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||||||||||||||III USOO5319027A United States Patent (19) 11 Patent Number: 5,319,027 Bott Et Al ||||||||||||||III USOO5319027A United States Patent (19) 11 Patent Number: 5,319,027 Bott et al. (45) Date of Patent: Jun. 7, 1994 (54) MISCIBLE BLENDS OF VINYL 4,598, 18 7/1986 Hansen et al. ...................... 525/2O7 ACETATE-ETHYLENE COPOLYMERS AND 4,657,975 4/1987 Kodama et al. ..... 525/207 COPOLYMERS OF ACRYLIC ACID OR 4,692,498 9/1987 Bodolus et al. ..... ... 525/285 4,855,363 8/1989 Moteki ................ 525/207 MALEC ANHYDRIDE 4,985,504 A199 Siol ...................... ... 525/206 75) Inventors: Richard H. Bott, Macungie, Pa.; 5,171,777 12/1992 Kuphal et al. ...................... 52.5/221 S.E. Fing FOREIGN PATENT DOCUMENTS p y es Hsueh-Chi Lee, Allentown, Pa.; 147850 4/1981 German Democratic Cajetan F. Cordeiro, Kutztown, Pa. Rep. a a - a - - - 525/207 s 56-050970 5/1981 Japan ... ... 525/2O7 73 Assignee: Air Products and Chemicals, Inc., 56-092945 7/1981 Japan. ... 525/207 Allentown, Pa. 58-069274 4/1983 Japan ................................... 52.5/221 * Notice: The portion of the term of this patent Primary Examiner-Carman J. Seccuro, Jr. subsequent to Dec. 15, 2010 has been Attorney, Agent, or Firm-Keith D. Gourley; James C. disclaimed. Simmons; William F. Marsh 21 Appl. No.: 921,535 57 ABSTRACT (22 Filed: Jul. 29, 1992 Polymeric compositions are disclosed containing misci ble blends of copolymers, one of which is a vinyl Related U.S. Application Data acetate/ethylene copolymer containing about 5 to 30 63 Continuation-in-part of Ser. No. 633,830, Dec. 26, weight percent ethylene and the other is a copolymer of 1990, Pat. No. 5,171,777, either acrylic acid or a maleic anhydride with a como s 8 nomer selected from styrene, ethyl acrylate, n-butyl 51) Int. Cl. ...................... to 3i's. acrylate and 2-ethylhexyl acrylate. Windows of misci 52 U.S. Cl. .................................... 57.25/50 bility for each of the copolymer blends have been de 8 525 72.85. 525/20 fined and the blends can be advantageously formed by 58 Field of Search ................ 525/207,285,221, 301 polymerizing the acrylic acid copolymer in the pres ence of an emulsion of the vinyl acetate/ethylene co 56) References Cited polymer in such a way that the polymerization takes U.S. PATENT DOCUMENTS place in the suspended vinyl acetate/ethylene copoly 3,957,908 5/1976 Heslinga et al. .................... so mer rather than in the aqueous phase. 4,332,917 6/1982 Heslinga et al. .................... 525/207 4,338,417 6/1982 Heslinga et al. .................... 52.5/207 9 Claims, No Drawings 5,319,027 1. 2 and polystyrene. Miscibility was noted for copolymers MISCIBLE BLENDS OF WINYL based upon vinyl acetate/acrylic acid and styrene/4- ACETATE-ETHYLENE COPOLYMERS AND vinyl pyridine. Also studied were blends of copolymers COPOLYMERS OF ACRYLIC ACID OR MALEIC of styrene with acrylic acid and styrene with vinyl ANHYDRIDE pyridine. The interaction between the polymer chains was said to be enhanced by introducing charge groups, CROSS REFERENCE TO RELATED namely the vinyl pyridine and acrylic acid into the APPLICATIONS system. The single phase was noted at 10% content of This application is a continuation-in-part of Applica the charge groups with improved compatibility and a tion Ser. No. 07/633,830, filed Dec. 26, 1990 which O Tg of the blend centered between the Tg of the compo issued as U.S. Pat. No. 5,171,777 on Dec. 15, 1992. nent copolymers at 30 mole percent of the charge group monomer. The reference teaches that each of the poly FIELD OF THE INVENTION mers of the blend must have one of the charge group This invention relates to miscible blends of copoly monomers in its composition. mers of vinyl acetate and ethylene with other copoly 15 U.S. Pat. No. 4,332,917, Heslinga, et al., (1982) de mers containing acrylic acid or maleic anhydride. In scribes polymer alloys formed from one or more poly another aspect the invention relates to a method of mers having anhydride groups and one or more poly forming such miscible blends by polymerizing acrylic mers able to hydrogen bond to the first polymer which acid or maleic anhydride in the presence of emulsified must be protolyzed, for example, a copolymer of sty vinyl acetate-ethylene copolymer. rene and maleic anhydride and poly(vinyl acetate). BACKGROUND OF INVENTION These polymers are said to be miscible in all proportions As uses for polymeric compositions have become at certain temperatures but at specific temperatures more sophisticated, the demand has grown for poly phase separation will take place. Physical interaction mers and polymer mixtures having physical properties 25 between the polymers is said to be improved by protol tailored to the desired end use. Vast numbers of poly ysis of the maleic anhydride portion of the copolymer in meric systems having 2, 3 or more monomers have been order to increase hydrogen bonding. This must be done developed in order