Semi-crystalline co-polyester compositions and articles with good strength and thermal stability
Patent Information
- Application Number
- PCT/US2025/032461
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-06-12
- Filing Date
- 2025-06-05
- Publication Date
- 2026-01-29
AI Technical Summary
Existing polymer-based resins, such as PET, fail to provide both high strength and thermal stability required for high-pressure applications like carbonated drink bottles, as they shrink during dishwashing due to low glass transition temperatures.
Development of copolyester compositions with a glass transition temperature exceeding 95°C, comprising specific ratios of terephthalic acid, isophthalic acid, 1,4-cyclohexanedimethanol, ethylene glycol, and optionally isosorbide, which are melt processed to create articles with improved strength and dishwasher stability.
The copolyester compositions exhibit excellent strength and thermal stability, maintaining dimensional integrity under elevated temperatures, suitable for carbonated drink bottles and other high-pressure applications.
Abstract
Description
SEMI-CRYSTALLINE CO-POLYESTER COMPOSITIONS AND ARTICLESWITH GOOD STRENGTH AND THERMAL STABILITYFIELD OF THE INVENTION
[0001] This invention belongs to the field of polymer-based resins useful for forming articles or components of articles intended for applications requiring a combination of high strength and sufficient dimensional stability at elevated temperature. In one aspect, the articles / components are intended for containers having high strength and high thermal stability, e.g., containers for carbonated beverages that also have excellent dishwasher stability.BACKGROUND OF THE INVENTION
[0002] Plastics are a preferred material for making articles / devices that are produced in relatively high volume or that have unique shapes, based on the relative efficiency of molding parts and articles of various shapes and designs. For example, food or beverage articles are often manufactured by molding plastic parts that form an assembly or molding a preform to produce the device or article, e.g., preform for blow molding.
[0003] For high pressure applications, e.g., carbonated drink appliance bottle application, the molded articles can undergo high pressure (e.g., bottles during a drink carbonation process). High material strength and proper bottle design is required for the bottles operating under high pressure for safety of the operation. PET, a semi crystalline plastic, is commonly used for the application. The crystallization rate of PET is slow enough so that a thick preform can be molded clear. With high draw down ratio during the bottle blowing process, the material is further strengthened by the strain induced crystallinity. Although PET material has good strength for this application, the PET bottles will shrink in a residential dishwashing process due to the low Tg (69°C) of the material under the elevated dishwashing temperature (70-80°C).
[0004] It would be beneficial to be able to provide polymer-based resins that can be melt processed and articles made from such compositions that do not have such drawbacks.SUMMARY OF THE INVENTION
[0005] Surprisingly, it had been discovered that articles molded from certain copolyester plastics have a combination of good strength and thermal (e.g., dishwasher) stability. In one aspect, articles requiring both high strength and thermal stability (i.e. , dimensional stability at elevated temperature) can be made from compositions of copolyesters that have a glass transition temperature (Tg) exceeding 95°C, or 100°C, or 105°C.
[0006] There are some amorphous copolyester materials with high Tg (above 95 or 100°C) and excellent dishwashing stability. However, the strength of the amorphous plastics is not comparable to that of crystalline (or semicrystalline) plastics. The wall thickness of the bottles made with amorphous copolyesters needs to be thicker to compensate the low strength if these types of amorphous materials are used for making the same type bottles. It has been discovered that certain blends (e.g., melt blends) of high Tg amorphous copolyesters and semi-crystalline copolyesters (e.g., PCTA) provide a copolyester composition that can be molded into articles having both good strength and dishwashing performance. Reactor grade copolyesters having similar composition to such blends are also provided that have both good strength and dishwashing performance.
[0007] In a first aspect of the invention, it is directed to a transparent article configured to accommodate high pressure applications and also be dishwasher compatible, e.g., carbonated drink appliance bottle applications. In embodiments, the transparent article is formed from a copolyester composition comprising at least one copolyester that comprises:(a) a dicarboxylic acid component comprising: i) 70 to 99.9, or 70 to 99.5 mole % of terephthalic acid residues; andii) 0.1 to 30, or 0.5 to 30 mole % of isophthalic acid residues; and(b) a glycol component comprising: i) 5 to 30, or 5 to 15 mole % of cyclic diol resides having a bicyclic structure with each individual ring in the bicyclic structure having 3 to 5 members; ii) 45 to 90 mole % of 1 ,4-cyclohexanedimethanol residues; and iii) 1 to 25, or 5 to 25 mole% of ethylene glycol residues, wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %; and wherein the inherent viscosity is 0.60 to 1.2 dL / g as determined in 60 / 40 (wt / wt) phenol / tetrachloroethane at a concentration of 0.5 g / 100 ml at 25°C; and wherein the polyester has a Tg of 95°C to 120°C, or 100°C to 115°C. In embodiments, the cyclic diol is isosorbide and the glycol component comprises 5 to 30, or 5 to 15 mole % isosorbide residues. In embodiments, the polyester has a transmittance greater than 60%, or at least 70, or 80, or 90%, measured according to ASTM D1003 using a 3.2 mm plaque after injection molding at a barrel set point of 249°C and a mold temperature of 80°C.
[0008] In embodiments, the copolyester composition has a Tg in the range from 100°C to 115°C. In embodiments, the copolyester composition has an inherent viscosity is 0.70 to 1.0 dL / g, or 0.75 to 0.95 dL / g. In embodiments, the copolyester composition has an inherent viscosity in a range from 0.85 to 1.0 dL / g, or 0.85 to 0.95 dL / g. In embodiments, the copolyester composition has an inherent viscosity in a range from 0.78 to 1 .0, or 0.78 to 095 dL / g.
[0009] In embodiments, the glycol component comprises: i) 5 to 30 mole% of isosorbide residues; and ii) 45 to 90 mole% of 1 ,4-cyclohexanedimethanol (CHDM) residues; and iii) 1 to 25, or 5 to 25 mole% of ethylene glycol residues.
[0010] In embodiments, the dicarboxylic acid component comprises: i) 95 to 99 mole% of terephthalic acid residues; and ii) 1 to 5 mole% of isophthalic acid residues.
[0011] In other embodiments, the dicarboxylic acid component comprises: i) 97.5 to 99 mole% of terephthalic acid residues; and ii) 1 to 2 5 mole% of isophthalic acid residues
[0012] In embodiments, the copolyester composition has a crystallization half time from 30 seconds to 10 minutes, or 30 seconds to 5 minutes.
[0013] In embodiments, the article is chosen from food or beverage containers or appliances (or components thereof). In embodiments, the at least one copolyester has a total transmittance of at least 60% and a haze of less than 1 % measured according to ASTM D1003 using a 3.2 mm plaque.
[0014] In a second aspect of the invention, it is directed to a carbonated drink appliance bottle. In embodiments, the bottle comprises a copolyester composition, wherein the copolyester composition has a Tg of at least 95°C, or at least 100°C, or at least 105°C, and good thermal resistance (e.g., good dimensional stability at elevated temperature, or at elevated temperature and humidity, such as good dishwasher compatibility).
[0015] In certain embodiments, the copolyester composition also has an HDT at 0.455 MPa of at least 85°C and at least one of the following properties chosen from: tensile modulus of greater than 1400 Pa as measured according to ASTM D638 using a 3.2 mm thick bar that has been subjected to 50% relative humidity for 40 hours at 23°C; a notched izod impact strength of greater than 600, or 700, or 800, or 900, or 1000 J / m as measured according to ASTM D256 at 23C using a 3.2 mm thick bar that has been subjected to 50% relative humidity for 40 hours at 23°C; a tensile stress at yield of at least 40 MPa, measured according to ASTM D638; a transmission of at least 70 measured according to ASTM D1003 using a 3.2 mm plaque after injection molding at a barrel set point of 249°C and a mold temperature of 80°C; or an L* color of atleast 850, measured according to ASTM E1348 using a 3.2 mm plaque after injection molding with a barrel temperature of 249°C and a mold temperature of 80°C. In embodiments, the copolyester composition has at least 2, or at least 3 of the listed properties. In embodiments, the chemical composition is intended for body contact or is a chemical composition used on high touch articles.
[0016] In embodiments of the invention, the shaped articles or components thereof can be chosen from blow molded articles, injection blow molded articles, injection stretch blow molded articles, extrusion blow molded articles, sheet or film extrusion articles.
[0017] In embodiments of the invention, the shaped article is chosen from transparent articles, see-through articles, and thin-walled articles. In certain embodiments, the shaped article is a transparent or see-through article configured formed by injection stretch blow molding.
[0018] In one embodiment of the injection molded article, the copolyester composition further comprises at least one property chosen from: tensile modulus of greater than 1400 MPa as measured according to ASTM D638 using a 3.2 mm thick bar that has been subjected to 50% relative humidity for 40 hours at 23°C; a notched izod impact strength of greater than 1000, or 1200, or 1400 J / m as measured according to ASTM D256 at 23C using a 3.2 mm thick bar that has been subjected to 50% relative humidity for 40 hours at 23°C; a tensile stress at yield of at least 40 MPa, measured according to ASTM D638; a transmission of at least 70 measured according to ASTM D1003 using a 3.2 mm plaque after injection molding at a barrel set point of 249°C and a mold temperature of 80°C; a AE value of less than 25, using a 3.2 mm plaque after injection molding with a barrel temperature of 249°C and a mold temperature of 80°C; or an L* color of at least 85, measured according to ASTM E1348 using a 3.2 mm plaque after injection molding with a barrel temperature of 249°C and a mold temperature of 80°C. In embodiments, the polymer-based resin comprises at least 2, or at least 3 of the listed properties.
