MASTERBATCH CONTAINING HEAT-SENSITIVE FUNCTIONAL ADDITIVE

Abstract

A heat-sensitive functional additive is protected from multiple heat histories by being mixed at ambient temperature with a pre-formed masterbatch, for let down into thermoplastic resin at the time of final-shaping of the plastic article.

Claims

1. A masterbatch, comprising: (a) heat-sensitive functional additive and (b) ethylene vinyl acetate and (c) optionally an inorganic filler, wherein the ethylene vinyl acetate comprises at least 35 weight percent of the masterbatch, and wherein the heat-sensitive functional additive has been absorbed into the masterbatch at ambient temperature.

2. The masterbatch of claim 1, wherein the masterbatch further comprises polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyoxymethylene (POM), polyamide (PA), polystyrene (PS), polymethylmethacrylate (PMMA), polyphenylene sulfide (PPS) or polylactic acid (PLA), any copolymer of any of them, any combination thereof.

3. The masterbatch of claim 1, wherein the heat-sensitive functional additive is selected from the group consisting of fragrances, colorants, ultraviolet or visible light absorbers, lubricants, anti-static agents, antimicrobial agents, and combinations thereof.

4. The masterbatch of claim 1, wherein the inorganic filler is selected from the group consisting of talc, mica, barium sulfate, titanium dioxide, calcium carbonate, silicon dioxide, and combinations thereof.

5. A polymer compound, comprising: (a) masterbatch of claim 1; (b) thermoplastic resin; and (c) optionally a functional additive selected from the group consisting of anti-oxidants, anti-stats, acetaldehyde scavengers, blowing agents, surfactants, biocides, exfoliated nanoclays, ultraviolet stabilizers, and combinations of them.

6. The compound of claim 5, wherein the thermoplastic resin is selected from the group consisting of polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyoxymethylene (POM), polyamide (PA), polystyrene (PS), polymethylmethacrylate (PMMA), polyphenylene sulfide (PPS), polylactic acid (PLA), any copolymer of any of them, and any combination thereof.

7. The compound of claim 5, wherein the compound further comprises adhesion promoters; biocides; anti-fogging agents; anti-static agents; bonding, blowing and foaming agents; dispersants; fillers, fibers, and extenders; flame retardants; smoke suppressants; impact modifiers; initiators; lubricants; micas; pigments, colorants and dyes; plasticizers; processing aids; release agents; silane coupling agents, titanates and zirconates coupling agents; slip and anti-blocking agents; stabilizers; stearates; ultraviolet light absorbers; viscosity regulators; PE waxes; catalyst deactivators, or combinations of them.

8. The compound of claim 5, wherein the amount of heat-sensitive functional additive ranges from about 0.01 to about 5 weight percent of the compound.

9. A method of making a masterbatch of claim 1, comprising the step of (a) melt-mixing ethylene vinyl acetate and optionally inorganic filler to form a masterbatch; (b) absorbing heat-sensitive functional additive into the masterbatch at a temperature below the vapor point of the heat-sensitive functional additive to form the masterbatch.

10. The method of claim 9, wherein the masterbatch further comprises polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyoxymethylene (POM), polyamide (PA), polystyrene (PS), polymethylmethacrylate (PMMA), polyphenylene sulfide (PPS), polylactic acid (PLA), any copolymer of any of them, and any combination thereof.

11. The method of claim 9, wherein the vapor point is less than about 150° C.

12. The method of claim 9, wherein the inorganic filler is calcium carbonate.

13. The method of claim 9, further comprising the step (c) of melt mixing the masterbatch with polymer resin and optionally other ingredients to form a polymer compound in its finally-shaped form.

14. The method of claim 13, wherein step (c) is selected from the group consisting of extrusion, molding, spinning, casting, thermoforming, calendering, spinning, or 3D printing.

15. The masterbatch of claim 2, wherein the heat-sensitive functional additive is selected from the group consisting of fragrances, colorants, ultraviolet or visible light absorbers, lubricants, anti-static agents, antimicrobial agents, and combinations thereof, and wherein the inorganic filler is selected from the group consisting of talc, mica, barium sulfate, titanium dioxide, calcium carbonate, silicon dioxide, and combinations thereof.

16. The compound of claim 5, wherein the masterbatch further comprises polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyoxymethylene (POM), polyamide (PA), polystyrene (PS), polymethylmethacrylate (PMMA), polyphenylene sulfide (PPS) or polylactic acid (PLA), any copolymer of any of them, any combination thereof.

