U.S. patent application number 11/843258 was filed with the patent office on 2008-02-21 for polyester based cobalt concentrates for oxygen scavenging compositions.
This patent application is currently assigned to EASTMAN CHEMICAL COMPANY. Invention is credited to Thomas Roger Clark, Robert Noah Estep, Benjamin Bradford Gamble, Emerson Eston JR. Sharpe, Steven Lee Stafford, Mark Edward Stewart, James Carl Williams.
Application Number | 20080045637 11/843258 |
Document ID | / |
Family ID | 36578423 |
Filed Date | 2008-02-21 |
United States Patent
Application |
20080045637 |
Kind Code |
A1 |
Stewart; Mark Edward ; et
al. |
February 21, 2008 |
POLYESTER BASED COBALT CONCENTRATES FOR OXYGEN SCAVENGING
COMPOSITIONS
Abstract
A solid concentrate is provided having a combination of a
transition metal present in an amount ranging from 1,000 to 40,000
ppm (weight by metal) and a polyester polymer present in an amount
of at least 40 wt. % based on the weight of the concentrate.
Concentrates made with highly modified polyester polymers are easy
to compound with transition metals forming less brittle polymer
upon melt extrusion. Bottle preforms and oxygen scavenging bottles
can be made from these concentrates by combining solid polyester
particles, solid polyamide particles, and solid these concentrate
particles c into an melt processing zone, forming a melt, and
forming an article directly from the melt. The b* color and the L*
color and the haze levels of the preforms are improved over the
preforms made with liquid carriers instead of solid concentrates.
The particles are also advantageously simultaneously dried in a
drying zone under conditions effective to at least partially remove
moisture from the blend to thereby further improve the b* color and
L* color.
Inventors: |
Stewart; Mark Edward;
(Kingsport, TN) ; Sharpe; Emerson Eston JR.;
(Kingsport, TN) ; Gamble; Benjamin Bradford;
(Kingsport, TN) ; Stafford; Steven Lee; (Gray,
TN) ; Estep; Robert Noah; (Kingsport, TN) ;
Williams; James Carl; (Blountville, TN) ; Clark;
Thomas Roger; (Nazareth, PA) |
Correspondence
Address: |
JENNIFER R. KNIGHT
P.O. BOX 511
KINGSPORT
TN
37662-5075
US
|
Assignee: |
EASTMAN CHEMICAL COMPANY
P.O. Box 511
Kingsport
TN
37662
|
Family ID: |
36578423 |
Appl. No.: |
11/843258 |
Filed: |
August 22, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11292441 |
Dec 2, 2005 |
7288586 |
|
|
11843258 |
Aug 22, 2007 |
|
|
|
60633524 |
Dec 6, 2004 |
|
|
|
Current U.S.
Class: |
524/386 ;
524/391 |
Current CPC
Class: |
C08L 77/00 20130101;
C08K 5/098 20130101; C08L 67/02 20130101; C08L 2666/14 20130101;
Y10T 428/1352 20150115; C08K 5/098 20130101; Y10T 428/1383
20150115; C08L 67/02 20130101; C08L 67/02 20130101 |
Class at
Publication: |
524/386 ;
524/391 |
International
Class: |
C08K 5/053 20060101
C08K005/053; C08K 3/08 20060101 C08K003/08; C08K 3/10 20060101
C08K003/10 |
Claims
1. A process for the manufacture of a preform comprising: combining
(i) solid polyester particles comprising a polyester polymer; (ii)
solid polyamide particles comprising a polyamide polymer; and (iii)
solid concentrate particles comprising: (A) a transition metal
provided in an oxidation state other than zero and in an amount of
1,000 ppm to 40,000 ppm (by metal), based upon the weight of the
concentrate: and (B) polyester polymers in an amount of at least 40
wt. %, based on the weight of the concentrate, wherein at least a
portion of the polyester polymers comprise highly modified
polyester polymers containing (a) polycarboxylic acid modifier
residues in an amount ranging from 20 mole % to 60 mole %; and/or
(b) hydroxyl modifier residues in an amount ranging from 20 mole %
to 60 mole % based on 100 mole percent of the polycarboxylic acid
residues and 100 mole percent hydroxyl residues in the polyester
polymer into a melt processing zone, forming a melt, and forming a
preform directly from the melt.
2. The process of claim 1, wherein the transition metal content
ranges from 1,000 ppm to 20,000 ppm.
3. The process of claim 2, wherein the transition metal content
ranges from 2,000 ppm to 10,000 ppm.
4. The process of claim 3, wherein the transition metal content
ranges from 3,000 ppm to 8,000 ppm.
5. The process of claim 1, wherein the transition metal comprises
cobalt, copper, rhodium, platinum, rhenium, ruthenium, palladium,
tungsten, osmium, cadmium, silver, tantalum, hafnium, vanadium,
titanium, chromium, nickel, zinc, or manganese.
6. The process of claim 1, wherein the transition metal is provided
as a compound comprising a carboxylate, oxide, borate, carbonate,
chloride, sioxide, hydroxide, nitrate, phosphate, sulfate,
silicate, or mixtures thereof.
7. The process of claim 6, wherein the carboxylate comprises
neodecanoates, octanoates, acetates, lactates, naphthalates,
malates, stearates, acetylacetonates, linoleates, oleates,
palmitates, 2-ethylhexanoates, or ethylene glycolates.
8. The process of claim 5, wherein the transition metal comprises
cobalt.
9. The process of claim 8, wherein the transition metal is provided
as a compound comprising cobalt neodecanoate, cobalt acetate, or
mixtures thereof.
10. The process of claim 9 wherein the transition metal is present
in an amount ranging from 2,000 ppm to 8,000 ppm (by metal) based
on the weight of the concentrate.
11. The process of claim 1, wherein the portion of highly modified
polyester polymers is at least 75 wt. % based on the total weight
of all polyester polymers present in the concentrate.
12. The process of claim 1, wherein the polyester polymer contained
in the polyester particles and/or the highly modified polyester
polymers contained in the concentrate particles comprise repeating
units of terephthalic acid residues, isophthalic acid residues,
naphthalienic acid residues, or mixtures thereof.
13. The process of claim 1, wherein said highly modified polyester
polymers are obtained by copolymerizing polycarboxylic acid
compounds with a hydroxyl compound and a hydroxyl modifier, such
that the polymer contains hydroxyl modifier residues in an amount
of at least 25 mole %, based on the moles of hydroxyl compound
residues present in the polymer.
14. The process of claim 13, wherein the amount of hydroxyl
modifier residues ranges from 30 mole % to 60 mole %, based on all
hydroxyl residues present in the polymer.
15. The process of claim 1, wherein the polyester polymer contained
in the polyester particles comprises: (i) a polycarboxylic acid
component comprising at least 92 mole % residues of terephthalic
acid, derivates of terephthalic acid, or mixtures thereof, and (ii)
a hydroxyl component comprising at least 40 mole % residues of
ethylene glycol; and/or the highly modified polyester polymer
contained in the concentrate particles comprises: (i) a
polycarboxylic acid component comprising at least 92 mole %
residues of terephthalic acid or derivates of terephthalic acid or
mixtures thereof, and (ii) a hydroxyl component comprising at least
40 mole % residues of ethylene glycol and at least 25 mole % and up
to 60 mole % residues of a hydroxyl modifier; each based on 100
mole percent of the polycarboxylic acid residues and 100 mole
percent hydroxyl residues in the polyester polymer.
16. The process of claim 1, wherein the hydroxyl modifier residue
comprises a residue of butanediol, 1,4-cyclohexane dimethanol,
2,4-dihydroxy-1,1,3,3-tetramethyl-cyclobutane, trimethylene glycol,
neopentyl glycol, or diethylene glycol or combinations thereof.
17. The process of claim 16, wherein the hydroxyl modifier residue
comprises a residue of 1,4-cyclohexane dimethanol.
18. The process of claim 1, wherein the concentrate is essentially
free of a polyamide polymer.
19. The process of claim 1, wherein the It.V. of the polyester
polymer contained in the polyester particles and/or the It.V. of
the highly modified polyester polymer provided to make the
concentrate is from 0.60 dL/g to 1.15 dL/g and is obtained without
solid state polymerization.
20. The process of claim 19, wherein the It.V. of the polyester
polymer contained in the polyester particles and/or the It.V. of
the highly modified polyester polymer provided to make the
concentrate is at least 0.70 dL/g.
21. The process of claim 1, wherein the concentrate particles have
an It.V. ranging from 0.60 dL/g to 1.15 dL/g.
22. The process of claim 21, wherein the concentrate particles have
an It.V. of at least 0.70 dL/g.
23. The process of claim 1, wherein the polyester polymer contained
in the polyester particles and/or the highly modified polyester
polymer contained in the concentrate is semicrystalline.
24. The process of claim 1, wherein the polyester polymer contained
in the polyester particles and/or the highly modified polyester
polymer contained in the concentrate is essentially amorphous and
has a DSC Tg of at least 70.degree. C.
25. The process of claim 1, wherein the transition metal is added
into a melt phase process for making the highly modified polyester
polymer.
26. The process of claim 1, wherein the concentrate is obtained by
melt compounding the highly modified polyester polymer with the
transition metal.
27. The process of claim 1, wherein the preform comprises a bottle
preform having a composition comprising from 1 to 10 wt. % of an
oxidizable polymer or an oxygen scavenging polymer, 30 to 300 ppm
cobalt, and polyester polymer present in an amount of at least 90
wt. %, each based on the weight of the preform.
28. The process of claim 27, wherein the preform comprises a bottle
preform having a composition comprising from 50 to 200 ppm
cobalt.
29. The process of claim 27, wherein the preform comprises a bottle
preform having a composition comprising from 1 to 5 wt. % of an
oxidizable polymer or an oxygen scavenging polymer.
30. The process of claim 29, wherein the preform comprises a bottle
preform having a composition comprising from 50 to 200 ppm
cobalt.
31. The process of claim 1, wherein the let down ratio of the
transition metal concentration in the concentrate to the transition
metal concentration in the preform composition ranges from 30:1 to
200:1.
32. The process of claim 31, wherein the let down ratio of the
transition metal concentration in the concentrate to the transition
metal concentration in the preform composition ranges from 30:1 to
100:1.
33. The process of claim 1, wherein the preform comprises the
transition metal present in an amount ranging from 30 ppm to 500
ppm based on the weight of the preform.
34. The process of claim 33, wherein the preform comprises the
transition metal present in an amount ranging from 50 ppm to 300
ppm based on the weight of the preform.
35. The process of claim 1, wherein the preform further comprises
zinc.
36. The process of claim 35, wherein the zinc is present in the
range of from 50 ppm to 300 ppm.
37. The process of claim 36, wherein the zinc is present in the
range of from 50 ppm to 150 ppm.
38. The process of claim 1, wherein the oxidizable polymer
comprises a polyamide polymer having repeating units with a
benzylic hydrogen atom.
39. The process of claim 38, wherein the polyamide polymer is
obtained from a reactant containing a xylylene moiety.
40. The process of claim 1, wherein the polyamide polymer has a
number average molecular weight Mn of 1,000 to 45,000.
41. The process of claim 40, wherein the polyamide polymer has a
number average molecular weight Mn of at least 3,500.
42. The process of claim 41, wherein the polyamide polymer has a
number average molecular weight Mn of less than 15,000.
43. The process of claim 1, wherein the polyester polymer
particles, the concentrate particles, and the polyamide polymer
particles are combined into the melt processing zone as individual
streams, as particle/particle dry blends, or as combinations
thereof.
44. The process of claim 1, further comprising combining an
additive comprising a colorant, acetaldehyde scavenger, reheat
agent, UV absorber or inhibitor, stabilizer, thermal stabilizer, or
mixtures thereof.
45. The process of claim 1, wherein the concentrate contains a
higher concentration of the transition metal than present in the
preform.
46. The process of claim 1, wherein neither the solid polyester
polymer particles nor the polyester polymer used to prepare the
concentrate are solid stated.
47. The process of claim 1, further comprising forming a bottle
from the preform, wherein the preform comprises 150 ppm or less of
cobalt based upon the weight of the preform, and wherein the bottle
has a sidewall haze of 4.0% or less.
48. The process of claim 47, wherein the bottle has a sidewall haze
of 3.5% or less.
49. A process for the manufacture of a preform comprising:
combining (i) solid polyester particles comprising a polyester
polymer comprising; (a) polycarboxylic acid component residues
comprising at least 80 mole % residues of terephthalic acid, or
derivates of terephthalic acid, or mixtures thereof; (b) hydroxyl
component residues comprising at least 40 mole % ethylene glycol;
based on 100 mole percent of the polycarboxylic acid residues and
100 mole percent hydroxyl residues in the polyester polymer; (ii)
solid polyamide particles comprising a polyamide polymer; and (iii)
solid concentrate particles comprising: (A) a transition metal
provided in an oxidation state other than zero and in an amount of
1,000 ppm to 40,000 ppm, based upon the weight of the concentrate:
and (B) polyester polymers in an amount of at least 80 wt. %, based
on the weight of the concentrate, wherein at least 50 wt % of the
polyester polymers comprise highly modified polyester polymers
containing (a) polycarboxylic acid component residues comprising at
least 80 mole % residues of terephthalic acid, or derivates of
terephthalic acid, or mixtures thereof; (b) hydroxyl component
residues comprising at least 40 mole % ethylene glycol, with at
least 20 mole % to 60 mole % of residues of a hydroxyl modifier
based on 100 mole percent of the polycarboxylic acid residues and
100 mole percent hydroxyl residues in the polyester polymer; and
(C) wherein the concentrate is free of polyamide polymer; into a
melt processing zone, forming a melt, and forming a preform
directly from the melt.
50. The process of claim 49, wherein the transition metal content
ranges from 1,000 ppm to 20,000 ppm.
51. The process of claim 50, wherein the transition metal content
ranges from 2,000 ppm to 10,000 ppm.
52. The process of claim 51, wherein the transition metal comprises
cobalt, copper, rhodium, platinum, rhenium, ruthenium, palladium,
tungsten, osmium, cadmium, silver, tantalum, hafnium, vanadium,
titanium, chromium, nickel, zinc, or manganese.
53. The process of claim 49, wherein the transition metal is
provided as a compound comprising a carboxylate, oxide, borate,
carbonate, chloride, sioxide, hydroxide, nitrate, phosphate,
sulfate, silicate, or mixtures thereof.
54. The process of claim 53, wherein the carboxylate comprises
neodecanoates, octanoates, acetates, lactates, naphthalates,
malates, stearates, acetylacetonates, linoleates, oleates,
palmitates, 2-ethylhexanoates, or ethylene glycolates.