[0019] In embodiments in accordance with the various aspects of the invention disclosed herein, the copolyester composition comprises at least one copolyester which comprises:(a) a dicarboxylic acid component comprising: i) 70 to 99 mole% of terephthalic acid residues; and ii) 1 to 30 mole% of isophthalic acid residues; and(b) a glycol component comprising: i) 5 to 30, or 5 to 15, mole % of cyclic diol resides having a bicyclic structure with each individual ring in the bicyclic structure having 3 to 5 members; and ii) 55 to 95 mole % of 1 ,4-cyclohexanedimethanol residues, wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %; and wherein the inherent viscosity is 0.55 to 1.2 dL / g as determined in 60 / 40 (wt / wt) phenol / tetrachloroethane at a concentration of 0.5 g / 100 ml at 25°C; and wherein the polyester has a Tg of 95°C to 115°C.
[0020] In certain embodiments, the copolyester composition comprises a copolyester which comprises a glycol component chosen from: (1) 5 to 20 mole % of the cyclic diol residues and 55 to 95 mole % of the 1 ,4- cyclohexanedimethanol residues; or (2) 5 to 10 mole % of the cyclic diol residues and 55 to 95 mole % of the 1 ,4-cyclohexanedimethanol residues.
[0021] In embodiments, the cyclic diol can be an alicyclic diol. In one embodiment, the alicyclic diol is isosorbide.
[0022] In embodiments, the dicarboxylic acid component comprises residues as follows: greater than 95 to 99.5 mole% TPA and 0.5 to less than 5 mole% I PA; 96 to 99.5 mole% TPA and 0.5 to 4 mole% I PA; 96.5 to 99.5 mole% TPA and 0.5 to 3.5 mole% IPA; 97 to 99.5 mole% TPA and 0.5 to 3 mole% I PA; 98 to 99.5 mole% TPA and 0.5 to 2 mole% IPA; 98.5 to 99.5 mole% TPA and 0.5 to 1.5 mole% IPA; greater than 95 to 99 mole% TPA and 1 to less than 5mole% I PA; 96 to 99 mole% TPA and 1 to 4 mole% I PA; 96.5 to 99 mole% TPA and 1 to 3.5 mole% IPA; 97 to 99 mole% TPA and 1 to 3 mole% IPA; 98 to 99 mole% TPA and 1 to 2 mole% I PA; 95 to 98.5 mole% TPA and 1 .5 to 5 mole%IPA; greater than 95 to 98.5 mole% TPA and 1 .5 to less than 5 mole% IPA; 96 to 98.5 mole% TPA and 1 .5 to 4 mole% IPA; 96.5 to 98.5 mole% TPA and 1 .5 to 3.5 mole% IPA; 97 to 98.5 mole% TPA and 1 .5 to 3 mole% IPA; 97.5 to 98.5 mole% TPA and 1.5 to 2.5 mole% IPA; 95 to 98 mole% TPA and 2 to 5 mole%I PA; greater than 95 to 98 mole% TPA and 2 to less than 5 mole% I PA; 96 to 98 mole% TPA and 2 to 4 mole% IPA; 96.5 to 98 mole% TPA and 2 to 3.5 mole% IPA; or 97 to 98 mole% TPA and 2 to 3 mole% IPA.
[0023] In embodiments, the glycol component comprises: i) 5 to 30 mole% of isosorbide residues; and ii) 45 to 90 mole% of 1 ,4-cyclohexanedimethanol (CHDM) residues; and iii) 1 to 25, or 5 to 25 mole% of EG residues.
[0024] In embodiments, the glycol component comprises residues as follows: 5 to 24 mole% isosorbide, 1 to 20 mole% EG and 75 to 90 mole% CHDM; 5 to 23 mole% isosorbide, 1 to 19 mole% EG and 76 to 90 mole% CHDM; 5 to 22 mole% isosorbide, 1 to 18 mole% EG and 77 to 90 mole% CHDM; 5 to 21 mole% isosorbide, 1 to 17 mole% EG and 78 to 90 mole% CHDM; 5 to 20 mole% isosorbide, 1 to 16 mole% EG and 79 to 90 mole% CHDM; 5 to 19 mole% isosorbide, 1 to 15 mole% EG and 80 to 90 mole% CHDM; 5 to 18 mole% isosorbide, 1 to 14 mole% EG and 81 to 90 mole% CHDM; 5 to 17 mole% isosorbide, 1 to 13 mole% EG and 82 to 90 mole% CHDM; 5 to 16 mole% isosorbide, 1 to 12 mole% EG and 83 to 90 mole% CHDM; 5 to 15 mole% isosorbide, 1 to 11 mole% EG and 84 to 90 mole% CHDM; 5 to 14 mole% isosorbide, 1 to 10 mole% EG and 85 to 90 mole% CHDM.
[0025] In embodiments, the copolyester composition comprises at least one copolyester which comprises:(a) a dicarboxylic acid component comprising: i) greater than 90 and up to 99 mole%, or 95 to 99 mole%, of terephthalic acid residues; and ii) 1 to less than 10 mole%, or 1 to 5 mole%, of isophthalic acid residues;(b) a glycol component comprising: i) 5 to 30 mole% of isosorbide residues; and ii) 45 to 90 mole% of 1 ,4-cyclohexanedimethanol (CHDM) residues; and iii) 1 to 25, or 5 to 25 mole% of EG residues, wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %; and wherein the inherent viscosity is 0.70 to 1 .0 d L / g, or 0.8078 to 0.95 dL / g as determined in 60 / 40 (wt / wt) phenol / tetrachloroethane at a concentration of 0.5 g / 100 ml at 25°C; and wherein the polyester has a Tg of 100°C to 115°C. In embodiments, the at least one copolyester is a melt blended copolyester having an IV of 0.75 to 0.95 dL / g, or 0.78 to 0.90 dL / g. In embodiments, the melt blended copolyester is solid stated to increase the IV. In embodiments, the solid stated copolyester has an IV from 0.80 to 1.0 dL / g, or 0.85 to 1.0 dL / g, or 0.87 to 0.97 dL / g, or 0.90 to 0.95 dL / g. In one embodiment, the dicarboxylic acid component is 100 mole% terephthalic acid residues.In embodiments, the copolyester composition is semi crystalline.
[0026] In embodiments, the at least one copolyester is a reactor grade polyester prepared by a process that includes a transesterification reaction of reaction mixture that includes all the monomers for the intended (monomeric) residues to be included in the copolyester. For example, a copolyester intended to include residues of TPA, IPA, CHDM, EG and isosorbide is prepared by a transesterification reaction that includes each of these monomers. In an embodiment, the reactor grade polyester is amorphous.
[0027] In embodiments, the at least one copolyester is a melt blend polyester prepared by a process that includes melt blending at least two different starting polyesters to provide a final copolyester that includes the monomeric residues contained in starting polyesters. For example, a PCTA copolyester containing residues of TPA, I PA and CHDM is melt blended with an isosorbide copolyester containing residues of TPA, CHDM, EG and isosorbide to provide a final copolyester having residues of TPA, I PA, CHDM, EG and isosorbide. In embodiments, the melt blended copolyester has residues in (net) amounts according to any of the embodiments for the copolyester (as described herein).
[0028] In embodiments, the melt blended copolyester is subjected to solid stating to increase the inherent viscosity (IV) of the copolyester. In embodiments, the solid stated copolyester has an IV according to any of the embodiments for the copolyester (as described herein).
[0029] In a third aspect, a method for improving strength of a high Tg and high impact resistant polyester (Polyester A) is provided, the method comprising:(1 ) providing Polyester A that comprises:(a) a dicarboxylic acid component comprising: i) 70 to 100 mole % of terephthalic acid residues;(b) a glycol component comprising: i) 15 to 30 mole % of cyclic diol resides having a bicyclic structure with each individual ring in the bicyclic structure having 3 to 5 members; ii) 45 to 75 mole % of 1 ,4-cyclohexanedimethanol residues; and iii) 5 to 30 mole% of ethylene glycol residues,wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %; and wherein the inherent viscosity is 0.55 to 1.2 dL / g as determined in 60 / 40 (wt / wt) phenol / tetrachloroethane at a concentration of 0.5 g / 100 ml at 25°C; and wherein the polyester has a Tg of at least 95°C and a notched Izod impact strength of 500 to 1000 J / m as measured according to ASTM D256 at 23C using a 3.2 mm thick bar that has been subjected to 50% relative humidity for 40 hours at 23°C;(2) combining Polyester A with Polyester B, wherein Polyester B is included in an amount sufficient to improve the impact strength of the combination of Polyesters A and B compared to that of Polyester A, wherein Polyester B comprises:(a) a dicarboxylic acid component comprising: i) 50 to 99, or 90 to 99 mole % of terephthalic acid residues; and ii) 1 to 50, or 1 to 10 mole% of isophthalic acid residues; and(b) a glycol component comprising: i) 95 to 100 mole % of 1 ,4-cyclohexanedimethanol residues, wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %;(3) blending Polyester A and Polyester B to provide a blended polyester composition.
[0030] In embodiments of the third aspect, the blended polyester composition comprises:(a) a dicarboxylic acid component comprising: i) 70 to 99.6, or 90 to 99.6 net mole % of terephthalic acid residues; ii) 0.4 to 30, or 0.4 to 10 net mole% of isophthalic acid residues;(b) a glycol component comprising:i) 5 to 30, or 5 to 15 net mole % of cyclic diol resides having a bicyclic structure with each individual ring in the bicyclic structure having 3 to 5 members; ii) 45 to 90 net mole % of 1 ,4-cyclohexanedimethanol residues; and iii) 1 to 25, or 5 to 25 net mole% of ethylene glycol residues, wherein the total net mole % of the dicarboxylic acid component is 100 mole %, and the total net mole % of the glycol component is 100 mole %; and wherein the inherent viscosity is 0.60 to 1.2 dL / g as determined in 60 / 40 (wt / wt) phenol / tetrachloroethane at a concentration of 0.5 g / 100 ml at 25°C; and wherein the polyester has a Tg of 95°C to 115°C.