to achieve certain balances of prop after the polymer is in solution in an organic solvent. erties. The degree that such properties can be con Relative proportions of the styrene and maleic anhy trolled becomes increasingly complex as the number of 30 dride are not disclosed but one example indicates that different monomers in such systems increases. It has about equal amounts were charged to a polymerization. become more practicable, therefore, to modify and Shiomi, et al., Macromolecules, 19, 2274 (1986) states tailor polymer properties by combining preformed pol that compatibility between high molecular weight poly ymers of known composition and behavior in mixtures mers is unusual in blend systems, but that specific inter or blends. As the general rule, however, polymers 35 action between two polymers does improve the poten which differ from each other significantly in composi tial for miscibility. The authors studied random copoly tion are incompatible and do not mix well in a manner mer blends in which the blended copolymer had a com which enables them to share their properties or enhance mon monomer, for example, vinyl acetate/ethylene and the properties of one of the base polymers. Basically, vinyl chloride/vinyl acetate copolymers. Another sys this incompatibility results because the polymers do not tem studied was the copolymer of styrene and maleic combine on a molecular level which would be the case anhydride blended with a copolymer of styrene and if the polymers were completely miscible with each acrylonitrile. other. Many polymer blends are disclosed in the literature The miscibility between polymers has been studied without actually addressing the problem of compatibil extensively, as by Olabisi, et al, "Polymer-Polymer 45 ity. For example Japanese Patent Application 60042476 Miscibility", Academic Press, New York, (1979). The (1985) describes vibration proof materials which in authors describe blends of miscible polymers which clude fiber and resin made from vinyl acetate/ethylene exhibit behavior similar to that which would be ex pected from a single phase system. This offers assurance copolymer and a styrene copolymerized with acrylic of mechanical compatibility with enhanced tensile 50 acid ester with a third monomer of acrylic acid being properties, noting that miscible polymer blends are optional. The compositions disclosed are, however, usually useful over the entire composition range of outside the range of miscibility with vinyl acetate/ethy components thereby offering great versatility in match lene copolymer (VAE). In like manner Japanese Patent ing price/performance requirements. Application 62070461 (1987) describes a varnish con The problem of blending normally incompatible pol 55 taining VAE having 10 to 40 weight percent ethylene ymers was addressed several years earlier by Murdock, and a copolymer of styrene with maleic acid, the VAE et al., U.S. Pat. No. 3,236,914 (1966). The solution of being in emulsion and the styrene copolymer in solu fered was to combine one linear polymer containing tion. In effect, this system would produce a mixture of nitrogen atoms with another linear polymer having emulsions so that the resultant cast film would consist of carboxylic acid groups, for example vinyl pyridine and 60 particles of VAE surrounded by the styrene resin and acrylic acid or methacrylic acid. The so-called "neu therefore would be phase separated. Also, U.S. Pat. No. tral' comonomers could be selected from a long list of 4,777,197, Nolken, et al. (1988) describes as a plastic polymers including styrene and vinyl chloride or buta dispersion a mixture of VAE containing 14 to 22% diene and methyl methacrylate. ethylene and a copolymer of styrene with maleic anhy Over two decades later, the problem of polymer 65 dride as a water soluble salt plus a dispersing agent. miscibility was addressed in a similar fashion by Hsieh Since the dispersion would contain particles of the and Wong, J. Chem. I. Ch. E., 19(1), 17(1988) who poly(vinyl ester), mixing would not occur on the molec studied phase separation between poly(vinyl acetate) ular level. 5,319,027 3 4 Cruz-Ramos, et al., Macromolecules, 22, 1289 (1989) commercially available and find a wide range of utility discloses that poly(vinyl chloride) is not miscible with as adhesives and coating materials. either poly(vinyl acetate) or polyethylene, but does This invention enables the modification of such VAE form miscible mixtures with some of the copolymers of polymers by incorporating by a blending within win vinyl acetate and ethylene containing about 15-55 5 dows of miscibility certain polymers of acrylic acid or weight percent ethylene. The authors discuss "miscibil maleic anhydride which are copolymerized with either ity windows' in homopolymer-copolymer blends, but styrene, ethyl acrylate, n-butyl acrylate, 2-ethylhexyl do not go beyond the studies made with poly(vinyl acrylate, or mixtures of such comonomers.
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