55. The process of claim 52, wherein the transition metal comprises
cobalt.
56. The process of claim 55, wherein the transition metal is
provided as a compound comprising cobalt neodecanoate, cobalt
acetate, or mixtures thereof.
57. The process of claim 49, wherein the portion of highly modified
polyester polymers is at least 75 wt. % based on the total weight
of all polyester polymers present in the concentrate.
58. The process of claim 49, wherein the highly modified polyester
polymers are obtained by copolymerizing polycarboxylic acid
compounds with a hydroxyl compound and a hydroxyl modifier, such
that the polymer contains hydroxyl modifier residues in an amount
of at least 25 mole %, based on the moles of hydroxyl compound
residues present in the polymer.
59. The process of claim 58, wherein the amount of hydroxyl
modifier residues ranges from 30 mole % to 60 mole %, based on all
hydroxyl residues present in the polymer.
60. The process of claim 49, wherein the hydroxyl modifier residue
comprises a residue of butanediol, 1,4-cyclohexane dimethanol,
2,4-dihydroxy-1,1,3,3-tetramethyl-cyclobutane, trimethylene glycol,
neopentyl glycol, or diethylene glycol or combinations thereof.
61. The process of claim 60, wherein the hydroxyl modifier residue
comprises a residue of 1,4-cyclohexane dimethanol.
62. The process of claim 49, wherein the It.V. of the polyester
polymer contained in the polyester particles and/or the It.V. of
the highly modified polyester polymer provided to make the
concentrate is from 0.60 dL/g to 1.15 dL/g and is obtained without
solid state polymerization.
63. The process of claim 62, wherein the It.V. of the polyester
polymer contained in the polyester particles and/or the It.V. of
the highly modified polyester polymer provided to make the
concentrate is at least 0.70 dL/g.
64. The process of claim 49, wherein the concentrate particles have
an It.V. ranging from 0.60 dL/g to 1.15 dL/g.
65. The process of claim 64, wherein the concentrate particles have
an It.V. of at least 0.70 dL/g.
66. The process of claim 49, wherein the polyester polymer
contained in the polyester particles and/or the highly modified
polyester polymer contained in the concentrate is
semicrystalline.
67. The process of claim 49, wherein the polyester polymer
contained in the polyester particles and/or the highly modified
polyester polymer contained in the concentrate is essentially
amorphous and has a DSC Tg of at least 70.degree. C.
68. The process of claim 49, wherein the transition metal is added
into a melt phase process for making the highly modified polyester
polymer.
69. The process of claim 49, wherein the concentrate is obtained by
melt compounding the highly modified polyester polymer with the
transition metal.
70. The process of claim 49, wherein the preform comprises a bottle
preform having a composition comprising from 1 to 10 wt. % of an
oxidizable polymer or an oxygen scavenging polymer, 30 to 300 ppm
cobalt, and polyester polymer present in an amount of at least 90
wt. %, each based on the weight of the preform.
71. The process of claim 70, wherein the preform comprises a bottle
preform having a composition comprising from 50 to 200 ppm
cobalt.
72. The process of claim 70, wherein the preform comprises a bottle
preform having a composition comprising from 1 to 5 wt. % of an
oxidizable polymer or an oxygen scavenging polymer.
73. The process of claim 72, wherein the preform comprises a bottle
preform having a composition comprising from 50 to 200 ppm
cobalt.
74. The process of claim 49, wherein the let down ratio of the
transition metal concentration in the concentrate to the transition
metal concentration in the preform composition ranges from 30:1 to
200:1.
75. The process of claim 74, wherein the let down ratio of the
transition metal concentration in the concentrate to the transition
metal concentration in the preform composition ranges from 30:1 to
100:1.
76. The process of claim 49, wherein the preform comprises the
transition metal present in an amount ranging from 30 ppm to 500
ppm based on the weight of the preform.
77. The process of claim 76, wherein the preform comprises the
transition metal present in an amount ranging from 50 ppm to 300
ppm based on the weight of the preform.
78. The process of claim 49, wherein the preform further comprises
zinc.
79. The process of claim 78, wherein the zinc is present in the
range of 50 ppm to 300 ppm.
80. The process of claim 79, wherein the zinc is present in the
range of 50 ppm to 150 ppm.
81. The process of claim 49, wherein the oxidizable polymer
comprises a polyamide polymer having repeating units with a
benzylic hydrogen atom.
82. The process of claim 81, wherein the polyamide polymer is
obtained from a reactant containing a xylylene moiety.
83. The process of claim 49, wherein the polyamide polymer has a
number average molecular weight Mn of 1,000 to 45,000.
84. The process of claim 83, wherein the polyamide polymer has a
number average molecular weight Mn of at least 3,500.
85. The process of claim 84, wherein the polyamide polymer has a
number average molecular weight Mn of less than 15,000.
86. The process of claim 49, wherein the polyester polymer
particles, the concentrate particles, and the polyamide polymer
particles are combined into the melt processing zone as individual
streams, as particle/particle dry blends, or as combinations
thereof.
87. The process of claim 49, further comprising combining an
additive comprising a colorant, acetaldehyde scavenger, reheat
agent, UV absorber or inhibitor, stabilizer, thermal stabilizer, or
mixtures thereof.
88. The process of claim 49, wherein the concentrate contains a
higher concentration of the transition metal than present in the
preform.
89. The process of claim 49, wherein the transition metal comprises
cobalt neodecanoate or cobalt acetate present in an amount ranging
from 2,000 ppm to 8,000 ppm (by metal) based on the weight of the
concentrate.
90. The process of claim 49, further comprising forming a bottle
from the preform, wherein the preform comprises 150 ppm or less of
cobalt based upon the weight of the preform, and wherein the bottle
has a sidewall haze of 4.0% or less.
91. The process of claim 90, wherein the bottle has a sidewall haze
of 3.5% or less.
92. A process for the manufacture of a preform comprising:
combining (i) solid polyester particles comprising a polyester
polymer comprising; (a) polycarboxylic acid component residues
comprising at least 92 mole % residues of terephthalic acid, or
derivates of terephthalic acid, or mixtures thereof; (b) hydroxyl
component residues comprising at least 40 mole % ethylene glycol,
based on 100 mole percent of the polycarboxylic acid residues and
100 mole percent hydroxyl residues in the polyester polymer; and
(ii) solid polyamide particles comprising a polyamide polymer; and
(iii) solid concentrate polymer comprising: (A) a transition metal
provided in an oxidation state other than zero and in an amount of
1,000 ppm to 20,000 ppm, based upon the weight of the concentrate:
and (B) highly modified polyester polymers in an amount of at least
80 wt. %, based on the weight of the concentrate, comprising: (a)
polycarboxylic acid component residues comprising at least 92 mole
% residues of terephthalic acid, or derivates of terephthalic acid,
or mixtures thereof; (b) hydroxyl component residues comprising at
least 40 mole % ethylene glycol, with at least 20 mole % to 60 mole
% of residues of 1,4-cyclohexane dimethanol, diethylene glycol, or
mixtures thereof based on 100 mole percent of the polycarboxylic
acid residues and 100 mole percent hydroxyl residues in the
polyester polymer; and (C) wherein the concentrate is free of
polyamide polymer; into a melt processing zone, forming a melt, and
forming a preform directly from the melt.
Description
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S.
application Ser. No. 11/292,441, filed Dec. 2, 2005, which claims
the benefit of U.S. Provisional Application Ser. No. 60/633,524
filed Dec. 6, 2004, fully incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention pertains to the manufacture of polyester
preforms and bottles, and more particularly to a concentrate
containing at least a polyethylene terephthalate polymer and
cobalt, useful for providing oxygen scavenging compositions,
preforms, bottles and other articles.
BACKGROUND OF THE INVENTION
[0003] Packaging for food, beverages and in particular beer and
fruit juices, cosmetics, medicines, and the like are sensitive to
oxygen exposure and require high barrier properties to oxygen and
carbon dioxide to preserve the freshness of the package contents
and avoid changes in flavor, texture and color. Blends containing
small amounts of high barrier polyamides, such as poly(m-xylylene
adipamide), typically known commercially as MXD6, with polyesters
such as poly(ethylene terephthalate), PET, enhance the passive
barrier properties of PET.
[0004] To further reduce the entry of oxygen into the contents of
the package, small amounts of transition metal salts, such as
cobalt salts, can be added to the blend of PET and polyamide to
catalyze and actively promote the oxidation of the polyamide
polymer, thereby further enhancing the oxygen barrier
characteristics of the package. The use of such active oxygen
scavengers, which chemically remove oxygen migrating through the
walls of the package, can be a very effective method to reduce the
oxygen transmission rates of plastics used in packaging. While
currently available scavengers have found some utility, they also
suffer from a variety of drawbacks that include lengthy induction
periods before full activity is achieved and/or life spans
(capacities) which are too short. In some instances, these
deficiencies can be partially addressed by increasing the level of
oxygen scavenger in the package structure. However, this typically
increases the cost of the final package and produces undesirable
effects on the appearance of the package, such as adding haze or
color. In addition, increasing the concentration of the oxygen
scavenger can complicate manufacture and recycling of the package.
Thus, there is a need for improved oxygen scavenging materials that
rapidly achieve high scavenging rates.
[0005] Transition metal salts have been added to PET polymers and
to blends of PET polymers with polyamide polymers to impart active
oxygen scavenging activity. Typical methods for incorporating these
metal salts into the PET composition include feeding the metal
contained in a liquid carrier into an extruder along with a feed of
bulk PET pellets. Alternatively, a metal such as cobalt is
frequently added to a melt phase process for the production of PET,
such that the PET pellets already contain cobalt when fed to the
extruder. In this method, the metal salts can be added in low
concentrations corresponding to the desired concentration in the
article, or in higher concentrations to form a masterbatch.
However, adding metal salts to a melt phase process for making the
polymer may result in discoloration or the generation of excessive
levels of other undesirable byproducts such as diethylene glycol
and acetaldehyde at the high temperature conditions and long
residence times employed in a PET polymerization reactor. This
condition is exacerbated if the metal is added early or the
residence time of the polymer melt containing the transition metal
is lengthy.
[0006] We have found that deficiencies in the oxygen scavenging
activity are partly attributable to the form in which the
transition metal is added to PET. We have also found that when
cobalt is added to a bulk polyester polymer in a form of a solid
concentrate comprising a polyester carrier, a number of advantages
are realized.
SUMMARY OF THE INVENTION
[0007] There is now provided a solid concentrate obtained by melt
compounding a transition metal in an amount ranging from 1000 ppm
to 40,000 ppm (by metal) and a polyester polymer having an It.V. of
at least 0.55 dL/g in an amount of at least 40 wt. %, each based on
the weight of the concentrate. By melt compounding, one has greater
flexibility to use polyester polymers with higher IV to compensate
for IV breakdown under melt conditions, to provide for a short
residence time of the metal in the melt, and to make a blend under
milder conditions that is typically encountered in a finisher or
final reactor for making the polymer. Articles made from the
concentrates of the invention may also more effectively scavenge
oxygen compared to articles made from polyester polymers to which
the transition metal was added in the melt phase. There is also
provided a process for the manufacture of a preform comprising
combining solid polyester particles comprising polyester polymers,
solid polyamide particles comprising polyamide polymers, and a
solid concentrate obtained by melt compounding a transition metal
compound in an amount ranging from 1000 ppm to 40,000 ppm and a
polyester polymer having an It.V. of at least 0.55 dL/g in an
amount of at least 40 wt. %, each based on the weight of the
concentrate, into a melt processing zone, forming a melt, and
forming an article directly from the melt.
[0008] There is also provided a drying process, comprising
simultaneously drying in a drying zone a blend comprising solid
polyester particles comprising polyester polymers, solid polyamide
particles comprising polyamide polymers, and a solid concentrate
comprising a polyester polymer and a transition metal present in an
amount ranging from 1000 ppm to 40,000, under conditions effective
to at least partially remove moisture from the blend.
[0009] There is further provided a solid concentrate comprising a
polyester polymer concentrate comprising a transition metal in an
amount of at least 1000 ppm, and polyester polymers in an amount of
least 40 wt. %, each based on the weight of the concentrate,
wherein at least a portion of the polyester polymers comprise
highly modified polyester polymers containing hydroxyl modifier
residues in an amount ranging from 20 mole % to 60 mole %, based on
the all the moles of hydroxyl compound residues present in the
polyester polymer and/or polycarboxylic acid modifiers in an amount
ranging from 20 mole % to 60 mole %, based on all the moles of
polycarboxylic acid residues present in the polyester polymer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a graphical illustration of the oxygen
transmission rate over time of bottles made from compositions of
the invention compared to resin compositions in which the cobalt
was added by other means
[0011] FIG. 2 is a graphical illustration of the oxygen
transmission rate over time of bottles made from various
compositions encompassed by the invention
[0012] FIG. 3 is a graphical illustration of the oxygen
transmission rate over time of bottles made from additional
compositions encompassed by the invention
[0013] FIG. 4 is a also graphical illustration of the oxygen
transmission rate over time of bottles made from additional
compositions encompassed by the invention
[0014] FIG. 5 is a graphical illustration of the long term
preformance of the oxygen transmission rate over time of bottles
made from additional compositions encompassed by the invention
[0015] FIG. 6 is a graphical illustration of the oxygen
transmission rate over time of bottles made from compositions in
which cobalt was added to the polyester during the melt
polymerization step
[0016] FIG. 7 is a graphical illustration of the oxygen
transmission rate over time of bottles made from compositions of
the invention compared to a resin composition in which the cobalt
was added via a liquid concentrate
[0017] FIG. 8 is a graphical illustration of the oxygen
transmission rate over time of bottles made from additional
compositions of the invention compared to a resin composition in
which the cobalt was added via a liquid concentrate
[0018] FIG. 9 is a graphical illustration of the oxygen
transmission rate over time of additional bottles made from
compositions of the invention compared to resin compositions in
which the cobalt was via liquid concentrates
[0019] FIG. 10 is a graphical illustration of the oxygen partial
pressure over time in sealed ampoules containing compositions of
the invention in which the components of the blend were "Codried"
compared to similar compositions in which the components were not
dried together prior to the injection molding step
DETAILED DESCRIPTION OF THE INVENTION
[0020] The present invention may be understood more readily by
reference to the following detailed description of the
invention.
[0021] It must also be noted that, as used in the specification and
the appended claims, the singular forms "a," "an" and "the" include
plural referents unless the context clearly dictates otherwise. For
example, reference to processing or making a "polymer," a
"preform," "article," "container," "concentrate" or "bottle" is
intended to include the processing or making of a plurality of
polymers, preforms, articles, containers or bottles. References to
a composition containing "an" ingredient or "a" polymer is intended
to include other ingredients or other polymers, respectively, in
addition to the one named.
