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Telechelic Polyester/Polycarbonate/Organoclay (19) & (11) EP 2 225 319 B1 (12) EUROPEAN PATENT SPECIFICATION (45) Date of publication and mention (51) Int Cl.: of the grant of the patent: C08K 3/34 (2006.01) C08K 9/04 (2006.01) 13.07.2011 Bulletin 2011/28 C08L 67/02 (2006.01) C08L 69/00 (2006.01) (21) Application number: 08868531.8 (86) International application number: PCT/US2008/088172 (22) Date of filing: 23.12.2008 (87) International publication number: WO 2009/086381 (09.07.2009 Gazette 2009/28) (54) TELECHELIC POLYESTER/POLYCARBONATE/ORGANOCLAY NANOCOMPOSITES, AND RELATED METHODS AND ARTICLES TELECHELE POLYESTER-/POLYCARBONAT-/ORGANOTON-NANOVERBUNDSTOFFE SOWIE ENTSPRECHENDE VERFAHREN UND ARTIKEL NANOCOMPOSITES POLYESTER/POLYCARBONATE/ORGANOARGILE TÉLÉCHÉLIQUES, ET PROCÉDÉS ET ARTICLES APPARENTÉS (84) Designated Contracting States: • KANNAN, Ganesh AT BE BG CH CY CZ DE DK EE ES FI FR GB GR Evansville HR HU IE IS IT LI LT LU LV MC MT NL NO PL PT Indiana 47712 (US) RO SE SI SK TR • MONTGOMERY, Steven James Evansville (30) Priority: 28.12.2007 US 966051 Indiana 47712 (US) • BRUNELLE, Daniel J. (43) Date of publication of application: Burnt Hills 08.09.2010 Bulletin 2010/36 New York 12027 (US) • BINASSI, Enrico (73) Proprietor: SABIC Innovative Plastics IP B.V. I-40134 Bologna (IT) 4612 PX Bergen op Zoom (NL) (74) Representative: Carpintero Lopez, Francisco (72) Inventors: Herrero & Asociados, S.L. • KARANAM, Sreepadaraj Alcalá 35 NL-4611 JX Bergen Op Zoom (NL) 28014 Madrid (ES) • SHERMAN, Robert Lee Jr. Mason (56) References cited: Ohio 45040 (US) EP-A- 0 940 443 US-A1- 2006 116 464 US-B1- 6 930 164 Note: Within nine months of the publication of the mention of the grant of the European patent in the European Patent Bulletin, any person may give notice to the European Patent Office of opposition to that patent, in accordance with the Implementing Regulations. Notice of opposition shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention). EP 2 225 319 B1 Printed by Jouve, 75001 PARIS (FR) EP 2 225 319 B1 Description BACKGROUND OF THE INVENTION 5 [0001] This disclosure relates to nanocomposites comprising telechelic ionomeric polyesters and organoclays, their methods of manufacture and articles formed therefrom. [0002] Nanocomposites are class of composites that are particle- filled polymers for which at least one of the dimensions of the dispersed phase is in the nanometer range (typically 10-250 nm). Polymer layered nanocomposites often have superior physical and mechanical properties over their microcomposite counterparts, including improved modulus, re- 10 duced gas permeability, flame retardancy and improved scratch resistance. Moreover, the nanoscale dispersion of the filler does not give rise to the brittleness and opacity typical of composites. [0003] Polymeric, intercalation-type nanocomposites have been the subject of extensive research over the past dec- ade. Much of the work in this area has been focused on polymeric nanocomposites derived from layered silicates such as montmorillonite clay. When the silicate platelets are isotropically dispersed in a continuous polymer matrix, the material 15 is termed "exfoliated." The best enhancements in physical properties can be achieved with an exfoliated morphology. Polymer nanocomposites comprising a semicrystalline polymer matrix are particularly attractive, due to the dramatic improvement in heat distortion temperature and modulus provided by the nanoparticle reinforcement and the high flow character inherent to most commodity semicrystalline themioplastics such as nylon-6, nylon-6,6, poly(butylene tereph- thalate), poly(ethylene terephthalate), polypropylene, polyethylene, and the like. Because of these desirable character- 20 istics, semicrystalline polymer nanocomposites have been shown to be well suited for application as injection moldable thermoplastics. [0004] Sulfonated poly(butylene terephthalate) (PBT) random ionomers have been blended by reactive extrusion with organically modified montmorillonite. Because of the ionic nature of the sulfonate groups and their expected insolubility in the polyester matrix, the presence of the sulfonate groups provide a thermodynamic driving force for the production 25 of nanocomposites derived from montmorillonite clays. Combining PBT-ionomers with montmorillonite clays results in exfoliation of the clays due to favorable electrostatic interactions between the charged surfaces of the silicate clay particles and the -SO3Na groups of the PBT-ionomer. As disclosed in U.S. Application Serial No. 11/001214 (U.S. Publication No. 2006/0116464), the presence of ionic groups at the end of the polymer chain has a positive effect on