[0031] In embodiments of the third aspect, Polyester A comprises:(a) a dicarboxylic acid component comprising: i) 100 mole % of terephthalic acid residues;(b) a glycol component comprising: i) 10 to 35 mole %, or 15 to 35 mole %, or 15 to 25 mole %, of isosorbide resides; ii) 40 to 80 mole %, or 50 to 75 mole %, 60 to 75 mole%, of 1 ,4-cyclohexanedimethanol residues; and iii) 5 to 30 mole %, or 7 to 25 mole %, or 8 to 16 mole%, of ethylene glycol residues.
[0032] In embodiments of the third aspect, Polyester B comprises:(a) a dicarboxylic acid component comprising: i) 70 to 95 mole % of terephthalic acid residues; and ii) 5 to 30 mole% of isophthalic acid residues; and(b) a glycol component comprising:i) 100 mole % of 1 ,4-cyclohexanedimethanol residues.
[0033] In embodiments of the third aspect, Polyester B is included in an amount to provide a weight ratio of Polyester A:B in a range from 90: 10 to 50:50, or 90:10 to 60:40, or 90:10 to 65:35, or 85: 15 to 50:50, or 85:15 to 60:40, or 85: 15 to 65:35, or 80:20 to 50:50, or 80:20 to 60:40, or 80:20 to 65:35, or 80:20 to 70:30.
[0034] In embodiments of the third aspect, blending step (3) comprise melt blending Polyester A and Polyester B. In embodiments, the blended polyester composition has a higher notched Izod impact compared to Polyester A (as tested according to the examples). In embodiments, the blended polyester composition has a notched Izod impact that is at least 10% higher compared to Polyester A (as tested according to the examples).
[0035] In embodiments, the shaped article is a transparent or see- through article made from the polyester composition.DETAILED DESCRIPTION
[0036] In one aspect of the invention, it is directed to a shaped article configured to accommodate high pressure applications and also have good thermal stability (i.e., maintains dimensional stability at elevated temperature in use), the article comprising a copolyester composition, wherein the copolyester composition has a Tg of at least 95°C, or at least 100°C, or at least 105°C, comprises a copolyester (as described herein), and good strength, e.g., suitable for carbonated drink appliance bottle applications.
[0037] In certain embodiments, the copolyester composition also has at least one of the following properties chosen from: tensile modulus of greater than 1400 MPa as measured according to ASTM D638 using a 3.2 mm thick bar that has been subjected to 50% relative humidity for 40 hours at 23°C; a notched izod impact strength of greater than 1000, or 1100, or 1200, or 1300, or 1400 J / m as measured according to ASTM D256 at 23C using a 3.2 mm thick bar that has been subjected to 50% relative humidity for 40 hours at 23°C;a tensile stress at yield of at least 40 MPa, measured according to ASTM D638; a transmission of at least 88 measured according to ASTM D1003 using a 3.2 mm plaque after injection molding at a barrel set point of 249°C and a mold temperature of 80°C; a AE value of less than 25, using a 3.2 mm plaque after injection molding with a barrel temperature of 249°C and a mold temperature of 80°C; or an L* color of at least 85, measured according to ASTM E1348 using a 3.2 mm plaque after injection molding with a barrel temperature of 249°C and a mold temperature of 80°C. In embodiments, the polymer-based resin has at least 2, or at least 3 of the listed properties.
[0038] The term “polyester,” as used herein, is intended to include “copolyesters” and is understood to mean a synthetic polymer prepared by the reaction of one or more difunctional carboxylic acids and / or multifunctional carboxylic acids with one or more difunctional hydroxyl compounds and / or multifunctional hydroxyl compounds. Typically, the difunctional carboxylic acid can be a dicarboxylic acid and the difunctional hydroxyl compound can be a dihydric alcohol such as, for example, glycols and diols. The term "glycol" as used in this application includes, but is not limited to, diols, glycols, and / or multifunctional hydroxyl compounds, for example, branching agents. Alternatively, the difunctional carboxylic acid may be a hydroxy carboxylic acid such as, for example, p-hydroxybenzoic acid, and the difunctional hydroxyl compound may be an aromatic nucleus bearing 2 hydroxyl substituents such as, for example, hydroquinone. The term “residue,” as used herein, means any organic structure incorporated into a polymer through a polycondensation and / or an esterification reaction from the corresponding monomer. The term “repeating unit,” as used herein, means an organic structure having a dicarboxylic acid residue and a diol residue bonded through a carbonyloxy group. Thus, for example, the dicarboxylic acid residues may be derived from a dicarboxylic acid monomer or its associated acid halides, esters, salts, anhydrides, or mixtures thereof. As used herein, therefore, the term dicarboxylic acid is intended to include dicarboxylic acids and any derivative of adicarboxylic acid, including its associated acid halides, esters, half-esters, salts, half-salts, anhydrides, mixed anhydrides, or mixtures thereof, useful in a reaction process with a diol to make polyester. Furthermore, as used in this application, the term "diacid" includes multifunctional acids, for example, branching agents. As used herein, the term "terephthalic acid" is intended to include terephthalic acid itself and residues thereof as well as any derivative of terephthalic acid, including its associated acid halides, esters, half-esters, salts, half-salts, anhydrides, mixed anhydrides, or mixtures thereof or residues thereof useful in a reaction process with a diol to make polyester.
[0039] In one embodiment, terephthalic acid may be used as the starting material. In another embodiment, dimethyl terephthalate may be used as the starting material. In yet another embodiment, mixtures of terephthalic acid and dimethyl terephthalate may be used as the starting material and / or as an intermediate material. In embodiments, at least a portion of the terephthalic acid or dimethyl terephthalate used as a starting material has recycle content derived directly or indirectly from recycle waste. In embodiments, the recycle content can be obtained from waste plastic that contains terephthalic acid residues, e.g., recovered monomers obtained through a solvolysis (e.g., methanolysis) process. In embodiments, the terephthalic acid residues present in the polyester (according to any of the embodiments herein) contains at least 50 mole%, or at least 75 mole%, or 100 mole% recycle content. In embodiments, the dicarboxylic acid component of the polyester comprises monomer residues having at least 50 mole% recycle content, or at least 75 mole% recycle content, or 100 mole% recycle content.
[0040] In embodiments, the polyester includes a diol component that comprises CHDM and / or isosorbide and / or EG residues. In embodiments, at least a portion of the CHDM and / or isosorbide and / or EG used as a starting material has recycle content derived directly or indirectly from recycle waste. In embodiments, the recycle content can be obtained from waste plastic that contains CHDM and / or isosorbide and / or EG residues, e.g., recoveredmonomers obtained through a solvolysis (e.g., methanolysis) process. In embodiments, the CHDM and / or isosorbide and / or EG residues present in the Polyester (according to any of the embodiments herein) contains at least 50 mole%, or at least 75 mole%, or 100 mole% recycle content. In embodiments, the glycol component of the Polyester comprises monomer residues having at least 50 mole% recycle content, or at least 75 mole% recycle content, or 100 mole% recycle content.
[0041] The polyester (as described herein) can have (or include) a recycle content that is provided by chemical recycling where waste material is broken down into small molecules that are then used to make the polyester, e.g., a waste stream (e.g., containing waste plastic) is gasified to produce syngas and the syngas is then utilized in one or more reaction schemes to produce the polyester.
[0042] A recycle content polyester can also be provided that has (or includes) recycle content using a mass balance approach. In a mass balance approach, a recycle content value is determined and then applied or associated with the polyester. A “recycle content value” is a unit of measure representative of a quantity of material having its origin in recycled waste, e.g., recycled plastic. The particular recycle content value can be determined by a mass balance approach or a mass ratio or percentage or any other unit of measure and can be determined according to any system fortracking, allocating, and / or crediting recycle content among various compositions. A recycle content value can be deducted from a recycle content inventory and applied to a product or composition (e.g., the polyester) to attribute recycle content to the product or composition (e.g., the polyester). A recycle content value can come from waste material (e.g., mixed waste plastic) and can be applied to the polyester based on a mass balance approach that takes into account the stoichiometry and efficiencies of the processes used to make the polyester.
[0043] The recycled content in the polyester can be at least partially derived from recycled polyester of the same type, providing a circular recyclingsolution. The circular recycling solution can include determining recycle content value (or credits) for waste polyester of the same type and applying at least a portion of such recycle value or credit to the new polyester (e.g., by a mass balance approach), or can be a closed loop process for providing a recycle polyester where at least a portion of the feedstock utilized in the process / reaction scheme to make the polyester is obtained from the same polyester type. In one aspect, the closed loop process is based on chemical recycling and not mechanical recycling.
[0044] In certain aspects, the closed loop can include end of life carbonated drink appliance bottle articles being used as feedstock to provide recycle content to renewed carbonated drink appliance bottle articles containing recycle content polyester compositions (as described herein). A closed loop process is differentiated from an open loop process in that the renewed articles made in an open loop process are different from the end-of-life articles recycled as a feedstock material. The match between recycled articles and renewed material made in a closed loop system does not have to be compositionally identical, e.g., the recycled articles can have a different polymer formulation but have a similar based polyester with the same types of monomer residues. The process to provide recycle content can be operated as a closed loop process and an open loop process simultaneously.
[0045] In various aspects, the polyester composition used to make the articles (as described herein) contains at least 10, or at least 15, or at least 20, or at least 25, or at least 30, or at least 40, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or 100 wt% recycle content, by any of the methods (or combinations of methods) for providing recycle content described herein. In certain embodiments, the polyester composition can include content sourced from renewable sources, such as bio-based materials. In one embodiment, the bio-based material is isosorbide. In embodiments, the polyester contains both recycle content and bio-based (or other renewablesource) content. In one embodiment, the polyester has at least 5, or at least 10, or at least 15, or at least 20 wt% renewable source content, and optionally also recycle content as described above.