[0022] By "comprising" or "containing" or "obtained by" is meant
that at least the named compound, element, particle, or method step
etc. must be present in the composition or article or method, but
does not exclude the presence of other compounds, catalysts,
materials, particles, method steps, etc., even if the other such
compounds, material, particles, method steps etc. have the same
function as what is named, unless expressly excluded in the
claims.
[0023] It is also to be understood that the mention of one or more
method steps does not preclude the presence of additional method
steps before or after the combined recited steps or intervening
method steps between those steps expressly identified. Moreover,
the lettering of process steps is a convenient means for
identifying discrete activities or steps, and unless otherwise
specified, recited process steps can be arranged in any sequence.
Expressing a range includes all integers and fractions thereof
within the range. Expressing a minimum or up to a temperature or a
temperature range in a process, or of a reaction mixture, or of a
melt or applied to a melt, or of a polymer or applied to a polymer
means in all cases that the reaction conditions are set to the
specified temperature or any temperature, continuously or
intermittently, within the range or above the lower stated amount
or below the upper stated amount; and that the reaction mixture,
melt or polymer are subjected to the specified temperature as set
points and it is not required that the particular reaction mixture,
melt or polymer actually reach or remain at that particular
temperature.
[0024] The intrinsic viscosity values described throughout this
description are set forth in dL/g units as calculated from the
inherent viscosity measured at 25.degree. C. in 60/40 wt/wt
phenol/tetrachloroethane according to the calculations immediately
prior to Example 1 below.
[0025] The L* value is a measure of brightness. This value is
measured in accordance with ASTM D 1746 for discs, plaques,
preforms or bottle sidewalls (transmission mode). Color measurement
theory and practice are discussed in greater detail in "Principles
of Color Technology", pp. 25-66 by John Wiley & Sons, New York
(1981) by Fred W. Billmeyer, Jr. Brightness is measured as L* in
the CIE 1976 opponent-color scale, with 100% representing a
colorless sample transmitting 100% at all wavelengths. An L* of 100
in a colorless sample in the transmittance mode would be perfectly
transparent, while an L* of 0 in a colorless sample would be
opaque.
[0026] When catalyzed with appropriate transition metals, such as
cobalt, blends of polyesters with polyamides can scavenge oxygen,
producing articles with very low oxygen transmission rates.
Addition of cobalt to such blends by way of a concentrate
comprising at least a polyester polymer and the transition metal
provides at least one advantage, if not a combination of several
advantages, over other methods of incorporating the cobalt, such as
liquid carrier addition or in other embodiments adding the metal to
the melt phase for the manufacture of the polyester polymer.
[0027] Not all embodiments will achieve all the advantages
described herein. However, at least one of the advantages can be
obtained in one or more of the embodiments described herein, such
advantages being: [0028] liquid carriers can volatilize when
introduced to warm (from the drying step) polyester and/or
polyamide pellets, either at the injection molding machine, or in a
separate preblending step. Volatilization can be significantly
reduced or eliminated through the use of a solid polyester based
metal concentrate; [0029] the addition of the solid concentrate
results in easier clean up than addition of cobalt in a liquid
carrier; [0030] a solid concentrate of transition metal and
polyester is more stable than the corresponding liquid carrier
containing the transition metal. For example, cobalt in a liquid
carrier may settle resulting in concentration variation throughout
the sample of carrier. We have also noticed significant changes
over time in the flow characteristics of some liquid concentrates,
while polyester based cobalt concentrates are stable; [0031] the
color of preforms and bottles stretch blow molded from the preforms
containing polyamides and made with the cobalt containing solid
concentrates have better b* and L* color than those made with
cobalt contained in a liquid carrier; [0032] significant
flexibility in the process for making blends of polyester,
polyamide and cobalt. In particular, the concentrate approach
allows all materials, including the concentrate pellets, polyester
pellets and polyamide pellets, to be mixed and then conveyed in
conventional PET processing equipment and dried at normal PET
drying conditions. Surprisingly, this "codrying" results in
materials with better color than similar compositions prepared
using liquid concentrates where the polyester and polyamide
components are dried separately prior to mixing; [0033] by using
solid concentrates containing cobalt over liquid carriers
containing cobalt, the haze level of bottle preforms is reduced
when the cobalt is obtained from a solid cobalt concentrate
relative to a comparable preform containing the same or less amount
of cobalt obtained from a liquid carrier; [0034] the addition of
cobalt through the use of solid concentrates is more effective as
an oxidation catalyst than cobalt which has been added during the
melt phase polymerization of the bulk polyester polymer; and [0035]
highly modified polyester polymers compounded with the transition
metals are easier to pelletize because such concentrates are not as
brittle and form fewer sticks compared to the same concentrates
made with polyester polymers which are only slightly modified.
[0036] In a first embodiment, there is provided a solid concentrate
obtained by melt compounding a transition metal compound in an
amount ranging from 1000 ppm to 40,000 ppm (by metal) and a
polyester polymer having an It.V. of at least 0.55 dL/g in an
amount of at least 40 wt. %, each based on the weight of the
concentrate.
[0037] In all embodiments, the pellet concentrate is a solid when
measured at 1 atmosphere and at 25.degree. C. In the first
embodiment, the concentrate contains a transition metal, added
during melt compounding, present in an amount ranging from 1000 ppm
to 40,000 based on the metal atom content. In one embodiment, the
amount of metal is suitable to provide a preform containing from 30
ppm, or from 50 ppm up to 500 ppm, or up to 300 ppm transition
metal. As used throughout, a stated ppm range of metal, or "by
metal" is based on the weight of the metal component of the metal
compound added and not on the weight of the metal compound.
Suitable amounts of metal within the concentrate range from at
least 1500 ppm, or at least 2000 ppm, or at least 2500 ppm.
Concentrates may contain amounts of metal within the concentration
range of at least 1000 ppm, or at least 2,000 ppm, or at least
3,000 ppm, and up to 40,000 ppm, or up to 20,000 ppm, or up to
15,000 ppm, or up to 10,000 ppm, or up to 8000 ppm, or up to 7000,
or up to 6000, or less than 5000. The amount of metal may be
measured by X-ray fluorescence (X-Ray) or Inductively Coupled
Plasma-Mass Spectrometry (ICP).
[0038] The type of transition metal present in the concentrate is
effective to activate or promote the oxidation of an oxidizable
polymer such as a polyamide polymer. The mechanism by which these
transition metals function to activate or promote the oxidation of
the polyamide polymer is not certain. For convenience, these
transition metals are referred to herein as an oxidation catalysts,
but the name does not imply that the mechanism by which these
transition metals function is in fact catalytic or follows a
catalytic cycle. The transition metal may or may not be consumed in
the oxidation reaction, or if consumed, may only be consumed
temporarily by converting back to a catalytically active state. As
noted in U.S. Pat. No. 5,955,527, incorporated fully herein by
reference, a measure of the catalyst may be lost in side reactions,
or the catalyst may be viewed as an initiator "generating free
radicals which through branching chain reactions leads to the
scavenging of oxygen out of proportion to the quantity of
"catalyst"."
[0039] Suitable examples of transition metals include cobalt,
copper, rhodium, platinum, rhenium, ruthenium, palladium, tungsten,
osmium, cadmium, silver, tantalum, hafnium, vanadium, titanium,
chromium, nickel, zinc, and manganese. Preferred is cobalt.
[0040] The use of the word "metal", or any of the specific metals
such as cobalt, means the metal in any oxidation state. Examples of
cobalt include cobalt added to or at least a portion of which is
present in the +2 or +3 oxidation state in the concentrate, or
cobalt metal in the 0 oxidation state as elemental cobalt. Most
preferred is cobalt added in the +2 oxidation state.
[0041] In an oxidation state other than 0, a metal is typically
added or present as a salt, oxide, or other counter-ion. Suitable
counter-ions to the metal among others include carboxylates, such
as neodecanoates, octanoates, acetates, lactates, naphthalates,
malates, stearates, acetylacetonates, linoleates, oleates,
palmitates, 2-ethylhexanoates, or ethylene glycolates; oxides;
borates; carbonates; chlorides; dioxides; hydroxides; nitrates;
phosphates; sulfates; or silicates and mixtures thereof.
[0042] Concentrates containing about 2000 to 8000 ppm cobalt, with
cobalt added in +2 oxidation state in the form of a salt are
preferred. Cobalt neodecanoate and cobalt acetate are examples of
preferred salts. Cobalt neodecanoate is particularly preferred.
[0043] The concentrates of the first embodiment may be prepared by
a variety of melt compounding methods known in the art. Any
suitable equipment designed to melt the polyester polymer pellets,
to combine the components of the concentrate, and mix them may be
used. Alternatively, the functions may be performed in more than
one piece of equipment. This may be in continuous or batch
processes. Example of equipment that may be used include, but are
not limited to, two-roll mills, two rotor mixers with open mixing
chambers, internal mixers with a single rotor, internal mixers with
multiple counterrotating rotors, internal mixers with multiple
corotating rotors, internal mixers with multiple mixing chambers,
single screw extruders, planetary screw extruders, corotating twin
screw extruders, counterrotating twin screw extruders conical
extruders, and the like. These mixing devices are well known in the
art and described in many references, such as W. Michaeli,
"Plastics Processing: An Introduction", Carl Hanser Verlag, Munich,
1995; "Polymer Mixing: Technology and Engineering", J. L. White, A.
Y. Coran and A. Moet, Eds., Carl Hanser Verlag, Munich, 2001; and
"Plastics Compounding: Equipment and Processing", D. B. Todd, Ed.,
Carl Hanser Verlag, Munich, 1998.
[0044] Alternatively, the components may also be mixed using static
mixers in which the mixing elements are stationary and the mixing
is accomplished by multiple reorientations of a melt stream
containing the molten polymer and the cobalt salt as it flows
through the static elements, or molten polymer may be mixed with
the cobalt salt in stirred vessels.
[0045] The cobalt salt may be a mixture of cobalt salts and may be
fed neat into the process for production of the concentrate, or in
a suitable carrier.
[0046] In a preferred embodiment, manufacture of a solid polyester
concentrate containing cobalt is accomplished by either dry feeding
a separate stream or streams of polyester pellet base resin(s) and
a separate stream of cobalt containing additive such as cobalt
neodecanoate or by dry blending the polyester with the cobalt
additive which may then be fed together to the melt processing zone
of a twin-screw compounder such as manufactured by Werner &
Pfleiderer for melt mixing at approximately 450-550 F and
dispersing of the cobalt into the polyester matrix. The
polyester/cobalt melt mixture is then quenched in water and cut
into cylindrical pellets for further use in downstream application.
The solidified pellets or concentrate can be used either in its
amorphous form or it can be crystallized by agitating and heating
above 300.degree. F. for an extended time.
[0047] The concentrate also comprises a solid polyester polymer in
an amount of at least 40 wt. %, or at least 50 wt. %, or at least
60 wt. %, or at least 80 wt. %, or at least 90 wt. %, or at least
95 wt. %, or at least 98 wt. % or at least 99 wt. %, based on the
weight of the concentrate. In one embodiment, the concentrate is
essentially free of polymers other than a polyester polymer.
[0048] The polyester polymers contained in the solid concentrate
may be the same as or different from bulk polyester polymer fed to
the melt processing zone for making the article. Suitable polyester
polymers are those which are solid at 1 atmosphere and at
25.degree. C. Preferred polyester polymers are those which contain
aromatic repeating units, such as those containing repeating units
of terephthalic acid residues, isophthalic acid residues, or
naphthalenic acid residues. Polyethylene terephthalate,
poly(dimethyl cyclohexane terephthalate), polytrimethylene
terephthalate, polyethylene naphthalate, and copolymers thereof
modified with up to 60 mole % of a modifier are preferred.
[0049] Suitable polyethylene terephthalate homopolymers and
copolymers are modified with one or more polycarboxylic acid
modifiers in a cumulative amount of 40 mole % or less, or 25 mole %
or less, or 15 mole % or less, or mole % or less, or 8 mole % or
less, and/or one or more hydroxyl compound modifiers in an amount
of 60 mol % or less, or 50 mole % or less, or 15 mole % or less, or
10 mole % or less, or 8 mole % or less (collectively referred to
for brevity as "PET") and polyethylene naphthalate homopolymers and
copolymers modified with a cumulative amount of 40 mole % or less,
or less than 15 mole %, or 10 mole % or less, or 8 mole % or less,
of one or more polycarboxylic acid modifiers or modified less than
60 mol %, or less than 50 mole %, or less than 15 mole %, or 10
mole % or less, or 8 mole % or less of one or more hydroxyl
compound modifiers (collectively referred to herein as "PEN"), and
blends of PET and PEN. A modifier polycarboxylic acid compound is a
compound other than an acid compound present in an amount of
greater than 50 mole %. A modifier h hydroxyl compound is a
compound other than ethylene glycol.
[0050] The preferred polyester polymer is polyalkylene
terephthalate, and most preferred is PET.
[0051] In a second embodiment, there is provided a polyester
polymer concentrate comprising at least 1000 ppm of a transition
metal, and polyester polymers in an amount of least 40 wt. %, each
based on the weight of the concentrate, wherein at least a portion
of the polyester polymers comprise highly modified polyester
polymers containing hydroxyl modifier residues in an amount ranging
from 20 mole % to 60 mole %, based on the all the moles of hydroxyl
compound residues present in the polyester polymer and/or
polycarboxylic acid modifiers in an amount ranging from 20 mole %
to 60 mole %, based on all the moles of polycarboxylic acid
residues present in the polyester polymer. Desirably, the amount of
highly modified polyester polymers is at least 25 wt. %, or at
least 50 wt. %, or at least 75 wt. %, or at least 80 wt. %, or at
least 90 wt. %, or at least 95 wt. %, or up to 100 wt. %, of the
total amount of polyester polymers present in the concentrate. The
technique for manufacturing the concentrate in this second
embodiment is not particularly limited.
[0052] The metal content in the second embodiment is not
particularly limited. Preferably, the transition metal
concentration content in the second embodiment is preferably at
least 1000 ppm, or at least 2,000 ppm, or at least 3,000 ppm, and
up to 40,000 ppm, or up to 20,000 ppm, or up to 15,000 ppm, or up
to 10,000 ppm, or up to 8000 ppm, or up to 7000, or up to 6000, or
less than 5000.
