resin. Aspect 21: The method for manufacturing a foamed PVC component according to any of Aspects 16 to 20, wherein the foamed PVC component comprising the mixture of process aids has a density that is at least 2 percent less than the density of the reference foamed PVC component. Aspect 22: The method for manufacturing a foamed PVC component according to any of Aspects 16 to 21, wherein the base polymer of the functionalized processing aid is derived from one or more monomers comprising monomers containing (meth)acrylic. Aspect 23: The method for manufacturing a foamed PVC component according to any of Aspects 16 to 23, wherein the functionalized process aid base polymer is derived from i) one or more monomers comprising (meth)acrylic-containing monomer and ii) at least one monomer selected from the group consisting of vinyl-containing monomers, styrene and styrene derivatives, olefins, dienes and mixtures thereof. Aspect 24: The method for manufacturing a foamed PVC component according to any of Aspects 16 to 23, wherein the reactive functional group epoxy, hydroxyl, β-ketoester, β-ketoamide, or carboxylic acid is derived from hydroxyl-substituted alkyl esters of (meth)acrylic acid; vinyl esters of linear or branched carboxylic acids; unsaturated C3-C6 monocarboxylic acids and unsaturated C4-C6 dicarboxylic acids; β-ketoesters of (meth)acrylic acids; β-ketoamides of (meth)acrylic acids; monomers containing epoxy groups; or mixtures thereof. Aspect 25: The method for manufacturing a foamed PVC component according to any of Aspects 16 to 24, wherein the base polymer is functionalized with a ML / t / ¿U¿¿ / UOOO4U reactive epoxy functional group derived from glycidyl methacrylate, glycidyl acrylate or mixtures thereof. Aspect 26: The method for manufacturing a foamed PVC component according to any of Aspects 16 to 25, wherein the non-functionalized processing aid comprises an acrylic polymer or an acrylic copolymer. Aspect 27: The method for manufacturing a foamed PVC component according to any of Aspects 16 to 26, wherein the functionalized process aid has a weight average molecular weight of at least 50,000 g / mol. Aspect 28: The method for manufacturing a foamed PVC component according to any of Aspect 16, wherein the non-functionalized processing aid comprises a polymer. Aspect 29: The method for manufacturing a foamed PVC component according to any of Aspects 16 to 28, wherein the non-functionalized processing aid comprises chlorinated polyethylene (PE-C). Aspect 30: The method for manufacturing a foamed PVC component in accordance with any of Aspects 16 to 29, wherein the foamed PVC component is a construction material. Aspect 31: A mixture of process aids, wherein the mixture of process aids comprises from 1% by weight to 60% by weight of a functionalized process aid, and from 99% to 40% by weight of a non-functionalized process aid. wherein the functionalized processing aid comprises at least one base polymer that is functionalized with from 0.1 wt% to 35 wt% of a reactive epoxy, hydroxyl, β-ketoester, β-ketoamide or carboxylic acid functional group or mixture thereof based on the total weight of the functionalized processing aid. Aspect 32: The process aid mixture according to Aspect 31, wherein the process aid mixture comprises from 1% by weight to 24% by weight of the functionalized process aid, and from 99% by weight to 76% by weight of non-functionalized process aid. Aspect 33: The mixture of processing aids according to Aspect 31 or Aspect 32, wherein the reactive functional group comprises at least 1% by weight of the functionalized processing aid. Aspect 34: The process aid mixture in accordance with any of Aspects 31 to 33, wherein the reactive functional group comprises at most 25% by weight of the functionalized process aid. Aspect 35: The process aid mixture in accordance with any of the MA / t / ¿U¿¿ / UOOO4U Aspects 31 to 34, wherein the base polymer of the functionalized process aid is derived from one or more monomers comprising monomers containing (meth)acrylic. Aspect 36: The process aid mixture according to any of Aspects 31 to 35, wherein the functionalized process aid base polymer is derived from i) one or more monomers comprising (meth)acrylic-containing monomer and ii) at least one monomer selected from the group consisting of vinyl-containing monomers, styrene and styrene derivatives, dienes, dienes and mixtures thereof. Aspect 37: The mixture of process aids according to any