the exfoliation of the clay and on the thermomechanical properties compared to compositions using unmodified PBT. In 30 particular, Dynamic Mechanical Thermal Analysis (DMTA) analyses have shown a consistent increase in heat distortion temperature respect to commercial PBT (up to 55°C) and to nanocomposites of standard PBT (30°C). The observed improvement in DMTA has been attributed to the formation of ionic interaction between the polymer end groups and the charged surface of the clay. Telechelic ionomers present a consistently lower melt viscosity compared to random iono- mers, since the interaction between the ionic groups give rise only to an electrostatic chain extension and not to the 35 formation of a crosslinking, as is the case in random ionomers. Therefore, in contrast to random ionomers, where only low weight average molecular weights (Mw) can be obtained, high molecular weight telechelic ionomers can be suc- cessfully obtained. [0005] Nonetheless, there remains a need in the art for nanocomposite polymer compositions that feature additional enhancements for use in the development of such materials. In particular, it has been difficult to obtain an optimal balance 40 between the ductility and the flexural modulus of nanocomposites. BRIEF DESCRIPTION OF THE INVENTION [0006] In one aspect, novel nanocomposite polymer compositions comprise at least one telechelic polyester; and at 45 least one organoclay, wherein the telechelic polyester comprises sulfonate end groups and structural units derived from at least one organic dicarboxylic acid and at least one diol. [0007] In another aspect, a composition comprises, based on the total weight of the composition, from 30 to 50 weight percent of an ionomeric telechelic polyalkylene ester comprising from 0.05 to 5 mole percent of sulfonate end groups; from 50 to 70 weight percent of a polycarbonate; from 0.1 to 10 weight percent of an organoclay; and from 2 to 12 weight 50 percent of an impact modifier. [0008] In another embodiment, a method of manufacture of the disclosed compositions comprises melt blending the components of the compositions. [0009] In another embodiment, an article comprises the disclosed compositions. 55 BRIEF DESCRIPTION OF THE DRAWINGS [0010] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters 2 EP 2 225 319 B1 represent like parts throughout the drawings, wherein: [0011] FIG. 1 shows the decrease in the molecular weight during the preparation of the nanocomposites as compared to the comparative example 1 [0012] FIGS. 2-5 show the exfoliation of the organoclay by the telechelic sulfonated poly(butylene terephthalate) 5 compared to the non-ionic poly(butylene terephthalate). [0013] FIG. 6 shows the DMTA chart of the telechelic sulfonated poly(butylene terephthalate) (examples 2,4 and 6) and comparative example 2 and PBT 195. [0014] FIG. 7 is a transmission electron micrograph (TEM) of poly(butylene terephthalate and 2% nanoclay composite (example C5). 10 [0015] FIG. 8 is a TEM of PBT-1% ionomer and 2% nanoclay composite (example C6). [0016] FIG. 9 is a TEM of PBT-0.5% ionomer and 2% nanoclay composite (example C7). [0017] FIG. 10 is a TEM of talc filled composite (example C9). [0018] FIG. 11 is a TEM of nanoclay filled composite (example E8). 15 DETAILED DESCRIPTION [0019] It has unexpectedly been found by the inventors hereof that nanocomposites having an improved balance between ductility and flexural modulus are obtained from compositions that comprise, based on the total weight of the composition, from 30 to 50 weight percent of an ionomeric telechelic polyalkylene ester comprising from 0.05 to 5 mole 20 percent of sulfonate end groups; from 50 to 70 weight percent of a polycarbonate; from 0.1 to 10 weight percent of an organoclay; and from 2 to 12 weight percent of an impact modifier. In particular, the nanocomposites exhibit improved flexural modulus and tensile elongation at break (TE, at break) at low temperature relative to a composition comprising a non-telechelic polyester. These properties are especially advantageous in automotive applications such as bumpers and body panels. 25 [0020] This disclosure can be understood more readily by reference to the following detailed description of preferred embodiments of the invention and the examples included therein. In the following specification and claims, reference will be made to a number of terms which shall be defined to have the following meanings. [0021] The singular forms "a", "an" and "the" include plural referents unless the context clearly dictates otherwise. [0022] "Optional" or "optionally" means that the subsequently described event or circumstance can or cannot occur, 30 and that
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