[0053] At least a portion of the polyester polymers used in the
concentrate of this second embodiment contain are copolymerized
with a polycarboxylic acid or hydroxyl modifier, more preferably a
hydroxyl modifier, such that the polymer contains the residues of
the modifier used in an amount of at least 20 mole %, or at least
25 mole %, or at least 30 mole %, and up to 60 mole %, based on the
moles of corresponding polycarboxylic acid residues or hydroxyl
compound residues present in the polymer. Desirably, the modifier
and especially the hydroxyl modifier is copolymerized in an amount
ranging from 25 mole % to 60 mole %, or 25 mole % to 50 mole %, or
30 mole % to 50 mole %, based on the corresponding residues present
in the polymer.
[0054] We have found that highly modified polyester polymers
compounded with the transition metals are easier to pelletize
because such blends are not as brittle compared to the same blends
made with polyester polymers which are only slightly modified.
Fewer "sticks" are formed during extrusion and cutting. A "stick"
is a rod which forms as a result of strands breaking at the cutter
blades. Sticks are characterized as rod shaped instead of pellet
shaped, often exceeding a length of 1/8''. Such sticks are
undesirable when fed at the throat of an injection molding
machine.
[0055] Since the highly modified polymers are less brittle when
compounded with transition metals, higher loadings of transition
metal into the polyester polymer are also now possible. Further, by
using highly modified polyester polymers, the processing
temperature of the melt in an extruder can lowered.
[0056] In this second embodiment, the transition metal may be added
into the melt phase process for making the polyester polymer or may
be added by melt compounding with a polyester polymer. However, it
is preferred to add the transition metal by melt compounding the
highly modified polyester polymer with the transition metal to
obtain more advantages as noted above with respect to melt
compounding.
[0057] More particularly, in this embodiment and preferably in
other embodiments as described herein, the preferred polyester
polymer used in the concentrate comprises: [0058] (i) a
polycarboxylic acid component comprising at least 60 mole %, or at
least 85 mole %, or at least 92 mole %, or at least 94 mole %,
residues of terephthalic acid, derivates of terephthalic acid,
naphthalene-2,6-dicarboxylic acid, derivatives of
naphthalene-2,6-dicarboxylic acid, or mixtures thereof, and [0059]
(ii) a hydroxyl component comprising at least 40 mole %, or at
least 50 mole %, and up to 80 mole % residues of ethylene glycol,
with at least 20 mole %, or at least 25 mole %, or at least 30 mole
%, and up to 60 mole %, of residues of a hydroxyl modifier based on
100 mole percent of the polycarboxylic acid residues and 100 mole
percent hydroxyl residues in the polyester polymer.
[0060] The reaction of a polycarboxylic acid compound with a
hydroxyl compound during the preparation of the polyester polymer
is not restricted to the stated mole % ratios since one may utilize
a large excess of a hydroxyl compound if desired, e.g. on the order
of up to 200 mole % relative to the 100 mole % of polycarboxylic
acid used. The polyester polymer made by the reaction does,
however, contain the stated amounts of aromatic dicarboxylic acid
residues and hydroxyl residues. Derivates of terephthalic acid and
naphthalane dicarboxylic acid include C.sub.1-C.sub.4
dialkylterephthalates and C.sub.1-C.sub.4 dialkylnaphthalates, such
as dimethylterephthalate and dimethylnaphthalate
[0061] In addition to a diacid component of terephthalic acid,
derivates of terephthalic acid, naphthalene-2,6-dicarboxylic acid,
derivatives of naphthalene-2,6-dicarboxylic acid, or mixtures
thereof, the polycarboxylic acid component(s) of the present
polyester may include one or more additional modifier
polycarboxylic acids. Such additional modifier polycarboxylic acids
include aromatic dicarboxylic acids preferably having 8 to 14
carbon atoms, aliphatic dicarboxylic acids preferably having 4 to
12 carbon atoms, or cycloaliphatic dicarboxylic acids preferably
having 8 to 12 carbon atoms. Examples of modifier dicarboxylic
acids useful as an acid component(s) are phthalic acid, isophthalic
acid, cyclohexanedicarboxylic acid, cyclohexanediacetic acid,
diphenyl-4,4'-dicarboxylic acid, succinic acid, glutaric acid,
adipic acid, azelaic acid, sebacic acid, and the like, with
isophthalic acid, naphthalene-2,6-dicarboxylic acid, and
cyclohexanedicarboxylic acid being most preferable. It should be
understood that use of the corresponding acid anhydrides, esters,
and acid chlorides of these acids is included in the term
"polycarboxylic acid". It is also possible for trifunctional and
higher order polycarboxylic acids to modify the polyester.
[0062] The hydroxyl component is made from hydroxyl compounds,
which are compounds containing 2 or more hydroxyl groups capable of
reacting with a carboxylic acid group. Preferred hydroxyl compounds
contain 2 or 3 hydroxyl groups, more preferably 2 hydroxyl groups,
and preferably are C.sub.2-C.sub.4 alkane diols, such as ethylene
glycol, propane diol, and butane diol, among which ethylene glycol
is most preferred for container applications.
[0063] In addition to these diols, other modifier hydroxyl compound
component(s) may include diols such as cycloaliphatic diols
preferably having 6 to 20 carbon atoms and/or aliphatic diols
preferably having 3 to 20 carbon atoms. Examples of such diols
include diethylene glycol; propane-1,3-diol and butane-1,4-diol
(each of which are considered modifier hydroxyl compounds if
ethylene glycol residues are present in the polymer in an amount of
greater than 50 mole % based on the moles of all hydroxyl compound
residues); triethylene glycol; 1,4-cyclohexanedimethanol;
pentane-1,5-diol; hexane-1,6-diol; 3-methylpentanediol-(2,4);
neopentyl glycol; 2-methylpentanediol-(1,4);
2,2,4-trimethylpentane-diol-(1,3); 2,5-ethylhexanediol-(1,3);
2,2-diethyl propane-diol-(1,3); hexanediol-(1,3);
1,4-di-(hydroxyethoxy)-benzene;
2,2-bis-(4-hydroxycyclohexyl)-propane;
2,4-dihydroxy-1,1,3,3-tetramethyl-cyclobutane;
2,2-bis-(3-hydroxyethoxyphenyl)-propane; and
2,2-bis-(4-hydroxypropoxyphenyl)-propane. Typically, polyesters
such as polyethylene terephthalate are made by reacting a glycol
with a dicarboxylic acid as the free acid or its dimethyl ester to
produce an ester monomer and/or oligomers, which are then
polycondensed to produce the polyester.
[0064] Preferred modifiers include isophthalic acid, naphthalenic
dicarboxylic acid, trimellitic anhydride, pyromellitic dianhydride,
butanediol, 1,4-cyclohexane dimethanol,
2,4-dihydroxy-1,1,3,3-tetramethyl-cyclobutane, trimethylene glycol,
neopentyl glycol, and diethylene glycol.
[0065] The amount of the polyester polymer in the formulated
polyester polymer composition ranges from greater than 50.0 wt. %,
or from 80.0 wt. %, or from 90.0 wt. %, or from 95.0 wt. %, or from
96.0 wt. %, or from 97 wt. %, and up to about 99.90 wt. %, based on
the combined weight of all polyester polymers and all other
polymers. The formulated polyester polymer compositions may also
include blends of formulated polyester polymer compositions with
other thermoplastic polymers such as polycarbonate. It is preferred
that the polyester composition should comprise a majority of the
formulated polyester polymer composition of the inventions, more
preferably in an amount of at least 80 wt. %, or at least 90 wt. %,
based on the weight of the composition (excluding fillers,
inorganic compounds or particles, fibers, impact modifiers, or
other polymers serve as impact modifiers or which form a
discontinuous phase such as may be found in cold storage food
trays).
[0066] The polyester polymers can be prepared by polymerization
procedures known in the art sufficient to effect esterification and
polycondensation. Polyester melt phase manufacturing processes
include direct condensation of a dicarboxylic acid with the diol,
optionally in the presence of esterification catalysts, in the
esterification zone, followed by polycondensation in the prepolymer
and finishing zones in the presence of a polycondensation catalyst;
or ester exchange usually in the presence of a transesterification
catalyst in the ester exchange zone, followed by prepolymerization
and finishing in the presence of a polycondensation catalyst, and
each may optionally be solid stated according to known methods.
[0067] In one embodiment, the It.V. of the concentrates made with
highly modified polyester polymers ranges from about at least 0.60,
or at least 0.70, or at least 0.75, and up to about 1.15 dL/g.
[0068] In another embodiment, the It.V. of the polyester polymers
used to make the concentrate in a melt compounding process, and
prior to preparation of the concentrate, ranges from about at least
0.55, or at least 0.65, or at least 0.70, or at least 0.75, and up
to about 1.15 dL/g. In this embodiment, the concentrates are made
by melt compounding the elements together.
[0069] The molten polymer from the melt phase polymerization may be
allowed to solidify and/or obtain any degree of crystallinity from
the melt. Alternatively, the molten polymer can be first solidified
and then crystallized from the glass.
[0070] In yet another embodiment, the polyester polymers used to
make the concentrate in a melt compounding process, or the
concentrates themselves made with highly modified polyester
polymers regardless of their method of preparation, preferably have
an It.V. of at least 0.68 dL/g, or at least 0.70 dL/g, or at least
0.72 dL/g, or at least 0.76 dL/g, and even at least 0.80 dL/g, such
It.V. obtained in the melt phase for the manufacture of the
polyester polymer. In other words, the It.V. of the polyester
polymer to which is blended the metal is obtained without solid
state polymerizing the polymer. Providing a polyester polymer with
high It.V. obtained in the melt phase polycondensation reaction
avoids the expensive and time consuming step of solid state
polymerizing the polymer to increase its It.V.
[0071] The polyester polymers in the concentrate may be either
semicrystalline or essentially amorphous in nature. However, if the
resulting polyester is essentially amorphous (5% crystallinity or
less), compositions having a DSC Tg of about 70.degree. C. or
greater are preferred.
[0072] The polyester polymer composition used as the bulk polyester
polymer fed to the melt processing zone also has a composition
within the scope of the foregoing description. The composition of
the polyester polymer in the concentrate can be tailored through
incorporation of comonomers such as 1,4 cyclohexanedimethanol,
isophthalic acid, naphthalene dicarboxylic acid, diethylene glycol,
and other modifiers to adjust properties of the final polyester
blend such as Tg and crystallization kinetics, or as needed to
match the composition of the bulk polyester polymer fed to the melt
processing zone for making the article.
[0073] The composition of the article is not particularly limited.
Examples of compositions are those in which a metal is effective to
enhance the reheat rate of preforms and trays, reduce the
coefficient of friction of bottles, impact modify, and scavenge
oxygen, relative to the same compositions which do not contain the
metal. For example, there is provided an article comprising an
oxidizable polymer or oxygen scavenging polymer in an amount
ranging from about 1 to about 10%, or from 1 to 5 wt. %, from about
30 to 300 ppm, or 50 to 200 ppm, of a transition metal such as Co,
and a polyester polymer present in an amount ranging from about 90
wt. % to 99 wt. % based on the weight of all ingredients contained
in the article. In such compositions, at least a portion of the
total amount of transition metal present in the article is added to
a melt processing zone by way of a solid concentrate containing the
metal. In an oxygen scavenging composition, the article also
preferably contains zinc in an amount ranging from 50 ppm to 300
ppm, preferably from 50 ppm to 150 ppm.
[0074] In all cases, the concentrate will contain a higher
concentration of the metal than present in the article composition.
Let down ratios of the metal concentration in the concentrate to
the metal concentration in the article composition can range from
30:1 up to 200:1.
[0075] Any conventional process used to add concentrates to a bulk
stream of polymer in a melt processing zone for making the article
is suitable. For example, pellets of polyester, scavenger and
polyester based cobalt concentrate can be blended, either prior to
or after drying, and fed to an injection molding machine or
extruder, followed by melt blending and forming into an article
such as a preform. Alternatively, the pellets may be fed to the
melt processing zone as individual streams, or in a combination of
streams with one or more of the streams being a combination of two
or more types of pellets.
[0076] An article which is effective to scavenge oxygen contains an
oxidizable polymer in addition to the polyester polymer. Oxidizable
polymers include polymers having an active methylene group, such as
may be found on allylic group hydrogen atoms, benzylic group
hydrogens, and alpha oxyalkylene hydrogens. Such hydrogen atoms may
be expressed in the following respective structural moieties or
repeating units as being linked to the carbons illustrated in bold:
##STR1## wherein R is a hydrogen or an alkyl group.
[0077] Examples of oxidizable polymers include polyamide polymers,
and copolymers of .alpha.-olefins such as 1,4-butadiene with a
polyester polymer. Most preferred are oxidizable polyamide
polymers, especially those containing a benzylic hydrogen. From a
viewpoint of their commercial availability, cost, and performance,
preferred polyamides are obtained from a reactant containing a
xylylene moiety, or a m-xylylene moiety, or a polymer containing
any one of these residues in the polymer chain. More preferred
examples include poly(m-xylylene adipamide) modified or unmodified
polyamides, and poly(m-xylylene adipamide-co-isophthalamide)
modified or unmodified polyamides. The polyamide polymer has a
number average molecular weight Mn of 45,000 or less, or 35,000 or
less, or 25,000 or less, or 15,000 or less, or 12,000 or less, or
8,000 or less, or 5,500 or less and greater than 1,000, or greater
than 3,500. While such low molecular weight polyamide polymers are
not considered to be of film forming molecular weight, their low
molecular weight increases the terminal amino group concentration
relative to using higher molecular weight polyamide polymers.
[0078] The concentrate of the invention is preferably substantially
free of a polyamide polymer. In an oxygen scavenging composition,
we have found that articles made from bulk polyester polymers fed
to a melt processing zone along with a single stream of concentrate
pellets made by melt blending a polyamide polymer, a polyester
polymer, and a metal such as cobalt surprisingly do not scavenge
oxygen as effectively as those made by feeding bulk polyester
polymer pellets to a melt processing zone along with two other
distinct streams of pellets, one comprising concentrates made by
melt blending a polyester polymer with the metal and another stream
comprising polyamide polymer pellets. Accordingly, the concentrate
particles of the invention are preferably substantially free of
(e.g. less than 0.5 wt. %), and more preferably does not contain
any added polyamide polymer.
[0079] The polyester polymer particles, the concentrate particles,
and the polyamide polymer particles may be fed to the melt
processing zone as individual streams or as combined streams of
particle/particle dry blends. In this preferred embodiment, the
polyamide polymers are not melt blended with the polyester polymers
in the concentrates. Preferably, the oxygen scavenging polymer is
fed to a melt processing zone as a distinct separate stream from
the concentrate particles.