of Aspects 31 to 36, wherein the reactive functional group epoxy, hydroxyl, β-ketoester, β-ketoamide or carboxylic acid is derived from hydroxyl-substituted alkyl esters of (meth)acrylic acid; vinyl esters of linear or branched carboxylic acids; unsaturated C3-C6 monocarboxylic acids and unsaturated C4-C6 dicarboxylic acids; β-ketoesters of (meth)acrylic acids; β-ketoamides of (meth)acrylic acids; monomers containing epoxy groups or mixtures thereof. Aspect 38: The process aid mixture according to any of Aspects 31 to 37, wherein the base polymer is functionalized with a reactive epoxy functional group derived from glycidyl methacrylate, or glycidyl acrylate, or mixtures thereof. Aspect 39: The process aid mixture according to any of Aspects 31 to 38, wherein the non-functionalized process aid comprises an acrylic polymer or an acrylic copolymer. Aspect 40: The process aid mixture according to any of Aspects 31 to 39, wherein the functionalized process aid has a weighted average molecular weight of at least 50,000 g / mol. Aspect 41: The process aid mixture according to any of Aspects 31 to 40, wherein the non-functionalized process aid comprises a polymer. Aspect 42: The process aid mixture according to any of Aspects 31 to 41, wherein the non-functionalized process aid comprises chlorinated polyethylene (PE-C). Aspect 43: A foamable PVC composition comprising: a) a polyvinyl chloride (PVC) resin; b) a weight Q in parts per hundred (phr) of PVC resin from a mixture of processing aids, wherein the mixture of processing aids comprises from 1% by weight to 60% by weight, based on weight Q, of a functionalized processing aid, and from 99% by weight to 40% by weight, based on weight Q, of a non-functionalized processing aid; and ML / t / ¿U¿¿ / UOOO4U c) an expansion agent (BA); wherein the functionalized processing aid comprises at least one base polymer that is functionalized with from 0.1 wt% to 35 wt% of a reactive epoxy, hydroxyl, β-ketoester, β-ketoamide or carboxylic acid functional group, or a mixture thereof, based on the total weight of the functionalized processing aid; and the foamable PVC composition, when foamed, provides a foamed PVC component having a lower density than a reference foamed PVC component comprising 100% by weight Q of the non-functionalized processing aid, and wherein the foamed PVC component and the reference foamed PVC component comprising 100% by weight, based on weight Q, of the non-functionalized processing aid are prepared using the same process conditions and additives. Examples Example 1: Melting force versus pulling speed A PVC formulation shown in Table 1 was blended in a 5-lb (2.27 kg) Henschel mixer with 3 phr of the processing aid blends shown in Table 2. The powdered PVC formulation was then pelletized using a laboratory-scale Brabender twin-conical screw extruder equipped with a pelletizer. The Brabender extruder used the following temperature profile for processing and pelletizing: 162°C / 164°C / 164°C / 164°C (Zone 1 / Zone 2 / Zone 3 / Die), respectively. The extruder screw speed was set to 20 RPM. The resulting PVC compound pellets were used for Rheotens rheological evaluations. The Rheotens test was performed on a Goettfert Rheograph capillary rheometer using a 2000 bar transducer. The material was allowed to equilibrate in the test cylinder for 5 minutes before starting the test.The samples were run using grooved stainless steel traction wheels. The experimental conditions were as follows: the processing temperature was set at 190°C. The die geometry used for strand extrusion was a 30 / 2 L / D (mm / mm) die with a 180-degree configuration. The wheel spacing was set at 0.2 mm and the wheel acceleration at 6 mm / s². The capillary piston diameter was 12 mm with a piston speed of 0.2 mm / s. The capillary shear rates were therefore 28.8 s⁻¹. The initial wheel speed, Vo, was 5.2 mm / s. The resulting curves are shown in Figure 1. These curves illustrate the effect on strength and elongation of the initial melt for each blend of processing aids. This data can be used to estimate foaming performance, i.e., how well a melt will expand and maintain its cellular structure. ML / t / ¿U¿¿ / UOOO4U when an expanding agent, such as a chemical or physical expanding agent, is added to the PVC formulation during extrusion to manufacture foamed PVC components. Table 1: PVC foam formulation used for the Rheotens evaluations in Example 1 ML / t / ¿U¿¿ / UOOO4U Component Component