Comb Polymer Compatibilizer for Chlorinated Thermoplastics

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Solution Overview

Problem

Chlorinated thermoplastic materials, particularly PVC-based, face poor compatibility with mineral fillers like calcium carbonate, leading to reduced mechanical and optical properties due to inadequate dispersion, which is exacerbated by the use of stearic acid or its salts, causing issues such as yellowing and die build-up.

Innovation Solution

Employing a comb polymer with a polyalkylene oxide group grafted onto an anionic monomer with ethylenic unsaturation as a compatibilizing agent to improve the compatibility of mineral fillers with chlorinated thermoplastic resins, thereby reducing or eliminating the need for stearic acid or its salts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If stearic acid or its salts are used as compatibilizing agents, then compatibility between mineral filler and chlorinated thermoplastic resin is improved, but yellowing and die build-up occur

Engineering Contradiction:

Improvecompatibility between filler and resinVSAvoidyellowing and die build-up

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical parameters of the compatibilizing agent by replacing stearic acid with a comb polymer containing polyalkylene oxide groups grafted on anionic monomers. This parameter change maintains compatibility improvement while eliminating the harmful side effects of yellowing and die build-up associated with stearic acid

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The comb polymer acts as an intermediary substance that mediates between the hydrophobic chlorinated thermoplastic resin and the hydrophilic mineral filler. The polyalkylene oxide groups provide hydrophilic character for filler interaction, while the anionic monomer backbone provides compatibility with the resin, thus eliminating the need for stearic acid as a mediator

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If calcium carbonate is dispersed in chlorinated thermoplastic resin without treatment, then processing is simplified, but poor dispersion and reduced mechanical properties occur

Engineering Contradiction:

Improveprocessing simplicityVSAvoidmechanical properties

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The comb polymer is introduced during the grinding stage to preliminarily treat the calcium carbonate surface, ensuring proper dispersion characteristics are established before the material enters the extrusion process. This preliminary action prevents poor dispersion and maintains mechanical properties without complicating subsequent processing

Inventive Principle:

Principle #10Preliminary action

3Object-generated harmful factors

If quantity of stearic acid is reduced to minimize harmful effects, then yellowing and die build-up are reduced, but compatibility between filler and resin deteriorates

Engineering Contradiction:

Improveyellowing and die build-upVSAvoidcompatibility between filler and resin

Core Design Contradiction:

Object-generated harmful factorsVSReliability

Solution Approach 1:

The comb polymer serves as a superior intermediary that replaces stearic acid entirely or partially. Its dual-character structure (hydrophilic polyalkylene oxide groups and hydrophobic anionic monomer backbone) provides effective compatibility between filler and resin without the harmful effects, allowing reduction or elimination of stearic acid while maintaining or improving compatibility

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enhances the impact resistance and brightness of the final material while minimizing the use of stearic acid, ensuring better filler dispersion and maintaining compatibility without the drawbacks of stearic acid, such as yellowing and die build-up.

Implementation Method 1

the compatibility of which between the said filler and the chlorinated thermoplastic resin is improved

Methodology Applied

Scientific EffectCompatibilizing:

Implementation Method 2

a comb polymer having at least one anionic monomer with ethylenic unsaturation, to which is grafted at least one polyalkylene oxide group

Methodology Applied

Scientific EffectGrafting:

Data Source

PatentUS8039571B2Use of a comb polymer with at least one polyalkylene oxide grafted function as a mineral charge compatibility agent for chlorinated thermoplastic materials

Publication Date: 2011.10.18 COATEX SA

AI summary

The invention firstly concerns the use as a compatibilizing agent, in a process to manufacture a chlorinated thermoplastic resin filled with a mineral material, of a comb polymer having at least one anionic monomer with ethylenic unsaturation, to which is grafted at least one polyalkylene oxide group.The invention also concerns the chlorinated thermoplastic materials thus obtained, which have an improved compatibility between the filler and the chlorinated thermoplastic resin, whilst reducing the quantity of compatibilizing agents as used in the chlorinated and filled thermoplastic materials according to the prior art, where the said compatibilizing agents used in the prior art were essentially fatty acids, and more specifically stearic acid or its salts.