[0080] Thus, in another embodiment, there is provided a process for
the manufacture of a preform comprising combining solid polyester
particles comprising polyester polymers, solid polyamide particles
comprising polyamide polymers, and solid concentrate particles
obtained by melt compounding together a polyester polymer in an
amount of at least 40 wt. % and a transition metal in an amount
ranging from 1000 ppm to 40,000 ppm, based on the weight of the
solid concentrate particles, into an melt processing zone, forming
a melt, and forming an article directly from the melt. In this
embodiment, it is more preferred that the solid concentrate is
substantially free of a polyamide polymer.
[0081] The polyester polymer and metal are separately, or in
combination, optionally dried in an atmosphere of dried air or
dried nitrogen. In one method of incorporation, the polyester
polymer particles and the metal are melt compounded, for example,
in a single or twin screw extruder. After completion of the melt
compounding, the extrudate is withdrawn in strand form, and
recovered according to the usual way such as cutting. By using a
highly modified polyester polymer, the strands are less brittle
when drawn through the water bath prior to cutting, resulting in
fewer strands shattering and fewer sticks, and providing the
benefit that higher loadings of transition metal are now
possible.
[0082] One the transition metal concentrate pellets are made, they
are fed into a melt extrusion zone for making the article. A
separate stream of polyester polymer particles, a third stream
containing a source of polyamide polymer, and optionally a fourth
stream containing other additives such as colorant, acetaldehyde
scavengers, reheat agents, UV absorbers or inhibitors, stabilizers,
thermal stabilizers, etc., are fed to a melt processing zone for
making the article, and the concentrate is let down into the melt
processing zone in an amount to provide the desired level of metal
in the finished article.
[0083] In yet another embodiment a blend comprising solid polyester
particles comprising polyester polymers, solid polyamide particles
comprising polyamide polymers, and a solid concentrate comprising a
polyester polymer and a transition metal present in an amount
ranging from 1000 ppm to about 40,000 ppm are simultaneously dried
in a drying zone, under conditions effective to at least partially
remove moisture from the blend. In this embodiment, the method for
making the concentrate is not particularly limited, and the types
of polyester polymers used and their molecular weight as determined
by It.V. are also not limited. The moisture level of the blend of
particles can be reduced down to less than 0.015 wt. %, or less
than 0.010 wt. %, or less than 0.005 wt. %. In an apparatus
containing a drying zone, radiant or convective heat, or
electromagnetic or microwave radiation, or any other source for
removal of moisture, is emitted from a drying zone or is passed
through at least a portion of the mechanical drying zone and
contacts the particle blend to remove at least a portion of surface
and/or internal water moisture. Surprisingly, this co-drying method
eliminates the need for multiple dryers and results in better color
(higher L*, lower, b*, lower Yl) than when the polyamide and
polyester are dried separately and cobalt is added via a liquid
concentrate.
[0084] In another embodiment, the preforms obtained using
concentrates have lower haze than those obtained by using cobalt in
a liquid carrier at comparable levels of cobalt. The haze levels of
bottle sidewalls made from preforms containing 150 ppm or less of
cobalt using the concentrates is preferably 4.0% or less, or 3.5%
or less.
[0085] The articles obtained by the concentrates of the invention
may be extruded products such as sheets and fibers, or injection
molded articles such as bottle preforms and other shapes. In a
preferred embodiment, the articles produced from the melt
processing zone are the preforms, sheets, and trays for packaging
food, pharmaceuticals, medical supplies, and beverages.
[0086] The articles are obtained directly from the melt in the melt
processing zone for forming the articles. By directly is meant that
the melt present in the melt processing zone for making the article
is not pelletized and then remelted at later date to form the
article.
[0087] The following non-limited examples further illustrate
various embodiments of the invention.
EXAMPLES
Oxygen Transmission Rate (OTR) Procedure
[0088] The oxygen transmission rate test is performed using stretch
blow molded bottles. The bottles are fitted following blow molding
for oxygen package transmission testing. Prior to measurement, the
bottle is sealed by gluing it to a brass plate that is connected to
a 4 way valve over the finish. This mounting technique seals the
bottle, while allowing for control of test gas access. The mounting
is assembled as follows. First a brass plate is prepared by
drilling two 1/8 inch holes into the plate. Two lengths of 1/8 soft
copper tubing (which will be designated A and B) are passed through
the holes in the plate and the gaps between the holes and the tubes
are sealed with epoxy glue. One end of each of these tubes is
attached to the appropriate ports on a 4-way ball valve (such as
Whitey model B-43YF2). Tubing (which will be designated C and D)
and connections are also attached to the other ports of the ball
valve to allow the finished assembly to be connected to an Oxtran
oxygen permeability tester (Modern Control, Inc. Minneapolis,
Minn.).
[0089] This mounting is then glued to the finish of the bottle to
be tested so that tubes A and B extend into the interior of the
bottle. The open end of one tube is positioned near the top of the
package and the open end of the other is positioned near the bottom
to ensure good circulation of the test gas within the bottle.
Gluing is typically performed in two steps using a quick setting
epoxy to make the initial seal and temporarily hold the assembly
together and then a second coating of a more rugged Metalset epoxy
is applied. If desired the brass plate may be sanded before
mounting to clean the surface and improve adhesion. If the 4 tubes
are correctly connected to the 4-way valve, then when the valve is
in the "Bypass" position, tubes A and B communicate and tubes C and
D communicate, but tubes A and B do not communicate with tubes C
and D. Thus the package is sealed. Similarly, when the valve is in
its "Insert" position, tubes A and D communicate and tubes B and C
communicate, but A and D do not communicate with tubes B and C,
except through the interior of the bottle. Thus the bottle can be
swept with purge or test gas.
[0090] Once the bottle is mounted on the assembly, it is swept with
an oxygen-free gas, and the conditioning period begins. After
several minutes of purging, the 4-way valve is moved to the Bypass
position, sealing the bottle. At that point the entire bottle and
mounting assembly may be disconnected from the purge gas supply
without introducing oxygen into the interior of the bottle.
Typically 2 or 3 bottles of each formulation are mounted for
testing.
[0091] When the oxygen transmission rate of the bottle is to be
tested, it is placed inside an environmental chamber. Under normal
operation these chambers control the external conditions at
23.degree. C. plus or minus 1.degree. C. and 50% relative humidity
plus or minus 10%. These chambers contain tubing connections to an
Oxtran 1050 or Oxtran 1050A instrument and the mounting is
connected to the Oxtran tester via tubes C and D. Carrier gas
(nitrogen containing on the order of 1% hydrogen), which is
humidified using a bubbler, is supplied to the instruments and the
tubing in the environmental chamber. Both the Oxtran 1050 and 1050A
use a coulometric sensor to measure oxygen transmission rates and
both have positions for 10 samples to be mounted on the instrument
at one time. Typically, 9 test bottles and 1 control package were
run in a set. Once samples were mounted in the chamber, the 4-way
valve is turned to the Insert position and the system is allowed to
recover from the perturbation caused by this process.
[0092] After allowing the system to recover, the test is then begun
by "inserting" the instrument sensor in-line. The test sequence is
controlled by a specially written LabView.TM. software interface
for the instrument. Basically, the instrument automatically
advances through the test cells using a preset interval that allows
the instrument to stabilize after each cell change as the test gas
from the bottle mounted on the cell is routed through the
coulometric sensor, generating a current. That current is passed
through a resistor, which creates a voltage that is proportional to
the oxygen transmission rate of the package plus the leak rate of
that cell and package assembly. Typically the instrument is allowed
to index through each of the cells 3 or more times and the average
of the last 3 measurements is used. Once these readings are
obtained, the 4-way valves are moved to their Bypass positions and
this process is repeated, providing a measure of the leak rate for
the cell and assembly. This value is subtracted from the value
obtained for the package, cell and assembly to yield the value for
the package. This value is corrected for the average barometric
pressure in the laboratory and reported as the oxygen transmission
rate (OTR) of the bottle (in either cc(STP) of oxygen/day or .mu.l
(STP) of oxygen/day). At this point the test is terminated and the
bottles are removed from the instrument (with the 4-way valves
still in the Bypass position).
[0093] Between tests, bottles are stored at ambient (RH, lighting,
barometric pressure) conditions in a lab (22.degree. C. plus or
minus 4.degree. C.) with the interior isolated from air. After a
period of time, the bottle is reconnected to the Oxtran and a new
set of transmission measurements collected. In this manner, it is
possible to monitor the behavior of the bottle over several weeks
or months.
[0094] The following cobalt concentrates were used in the examples
[0095] Solid Concentrate 1: is a polyester based concentrate of
cobalt neodecanoate (TEN-CEM.TM. 22.5%) in Polyester Polymer Resin
3. The concentrate can be made by mixing the cobalt salt into Resin
3 melt using a 30 mm Werner & Pfleiderer twin screw extruder.
The approximate level of cobalt in the concentrate is 3400 to 3900
ppm. Concentrate 1 is the concentrate for Examples 1, 2, 3, 6, 7
and 8. [0096] Solid Concentrate 2 is a polyester based concentrate
of cobalt acetate in Polyester Polymer Resin 4 produced by mixing
the cobalt salt into a PET melt using a 30 mm Werner &
Pfleiderer twin screw extruder. The approximate level of cobalt in
the concentrate is 3400 to 3900 ppm. [0097] Liquid Concentrate 1 is
a concentrate of cobalt neodecanoate in a liquid dispersion with
approximately 63,000 to 68,000 ppm cobalt. [0098] Liquid
Concentrate 2 is concentrate of cobalt neodecanoate in a liquid
dispersion with approximately 35,000 to 40,000 ppm cobalt. [0099]
PA-A: is a poly(m-xyxlenediamine adipamide) commercially available
from Mitsubishi Gas Chemical America, Inc., New York, N.Y. as MXD-6
grade 6007. [0100] PA-B: is a poly(m-xyxlenediamine adipamide)
commercially available from Mitsubishi Gas Chemical America, Inc.,
New York, N.Y. as MXD-6 grade 6121. [0101] Polyester Polymer Resin
1: About a 0.87 intrinsic viscosity (It.V.) solid stated polyester
polymer composition containing residues of dimethyl terephthalate,
ethylene glycol, and cyclohexane dimethanol, with cyclohexane
dimethanol residues representing about 1.8 mol % of the glycol
residues, containing Ti, Mn, and Sb metal residues, phosphorus,
iron, and UV dye and red and blue toners. [0102] Polyester Polymer
Resin 2: About a 0.80 ItV solid stated polyester polymer
composition containing residues of terephthalate acid, ethylene
glycol, and cyclohexane dimethanol, with cyclohexane dimethanol
residues representing about 1.5 mole % of the glycol residues and
red and blue toners and with Sb as a catalyst and phosphorus.
[0103] Polyester Polymer Resin 3: About a 0.80 ItV solid stated
polyester polymer composition containing residues of dimethyl
terephthalate, ethylene glycol, and cyclohexane dimethanol, with
cyclohexane dimethanol residues representing about 3.5 mol % of the
glycol residues, with red and blue toners and Ti, Mn and Sb
catalyst residues along with phosphorus. [0104] Polyester Polymer
Resin 4: About a 0.76 ItV solid stated polyester polymer
composition containing residues of dimethyl terephthalate, ethylene
glycol and cyclohexane dimethanol with cyclohexane dimethanol
residues representing about 1.8 mole % of the glycol residues, Sb,
phosphorus, and Zn catalyst residues, along with red and blue
toners. [0105] Polyester Polymer Resin 5: About a 0.78 It.V. solid
stated polyester polymer composition containing residues of
dimethyl terephthalate and ethylene glycol, cyclohexane dimethanol,
with cyclohexane dimethanol residues representing about 1.8 mol %
of the glycol residues with Zn and Sb catalyst residues,
phosphorous, Fe, along with UV dye and red and blue toners. [0106]
Polyester Polymer Resin 6: a 0.81 It.V. solid stated polyester
polymer composition containing residues of dimethyl terephthalate
and ethylene glycol, cyclohexane dimethanol, with cyclohexane
dimethanol residues representing about 1.8 mol % of the glycol
residues, with Zn and Sb catalyst residues, phosphorous, Fe, and UV
dye and red and blue toners [0107] Polyester Polymer Resin 7: a
0.82 It.V. solid stated polyester polymer composition containing
residues of dimethyl terephthalate and ethylene glycol, cyclohexane
dimethanol, with cyclohexane dimethanol residues representing about
1.8 mol % of the glycol residues, with Zn and Sb catalyst residues,
phosphorous, Fe, and UV dye and red and blue toners. [0108]
Polyester Polymer Resin 8: a 0.78 ItV solid stated polyester
polymer composition containing residues of dimethyl terephthalate
and ethylene glycol, Sb catalyst residue, phosphorous, Zn catalyst
residue, and cobalt in an amount of 55 to 65 ppm. [0109] Polyester
Polymer Resin 9: a 0.71 ItV solid stated polyester polymer
composition containing residues of dimethyl terephthalate, ethylene
glycol and dimethyl isophthalate with dimethyl isophthalate
residues representing about 2 mole % of the acid residues, Sb,
phosphorous, Zn, and cobalt in an amount of 60 to 90 ppm. [0110]
Polyester Polymer Resin 10: is a 0.76 ItV solid stated polyester
polymer composition containing residues of dimethyl terephthalate,
ethylene glycol and dimethyl isophthalate with dimethyl
isophthalate residues representing about 2 mole % of the acid
residues, Sb, phosphorous, Zn, and cobalt in an amount of 60 to 70
ppm. [0111] Polyester Polymer Resin 11: a 0.81 ItV solid stated
polyester polymer composition containing residues of dimethyl
terephthalate, ethylene glycol and dimethyl isophthalate with
dimethyl isophthalate residues representing about 1.9 mole % of the
acid residues, Sb, phosphorous, Mn, Ti, and cobalt in an amount of
100 to 110 ppm. [0112] Polyester Polymer Resin 12: About a 0.76 ItV
solid stated polyester polymer composition containing residues of
terephthalic acid, ethylene glycol and cyclohexane dimethanol with
cyclohexane dimethanol residues representing about 1.8 mole % of
the glycol residues, Sb, phosphorous, and red and blue toners.
[0113] Polyester Polymer Resin 13: About a 0.80 ItV solid stated
polyester polymer composition containing residues of dimethyl
terephthalate, ethylene glycol, and cyclohexane dimethanol, with
cyclohexane dimethanol residues representing about 4.5 mol % of the
glycol residues, with red and blue toners and Zn and Sb catalyst
residues along with phosphorus. [0114] Polyester Polymer Resin 14.