Detail phr grams PVC Resin Shintech SE750 100 2500 PMC Stabilizer Organometallix Thermolite® 161 2 50 Paraffin Wax Honeywell Rheolub® 165 1 25 Calcium Stearate Norac COAD® 10 0.7 17.5 Oxidized Polyethylene Honeywell AC® 629A 0.2 5 High Pm Variable Process Aid 3 75 Lubrication Process Aid Arkema, Inc. Plastistrength® 770 1.5 37.5 Calcium Carbonate OMYA Omyacarb® UFT 10 250 Titanium Dioxide Millennium, Inc. RCL- 4 5 125 Total 123.4 3085 Table 2: Process aid mixtures from Example 1 in weight proportions added to PVC Weight proportions in the mixture of processing aids Mixture A (non-functionalized acrylic-based processing aid) B (functionalized acrylic-based processing aid) 1 (invention) 75 25 2 (comparative) 50 50 3 (comparative) 25 75 4 (comparative) 100 0 5 (comparative) 0 100 6 (invention) 80 20 7 (invention 85 15 As can be seen in Figure 1, the PVC composition comprising only the non-functionalized processing aid (A), but no functionalized processing aid (B), had good melt extensibility but poor initial melt strength. Poor initial melt strength is associated with lower-quality foams when foaming PVC. Conversely, the PVC composition comprising only the functionalized processing aid (B), but no non-functionalized processing aid (A), had good initial melt strength but poor melt extensibility, as the extruded strand broke at a tensile speed of approximately 25 mm / second.PVC compositions using process aid blends A and B comprising half or more by weight as functionalized process aid (B) exhibited better melt strength than even the 100% functionalized process aid, but melt elongation was still too low to produce acceptable foam. PVC formulations using process aid blends comprising more than half by weight of non-functionalized process aid (A), with the remainder of the process aid blend being functionalized process aid (B), surprisingly showed minimal deterioration in initial melt strength but dramatically improved elongation compared to PVC compositions using process aid blends comprising more than half by weight of functionalized process aids.Therefore, these results illustrate the surprising effect that not only is the combination of functionalized and non-functionalized process aids necessary, but also a specific range of the relative amounts of each of the functionalized and non-functionalized process aids to achieve a high quality of the foamed PVC component. Example 2: Foam density and cell structure PVC foam samples were prepared using four different feed rates of a chemical blowing agent (CBA) and two different processing aids. PVC foam extrusion was performed using a Cincinnati Milacron CM-55 twin-screw conical extruder. The foam extrusion utilized a barrel and die zone temperature profile set at: 285 °F (140 °C) / 300 °F (150 °C) / 320 °F (160 °C) / 385 °F (200 °C) / 360 °F (180 °C) (Barrel Zone 1 / Zone 2 / Zone 3 / Zone 4 / Die Zone, respectively). Oil was used to cool the screws and die. The screw oil running through the extruder screws was set at 265 °F (130 °C), while the oil at the edge of the sheet die was set at 355 °F (180 °C). The PVC sheet was extruded using a 9-inch (22.9 cm) wide Cloeren sheet nozzle with a 0.250-inch (0.64 cm) nozzle opening.The molten PVC mass coming out of the nozzle was fed through a stack of three rollers where the PVC foam sheet was formed to a thickness of approximately 0.500 inches (1.27 cm). Except for the addition of the processing aids, the PVC compositions and processing conditions were identical. The PVC formulation was the same as shown in Table 1, but with the total amount of processing aid or mixtures of processing aids added at 5 phr instead of the 3 phr used in Example 1. The processing aids were: 1) Weight ratio of 70:30 of non-functionalized processing aid (A) to functionalized processing aid (B); and 2) 100% non-functionalized process aid (A). The density of each sample was measured as follows: 1-in-1 x 1-in-1 x 1-in-1 thick samples were cut from the center of a 9-in-1 x 3-in-1 x 1-in-1 thick PVC foam sheet. The density values ​​of the samples were then obtained using an Alfa Mirage MD-300S electronic densimeter following ASTM D792 Standard Test Methods for Density and Specific Gravity (Relative Density) of Plastics by Displacement, Test Method A: Testing Solid Plastics in (Deionized) Water. This process was repeated three times using three individual test specimens collected over a five (5) minute period to obtain an average density. The results