[0046] The polyesters used in the present invention typically can be prepared from dicarboxylic acids and diols which react in substantially equal proportions and are incorporated into the polyester polymer as their corresponding residues. The polyesters of the present invention, therefore, can contain substantially equal molar proportions of acid residues (100 mole%) and diol (and / or multifunctional hydroxyl compounds) residues (100 mole%) such that the total moles of repeating units is equal to 100 mole%. The mole percentages provided in the present disclosure, therefore, may be based on the total moles of acid residues, the total moles of diol residues, or the total moles of repeating units. For example, a polyester containing 4 mole% isophthalic acid, based on the total acid residues, means the polyester contains 4 mole% isophthalic acid residues out of a total of 100 mole% acid residues. Thus, there are 4 moles of isophthalic acid residues among every 100 moles of acid residues. In another example, a polyester containing 15 mole% isosorbide, based on the total diol residues, means the polyester contains 15 mole% isosorbide residues out of a total of 100 mole% diol residues. Thus, there are 15 moles of isosorbide residues among every 100 moles of diol residues.
[0047] In other aspects of the invention, the Tg of the polyesters useful in the invention can be at least one of the following ranges: 95 to 115°C; 95 to 110°C; 95 to 105°C; 95 to 100°C; 100 to 115°C; 100 to 1 10°C; 100 to 105°C; 105 to 115°C; 105 to 110°C; and 110 to 115°C.
[0048] In embodiments, the copolyester composition comprises at least one copolyester which comprises:(a) a dicarboxylic acid component comprising: i) 70 to 99.9, or 70 to 99 mole % of terephthalic acid residues; andii) 0.1 to 30, or 1 to 30 mole% of isophthalic acid residues; and(b) a glycol component comprising: i) 5 to 30, or 5 to 15 mole % of cyclic diol resides having a bicyclic structure with each individual ring in the bicyclic structure having 3 to 5 members; ii) 45 to 90 mole % of 1 ,4-cyclohexanedimethanol residues; and iii) 1 to 25, or 5 to 25 mole% of ethylene glycol residues, wherein the total mole % of the dicarboxylic acid component is 100 mole%, and the total mole % of the glycol component is 100 mole %; and wherein the inherent viscosity is 0.55 to 1.2 dL / g as determined in 60 / 40 (wt / wt) phenol / tetrachloroethane at a concentration of 0.5 g / 100 ml at 25°C; and wherein the polyester has a Tg of 95°C to 115°C.
[0049] In embodiments, the copolyester composition comprises a copolyester which comprises a glycol component chosen from: (1 ) 5 to 20 mole % of the cyclic diol residues and 55 to 95 mole % of the 1 ,4- cyclohexanedimethanol residues; or (2) 5 to 15 mole % of the cyclic diol residues and 55 to 95 mole % of the 1 ,4-cyclohexanedimethanol residues; or (3) 5 to 10 mole % of the cyclic diol residues and 55 to 95 mole % of the 1 ,4- cyclohexanedimethanol residues.
[0050] In embodiments, the copolyester composition comprises a copolyester which comprises a glycol component chosen from: (1 ) 5 to 22 mole % of the cyclic diol residues and 55 to 90 mole % of the 1 ,4- cyclohexanedimethanol residues; or (2) 5 to 22 mole % of the cyclic diol residues and 55 to 85 mole % of the 1 ,4-cyclohexanedimethanol residues; or (3) greater than 5 to 22 mole % of the cyclic diol residues and 55 to less than 85 mole % of the 1 ,4-cyclohexanedimethanol residues. In embodiments, the cyclic diol can be an aliphatic cyclic diol or an aromatic cyclic diol. Inembodiments, the cyclic diol can be an alicyclic diol. In one embodiment, the alicyclic diol is isosorbide.
[0051] In embodiments, the glycol component for the polyesters useful in the invention include but are not limited to at least one of the following combinations of ranges: 9 to 16 mole % isosorbide and 70 to 91 mole % 1 ,4- cyclohexanedimethanol; 9 to 15 mole % isosorbide and 71 to 91 mole % 1 ,4- cyclohexanedimethanol; 9 to 14 mole % isosorbide and 72 to 91 mole % 1 ,4- cyclohexanedimethanol; 9 to 13 mole % isosorbide and 73 to 91 mole % 1 ,4- cyclohexanedimethanol; 9 to 12 mole % isosorbide and 74 to 91 mole % 1 ,4- cyclohexanedimethanol; 9 to 11 mole % isosorbide and 75 to 91 mole % 1 ,4- cyclohexanedimethanol; 10 to 16 mole % isosorbide and 70 to 90 mole % 1 ,4- cyclohexanedimethanol; 10 to 15 mole % isosorbide and 71 to 90 mole % 1 ,4- cyclohexanedimethanol; 10 to 14 mole % isosorbide and 72 to 90 mole % 1 ,4- cyclohexanedimethanol; 10 to 13 mole % isosorbide and 73 to 90 mole % 1 ,4- cyclohexanedimethanol; 10 to 12 mole % isosorbide and 74 to 90 mole % 1 ,4- cyclohexanedimethanol; 11 to 16 mole % isosorbide and 70 to 89 mole % 1 ,4- cyclohexanedimethanol; 11 to 15 mole % isosorbide and 71 to 89 mole % 1 ,4- cyclohexanedimethanol; 11 to 14 mole % isosorbide and 72 to 89 mole % 1 ,4- cyclohexanedimethanol; 11 to 13 mole % isosorbide and 73 to 89 mole % 1 ,4- cyclohexanedimethanol; 12 to 16 mole % isosorbide and 70 to 88 mole % 1 ,4- cyclohexanedimethanol; 12 to 15 mole % isosorbide and 71 to 88 mole % 1 ,4- cyclohexanedimethanol; 12 to 14 mole % isosorbide and 72 to 88 mole % 1 ,4- cyclohexanedimethanol; 13 to 16 mole % isosorbide and 70 to 87 mole % 1 ,4- cyclohexanedimethanol; 13 to 15 mole % isosorbide and 71 to 87 mole % 1 ,4- cyclohexanedimethanol; 14 to 16 mole % isosorbide and 70 to 86 mole % 1 ,4- cyclohexanedimethanol.
[0052] For certain embodiments of the invention, the polyesters useful in the invention may exhibit at least one of the following inherent viscosities as determined in 60 / 40 (wt / wt) phenol / tetrachloroethane at a concentration of 0.5 g / 100 ml at 25°C: 0.60 to 1.2 dL / g; 0.60 to 1.1 dL / g; 0.60 to 1 dL / g; 0.60 to lessthan 1 dL / g; 0.60 to 0.98 d L / g; 0.60 to 0.95 dL / g; 0.60 to 0.90 dL / g; 0.60 to 0.85 dL / g; 0.60 to 0.80 dL / g; 0.60 to 0.75 dL / g; 0.60 to less than 0.75 dL / g; 0.60 to 0.72 dL / g; 0.60 to 0.70 dL / g; 0.60 to less than 0.70 dL / g; 0.60 to 0.68 dL / g; 0.60 to less than 0.68 dL / g; 0.60 to 0.65 dL / g; 0.65 to 1.2 dL / g; 0.65 to 1.1 dL / g; 0.65 to 1 dL / g; 0.65 to less than 1 dL / g; 0.65 to 0.98 dL / g; 0.65 to 0.95 dL / g; 0.65 to 0.90 dL / g; 0.65 to 0.85 dL / g; 0.65 to 0.80 dL / g; 0.65 to 0.75 dL / g; 0.65 to less than 0.75 dL / g; 0.65 to 0.72 dL / g; 0.65 to 0.70 dL / g; or 0.65 to less than 0.70 dL / g; 0.70 to 1.2 dL / g; 0.70 to 1.1 dL / g; 0.70 to 1 dL / g; 0.70 to less than 1 dL / g; 0.70 to 0.98 dL / g; 0.70 to 0.95 dL / g; 0.70 to 0.90 dL / g; 0.70 to 0.85 dL / g; 0.70 to 0.80 dL / g; 0.70 to 0.75 dL / g; 0.70 to less than 0.75 dL / g; 0.75 to 1.2 dL / g; 0.75 to 1 .1 dL / g; 0.75 to 1 dL / g; 0.75 to less than 1 dL / g; 0.75 to 0.98 dL / g; 0.75 to 0.95 dL / g; 0.75 to 0.90 dL / g; 0.75 to 0.85 dL / g; 0.75 to 0.80 dL / g; 0.75 to less than 0.80 dL / g; 0.80 to 1.2 dL / g; 0.80 to 1.1 dL / g; 0.80 to 1 dL / g; 0.80 to less than 1 dL / g; 0.80 to 0.98 dL / g; 0.80 to 0.95 dL / g; 0.80 to 0.90 dL / g; 0.80 to 0.85 dL / g; 0.80 to less than 0.85 dL / g; 0.85 to 1.2 dL / g; 0.85 to 1.1 dL / g; 0.85 to 1 dL / g; 0.85 to less than 1 dL / g; 0.85 to 0.98 dL / g; 0.85 to 0.95 dL / g; 0.85 to 0.90 dL / g; 0.85 to less than 0.90 dL / g; 0.90 to 1.2 dL / g; 0.90 to 1.1 dL / g; 0.90 to 1 dL / g; 0.90 to less than 1 dL / g; 0.90 to 0.98 dL / g; 0.90 to 0.95 dL / g; or 0.90 to less than 0.95 dL / g. It is contemplated that the polyester compositions of the invention can possess at least one of the inherent viscosity ranges described herein and at least one of the monomer ranges for the compositions described herein unless otherwise stated. It is also contemplated that the polyester compositions of the invention can possess at least one of the Tg ranges described herein and at least one of the monomer ranges for the compositions described herein unless otherwise stated. It is also contemplated that the polyester compositions of the invention can possess at least one of the Tg ranges described herein, at least one of the inherent viscosity ranges described herein, and at least one of the monomer ranges for the compositions described herein unless otherwise stated.