About a 0.80 ItV polyester polymer composition containing residues
of dimethyl terephthalate, ethylene glycol, and cyclohexane
dimethanol, with cyclohexane dimethanol residues representing about
31 mol % of the glycol residues, with red and blue toners and Ti
and Mn catalyst residues along with phosphorus. The It.V. of this
resin is obtained in a melt phase polymerization and is not solid
state polymerized. [0115] Polyester Polymer Resin 15. About a 0.80
ItV polyester polymer composition containing residues of dimethyl
terephthalate, ethylene glycol, and cyclohexane dimethanol, with
cyclohexane dimethanol residues representing about 31 mol % of the
glycol residues, with red and blue toners and Ti and Mn catalyst
residues along with phosphorus. The It.V. of this resin is obtained
in a melt phase polymerization and is not solid state
polymerized
[0116] The glycol portion of each of the PET resins also contains
low levels (less than 5 mol %) DEG residues, which are present as a
natural byproduct of the melt polymerization process and may also
be intentionally added as a modifier.
Example 1
[0117] This example demonstrates that it is preferred to let down
the concentrate free of added polyamide polymer into an injection
molding machine. 25 gram preforms and 20 oz straightwall bottles
were produced from the following (nominal) oxygen scavenging
compositions set forth in Table 1. TABLE-US-00001 Cobalt Method of
addition PA-A content amt to Melt Processing Zone Sample # (wt %)
(ppm) PA-A Cobalt 1 0 0 NA NA 2 3 0 Neat PA-A pellets NA 3 3 150
PA-A/Cobalt Concentrate 4 3 150 Neat PA-A pellets Solid Concentrate
1 5 3 70 Neat PA-A pellets Solid Concentrate 1 6 2 100 PA-A/Cobalt
Concentrate
[0118] The bulk polyester polymer pellets fed to the injection
molding machine is Polyester Polymer Resin 1. The concentrate used
in the preparation of samples 3 and 6 is a polyester based
concentrate of cobalt neodecanoate (TEN-CEM 22.5%) and PA-A in
Polyester Polymer Resin 3. The concentrate can be made by mixing
the cobalt salt and PA-A into Resin 3 using a 30 mm Werner &
Pfleiderer twin screw extruder. The approximate level of cobalt in
the concentrate is about 2000 ppm and the approximate level of PA-A
in the concentrate is 40%. The components of this concentrate were
dried prior to its preparation. The cobalt neodecanoate was dried
overnight at 40.degree. C. under vacuum, Polyester Polymer Resin 3
was dried with dehumidified air for 6 hrs at 325.degree. F., and
the PA-A was dried with dehumidified air for 6 hrs at 150.degree.
F.
[0119] The preforms are made by introducing the bulk Polyester
Polymer Resin 1 pellets and the sources of cobalt and/or PA-A by
the following method:
[0120] The PA-A and the PA-A/Co Concentrate were dried at 150 F
while the bulk PET resin was dried in a separate system at 325 F.
Solid Concentrate 1 was not dried. After drying but before
injection molding, the PA-A or PA-A/Co Concentrate, bulk PET, and
Solid Concentrate 1 were physically blended using a ribbon mixer.
The blend was fed into a drying hopper with a temperature set point
of 325 F, located directly over the feed throat of the injection
molding machine. Extruder and manifold temperatures were set at
275.degree. C. Clear preforms were molded using a Husky
LX160PET-P60/50-E42 and an 8 cavity, 25 gram preform mold with a 28
mm finish.
[0121] Straight wall, 20 oz., carbonated soft drink style
containers were blow molded using a Sidel SBO 2/3 at an output rate
of 1200 bottles/hour/mold. A water temperature setting of 50 F was
used to chill the blow mold cavities. Blow mold processing
conditions were adjusted to produce containers with equivalent
distribution of material throughout the bottle for each Sample to
be submitted for OTR testing. Material distribution was
characterized by dividing the container into sections and weighing
each section. Material distribution was also characterized by
measuring the thickness of the container wall using a Hall effect
sensor by Magna-Mike Model 8000. Oven power was the primary
adjustment made to achieve equivalent material distribution for
each Sample. Oven profile configuration and pre-blow timing were
also adjusted in some instances.
[0122] 2 bottles per set were mounted and purged with oxygen free
gas about 2 days after blowing and the OTR's of these samples were
tested periodically. Results of these tests are presented in Table
2. FIG. 1 is a graphical illustration of the data presented in
Table 2. As can be seen from the graph, the OTR of bottles made by
letting down the stream of solid concentrate pellets of melt
blended polyester polymers and cobalt, and a separate distinct
stream of PA-A polyamide polymer pellets was lower and the
induction period shorter than bottles made with a stream of
concentrate melt blended pellets of PA-A polyamide polymer,
polyester polymer, and metal. TABLE-US-00002 TABLE 2 Days Sample 1
Sample 2 Sample 3 Sample 4 Sample 5 Sample 6 since OTR OTR OTR OTR
OTR OTR blowing (cc/day) bottle # (cc/day) bottle # (cc/day) bottle
# (cc/day) bottle # (cc/day) bottle # (cc/day) bottle # 9 0.0559 2
0.0382 2 0.0367 2 0.0193 2 0.0364 2 0.0405 2 10 0.0571 1 0.0395 1
-- -- 0.0280 1 0.0379 1 13 0.0559 1 -- -- 0.0386 1 -- -- 0.0388 1
20 -- -- 0.0271 1 0.0383 2 0.0007 2 0.0286 2 46 0.0558 1 0.0360 1
0.0340 2 0.0006 2 0.0008 1 0.0342 1 49 0.0543 1 0.0374 2 0.0303 1
0.0008 1 -0.0036 2 0.0339 2 55 0.0523 1 0.0361 1 0.0320 2 0.0009 2
0.0007 1 0.0340 1 80 0.0515 2 -- -- 0.0268 2 0.0019 1 0.0009 1
0.0289 2 83 0.0525 1 0.0340 1 0.0239 1 0.0008 2 0.0012 2 0.0262 1
83 0.0501 2 0.0346 2 -- -- -- -- 0.0011 1 109 -- -- 0.0373 3 0.0277
1 0.0004 2 -- -- 0.0301 2 109 -- -- -- -- -- -- 0.0008 1 -- --
0.0300 1 158 0.0533 1 0.0277 1 0.0174 2 0.0010 1 0.0014 2 0.0223 2
158 0.0564 2 0.0327 2 0.0191 1 0.0007 2 0.0019 1 0.0222 1
Example 2
[0123] This example demonstrates that concentrates are effective at
catalyzing oxygen scavenging activity over a range of
compositions.
[0124] 25 gram preforms and 20 oz straightwall bottles were
produced from the following (nominal) oxygen scavenging
compositions set forth in Table 3. TABLE-US-00003 TABLE 3 PA target
Co amount Sample # Bulk PET amt (wt %) PA Type (ppm) 7 Resin 2 1
PA-A 100 8 Resin 2 3 PA-A 100 9 Resin 2 5 PA-A 100 10 Resin 2 3
PA-B 30 11 Resin 2 3 PA-B 150 12 Resin 2 5 PA-B 30 13 Resin 2 5
PA-B 150 14 Resin 1 3 PA-A 100
[0125] In Samples 7-14, the source of cobalt was Solid Concentrate
1. The amount of cobalt added to the melt processing zone in the
injection molding machine is varied to yield the stated amounts of
cobalt in the article. The stream of bulk polyester polymer
particles is as set forth in the second column of Table 3. The PA
was fed to the injection molding machine as a separate stream of
polyamide pellets.
[0126] The preforms and bottles are prepared by the following
method:
[0127] Both types of PA were dried at 150 F while the bulk PET
resin was dried in a separate system at 325 F. Solid Concentrate 1
was not dried. After dryng but before injection molding, the
selected PA, bulk PET, and Solid Concentrate 1 were physically
blended using a ribbon mixer. The blend was fed into a drying
hopper with a temperature set point of 325 F, located directly over
the feed throat of the injection molding machine. Extruder and
manifold temperatures were set at 536 F. Clear preforms were molded
using a Husky LX160PET-P60/50-E42 and an 8 cavity, 25 gram perform
mold with a 28 mm finish.
[0128] Straight wall, 20 oz., carbonated soft drink style
containers were blow molded using a Sidel SBO 2/3 at an output rate
of 1200 bottles/hour/mold. A water temperature setting of 50 F was
used to chill the blow mold cavities. Blow mold processing
conditions were adjusted to produce containers with equivalent
distribution of material throughout the bottle for each Sample to
be submitted for OTR testing. Material distribution was
characterized by dividing the container into sections and weighing
each section. Material distribution was also characterized by
measuring the thickness of the container wall using a Hall effect
sensor by Magna-Mike Model 8000. Oven power was the primary
adjustment made to achieve equivalent material distribution for
each Sample. Oven profile configuration and pre-blow timing were
also adjusted in some instances.
[0129] 3 bottles per set were mounted and purged with oxygen free
gas the day following blowing and the OTR's of these samples were
tested periodically. Results of these tests are presented in Table
4. FIGS. 2 through 4 graphically illustrate portions of the data
presented in Table 4. As shown in the Figures, each of the bottles
made from Concentrate 1 over a variety of cobalt concentrations, a
variety of polyamide polymers, and a variety of bulk polyester
polymers scavenge oxygen, although those containing about more than
50 ppm cobalt and/or more than 1 wt % of the polyamide polymer were
more effective. TABLE-US-00004 TABLE 4 Days Sample 7 Sample 8
Sample 9 Sample 10 Sample 11 Sample 12 Sample 13 Sample 14 since
OTR OTR OTR OTR OTR OTR OTR OTR blowing (cc/day) # (cc/day) #
(cc/day) # (cc/day) # (cc/day) # (cc/day) # (cc/day) # (cc/day) # 7
0.0463 3 0.0006 2 0.0034 2 0.0381 3 0.0195 2 0.0263 1 -0.0040 1
0.0378 3 7 -- -- -- -- -- -- -- -- -- -- 0.0266 2 -- -- -- -- 11
0.0523 2 0.0011 2 0.0006 1 0.0372 2 -- -- 0.0274 3 0.0015 2 0.0350
2 11 0.0499 1 0.0013 3 0.0012 3 -- -- -- -- -- -- -- -- -- -- 14 --
-- -- -- -- -- 0.0405 1 0.0017 3 -- -- -- -- 0.0257 1 14 -- -- --
-- -- -- -- -- 0.0013 1 -- -- -- -- -- -- 19 -- -- -- -- -- -- --
-- -- -- -- -- 0.0011 3 -- -- 32 0.0425 2 0.0005 1 0.0006 3 0.0332
3 0.0191 2 0.0054 2 0.0013 1 -- -- 32 0.0502 3 -- -- -- -- -- -- --
-- -- -- -- -- -- -- 36 -- -- -- -- -- -- -- -- -- -- 0.0032 1 --
-- -- -- 41 0.0280 1 0.0004 2 -0.0001 1 0.0079 1 0.0006 1 0.0019 3
-- -- 0.0035 2 41 -- -- 0.0012 3 -- -- -- -- -- -- -- -- -- -- --
-- 46 -- -- -- -- 0.0014 2 0.0098 2 0.0003 3 -- -- 0.0007 1 0.0061
1 46 -- -- -- -- -- -- 0.0355 1 -- -- -- -- -- -- 0.0018 3 53
0.0160 1 0.0009 3 0.0014 1 -- -- 0.0007 1 0.0018 3 -- -- -0.0011 2
53 -- -- -- -- -- -- -- -- 0.0003 3 -- -- -- -- -- -- 64 0.0504 3
0.0006 1 0.0005 3 -- -- -- -- -- -- 0.0008 2 -- -- 76 -- -- -- --
-- -- 0.0049 3 -- -- 0.0009 2 -- -- 81 0.0038 2 0.0004 2 -- -- --
-- 0.0189 2 0.0010 1 0.0007 3 -- -- 95 -- -- -- -- 0.0006 2 0.0322
1 -- -- -- -- 0.0008 1 0.0017 3 95 -- -- -- -- -- -- -- -- -- -- --
-- -- -- 0.0010 2 97 0.0024 1 0.0008 3 -- -- -- -- -- -- -- -- --
-- -- -- 103 0.0264 3 -- -- -- -- 0.0039 2 0.0006 1 -- -- 0.0006 3
-- -- 109 0.0208 3 -- -- -- -- 0.0032 2 0.0005 1 -- -- 0.0004 3 --
-- 113 -- -- 0.0009 1 -- -- -- -- 0.0008 3 0.0010 2 -- -- -- -- 113
-- -- -- -- -- -- -- -- -- -- 0.0023 3 -- -- -- -- 120 0.0074 2
0.0004 2 0.0007 1 0.0145 3 0.0158 2 0.0017 1 0.0003 2 0.0012 1 120
-- -- -- -- 0.0008 3 -- -- -- -- -- -- -- -- -- -- 123 0.0049 1 --
-- -- -- 0.0085 3 0.0007 3 -- -- -- -- -- -- 137 0.0089 2 -- -- --
-- 0.0252 1 0.0145 2 -- -- -- -- -- -- 137 0.0079 3 -- -- -- --
0.0069 2 0.0005 1 -- -- -- -- -- -- 152 -- -- -- -- 0.0034 2 -- --
-- -- 0.0022 3 -- -- 0.0007 3 158 -- -- 0.0006 1 -- -- -- -- 0.0006
3 -- -- 0.0004 1 0.0006 2 158 -- -- 0.0008 3 -- -- -- -- -- -- --
-- -- -- -- -- 165 0.0057 1 -- -- -- -- -- -- -- -- -- -- -- -- --
-- 165 0.0080 2 -- -- -- -- -- -- -- -- -- -- -- -- -- -- 187
0.0084 3 -- -- 0.0007 1 -- -- -- -- -- -- -- -- -- -- 268 0.0222 3
0.0011 2 -- -- -- -- -- -- -- -- -- -- -- -- 353 0.0295 3 0.0005 1
-- -- -- -- -- -- -- -- -- -- -- -- 363 0.0312 1 -- -- -- -- -- --
-- -- -- -- -- -- -- -- 363 0.0324 2 -- -- -- -- -- -- -- -- -- --
-- -- -- --
Example 3
[0130] This example demonstrates that solid concentrates are an
effective means for adding oxidation catalysts to a range of bulk
polyester polymer compositions. 25 gram preforms and 20 oz
straightwall bottles were prepared from the following compositions
using Solid Concentrate 1. TABLE-US-00005 TABLE 5 PA-A target amt
Measured Co Sample # Bulk PET (wt %) amount (ppm)* 15 Resin 1 3 101
16 Resin 5 3 95 17 Resin 6 3 86 18 Resin 7 3 93 *by XRF.
[0131] In Samples 15-18, the source of cobalt was Solid Concentrate
1. The amount of Solid Concentrate 1 added to the melt processing
zone in the injection molding machine is varied to yield the
amounts of cobalt set forth in Table 5. The stream of bulk
polyester polymer particles is as set forth in the second column of
Table 5. The PA-A was fed to the injection molding machine as a
separate stream of polyamide pellets.