are shown in Figure 2. Table 3 shows the measured density for the PVC samples, as well as the percentage reduction in density resulting from the use of the process aid mixture compared to the non-functionalized process aid alone. The percentage reduction in density was calculated as: Percentage of density reduction = 100 x [(pnf - pb) / pnf] where: pnf = density of foamed PVC manufactured only with non-functionalized process aids and pb = density of foamed PVC manufactured with a mixture of functionalized and non-functionalized process aids. ML / t / ¿U¿¿ / UOOO4U Table 3: Densities of the foamed PVC components of Example 2 Density (g / cm3) Density reduction (%) CBA Supply Rate (kg / h) 100% (A) (no f PA) 70% (A) (no f PA) 30% (B) (f-PA) 70 / 30 (A / B) vs. 100 A 1.43 0.559 0.548 2.0 1.50 0.522 - 1.56 0.514 - 1.63 0.506 (gaps) 0.501 1.0 PVC foam samples manufactured using 5 phr of processing aid were analyzed using optical microscopy. A Nikon ME600 optical microscope and a Nikon D850 DSLR were used for the optical microscopy analysis. Prior to imaging and analysis, the PVC foam samples were polished and painted with ink to aid in cell size measurement. WaveMetrics' IGOR Pro® 7 was used to analyze cell uniformity through average cell size (2D particle) measurements to show the differences in cell structure resulting from the processing aid blends used in the PVC foam formulations. The software applies a Hough transform to the image, or alternatively, the user can manually identify the cells to begin the analysis and view the average cell size.After identifying cells or voids in the PVC foam structure, the images are transformed from an 8-bit grayscale to a binary format where, for example, foam cells are assigned a 1 and non-cell areas are assigned a 0. Using a reference, the pixels are scaled to a known micrometer measurement, and the cell size can then be assigned. A scale bar provided by Nikon was used to calibrate the samples shown in Figure 3 and Table 4. Table 4 shows the differences between foamed PVC using only a non-functionalized processing aid (A) versus the processing aid mixture (70 / 30 A / B). Cell size and uniformity analysis was taken from the foam cell structure at the center of 72” extruded PVC foam sheets.Furthermore, Figure 3 shows PVC foam using only the non-functionalized processing aid (A) and PVC foam using a blend of processing aids (A:B in a 70:30 ratio). As can be seen in the figure, the PVC foam made with 100% non-functionalized processing aid not only had a higher density but also lower cell uniformity compared to the 70:30 weight ratio blend of non-functionalized to functionalized processing aid. As mentioned in Table 3 and Figure 2, voids can begin to appear in a foamed PVC article when the PVC's strength is no longer able to capture the gas released from the CBA used in the formulation. Figure 4 shows an image of a void in the cell structure.In foam articles where voids form, the reduction in density may appear greater due to the large open cell structure; however, cell uniformity is poor and undesirable. Table 4. Analysis of cell structure using optical microscopy ML / t / ¿U¿¿ / UOOO4U Processing aid CBA supply rate (kg / h) Average cell size (pm) A 1.43 145 ±89 A 1.63 135 ±71 70 / 30 (A / B) 1.43 133 ± 56 70 / 30 (A / B) 1.63 113 ±48 Within this descriptive document, the embodiments have been described in a manner that allows for the drafting of a clear and concise specification, but it is intended and will be appreciated that the embodiments can be combined or separated in various ways without departing from the invention. For example, it will be appreciated that all the preferred features described herein are applicable to all aspects of the invention described herein. The foregoing description of various forms of the invention has been presented for illustrative and descriptive purposes. It is not intended to be exhaustive, nor to limit the invention to the precise forms described. Numerous modifications or variations may be made in light of the foregoing. The forms discussed were chosen and described to provide a better illustration of the principles of the invention and their practical application, thereby enabling a person skilled in the art to use the invention in various forms and with various modifications as appropriate for the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted to the fullest extent to which they are justly, legally, and equitably entitled.