[0053] In certain embodiments, terephthalic acid, or an ester thereof, such as, for example, dimethyl terephthalate, or a mixture of terephthalic acid and an ester thereof, makes up most or all of the dicarboxylic acid component used to form the polyesters useful in the invention. In certain embodiments, terephthalic acid residues can make up a portion or all of the dicarboxylic acid component used to form the present polyester at a concentration of at least 70 mole %, such as at least 80 mole %, at least 90 mole%, at least 95 mole%, at least 97 mole%. In certain embodiments, polyesters with higher amounts of isophthalic acid can be used in order to produce higher impact strength properties. For purposes of this disclosure, the terms "terephthalic acid" and "dimethyl terephthalate” are used interchangeably herein. In one embodiment, dimethyl terephthalate is the majority of the dicarboxylic acid component used to make the polyesters useful in the present invention. In all embodiments, ranges of from 70 to 99.9 mole %; or 80 to 99.9 mole %; or 90 to 99.9 mole %; or 95 to 99.9 mole % terephthalic acid and / or dimethyl terephthalate and / or mixtures thereof may be used.
[0054] In certain embodiments, in addition to terephthalic and isophthalic acid residues, the dicarboxylic acid component of the polyesters useful in the invention can comprise up to 30 mole %, up to 20 mole %, up to 10 mole %, up to 5 mole %, or less than 5 mole%, or up to 3 mole%, or up to 2 mole%, or up to 1 mole % of one or more modifying aromatic dicarboxylic acids. In embodiments, the amount of one or more modifying aromatic dicarboxylic acids can range from any of these preceding endpoint values including, for example, from 0.01 to 30 mole %, from 0.01 to 20 mole %, from 0.01 to 10 mole %, from 0.01 to 5 mole %, from 0.01 to less than 5 mole %, from 0.01 to 4 mole %, from 0.01 to 3 mole %, from 0.01 to 2 mole %, or from 0.01 to 1 mole % of one or more modifying aromatic dicarboxylic acids. In certain embodiments, the amount of one or more modifying aromatic dicarboxylic acids can range from 1 to 5 mole %, from 1 to less than 5 mole %, from 1 to 4 mole %, from 1 to 3 mole %, from 1 to 2 mole %, or from 1 .5 to 5 mole %, from 1 .5 to less than 5 mole%, from 1.5 to 4 mole %, from 1.5 to 3.5 mole %, from 1.5 to 3 mole %, from 1 .5 to 2.5 mole %, from 1 .5 to 2 mole %, or from 2 to 5 mole %, from 2 to less than 5 mole %, from 2 to 4 mole %, from 2 to 3.5 mole %, from 2 to 3 mole %, from 2 to 2.5 mole %, or from 2.5 to 5 mole %, from 2.5 to less than 5 mole %, from 2.5 to 4 mole %, from 2.5 to 3.5 mole %, from 2.5 to 3 mole %, or from 3 to 5 mole %, from 3 to less than 5 mole %, from 3 to 4 mole %, from 3 to 3.5 mole %, or from 3.5 to 5 mole %, from 3.5 to less than 5 mole %, from 3.5 to 4 mole %, from 4 to 5 mole %, from 4 to less than 5 mole %, of one or more modifying aromatic dicarboxylic acids.
[0055] In one embodiment, modifying aromatic dicarboxylic acids that may be used in the present invention include but are not limited to those having up to 20 carbon atoms, and that can be linear, para-oriented, or symmetrical. Examples of modifying aromatic dicarboxylic acids which may be used in this invention include, but are not limited to, 4,4'-biphenyldicarboxylic acid, 1 ,4-, 1 ,5- , 2,6-, 2,7-naphthalenedicarboxylic acid, and trans-4,4'-stilbenedicarboxylic acid, and esters thereof. One embodiment of the invention is for 100% of the dicarboxylic acid component based on terephthalic and isophthalic acid residues.
[0056] The carboxylic acid component of the polyesters useful in the invention can be further modified with up to 10 mole %, such as up to 5 mole % or up to 1 mole % of one or more aliphatic dicarboxylic acids containing 2-16 carbon atoms, such as, for example, malonic, succinic, glutaric, adipic, pimelic, suberic, azelaic and dodecanedioic dicarboxylic acids. Certain embodiments can also comprise 0.01 or more mole %, such as 0.1 or more mole %, 1 or more mole %, 5 or more mole %, or 10 or more mole % of one or more modifying aliphatic dicarboxylic acids. In one preferred embodiment, the polyester contains 0 mole % modifying aliphatic dicarboxylic acids. Thus, if present, it is contemplated that the amount of one or more modifying aliphatic dicarboxylic acids can range from any of these preceding endpoint values including, forexample, from 0.01 to 10 mole % and from 0.1 to 10 mole %. The total mole % of the dicarboxylic acid component is 100 mole %.
[0057] Esters of terephthalic and / or isophthalic acid and the other modifying dicarboxylic acids or their corresponding esters and / or salts may be used instead of the dicarboxylic acids. Suitable examples of dicarboxylic acid esters include, but are not limited to, the dimethyl, diethyl, dipropyl, diisopropyl, dibutyl, and diphenyl esters. In one embodiment, the esters are chosen from at least one of the following: methyl, ethyl, propyl, isopropyl, and phenyl esters.
[0058] The 1 ,4-cyclohexanedimethanol may be cis, trans, or a mixture thereof, for example, a cis / trans ratio of 60:40 to 40:60. In another embodiment, the trans-1 ,4-cyclohexanedimethanol can be present in the amount of 60 to 80 mole %.
[0059] In embodiments where the cyclic diol is isosorbide, the glycol component of the polyester portion of the polyester compositions useful in the invention can contain 15 mole % or less of one or more modifying glycols which are not isosorbide, EG or 1 ,4-cyclohexanedimethanol; in another embodiment, the polyesters useful in the invention can contain 10 mole % or less of one or more modifying glycols. In another embodiment, the polyesters useful in the invention can contain 5 mole % or less of one or more modifying glycols. In another embodiment, the polyesters useful in the invention can contain 3 mole % or less of one or more modifying glycols. In the preferred embodiment, the polyesters useful in the invention may contain 0 mole % modifying glycols. Certain embodiments can also contain 0.01 or more mole %, such as 0.1 or more mole %, 1 or more mole %, 5 or more mole %, or 10 or more mole % of one or more modifying glycols. Thus, if present, it is contemplated that the amount of one or more modifying glycols can range from any of these preceding endpoint values including, for example, from 0.1 to 10 mole %.
[0060] In embodiments where the cyclic diol is isosorbide, modifying glycols useful in the polyesters useful in the invention refer to diols other than isosorbide, EG and 1 ,4-cyclohexanedimethanol and may contain 2 to 16 carbonatoms. Examples of suitable modifying glycols include, but are not limited to, 2,2,4,4-tetramethyl-1 ,3-cyclobutanediol (TMCD), diethylene glycol, 1 ,2- propanediol, 1 ,3-propanediol, neopentyl glycol, 1 ,4-butanediol, 1 ,5- pentanediol, 1 ,6-hexanediol, p-xylene glycol or mixtures thereof. In one embodiment, the modifying glycol is TMCD. In another embodiment, the modifying glycols include but are not limited to 1 ,3-propanediol and / or 1 ,4- butanediol. In another embodiment, TMCD is excluded as a modifying diol. In another embodiment, 1 ,3-propanediol and 1 ,4-butanediol are excluded as modifying diols. In another embodiment, 2,2-dimethyl-1 ,3-propanediol is excluded as a modifying diol. The polyesters useful the invention can comprise from 0 to 10 mole percent, for example, from 0.01 to 5 mole percent, from 0.01 to 1 mole percent, from 0.05 to 5 mole percent, from 0.05 to 1 mole percent, or from 0.1 to 0.7 mole percent, or 0.1 to 0.5 mole percent, based the total mole percentages of either the diol or diacid residues; respectively, of one or more residues of a branching monomer, also referred to herein as a branching agent, having 3 or more carboxyl substituents, hydroxyl substituents, or a combination thereof. In certain embodiments, the branching monomer or agent may be added prior to and / or during and / or after the polymerization of the polyester. The polyester(s) useful in the invention can thus be linear or branched. In certain embodiments, the branching monomer or agent may be added prior to and / or during and / or after the polymerization.
[0061] Examples of branching monomers include, but are not limited to, multifunctional acids or multifunctional alcohols such as trimellitic acid, trimellitic anhydride, pyromellitic dianhydride, trimethylolpropane, glycerol, pentaerythritol, citric acid, tartaric acid, 3-hydroxyglutaric acid and the like. In one embodiment, the branching monomer residues can comprise 0.1 to 0.7 mole percent of one or more residues chosen from at least one of the following: trimellitic anhydride, pyromellitic dianhydride, glycerol, sorbitol, 1 ,2,6- hexanetriol, pentaerythritol, trimethylolethane, and / or trimesic acid. The branching monomer may be added to the polyester reaction mixture or blendedwith the polyester in the form of a concentrate as described, for example, in U.S. Patent Nos. 5,654,347 and 5,696, 176, whose disclosure regarding branching monomers is incorporated herein by reference.
[0062] The polyesters useful in the invention can be made by processes known from the literature such as, for example, by processes in homogenous solution, by transesterification processes in the melt, and by two phase interfacial processes. Suitable methods include, but are not limited to, the steps of reacting one or more dicarboxylic acids with one or more glycols at a temperature of 100°C to 315°C at a pressure of 0.1 to 760 mm Hg for a time sufficient to form a polyester. See U.S. Patent No. 3,772,405 for methods of producing polyesters, the disclosure regarding such methods is hereby incorporated herein by reference.
[0063] The polyesters useful in this invention can also be prepared by reactive melt blending and extrusion of two polyesters. For example: a polyester containing diacid residues of about 95 mole% terephthalic acid residues and about 5 mole% isophthalic acid residues; and diol residues of about 10 mole% isosorbide residues, about 5 mole% EG and about 85 mole% 1 ,4- cyclohexanedimethanol can be prepared by reactive melt blending and extrusion of equal amounts of a copolyester containing 90 mole% terephthalic residues, 10 mole% isophthalic acid residues and 100% 1 ,4- cyclohexanedimethanol with another copolyester containing 100 mole% terephthalic residues; 70 mole % 1 ,4-cyclohexanedimethanol residues, 10 mole% EG residues and 20 mole% isosorbide residues.