[0132] The preforms and bottles are prepared by the following
method:
[0133] The PA-A was dried at 150 F while the bulk PET resin was
dried in a separate system at 325 F. Solid Concentrate 1 was not
dried. After drying but before injection molding, the PA-A, bulk
PET, and Solid Concentrate 1 were physically blended using a ribbon
mixer. The blend was fed into a drying hopper with a temperature
set point of 325 F, located directly over the feed throat of the
injection molding machine. Extruder and manifold temperatures were
set at 536 F. Clear preforms were molded using a Husky
LX160PET-P60/50-E42 and an 8 cavity, 25 gram preform mold with a 28
mm finish.
[0134] Straight wall, 20 oz., carbonated soft drink style
containers were blow molded using a Sidel SBO 2/3 at an output rate
of 1200 bottles/hour/mold. A water temperature setting of 50 F was
used to chill the blow mold cavities. Blow mold processing
conditions were adjusted to produce containers with equivalent
distribution of material throughout the bottle for each Sample to
be submitted for OTR testing. Material distribution was
characterized by dividing the container into sections and weighing
each section. Material distribution was also characterized by
measuring the thickness of the container wall using a Hall effect
sensor by Magna-Mike Model 8000. Oven power was the primary
adjustment made to achieve equivalent material distribution for
each Sample. Oven profile configuration and pre-blow timing were
also adjusted in some instances.
[0135] 3 bottles per set were mounted and purged with oxygen free
gas the day following blowing. OTR's of these samples were tested
periodically. Results of these tests are presented in Table 6 and
in the corresponding FIG. 5, which graphically illustrates the OTR
results in Table 6. TABLE-US-00006 TABLE 6 Sample 15 Sample 16
Sample 17 Sample 18 Days since OTR OTR OTR OTR blow (ccSTP/ (ccSTP/
(ccSTP/ (ccSTP/ molding day) bottle # day) bottle # day) bottle #
day) bottle # 4 0.0346 3 0.0016 1 0.0012 3 0.0012 2 4 -- -- 0.0012
2 0.0014 1 0.0017 1 4 -- -- -- -- 0.0011 2 -- -- 8 0.0323 2 0.0010
3 -- -- 0.0012 3 8 0.0327 1 -- -- -- -- -- -- 11 0.0283 1 -- -- --
-- -- -- 11 0.0237 2 -- -- -- -- -- -- 14 0.0256 1 -- -- -- -- --
-- 14 0.0193 2 -- -- -- -- -- -- 17 0.0142 3 -- -- -- -- -- -- 20
0.0194 1 0.0004 3 0.0003 3 0.0008 1 20 0.0083 3 -- -- -- -- -- --
21 0.0146 2 -- -- -- -- -- -- 24 0.0059 3 -- -- -- -- -- -- 24
0.0113 2 -- -- -- -- -- -- 24 0.0174 1 -- -- -- -- -- -- 29 0.0038
3 -- -- -- -- -- -- 29 0.0082 2 -- -- -- -- -- -- 29 0.0107 1 -- --
-- -- -- -- 36 0.0064 1 -- -- -- -- -- -- 36 0.0051 2 -- -- -- --
-- -- 38 0.0054 1 -- -- -- -- -- -- 38 0.0043 2 -- -- -- -- -- --
40 0.0037 1 0.0003 1 0.0007 2 0.0006 2 40 0.0031 2 -- -- -- -- --
-- 40 0.0018 3 -- -- -- -- -- -- 42 0.0029 1 -- -- -- -- -- -- 50
0.0017 1 -- -- -- -- -- -- 53 0.0012 2 0.0005 1 0.0003 2 0.0005 2
59 0.0006 3 59 0.0005 1 0.0004 1 0.0012 1 0.0002 3 70 0.0007 1
0.0010 1 0.0010 1 0.0003 3 80 0.0013 1 -- -- -- -- -- -- 89 0.0004
2 0.0004 2 0.0006 1 0.0002 2 89 0.0007 3 -- -- -- -- -- -- 96
0.0004 1 0.0006 2 0.0004 2 0.0004 3 102 -0.0013 2 0.0003 3 0.0006 1
0.0007 1 110 0.0004 1 0.0004 1 119 0.0006 3 0.0005 2 0.0004 2
0.0003 3 126 0.0003 2 -- -- -- -- -- -- 126 0.0006 1 -- -- -- -- --
-- 137 -0.0014 2 0.0024 1 0.0007 1 0.0003 2 150 0.0012 1 0.0003 3
0.0004 2 0.0003 3 174 0.0007 3 0.0002 3 0.0004 2 0.0003 1 174
-0.0016 1 -- -- -- -- -- -- 194 0.0008 1 0.0006 1 0.0008 1 0.0003 3
208 0.0005 2 -- -- -- -- -- -- 211 0.0003 3 0.0005 2 0.0006 2
0.0005 3 215 0.0005 1 -- -- -- -- -- -- 246 0.0008 1 0.0006 1
0.0009 1 0.0011 1 253 -0.0004 2 0.0009 3 -- -- -- -- 260 0.0008 1
-- -- 0.0012 2 0.0007 2 283 0.0008 3 0.0006 2 -- -- -- --
[0136] These examples further demonstrate that PET based cobalt
concentrates are effective at catalyzing the oxygen scavenging
activity over a range of bulk polyester compositions.
Example 4
[0137] This example illustrates that the addition of cobalt is not
effective as an oxidation catalyst if added to a polyester polymer
undergoing melt phase polymerization, whereas if added as a
concentrate, the composition actively scavenges oxygen. 37 gram
preforms and 16 oz bottles are prepared using the bulk PET resins
listed in Table 7. PA-A is first heat treated. The compositions of
these samples are set forth in Table 7. TABLE-US-00007 TABLE 7
Approximate Actual Co Level PA-A amt Sample # Bulk PET from X-ray:
(wt %) 19 Resin 8 62 1.2 20 Resin 9 88 1.5 21 Resin 10 68 1.6 22
Resin 11 105 1.3
[0138] In Samples 19-22, the presence of cobalt in the preforms was
solely as a result of adding cobalt acetate to the melt phase
reaction during polycondensation for the polymerization of the bulk
PET. None of the cobalt present in the sample was added by way of a
concentrate. The PA-A was fed to the injection molding machine as a
separate stream of polyamide pellets.
[0139] Preforms and bottles were prepared and mounted and purged
with oxygen free gas 12 days after blowing. The OTR's of these
samples were tested periodically. Results of these tests are
presented in Table 8, and graphically illustrated in FIG. 6. These
comparative examples demonstrate that about 60 to 100 ppm cobalt
added during the PET polymerization step is not effective at
catalyzing the oxygen scavenging reactions in PET/PA-A blends, even
though shown in other foregoing examples, this same level of cobalt
is effective when the cobalt is added by way of a solid
Concentrate. TABLE-US-00008 TABLE 8 Sample 19 Sample 20 Sample 21
Sample 22 Days since OTR OTR OTR OTR blowing (cc/day) Bottle #
(cc/day) Bottle # (cc/day) Bottle # (cc/day) Bottle # 16 -- --
0.0305 2 0.0294 2 0.0258 1 19 0.0353 2 0.0342 3 0.0287 1 0.0315 2
19 0.0349 3 -- -- -- -- -- -- 23 0.0288 2 0.0296 1 0.0291 3 0.0192
3 26 0.0274 2 0.0279 3 0.0268 2 0.0274 1 26 0.0284 3 -- -- -- -- --
-- 32 0.0328 3 0.0322 2 0.0334 1 0.0302 2 32 -- -- -- -- -- --
0.0258 3 39 0.0316 2 0.0322 1 0.0319 3 0.0302 1 45 0.0360 3 0.0323
3 0.0318 2 0.0294 2 45 -- -- -- -- -- -- 0.0247 3 47 0.0281 2
0.0286 2 0.0300 1 0.0266 1 61 0.0272 3 0.0274 1 0.0272 3 0.0258 2
73 0.0259 2 0.0260 3 -- -- -- -- 79 -- -- -- -- 0.0278 2 0.0163 3
82 0.0305 3 0.0301 2 0.0307 1 0.0281 1 93 -- -- -- -- -- -- 0.0269
2 98 0.0301 2 0.0315 1 0.0316 3 -- --
Example 5
[0140] This example demonstrates that the cobalt added by way of a
solid concentrate is as effective at catalyzing oxygen scavenging
reactions as cobalt added by way of a liquid carrier.
[0141] 48 gram preforms and 1 liter bottles were prepared using
Resin 5 as the bulk PET, PA-A pellets added neat, and two different
cobalt sources, LIQ1 and Solid Concentrate 2. The composition of
the preforms is as set forth in Table 9. TABLE-US-00009 TABLE 9 Co
PA-A Sample # Source Zn Co Sb P wt % 23 LIQ1 60 103 231 76 1.24 24
Conc 2 60 65 231 76 1.99 25 Conc 2 61 97 232 77 1.4 *by HNMR, metal
levels by XRF
[0142] The PA-A was fed to the injection molding machine as a
separate stream of polyamide pellets. The preforms and bottles are
prepared by the following method:
[0143] The PA-A was dried at 150 F while the bulk PET resin was
dried in a separate system at 325 F. The solid cobalt Concentrates
were dried overnight at 150.degree. F. After drying but before
injection molding, the PA-A, bulk PET, and Co Concentrate were
physically blended using a ribbon mixer. The blend was fed into a
drying hopper with a temperature set point of 325 F, located
directly over the feed throat of the injection molding machine.
Extruder and manifold temperatures were set at 536 F. Clear
preforms were molded using a Husky LX160PET-P60/50-E42 and a 4
cavity, 48 gram preform mold with a 43 mm finish.
[0144] One liter heatset containers were blow molded using a Sidel
SBO 2/3-HR at an output rate of 1000 bottles/hour/mold. An oil
temperature setting of 257 F was used to heat the blow mold
cavities. The water heating the mold base was set to a target
temperature of 176 F. Blow mold processing conditions were adjusted
to produce containers with equivalent distribution of material
throughout the bottle for each Sample to be submitted for OTR
testing. Material distribution was characterized by dividing the
container into sections and weighing each section. Material
distribution was also characterized by measuring the thickness of
the container wall using a Hall effect sensor by Magna-Mike Model
8000. Oven power was the primary adjustment made to achieve
equivalent material distribution for each Sample. Oven profile
configuration and pre-blow timing were also adjusted in some
instances.
[0145] 3 bottles of each set were mounted and purged with oxygen
free gas the day following blowing. OTR's were monitored
periodically. The results are set forth in Table 10 and graphically
illustrated in FIG. 7. TABLE-US-00010 TABLE 10 Sample 23 Sample 24
Sample 25 Days since OTR OTR OTR blowing (cc/day) Bottle # (cc/day)
Bottle # (cc/day) Bottle # 5 0.0574 1 0.0437 1 0.0461 1 5 -- -- --
-- 0.0435 2 8 0.0485 1 0.0138 1 0.0205 1 8 -- -- -- 0.0236 2 12
0.0290 2 0.0015 2 0.0024 3 12 -- -- 0.0011 3 -- -- 15 0.0193 3
0.0015 1 0.0010 1 15 -- -- -- -- 0.0016 2 18 0.0238 1 0.0008 2
0.0006 3 18 0.0020 2 0.0009 3 -- -- 22 0.0022 3 -- -- -- -- 27
0.0006 1 -- -- -- -- 27 0.0020 2 -- -- -- -- 44 0.0005 3 -- --
0.0001 3 47 -- -- 0.0004 3 -- -- 110 -- -- 0.0012 1 -- --
[0146] The results demonstrate that cobalt added by way of a solid
concentrate is at least as effective as cobalt added by way of a
liquid carrier. In addition, clean up was much quicker with the
samples prepared using solid concentrates, as the liquid carriers
left a residue on the equipment used to blend and feed the pellets
to the injection molding machine. This residue had to be physically
removed so that it did not contaminate the machine for future use.
This cleaning was time consuming. In contrast, any remaining
pellets of the solid concentrates could be quickly removed by
brushing or using compressed air to blow the solid concentrate off
of the equipment. In addition, spills of liquid concentrate outside
the blending and feed equipment presented the same clean up issues,
while spills of the solid concentrate were again much easier to
move. Since spills and formulation changes are to be expected in a
manufacturing operation, this represents a significant advantage
for the solid concentrate.
Example 6
[0147] This example illustrates the effectiveness of solid
concentrates at reducing haze relative to the addition of cobalt
added by way of a liquid carrier. 25 gram preforms and 20 oz
straightwall bottles were prepared from the compositions set forth
in Table 11. TABLE-US-00011 TABLE 11 Sample Bulk PET Co Source Co
level (ppm) PA-A wt % 26 Resin 12 Conc 1 103 1.23 27 Resin 4 Conc 1
126 1.39 28 Resin 5 Conc 1 113 1.31 29 Resin 5 LIQ2 101 1.33
[0148] PA-A was added neat as a separate stream of pellets. The
preforms were made by the following method:
[0149] The PA-A was used as received from an unopened bag without
further drying while the bulk PET resin was dried in a separate
system at 325 F. None of the cobalt Concentrates were dried. After
drying but before injection molding, the PA-A, bulk PET, and Co
Concentrate were physically blended using a ribbon mixer. The blend
was fed into a drying hopper with a temperature set point of 325 F,
located directly over the feed throat of the injection molding
machine. Extruder and manifold temperatures were set at 536 F.
Clear preforms were molded using a Husky LX160PET-P60/50-E42 and an
8 cavity, 25 gram preform mold with a 28 mm finish.
[0150] Straight wall, 20 oz., carbonated soft drink style
containers were blow molded using a Sidel SBO 2/3 at an output rate
of 1200 bottles/hour/mold. A water temperature setting of 50 F was
used to chill the blow mold cavities. Blow mold processing
conditions were adjusted to produce containers with equivalent
distribution of material throughout the bottle for each Sample to
be submitted for OTR testing. Material distribution was
characterized by dividing the container into sections and weighing
each section. Material distribution was also characterized by
measuring the thickness of the container wall using a Hall effect
sensor by Magna-Mike Model 8000. Oven power was the primary
adjustment made to achieve equivalent material distribution for
each Sample. Oven profile configuration and pre-blow timing were
also adjusted in some instances.