Claims

1. A foamed polyvinyl chloride (PVC) component characterized in that it comprises: a) a PVC resin; b) a weight Q in parts per hundred (phr) of the PVC resin from a processing aid mixture, wherein the processing aid mixture comprises from 1 wt% to 60 wt%, based on weight Q, of a functionalized processing aid, and from 99 wt% to 40 wt% with respect to weight Q, of a non-functionalized processing aid, wherein the functionalized processing aid comprises at least one base polymer that is functionalized with from 0.1% by weight to 35% by weight of a reactive functional group epoxy, hydroxyl, β-ketoester, β-ketoamide or carboxylic acid or mixture thereof based on the total weight of the functionalized processing aid; and the foamed PVC component comprising the processing aid mixture has a lower density than a reference foamed PVC component comprising 100% by weight, based on weight Q, of the non-functionalized processing aid, wherein the foamed PVC component comprising weight Q of the processing aid mixture and the reference foamed PVC component comprising 100% by weight Q of the non-functionalized processing aid are manufactured using the same process conditions and additives.

2. The foamed PVC component according to claim 1, characterized in that the process aid mixture comprises from 1% by weight to 25% by weight, based on weight Q, of the functionalized process aid, and from 99% by weight to 75% by weight, based on weight Q, of the non-functionalized process aid.

3. The foamed PVC component according to claim 1, characterized in that the functionalized processing aid comprises at least 1% by weight of the reactive functional group.

4. The foamed PVC component according to claim 3, characterized in that the functionalized processing aid comprises at most 25% by weight of the reactive functional group.

5. The foamed PVC component according to claim 1, characterized in that the weight Q is from 0.1 to 15 parts per hundred (pH) by weight of the PVC resin. ML / t / ¿U¿¿ / UOOO4U 6. The foamed PVC component according to claim 1, characterized in that the foamed PVC component comprising the process aid mixture has a density that is at least 2 percent less than the density of the reference foamed PVC component.

7. The foamed PVC component according to claim 1, characterized in that the base polymer of the functionalized processing aid is derived from one or more monomers comprising monomers containing (meth)acrylic.

8. The foamed PVC component according to claim 1, characterized in that the base polymer of the functionalized processing aid is derived from i) one or more monomers comprising monomer containing (meth)acrylic and i) at least one monomer selected from the group consisting of monomers containing vinyl, styrene and styrene derivatives, olefins, dienes and mixtures thereof.

9. The foamed PVC component according to claim 1, characterized in that the reactive functional group epoxy, hydroxyl, β-ketoester, β-ketoamide or carboxylic acid is derived from hydroxyl-substituted alkyl esters of (meth)acrylic acid; vinyl esters of linear or branched carboxylic acids; unsaturated C3-C6 monocarboxylic acids and unsaturated C4-C6 dicarboxylic acids; β-ketoesters of (meth)acrylic acids; β-ketoamides of (meth)acrylic acids; monomers containing epoxy groups; or mixtures thereof.

10. The foamed PVC component according to claim 1, characterized in that the non-functionalized processing aid comprises an acrylic polymer or an acrylic copolymer.

11. The foamed PVC component according to claim 1, characterized in that the functionalized processing aid has a weight average molecular weight of at least 50,000 g / mol.

12. The foamed PVC component according to claim 1, characterized in that the non-functionalized processing aid comprises a polymer.

13. The foamed PVC component according to claim 13, characterized in that the non-functionalized processing aid comprises chlorinated polyethylene (PE-C).

14. The foamed PVC component according to claim 1, characterized in that the foamed PVC component is a building material or flooring.