17. The compound of claim 16, wherein the thermoplastic resin is selected from the group consisting of polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyoxymethylene (POM), polyamide (PA), polystyrene (PS), polymethylmethacrylate (PMMA), polyphenylene sulfide (PPS), polylactic acid (PLA), any copolymer of any of them, and any combination thereof.

18. The compound of claim 16, wherein the compound further comprises adhesion promoters; biocides; anti-fogging agents; anti-static agents; bonding, blowing and foaming agents; dispersants; fillers, fibers, and extenders; flame retardants; smoke suppressants; impact modifiers; initiators; lubricants; micas; pigments, colorants and dyes; plasticizers; processing aids; release agents; silane coupling agents, titanates and zirconates coupling agents; slip and anti-blocking agents; stabilizers; stearates; ultraviolet light absorbers; viscosity regulators; PE waxes; catalyst deactivators, or combinations of them.

19. The compound of claim 16, wherein the amount of heat-sensitive functional additive ranges from about 0.01 to about 5 weight percent of the compound.

20. The compound of claim 19, wherein the heat-sensitive functional additive is selected from the group consisting of fragrances, colorants, ultraviolet or visible light absorbers, lubricants, anti-static agents, antimicrobial agents, and combinations thereof, and wherein the inorganic filler is selected from the group consisting of talc, mica, barium sulfate, titanium dioxide, calcium carbonate, silicon dioxide, and combinations thereof.

Description

EXAMPLES

[0043] Examples 1-8 and Comparative Examples A-E were masterbatches made by melt-mixing the carrier resin(s) and optional filler(s) at a temperature of 170-200° C. using a twin screw extruder which formed pellets. Then, an amount of fragrance was mixing into each masterbatch, with success being 10% or more weight percent of absorption into the masterbatch. Table 3 shows the ingredients and results.

TABLE-US-00003 TABLE 3 Ingredient (Wt. %) Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 PP-Y-3700 Polypropylene 20 30 Carrier Resin (Jinshan) Elvax Ethylene-Vinyl Acetate 39.98 50 50 60 40 50 50 Copolymer Carrier Resin (DuPont) LOTRENE LA0710 low 20 50 density polyethylene (LDPE) Carrier Resin (ATO Fina) ABS CYCOLAC X17 Carrier 20 Resin (SABIC) NCC-610 Calcium Carbonate 40 50 20 40 40 30 Filler (Formosa Carbide) Ti-Pure Filler (DuPont) R-103 Bayferrox Red 130 M 0.02 synthetic red iron oxide colorant (Lanxess) Wt. % Total 100 100 100 100 100 100 100 Test Results Success Success Success Success Success Success Success Comp. Comp. Comp. Comp. Comp. Ingredient (Wt. %) Example 8 Example A Example B Example C Example D Example E PP-Y-3700 Polypropylene 30 40 Carrier Resin (Jinshan) Elvax Ethylene-Vinyl Acetate 50 33.3 20 20 25 30 Copolymer Carrier Resin (DuPont) LOTRENE LA0710 low 66.7 40 75 density polyethylene (LDPE) Carrier Resin (ATO Fina) ABS CYCOLAC X17 Carrier Resin (SABIC) NCC-610 Calcium Carbonate 40 40 70 Filler (Formosa Carbide) Ti-Pure Filler (DuPont) 20 R-103 Bayferrox Red 130 M synthetic red iron oxide colorant (Lanxess) Wt. % Total 100 100 100 100 100 100 Test Results Success Failure Failure Failure Failure Failure Test: SES013402 Fragrance from Givaudan was mixed at ambient temperature for 24 hours. If 10 weight % or more of the fragrance was absorbed, then the experiment was a success.

[0044] Examples 1-8 demonstrated that EVA is a required carrier resin for this particular fragrance to be absorbed into the masterbatch after the first heat history for that masterbatch and before let down via melt-mixing into thermoplastic resin at the second heat history of the masterbatch.

[0045] Comparative Examples A-E distinguish from Examples 1-8, in that the amount of weight percent of EVA must be at least about 35 weight percent, desirably about 37.5 weight percent, and preferably at least about 40 weight percent in order for the absorption of the fragrance to succeed in 10 or more weight percent.

[0046] The invention is not limited to the above embodiments. The claims follow.