[0064] In embodiments, the at least one copolyester is a melt blend polyester prepared by a process that includes melt blending at least two different starting polyesters to provide a final copolyester that includes the monomeric residues contained in starting polyesters. For example, a PCTA copolyester containing residues of TPA, I PA and CHDM is melt blended with an isosorbide copolyester containing residues of TPA, CHDM, EG and isosorbide to provide a final copolyester having residues of TPA, I PA, CHDM,EG and isosorbide. In embodiments, the melt blended copolyester has residues in (net) amounts according to any of the embodiments for the copolyester (as described herein).
[0065] In embodiments, the polyesters of this invention, prepared in a reactor or by melt blending / extrusion, can subsequently be crystallized if needed and solid stated by techniques known in the art to further increase the IV.
[0066] In another aspect, a method for improving strength of an amorphous high Tg and high impact resistant polyester (Polyester A) is provided, the method comprising:(1 ) providing Polyester A that comprises:(a) a dicarboxylic acid component comprising: i) 1 to 100 mole % of terephthalic acid residues;(b) a glycol component comprising: i) 15 to 30 mole % of cyclic diol resides having a bicyclic structure with each individual ring in the bicyclic structure having 3 to 5 members; and ii) 45 to 75 mole % of 1 ,4-cyclohexanedimethanol residues; and iii) 5 to 30 mole% of ethylene glycol residues, wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %; and wherein the inherent viscosity is 0.55 to 1.2 dL / g as determined in 60 / 40 (wt / wt) phenol / tetrachloroethane at a concentration of 0.5 g / 100 ml at 25°C; and wherein the polyester has a Tg of at least 100°C and a notched Izod impact strength of 500 to 1000 J / m as measured according to ASTM D256 at 23C using a 3.2 mm thick bar that has been subjected to 50% relative humidity for 40 hours at 23°C;(2) combining Polyester A with Polyester B, where Polyester B is included in an amount sufficient to improve the aesthetic chemical resistance to degradation chemicals of the combination compared to that of Polyester A, wherein Polyester B comprises:(a) a dicarboxylic acid component comprising: i) 70 to 99.9, or 90 to 99 mole % of terephthalic acid residues; and ii) 0.1 to 30, or 1 to 10 mole% of isophthalic acid residues; and(b) a glycol component comprising: i) 95 to 100 mole % of 1 ,4-cyclohexanedimethanol residues, wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %;(3) blending Polyester A and Polyester B to provide a combined polyester composition.
[0067] In embodiments, Polyester A comprises:(a) a dicarboxylic acid component comprising: i) 100 mole % of terephthalic acid residues;(b) a glycol component comprising: i) 10 to 35 mole %, or 15 to 35 mole %, or 15 to 25 mole %, of isosorbide resides; ii) 40 to 80 mole %, or 50 to 75 mole %, 60 to 75 mole%, of 1 ,4-cyclohexanedimethanol residues; and iii) 5 to 30 mole %, or 7 to 25 mole %, or 8 to 16 mole%, of ethylene glycol residues.
[0068] In embodiments, Polyester B comprises:(a) a dicarboxylic acid component comprising:i) 90 to 95 mole % of terephthalic acid residues; and ii) 5 to 10 mole% of isophthalic acid residues, and(b) a glycol component comprising: i) 100 mole % of 1 ,4-cyclohexanedimethanol residues.
[0069] In embodiments, Polyester B is included in an amount to provide a weight ratio of Polyester A: B in a range from 90:10 to 50:50, or 90: 10 to 60:40, or 90:10 to 65:35, or 85:15 to 50:50, or 85: 15 to 60:40, or 85:15 to 65:35, or 80:20 to 50:50, or 80:20 to 60:40, or 80:20 to 65:35, or 80:20 to 70:30.
[0070] In embodiments, blending step (3) comprise melt blending Polyester A and Polyester B.
[0071] In embodiments, the article made from copolyester composition can be semi-crystalline, e.g., by crystallizing with heat. In embodiments, the article of the invention has a crystallinity of from 1 to 40%, or 1 to 35%, or 1 to 30%, or 5 to 40%, or 5 to 35%, or 5 to 30%, or 10 to 40%, or 10 to 35%, or 10 to 30%.
[0072] In other embodiments, the article made from the copolyester composition can have strain induced crystallinity. Strain induced crystallization refers to a phenomenon in which an initially amorphous solid material undergoes a phase transformation in which some amorphous domains are converted to crystalline domains due to the application of strain. This phenomenon has important effects in strength and fatigue properties.
[0073] In embodiments, the article of the invention has a strain induced crystallinity of from 1 to 40%, or 1 to 35%, or 1 to 30%, or 5 to 40%, or 5 to 35%, or 5 to 30%, or 10 to 40%, or 10 to 35%, or 10 to 30%, when stretched at a temperature above the Tg of the polyester, e.g., during molding or forming processes, such as stretch blow molding.
[0074] In embodiments, the article is a clear semi-crystalline article comprising a copolyester that has a crystallization half-time of less than 10 minutes but greater than about 30 seconds. In embodiments, the copolyesterhas a crystallization half-time from 30 seconds to 5 minutes, or 30 seconds to 3 minutes, or 30 seconds to 2 minutes, or 30 seconds to 1 .5 minutes.
[0075] In embodiments, the article of the invention can comprise the polyester of the invention having a melting temperature (Tm) from 260°C to 300°C.
[0076] In addition, the polyester useful in this invention may also contain from 0.01 to 25% by weight or 0.01 to 20% by weight or 0.01 to 15% by weight or 0.01 to 10% by weight or 0.01 to 5% by weight of the total weight of the polyester composition of common additives such as colorants, dyes, mold release agents, reheat additives, flame retardants, plasticizers, stabilizers, including but not limited to, UV stabilizers, thermal stabilizers and / or reaction products thereof, fillers, and impact modifiers. Examples of typical commercially available impact modifiers well known in the art and useful in this invention include, but are not limited to, ethylene / propylene terpolymers; functionalized polyolefins, such as those containing methyl acrylate and / or glycidyl methacrylate; styrene-based block copolymeric impact modifiers; and various acrylic core / shell type impact modifiers. For example, UV additives can be incorporated into articles of manufacture through addition to the bulk, through application of a hard coat, or through coextrusion of a cap layer. Residues of such additives are also contemplated as part of the polyester composition.
[0077] The polyesters useful in the invention can comprise at least one chain extender. Suitable chain extenders include, but are not limited to, multifunctional (including, but not limited to, bifunctional) isocyanates, multifunctional epoxides, including for example, epoxylated novolacs, and phenoxy resins. In certain embodiments, chain extenders may be added at the end of the polymerization process or after the polymerization process. If added after the polymerization process, chain extenders can be incorporated by compounding or by addition during conversion processes such as injection molding or extrusion. The amount of chain extender used can vary dependingon the specific monomer composition used and the physical properties desired but is generally about 0.1 percent by weight to about 10 percent by weight, preferably about 0.1 to about 5 percent by weight, based on the total weight of the polyester.
[0078] Thermal stabilizers are compounds that stabilize polyesters during polyester manufacture and / or post polymerization including, but not limited to, phosphorous compounds including but not limited to phosphoric acid, phosphorous acid, phosphonic acid, phosphinic acid, phosphonous acid, and various esters and salts thereof. These can be present in the polyester compositions useful in the invention. The esters can be alkyl, branched alkyl, substituted alkyl, difunctional alkyl, alkyl ethers, aryl, and substituted aryl. In one embodiment, the number of ester groups present in the particular phosphorous compound can vary from zero up to the maximum allowable based on the number of hydroxyl groups present on the thermal stabilizer used. The term "thermal stabilizer" is intended to include the reaction products thereof. The term "reaction product" as used in connection with the thermal stabilizers of the invention refers to any product of a polycondensation or esterification reaction between the thermal stabilizer and any of the monomers used in making the polyester as well as the product of a polycondensation or esterification reaction between the catalyst and any other type of additive.
[0079] Reinforcing materials may be useful in the compositions of this invention. The reinforcing materials may include, but are not limited to, carbon filaments, silicates, mica, clay, talc, titanium dioxide, Wollastonite, glass flakes, glass beads and fibers, and polymeric fibers and combinations thereof. In one embodiment, the reinforcing materials are glass, such as, fibrous glass filaments, mixtures of glass and talc, glass and mica, and glass and polymeric fibers.
[0080] In embodiments, the articles having improved strength and high Tg can include, but are not limited to, blow molded articles, injection blow molded articles, injection stretch blow molded articles, extrusion blow moldedarticles, extrusion stretch blow molded articles, sheet or film extrusion articles. Methods of making the articles of manufacture, include, but are not limited to, extrusion blow molding, extrusion stretch blow molding, injection blow molding, injection stretch blow molding, stretch oriented sheet or film extrusion.
[0081] In embodiments, the articles can include film(s) and / or sheet(s) comprising the polyester compositions that are formed into the articles of the invention. The methods of forming the polyesters into film(s) and / or sheet(s) are well known in the art. Examples of film(s) and / or sheet(s) of the invention including but not limited to extruded film(s) and / or sheet(s),. Methods of making film and / or sheet include but are not limited to extrusion with stretching capability.
[0082] In embodiments of the invention, the copolyester composition has a notched izod impact strength of at least 1000 J / m, or at least 1200 J / m, as measured according to ASTM D256 using a 3.2 mm thick bar hat has been subjected to 50% relative humidity for 48 hours at 23°C. In certain embodiments, the polymer-based resin has a notched izod impact strength of at least 1300 J / m, or at least 1400 J / m, as measured according to ASTM D256 using a 3.2 mm thick bar that has been subjected to 50% relative humidity for 48 hours at 23°C.