15. A method for manufacturing a foamed polyvinyl chloride (PVC) component, wherein the method comprises combining: a) a polyvinyl chloride (PVC) resin, ML / t / ¿U¿¿ / UOOO4U; b) a weight Q in parts per hundred (phr) of the PVC resin from a mixture of processing aids, wherein the mixture of processing aids comprises from 1 wt% to 60 wt%, based on weight Q, of a functionalized processing aid, and from 99 wt% to 40 wt%, based on weight Q, of a non-functionalized processing aid; and c) a blowing agent (BA); to form a foamable PVC composition; and processing the foamable PVC composition to form the foamed PVC component; wherein the functionalized processing aid comprises at least one base polymer that is functionalized with from 0.1% by weight to 35% by weight of a reactive functional group epoxy, hydroxyl, β-ketoester, β-ketoamide or carboxylic acid, or mixture thereof, based on the total weight of the functionalized processing aid; and the foamed PVC component comprising the processing aid mixture has a lower density than a reference foamed PVC component comprising 100% by weight Q of the non-functionalized processing aid, wherein the foamed PVC component comprising weight Q of the processing aid mixture and the reference foamed PVC component comprising 100% by weight, based on weight Q, of the non-functionalized processing aid is manufactured using the same process conditions and additives.

16. The method according to claim 15, characterized in that the process aid mixture comprises from 1% by weight to 25% by weight, based on weight Q, of the functionalized process aid, and from 99% by weight to 75% by weight, based on weight Q, of the non-functionalized process aid.

17. The method for manufacturing a foamed polyvinyl chloride (PVC) component according to claim 15, characterized in that the process aid mixture comprises at least 1% by weight of the functionalized process aid.

18. The method for manufacturing a foamed PVC component according to claim 17, characterized in that the process aid mixture comprises at most 25% by weight of the functionalized process aid.

19. The method for manufacturing a foamed PVC component according to claim 15, characterized in that the weight Q is from 0.1 to 15 parts per hundred (phr) by weight of the PVC resin.

20. The method for manufacturing a foamed PVC component according to claim 15, characterized in that the foamed PVC component comprising the ML / t / ¿U¿¿ / UOOO4U process aid mixture has a density that is at least 2 percent less than the density of the reference foamed PVC component.

21. The method for manufacturing a foamed PVC component according to claim 15, characterized in that the base polymer of the functionalized processing aid is derived from one or more monomers comprising monomers containing (meth)acrylic.

22. The method for manufacturing a foamed PVC component according to claim 15, characterized in that the base polymer of the functionalized processing aid is derived from i) one or more monomers comprising monomer containing (meth)acrylic and i) at least one monomer selected from the group consisting of monomers containing vinyl, styrene and styrene derivatives, olefins, dienes and mixtures thereof.

23. The method for manufacturing a foamed PVC component according to claim 15, characterized in that the reactive functional group epoxy, hydroxyl, β-ketoester, β-ketoamide or carboxylic acid is derived from hydroxyl-substituted alkyl esters of (meth)acrylic acid; vinyl esters of linear or branched carboxylic acids; unsaturated C3-C6 monocarboxylic acids and unsaturated C4-C6 dicarboxylic acids; β-ketoesters of (meth)acrylic acids; β-ketoamides of (meth)acrylic acids; monomers containing epoxy groups; or mixtures thereof.

24. The method for manufacturing a foamed PVC component according to claim 23, characterized in that the base polymer is functionalized with a reactive epoxy functional group derived from glycidyl methacrylate, or glycidyl acrylate, or mixtures thereof.

25. The method for manufacturing a foamed PVC component according to claim 15, characterized in that the non-functionalized processing aid comprises an acrylic polymer or an acrylic copolymer.

26. The method for manufacturing a foamed PVC component according to claim 15, characterized in that the functionalized process aid has a weight average molecular weight of at least 50,000 g / mol.

27. The method for manufacturing a foamed PVC component according to claim 15, characterized in that the non-functionalized processing aid comprises a polymer.

28. The method for manufacturing a foamed PVC component according to claim 27, characterized in that the non-functionalized processing aid comprises chlorinated polyethylene (PE-C).

29. The method for manufacturing a foamed PVC component according to claim 15, characterized in that the foamed PVC component is a building or flooring material.