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Universal Masterbatch Europaisches Patentamt (19) European Patent Office Office europeenpeen des brevets EP 0 705 875 A1 (12) EUROPEAN PATENT APPLICATION (43) Date of publication: (51) intci.e: C08K 9/08, C08J 3/22, 10.04.1996 Bulletin 1996/15 C08L 53/02 (21) Application number: 95305736.1 (22) Date of filing: 17.08.1995 (84) Designated Contracting States: (72) Inventors: AT BE CH DE DK ES FR GB GR IE IT LI LU MC • Petiniot, Nicole NL PT SE B-4000 Liege (BE) • Rasquin, Philippe (30) Priority: 29.08.1994 US 297674 B-4620 Fleron (BE) (71) Applicant: CABOT CORPORATION (74) Representative: Attfield, Donald James et al Boston, Massachusetts 02109-2806 (US) Barker, Brettell & Duncan 138 Hagley Road Edgbaston Birmingham B16 9PW (GB) (54) Universal masterbatch (57) A universal masterbatch composition for adding ymers and a remainder quantity of a styrene butadiene fillers and particularly pigment to polymers, having up to block copolymer. The composition preferably further in- 85%, by weight, of at least one filler being carbon black, cludes up to 5%, by weight, of at least one processing titanium dioxide or ultramarine blue, up to 25%, by aid in the form of metallic stearates, stearic acid, organic weight, of at least one viscosity modifier being ethylene stearates or fluoroelastomer and up to 2%, by weight, of bis stearamide, polybutylene or hot melt acrylate copol- at least one antioxidant. < Is- 00 LO o Is- o a. LU Printed by Jouve (FR), 18, rue Saint-Denis, 75001 PARIS EP 0 705 875 A1 Description FIELD OF THE INVENTION: 5 The present invention relates to pigment containing masterbatch resin compositions which are compatible with a broad range of base polymers, produced by the mixture of the plastic composition masterbatch resin and base polymers. BACKGROUND: 10 The term "masterbatch" is generally used to connote a carrier resin containing one or more additives. The most common additive is a pigment which imparts color to the final polymer system. The masterbatch is generally added to, and mixed with, abase polymer to add a desired level of pigment. The amount of masterbatch mixed with abase polymer varies depending on the pigmentation desired in the base polymer. Typically, 0.5 to 30%, by weight of masterbatch is added to the base polymer. The term "universal masterbatch" is utilized to refer to a masterbatch which is applicable is for use with a variety of base polymers. For purposes of the present invention, base polymers shall mean thermoplastic polymers, including polyethylene, polypropylene, polystyrene homo and copolymers, ABS (acrylonitrile polymer with butadiene styrene terpolymer), PA (polyamide), PC (polycarbonate), PUR (polyurethane), PBT (polybutylene terephthalate), PET and thermoplastic alloys containing at least one of the above polymers. 20 Generally known universal masterbatch compositions utilize ethylene vinyl acetate copolymer (EVA) as a carrier resin. These carrier resins have the compatibility due to the polar vinyl acetate monomer but also suffer from the thermal decomposition of the same monomer at temperatures above about 230° C giving acidic volatiles. Therefore, masterbatch compositions utilizing EVA as a carrier resin are generally not suitable for use in thermoplastic polymers that will be exposed to temperatures greater than 230° C during processing. Additionally chemical reactions could occur between 25 the acidic residue and certain thermoplastics such as polyamide or polycarbonate resulting in a degradation of mechan- ical properties. Fillers, including pigments, are added to masterbatch compositions to impart desired properties to the thermoplastic polymer that will incorporate the masterbatch. Typical fillers and pigments for masterbatch compositions include carbon black, titanium dioxide, calcium carbonate, talc, lithopone, silica, iron oxide and organic pigments. Other additives, such 30 as ultraviolet stabilizers, antioxidants, slip stabilizers, lubricants, optical brighteners, antifog and antistatic agents may be incorporated into the masterbatch composite. In addition to imparting desirable properties to the masterbatch and the thermoplastic polymer that will incorporate the masterbatch, carbon black has been utilized as a black pigment. Similarly, titanium dioxide has been utilized as a white pigment in masterbatch compositions. To some degree, thermoplastic polymers suffer a decrease in mechanical performance when pigments are added. 