[0083] In embodiments of the invention, the polymer-based resin has a AE value of less than 25, or less than 20, or less than 15, or less than 14, or less than 13, or less than 12, or less than 11 , or less than 10, or less than 9, or less than 8, or less than 7, or less than 6, or less than 5, using a 3.2 mm plaque after injection molding with a barrel temperature of 249°C and a mold temperature of 80°C, wherein AE is determined by the following equation: ((L* - 100)2+ (a* - 0)2+ (b* -0)2)1 / 2, where the L*, a*, and b* color components were measured according to ASTM E1348. In certain embodiments, the polymer- based resin has a AE value in the range from 2 to 25, or from 2 to 20, or from 2 to 15, or from 2 to 14, or from 2 to 13, or from 2 to 12, or from 2 to 11 , or from 2 to 10, or from 2 to 9, or from 2 to 8, or from 2 to 7, or from 2 to 6, or from 2 to5, using a 3.2 mm plaque after injection molding with a barrel temperature of 249°C and a mold temperature of 80°C, wherein AE is determined by the following equation: ((L* - 100)2+ (a* - 0)2+ (b* -0)2)1 / 2, where the L*, a*, and b* color components were measured according to ASTM E1348.
[0084] In embodiments of the invention, the polymer-based resin has an L* color of at least 85, or at least 86, or at least 87, or at least 88, or at least 89, or at least 90, or at least 91 , or at least 92, or at least 93, or at least 94, or at least 95, measured according to ASTM E1348 using a 3.2 mm plaque after injection molding with a barrel temperature of 249°C and a mold temperature of 80°C. In certain embodiments, the polymer-based resin has an L* color in the range from 85 to 98, or from 85 to 97, or from 85 to 96, or from 85 to 95, measured according to ASTM E1348 using a 3.2 mm plaque after injection molding with a barrel temperature of 249°C and a mold temperature of 80°C.
[0085] In embodiments of the invention, the polymer-based resin has a b* value is less than 15, or less than 12, or less than 10, or less than 9, or less than 8, or less than 7, or less than 6, or less than 5, or less than 4, measured according to ASTM E1348 using a 3.2 mm plaque after injection molding with a barrel temperature of 249°C and a mold temperature of 80°C. In certain embodiments, the polymer-based resin has a b* color in the range from 0 to 15, or from 0 to 10, or from 0 to 8, or from 0 to 5, measured according to ASTM E1348 using a 3.2 mm plaque after injection molding with a barrel temperature of 249°C and a mold temperature of 80°C.
[0086] In aspects of this invention, it is directed to shaped articles. In certain embodiments, the shaped articles are not continuously extruded films that are infinite (or continuous) in one direction and fixed in width and thickness in the other two directions, as would be the case in a rolled film. In certain embodiments, a film or sheet can be converted into a shaped article, e.g., by thermoforming into a three-dimensional object, such as a cup or bowl. In embodiments of the invention, the shaped article is not a film or is not a sheet. In embodiments of the invention, the shaped articles can be chosen frominjection molded articles, extrusion molded articles, rotational molded articles, compression molded articles, blow molded articles, injection blow molded articles, injection stretch blow molded articles, extrusion blow molded articles, sheet or film extrusion articles, profile extrusion articles, gas assist molding articles, structural foam molded articles, or thermoformed articles.
[0087] In embodiments of the invention, the shaped article is chosen from transparent articles, see-through articles, thin-walled articles, technical articles (e.g., articles having a complex design), containers, household articles, general consumer products, packaging articles, medical articles, high touch articles, or components thereof, where the article is configure to accommodate high pressure applications and also have good dimension stability at elevated temperature.
[0088] The methods of forming the polyester compositions into films, molded articles, and sheeting can be according to methods known in the art. In embodiments, the polyester composition can be over molded onto itself or a different polyester composition and retain an interface bond (or weld line) strength that will not separate (or delaminate) when an article (having such an over mold interface) is used for its intended purpose.
[0089] In one embodiment, the copolyester composition forming the articles, e.g., injection molded article, comprises at least one copolyester that comprises:(a) a dicarboxylic acid component comprising: i) 92 to 99 mole% of terephthalic acid residues; and ii) 1 to 8 mole% of isophthalic acid residues;(b) a glycol component comprising: i) 0.4 to 30, or 9 to 16 mole % isosorbide; and ii) 70 to 99, or 70 to 91 mole % of 1 ,4- cyclohexanedimethanol residues,wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %; and wherein the inherent viscosity is 0.70 to 1 .0 d L / g , or 0.75 to 0.95 d L / g as determined in 60 / 40 (wt / wt) phenol / tetrachloroethane at a concentration of 0.5 g / 100 ml at 25°C; and wherein the polyester has a Tg of 95°C to 115°C. In one embodiment, the dicarboxylic acid is 100 mole% terephthalic acid residues. In one embodiment, the glycol component further comprises 1 to 25, or 1 to 20, or 5 to 20, or 5 to 10, or 5 to 9, or 6 to 10, or 6 to 9 mole% ethylene glycol.
[0090] Properties disclosed herein requiring a test method can be determined as follows:Test Methods
[0091] Properties disclosed throughout this application can be determined according to the test methods described herein. Samples were (or can be) evaluated using standard ASTM test methods with any special conditions noted below.Test Methods
[0092] The inherent viscosity of the polyesters was determined in 60 / 40 (wt / wt) phenol / tetrachloroethane at a concentration of 0.5 g / 100 ml at 25°C (according to ASTM D4603).
[0093] The glycol content was determined by proton nuclear magnetic resonance (NMR) spectroscopy. All NMR spectra were recorded on a JEOLEclipse Plus 600MHz nuclear magnetic resonance spectrometer using either chloroform-trifluoroacetic acid (70-30 volume / volume). Peak assignments for 2,2,4,4-tetramethyl-1 ,3-cyclobutanediol resonances were made by comparison to model mono- and dibenzoate esters of 2,2,4,4-tetramethyl- 1 ,3-cyclobutanediol. These model compounds closely approximate the resonance positions found in the polymers.
[0094] The crystallization half-time, ti / 2, was determined by measuring the light transmission of a sample via a laser and photo detector as a function of time on a temperature controlled hot stage. This measurement was done by exposing the polymers to a temperature, T max, and then cooling it to the desired temperature. The sample was then held at the desired temperature by a hot stage while transmission measurements were made as a function of time. Initially, the sample was visually clear with high light transmission and became opaque as the sample crystallized. The crystallization half-time was recorded as the time at which the light transmission was halfway between the initial transmission and the final transmission. Tmax is defined as the temperature required to melt the crystalline domains of the sample (if crystalline domains are present). The Tmax reported in the examples below represents the temperature at which each sample was heated to condition the sample prior to crystallization half time measurement. The Tmax temperature is dependent on composition and is typically different for each polyester. For example, PCT may need to be heated to some temperature greater than 290°C to melt the crystalline domains.
[0095] Differential scanning calorimetry (DSC) was performed using TA Instruments Model 2920 with a liquid nitrogen cooling accessory. The sample weight, in the range of 8 to 12 mg, was measured and recorded. Samples were first heated (1stheating scan) from 0 to 320 °C at 20 °C / min, followed by cooling to 0 °C at 20 °C / min (cooling scan), and then heated again from 0 to 320 °C at 20 °C min. Various thermal parameters were measured and recorded. Hcc(cal / g) is the heat of crystallization measured from the cooling scan. Tccis thecrystallization peak temperature on the cooling scan. Tgis the glass transition temperature measured from 2ndheating scan. Tm is the melting point measured during the 2ndheating scan. HCM (cal / g) is the heat of crystallization measured during the 1stheating scan. Hmi (cal / g) is the heat of melting measured during the 1stheating scan.
[0096] The percent crystallinity formed during cooling is calculated by equation (1 ), assuming a specific heat of fusion of 29 cal / g (based on unmodified PCT). x c= x10029(1 )The peak temperature in the crystallization exotherm (Tcc) occurs at 227°C for unmodified PCT.
[0097] The percentage of strain induced crystallinity (c) was determined by equation (2) from the first heating scan of films evaluated in a DSC.
[0098] As used herein, the abbreviation "wt" means "weight".
[0099] The following examples further illustrate how the compositions of matter of the invention can be made and evaluated, and are intended to be purely exemplary of the invention and are not intended to limit the scope thereof. Unless indicated otherwise, parts are parts by weight, temperature is in degrees C or is at room temperature, and pressure is at or near atmospheric.EXAMPLESExample A - Blends for Examples 1-2
[0100] Melt blend copolyester compositions were prepared by mixing an amorphous polyester resin 1 or 2 with an amorphous or semicrystalline polyester resin 3. The pellets were melt blended by compounding in a Coperion26 mm TSE (#16) extruder with a general purpose screw at 250 rpm using a 2 hole die. The extruder used zone temperatures of 180 / 260 / 260 / 260°C and melt temperature of 305°C.
[0101] The composition of the resins are shown below in Table 1. The blends of the resins are shown in T able 2.Table 1. Resin used in making the blendsTable 2. Blends with Resins 1- 3
[0102] Physical properties of the resin blends according to the examples are shown below in Table 3.Table 3. General Properties for Resins 1 and 2Example B - Test Bars / Notched and Un-Notched ImpactTest Bar Production
[0103] Pellets of copolyester blend materials from Example A were injection molded to form standard test bars 0.5 inch x 5 inch x 0.125 inch (1.27 cm x 12.7 cm x 0.3 cm) and ASTM tensile bars. The pellets were molded in A110 Ton Toyo injection molding machine with barrel capacity 3.4 oz. The copolyester material was injection molded at 1 in / sec injection speed into four test bars per shot with barrel temperature nominally of about 249°C (480°F) and mold temperature of about 80°C.Test Results
[0104] The example blends were tested for physical and thermal properties. The results are listed in table 4 below. Table 4. Properties for Examples 1 and 2
[0105] A review of Table 4 reveals that the copolyester of EX 1 had higher notched Izod impact (at 23C), higher HDT at 0.455 MPa, and higher Tg than EX 2.
[0106] The resins from Examples 1 and 2 were subjected to solid stating by holding the pellets at a temperature of 225°C under a vacuum or 1 Torr for 24 hours. The IV was measure every 4 hours. The results of the IV change over time is shown below in Table 5.Table 5. IV vs. Time
[0107] A review of Table 5 reveals that the IV increase over time as a result of the solid stating for both resins.
[0108] The resins from Examples 1 and 2 were formed into films by extruding films using a 1.5” Killion single screw extruder. The extruder conditions included drying the polymer pellets for 6-8 hours at 120°C and then extruding with a barrel temperature of 285-290°C and with a die having a target film width of 8 inches (20.3 cm) and film thickness of 10 mil (0.25 mm). Samples of the extruded film were cut into 100 mm x 100 mm square samples and were stretched at a ratio of 4 times at a stretch temperature of 140°C, and at varying stretch rates, using a Bruckner machine. The films were stretched in the machine direction, while the cross direction was maintained at a fixed dimension. Each film was subjected to 6 different stretching conditions as follows: (1 ) stretch rate 10% / sec, (2) stretch rate 50% / sec, (3) stretch rate 100% / sec, (4) stretch rate 200% / sec, (5) stretch rate 300% / sec, and (6) stretch rate 300% / sec and then setting at a temperature of 180°C for 30 seconds.
[0109] Each stretched film sample was tested for tensile properties, including yield stress, yield strain, break stress, break strain and young’s modulus. The tensile properties were measured using the stretched film samples according to ASTM D638 at 23°C. The results are shown below in Tables 6 and 7.Table 6 - Test results for Example 1 filmsTable 7 - Test results for Example 2 films
[0110] A review of tables 6 and 7 reveals that there was a generally similar effect of stretch conditions on the measured properties for Example 1 and 2 films.
[0111] Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the embodiments disclosed herein. It will be understood that variations and modifications can be affected within the spirit and scope of the disclosed embodiments. It is further intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the disclosed embodiments being indicated by the following claims.
Claims
THAT WHICH IS CLAIMED IS:
1. A transparent article comprising a copolyester composition, said copolyester composition comprising at least one copolyester that comprises:(a) a dicarboxylic acid component comprising: i) 70 to 99.9, or 70 to 99 mole % of terephthalic acid residues; and ii) 0.1 to 30, or 1 to 30 mole% of isophthalic acid residues; and(b) a glycol component comprising: i) 5 to 30, or 5 to 15 mole % of cyclic diol resides having a bicyclic structure with each individual ring in the bicyclic structure having 3 to 5 members; ii) 45 to 90 mole % of 1 ,4-cyclohexanedimethanol residues; and iii) 1 to 25, or 5 to 25 mole% of ethylene glycol residues, wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %; and wherein the inherent viscosity is 0.60 to 1.2, or 0.7 to 1.2 dL / g as determined in 60 / 40 (wt / wt) phenol / tetrachloroethane at a concentration of 0.5 g / 100 ml at 25°C; wherein the at least one copolyester has a Tg of 95°C to 120°C, or 100°C to 115°C; and wherein the at least one copolyester has a crystallinity from 1 to 40%.
2. The article according to claim 1 , wherein the copolyester composition has a Tg in the range from 105°C to 115°C.
3. The article according to claim 2, wherein the copolyester composition has an inherent viscosity is 0.70 to 1 .0 dL / g, or 0.75 to 0.95 dL / g.
4. The article according to any one of claims 1 to 3, wherein the glycol component comprises: i) 5 to 30 mole% of isosorbide residues; and ii) 45 to 90 mole% of 1 ,4-cyclohexanedimethanol (CHDM) residues; andiii) 5 to 25 mole% of ethylene glycol residues.
5. The article according to any one of claims 1 to 4, wherein the dicarboxylic acid component comprises 100 mole% terephthalic acid residues.
6. The article according to any one of claims 1 to 4, wherein the dicarboxylic acid component comprises: i) 95 to 99.5 mole% of terephthalic acid residues; and ii) 0.5 to 5 mole% of isophthalic acid residues.
7. The article according to claim 6, wherein the dicarboxylic acid component comprises: i) 97 to 99.5 mole% of terephthalic acid residues; and ii) 0.5 to 3 mole% of isophthalic acid residues.
8. The article according to any one of claims 1 to 7, wherein the copolyester composition has a crystallization half time from 30 seconds to 5 minutes.
9. The article according to any one of claims 1 to 8, wherein the article is a food or beverage container.
10. The article according to any one of claims 1 to 9, wherein the article has a strain induced crystallinity of from 1 to 40%.
11. The article according to any one of claims 1 to 10, wherein the at least one copolyester has a total transmittance of at least 90% and a haze of less than 1% measured according to ASTM D1003.
12. A method for improving strength of an amorphous high Tg and high impact resistant polyester (Polyester A), said method comprising:(1) providing Polyester A that comprises:(a) a dicarboxylic acid component comprising: i) 70 to 100 mole % of terephthalic acid residues;(b) a glycol component comprising: i) 15 to 30 mole % of cyclic diol resides having a bicyclic structure with each individual ring in the bicyclic structure having 3 to 5 members; andii) 45 to 80 mole % of 1 ,4-cyclohexanedimethanol residues; and iii) 5 to 30 mole% of ethylene glycol residues, wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %; and wherein the inherent viscosity is 0.55 to 1.2 dL / g as determined in 60 / 40 (wt / wt) phenol / tetrachloroethane at a concentration of 0.5 g / 100 ml at 25°C; and wherein the polyester has a Tg of at least 95°C and a notched Izod impact strength of 500 to 1000 J / m as measured according to ASTM D256 at 23C using a 3.2 mm thick bar that has been subjected to 50% relative humidity for 40 hours at 23°C;(2) combining Polyester A with Polyester B, wherein Polyester B is included in an amount sufficient to improve the strength of the combination of Polyesters A and B compared to that of Polyester A and maintaining the Tg of the combination of Polyesters A and B with 2% of the Tg Polyester A, wherein Polyester B comprises:(a) a dicarboxylic acid component comprising: i) 70 to 99, or 95 to 99 mole % of terephthalic acid residues; and ii) 1 to 30, or 1 to 5 mole% of isophthalic acid residues; and(b) a glycol component comprising: i) 95 to 100 mole % of 1 ,4-cyclohexanedimethanol residues, wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %;(3) blending Polyester A and Polyester B to provide a blended polyester composition.
13. The method according to claim 12, wherein the blended polyester composition comprises:(a) a dicarboxylic acid component comprising:i) 70 to 99.6 net mole % of terephthalic acid residues; and ii) 0.4 to 30 net mole% of isophthalic acid residues; and(b) a glycol component comprising: i) 5 to 30, or 5 to 15 net mole % of cyclic diol resides having a bicyclic structure with each individual ring in the bicyclic structure having 3 to 5 members; ii) 45 to 90 net mole % of 1 ,4-cyclohexanedimethanol residues; and iii) 1 to 25, or 5 to 25 net mole% of ethylene glycol residues, wherein the total net mole % of the dicarboxylic acid component is 100 mole %, and the total net mole % of the glycol component is 100 mole %; and wherein the inherent viscosity is 0.60 to 1.2, or 0.7 to 1.2 dL / g as determined in 60 / 40 (wt / wt) phenol / tetrachloroethane at a concentration of 0.5 g / 100 ml at 25°C; and wherein the polyester has a Tg of 95°C to 115°C.
14. The method according to claim 12 or 13, wherein Polyester A comprises:(a) a dicarboxylic acid component comprising: i) 100 mole % of terephthalic acid residues;(b) a glycol component comprising: i) 15 to 30 mole %, or 15 to 25 mole %, of isosorbide residues; ii) 45 to 75 mole %, or 65 to 75 mole %, of 1 ,4- cyclohexanedimethanol residues; and iii) 5 to 30 mole%, or 5 to 15 mole% of ethylene glycol residues.
15. The method according to claim 12 or 13, wherein Polyester A comprises: (a) a dicarboxylic acid component comprising: i) 100 mole % of terephthalic acid residues;(b) a glycol component comprising: i) 15 to 30 mole %, or 15 to 25 mole %, of isosorbide resides; ii) 45 to 75 mole %, or 65 to 75 mole %, of 1 ,4- cyclohexanedimethanol residues; and iii) 5 to 30 mole %, or 5 to 15 mole % of ethylene glycol residues.
16. The method according to any one of claims 12 to 15, wherein Polyester B comprises:(a) a dicarboxylic acid component comprising: i) 95 to 99 mole % of terephthalic acid residues; and ii) 1 to 5 mole % of isophthalic acid residues, and(b) a glycol component comprising: i) 100 mole % of 1 ,4-cyclohexanedimethanol residues.
17. The method according to any one of claims 12 to 16, wherein Polyester B is included in an amount to provide a weight ratio of Polyester A: B in a range from 90:10 to 50:50, or 90:10 to 60:40, or 90:10 to 65:35, or 85:15 to 50:50, or 85: 15 to 60:40, or 85: 15 to 65:35, or 80:20 to 50:50, or 80:20 to 60:40, or 80:20 to 65:35, or 80:20 to 70:30.
18. The method according to any one of claims 12 to 17, wherein blending step (3) comprise melt blending Polyester A and Polyester B.
19. The method according to any one of claims 12 to 18, wherein the blended polyester composition has a higher notched Izod impact compared to Polyester A.
Citation Information
Patent Citations
Polyester resin and method for preparing the same
US20160222157A1
Polyester copolymer having excellent strength, and product comprising the same
US20230399461A1
Copolymer polyester resin and preparation method therefor
WO2023121283A1