35 While not wishing to be so limited, the inventors attribute the decrease in performance to non-uniform dispersions of the pigment. While some attempts have been made in altering the viscosity of the thermoplastic to achieve improved dis- persion, a masterbatch which achieves uniform pigment dispersion at elevated loadings; which is compatible over a broad range of thermoplastic polymers; and which maintains or improves the mechanical properties of the thermoplastic would be a considerable improvement in the art. 40 An object of the present invention is to overcome the limitations associated with masterbatches using EVA as a carrier resin. Another object is to maintain or improve on the mechanical impact properties of pigmented containing thermoplastic base polymer utilized. 45 SUMMARY OF THE INVENTION: Accordingly, we have discovered a masterbatch composition comprising up to 85% by weight of at least one filler, up to 25 % by weight of at least one viscosity modifier; and a balance by weight of a styrene butadiene styrene block copolymer(SBS) as a carrier resin. Due to the stability characteristics at high temperatures such as 260°C, styrene so butadiene styrene block linear or star copolymers as carrier resins show a superior advantage to EVA carrier resins in universal masterbatches. Styrene butadiene styrene (SBS), has been utilized in masterbatch compositions as an impact modifier to improve the mechanical performance of the carrier resin. Generally, when SBS is utilized in a masterbatch in combination with high levels of fillers, the viscosity of the masterbatch becomes unacceptably high. The masterbatch composition of the 55 present invention overcomes this problem. In an alternate embodiment, the masterbatch composition of the present invention may additionally include up to 5%, by weight, of at least one processing aid, which is preferably a metal or organic stearate, stearic acid or fluroelas- tomer. In yet a further embodiment, the masterbatch composition of the present invention may further include up to 2%, 2 EP 0 705 875 A1 by weight of at least one antioxidant. The masterbatch composition of the present invention may be prepared by methods known to those of ordinary skill in the art for preparing resin compositions. Typically, the components of the masterbatch are admixed with the SBS carrier resin, at above the softening point of the SBS, in a conventional batch or continuous mixing apparatus, such as 5 an extruder, kneader or Banbury mixer. The final plastic composition of the present invention comprises 0.5 to 30%, by weight, and preferably 1 to 1 5%, by weight of the masterbatch of the present invention, with the remainder being a thermoplastic resin. The masterbatch composition comprises: up to 85%, by weight, of at least one filler; up to 25%, by weight, of at least one viscosity modifier selected from a group consisting of ethylene bis stearamide, polybutylene and hot melt acrylic copolymers with a melt 10 index of greater than 50; and a remainder quantity of preferably of a styrene butadiene styrene block linear or star copolymer totalling up to 100% by weight of the masterbatch. As set forth above, the masterbatch composition used in the plastic composition may additionally include up to 5%, by weight, of at least one processing aid, which is preferably a metal or organic stearate or a fluroelastomer. The mas- terbatch composition used in the plastic composition may further include up to 2 %, by weight of at least one antioxidant. is The thermoplastic composition of the present invention may be prepared by conventional thermoplastic processing methods, for injection molding, for example by incorporating the masterbatch into the plastic at a temperature above the softening temperature of the plastic in a conventional processing apparatus, such as an extruder, kneader or mixer, or injection molding equipment. An advantage of the masterbatch of the present invention is that the masterbatch is compatible with a wide variety 20 of thermoplastics and can be easily incorporated into these plastics. Another advantage of the masterbatch of the present invention is that the masterbatch will generally maintain, and often improve, the impact resistance and tensile strength of thermoplastics incorporating the masterbatch. A further advantage of the masterbatch of the present invention is that the masterbatch is stable at higher temper- atures, than those generally utilized with masterbatches having an EVA as a carrier polymer. 25 A still further advantage of the present invention is that the masterbatch has lower hygroscopicity due to lower polarity. Further details and advantages of the present invention, will become apparent from the following description and examples. 30 DETAILED DESCRIPTION OF THE INVENTION: According to the present invention, a masterbatch composition is disclosed having a carrier resin which is a styrene butadiene styrene (SBS) block or star copolymer. Preferably, the SBS comprises at least 20% styrene with the remainder polybutadiene to facilitate ease of processing and mixing. SBS copolymers containing elevated styrene levels which
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