[0151] Sidewalls were cut from these bottles and mounted on Mocon
Oxtran 1000 instruments 3 days after blowing. On the instruments
one side of the sidewall was swept with humidified oxygen free
carrier gas and the other side was swept with humidified breathing
quality air and the apparent sidewall permeability (the oxygen flux
through the sidewall, times the average thickness of the sidewall,
divided by the driving force for permeation) was monitored over
time. Samples were maintained at 23.degree. C..+-.1.degree. C. for
the duration of the test.
[0152] These results (in cc(STP) mil/100 in.sup.2/day/atm) are
presented in Table 12 and the results for days 4 through 98 days
after blowing are graphically illustrated in FIG. 8. As can be seen
from FIG. 8, all samples scavenged oxygen, as at time greater than
about 5 days after blowing through the end of the test, the
apparent oxygen permeability for all Samples is less than 4, which
is the approximate value for PET sidewalls prepared under the same
conditions. TABLE-US-00012 TABLE 12 Apparent permeabilities
(cc(STP)mil/100 in.sup.2/day/atm) Days since blowing Sample 26
Sample 27 Sample 28 Sample 29 3 8.48 4.43 6.14 8.40 4 4.10 2.33
3.00 4.09 5 3.59 1.54 2.20 3.32 6 3.71 0.63 1.03 3.07 7 3.53 0.28
0.30 2.62 8 3.48 0.10 0.01 2.26 9 3.42 0.03 -0.02 1.24 10 3.32 0.02
-0.02 0.81 11 3.26 0.02 -0.01 0.58 14 2.86 0.02 0.01 0.08 18 2.14
0.02 0.03 0.03 21 1.69 0.01 0.00 0.00 24 1.37 -0.01 -0.03 -0.02 31
0.91 0.01 -0.02 -0.01 38 0.76 0.03 0.02 0.01 42 0.63 -0.02 -0.02
-0.04 46 0.54 0.02 0.04 0.01 49 0.49 0.00 -0.02 -0.02 56 0.33 -0.03
-0.02 -0.02 64 0.17 -0.03 -0.03 -0.02 72 0.13 -0.03 -0.01 -0.01 81
0.09 -0.01 0.04 -0.02 88 0.07 0.12 0.08 -0.01 98 0.10 0.03 0.01
0.01
[0153] The haze levels for sidewalls of each sample were also
measured according to ASTM D-1003 using a Gardner Haze meter. The
haze result for Sample 26 was 2.6%; for Sample 27 was 2.8%, for
Sample 28 was 3.65%, and for Sample 29 was 6.04%. Each of these
values represents the average of three sidewalls. The sample
containing the cobalt added by way of a liquid carrier has the
highest haze at comparable cobalt and polyamide loadings, while
preforms and bottles containing cobalt added by way of a solid
concentrate have reduced haze levels.
Example 7
[0154] This example illustrates the effect of liquid carriers and
solid concentrates on volatility and changes in viscosity. 48 gram
preforms and 1 liter bottles were prepared using Resin 5 as the
bulk PET, PA-A and four different cobalt sources: LIQ1, LIQ 2,
Solid Concentrate 1 and Solid Concentrate 2. The preform
compositions contained the amounts of cobalt and polyamide as set
forth in Table 13. TABLE-US-00013 TABLE 13 Co level by Sample # Co
Source X-ray (ppm) PA-A 30 LIQ1 113 1.4 31 LIQ2 135 1.4 32 Solid 1
125 1.2 33 Solid 2 116 1.3
[0155] LIQ1 was no longer free flowing at room temperature
(.about.9 months after receipt.) In addition, when LIQ2 was added
to the warm pellets of Resin 5 bulk PET and PA-A, considerable
quantities of volatiles were generated that produced an
objectionable odor. Changes in viscosity and generation of
volatiles are both undesirable in a preform manufacturing
operation. No such changes in viscosity or volatiles were noted
with the solid Concentrates.
[0156] Preforms were made by the following procedure: The PA-A was
dried at 150 F while the bulk PET resin was dried in a separate
system at 325 F. None of the cobalt Concentrates were dried. After
drying but before injection molding, the PA-A, bulk PET, and Co
Concentrate were physically blended using a ribbon mixer. The blend
was fed into a drying hopper with a temperature set point of 325 F,
located directly over the feed throat of the injection molding
machine. Extruder and manifold temperatures were set at 536 F.
Clear preforms were molded using a Husky LX160PET-P60/50-E42 and a
4 cavity, 48 gram preform with a 43 mm finish.
[0157] One liter heatset containers were blow molded using a Sidel
SBO 2/3-HR at an output rate 1000 bottles/hour/mold. An oil
temperature setting of 257 F was used to heat the blow mold
cavities. The water heating the mold base was set to a target
temperature of 176 F. Blow mold processing conditions were adjusted
to produce containers with equivalent distribution of material
throughout the bottle for each Sample to be submitted for OTR
testing. Material distribution was characterized by dividing the
container into sections and weighing each section. Material
distribution was also characterized by measuring the thickness of
the container wall using a Hall effect sensor by Magna-Mike Model
8000. Oven power was the primary adjustment made to achieve
equivalent material distribution for each Sample. Oven profile
configuration and pre-blow timing were also adjusted in some
instances.
[0158] Bottles stretch blow molded from the preforms were mounted
and purged with oxygen free gas 1 day after blowing and OTR's were
measured periodically. Results are set forth in Table 14 and
graphically illustrate in FIG. 9. The results show that all samples
scavenged oxygen at acceptable rates. TABLE-US-00014 TABLE 14
Sample 30 Sample 31 Sample 32 Sample 33 Days since OTR OTR OTR OTR
blowing (cc/day) bottle # (cc/day) bottle # (cc/day) bottle #
(cc/day) bottle # 6 0.0587 1 0.0561 1 0.0517 1 0.0578 3 6 0.0516 2
0.0468 2 0.0544 3 0.0536 1 13 0.0497 3 0.0240 3 0.0281 2 0.0568 2
17 0.0478 1 0.0132 1 0.0106 1 0.0487 1 23 -- -- 0.0025 2 -- -- --
-- 26 0.0208 2 -- -- 0.0138 3 0.0446 3 31 0.0034 3 0.0016 3 0.0005
2 0.0364 2 39 0.0058 1 -- -- 0.0009 1 0.0130 1 56 0.0006 2 -- -- --
-- 0.0030 3
Example 8
[0159] This example illustrates the superior color properties in
b*, L*, and Yellowness Index (Y1) in bottles made with concentrates
relative to bottles made with liquid carriers. This example also
demonstrates the superior color property in b* and Yl in bottles
made from concentrates which are co-dried relative to bottles made
with liquid concentrates in which the polyamide and polyester
particles are individually dried.
[0160] 25.6 gram preforms were produced on a BOY 22S injection
molding machine using a single preform cavity mold. In all samples,
Resin 5 pellets, PA-A pellets, and a cobalt source were fed to the
injection molding machine in the measured amounts and by the type
of cobalt source as shown in Table 15. Samples 34 through 43 were
mixed after drying the polyamide and PET resin and prior to
addition to the hopper of the BOY 22S. Samples 44 and 45 were mixed
prior to drying. TABLE-US-00015 TABLE 15 Co Metals by X-ray (ppm)
HNMR Sample # Source Zn: Co: Mn: Ti: Sb: P: PA-A wt %: 34 Solid 57
43 1 1 221 72 1.39 Conc 1 35 Solid 57 95 1 1 223 76 1.24 Conc 1 36
Solid 57 186 3 1 221 79 1.38 Conc 1 37 Solid 58 46 0 0 224 72 1.01
Conc 2 38 Solid 59 91 -1 0 225 72 1.43 Conc 2 39 Solid 59 172 0 0
220 73 1.42 Conc 2 40 LIQ2 58 47 -1 0 220 72 1.55 41 LIQ2 59 103 -1
0 221 72 1.55 42 LIQ2 59 108 0 0 220 71 1.43 43 LIQ2 58 204 0 0 220
72 1.72 44* Solid 56 103 1 0 222 76 1.30 Conc 1 45* Solid 58 89 -1
0 222 74 1.29 Conc 2 *all components dried at PET conditions prior
to molding, components dried separately for other samples.
[0161] The preforms and bottles were made by the following
procedure:
[0162] For the samples that were prepared without codrying, the
PA-A was dried at 60.degree. C. while the bulk PET resin was dried
in a separate system at 168.degree. C. and the cobalt concentrates
were not dried. After drying, but before injection molding, the
PA-A, bulk PET, and Co Concentrate were physically paddle blended
by hand. The mixture was fed into a hopper, located directly over
the feed throat of the injection molding machine. Extruder and
manifold temperatures were set at 270 C. Clear preforms were molded
using a BOY Model 22D and a 1 cavity, 25.6 gram preform with a 28
mm finish.
[0163] For the samples that were codried prior to injection
molding, the PA-A, PET and solid cobalt Concentrates were mixed
same as above and then dried at 168.degree. C. for 8 hrs. Following
drying, the mixture was fed into a hopper, located directly over
the feed throat of the BOY Model 22D injection molded machine and
preforms were produced as described above.
[0164] Color measurements for the preforms were taken and the
results are reported in Table 16. TABLE-US-00016 TABLE 16 Avg. Avg.
Avg. Avg. Avg. Sample # Sample description L*: a*: b* YI: WI: Co
@50 ppm 34 Solid Conc 1 72.03 -1.08 -1.62 -5.04 52.94 37 Solid Conc
2 73.27 -1.28 -0.97 -3.60 51.09 40 LIQ2 71.26 -1.38 1.64 2.64 33.06
Co @100 ppm 35 Solid Conc 1 68.61 -0.87 -3.73 -10.63 61.04 38 Solid
Conc 2 70.58 -1.17 -2.34 -7.06 55.18 41, 42 LIQ2 66.02 -0.42 2.99
7.23 16.94 (Avg.) Co @200 ppm 36 Solid Conc 1 65.37 0.71 -7.74
-20.84 82.06 39 Solid Conc 2 64.71 0.15 -5.78 -15.95 69.72 43 LIQ2
53.17 1.50 5.33 17.69 -17.41 Codried (Co @ 100 ppm) 44 Solid Conc 1
69.04 -1.18 -0.14 -1.56 40.25 45 Solid Conc 2 69.28 -1.31 -1.01
-3.92 45.79 Control NA No Conc, PA 79.36 -1.03 3.00 5.70 39.65
[0165] The results indicate that the preforms made with solid
concentrates exhibit better color than preforms made with liquid
carriers at equivalent loadings of cobalt, as shown by the lower
b*, lower Yl, and higher L* values of the preforms made with
concentrates. Compare Samples 34-39 with Samples 40-43.
[0166] A comparison of Samples 44 and 45 against 41 and 42
indicates that the color of preforms in which all components were
"codried" (dried together prior to injection molding), had better
visual appearance and color values than preforms in which the
pellets streams were individually dried and cobalt was added as a
liquid concentrate at similar cobalt and polyamide loadings.
[0167] Preforms corresponding to Samples 35, 38, 44 and 45 were
ground through a 3 mm screen and 1 gram samples were loaded into 20
ml prescored glass ampoules (Wheaton #176782) containing an OxyDot
(OxySense Inc., 1311 North Central Expressway Suite 44, Dallas,
Tex. 75243, USA) glued on the side of the ampoule with silicon
adhesive. Two such ampoules were prepared for each Sample tested.
These ampoules were then sealed and placed in an oven maintained at
75.degree. C. The partial pressure of oxygen in each of the
ampoules (PO.sub.2) was then monitored periodically using an
OxySense instrument (OxySense Inc.) to assess the oxygen scavenging
performance of the compositions. The results are graphically
illustrated in FIG. 10.
[0168] As shown in FIG. 10, the codrying process surprisingly
improves the scavenging performance of the Samples as indicated by
the lower PO.sub.2 for the codried samples in this OxySense
test.
[0169] Thus, codrying the bulk PET, polyamide pellets, and the
concentrates improved the oxygen scavenging characteristics of the
preforms while maintaining better color in terms of b* color, L*
color, Yl than the samples prepared with a liquid concentrate.
Example 9
[0170] LIQ2 was stored for approximately 12 weeks at laboratory
conditions. Gradations in consistency of the dispersion were
evident. Changes in consistency over time, whether due to settling
of the cobalt salt or other causes, would complicate manufacturing
procedures using the dispersion. No such variations were noted
after storage of polyester based Solid Concentrates 1 and 2.
Example 10
[0171] This example demonstrates the improved capability of
compounding high levels of cobalt into polymers of increasing
cyclohexane dimethanol (CHDM) levels. This example demonstrates
that the metal loading can be raised in a commercial manufacturing
scaleable process.
[0172] Different levels of cobalt neodecanoate were melt blended
into polyester polymers or polymer mixtures of increasing levels of
CHDM in a pilot scale 57 mm twin-screw extruder according to the
attached table. Separate feeds of polyester polymer resin and resin
mixtures and cobalt neodecanoate, in the form of a pastel and
supplied as Cobalt Ten-Cem 22.5% from OMG (22.5% of the Cobalt
Ten-Cem represents the amount by weight of cobalt), were fed into a
twin-screw and melt blended at a set point of approximately
235.degree. C. Molten polymer exited the extruder in the form of
approximate 0.08'' diameter strands which are water quenched and
cut into approximate 0.125'' length pellets. 50-200 lbs of each
composition were extruded and qualitative judgments were made about
the ability to strand and cut each material. Polyester polymer
resins with the higher amount of CHDM modification processed the
best at the higher loadings of cobalt neodecanoate. The reported
amounts are based on the weight of the compound. The weight of the
cobalt content can be calculated by multiplying the cobalt
neodecanoate compound weight by 0.225.
[0173] Sample 46: 97.78% Polyester Polymer Resin 3; 2.22 wt. %
cobalt neodecanoate; CHDM content of the polyester=3.5 mole %
[0174] Results: brittle strands, a few "sticks" as strands
shattered in the cutter. Sticks are referred to herein as strands
which were cut into pieces longer than the typical 1/8''
pellet.
[0175] Sample 47: 96.33% Polyester Polymer Resin 3; 3.67 wt. %
cobalt neodecanoate; CHDM content of the polyester=3.5 mole %
[0176] Results: brittle strands, lots of "sticks"
[0177] Sample 48: 96.33% Polyester Polymer Resin 13: 3.67% cobalt
neodecanoate; CHDM content of the polyester=4.5 mole % [0178]
Results: brittle strands, lots of "sticks", slightly better than
Sample 47
[0179] Sample 49: 70.40% Polyester Polymer Resin 13 and 27.38%
Polyester Polymer Resin 14; 2.22 wt. % cobalt neodecanoate; CHDM
content of the resulting polyester=11 mole % [0180] Results:
brittle strands, "sticks"
[0181] Sample 50: 70.40% Polyester Polymer Resin 3 and 27.38%
Polyester Polymer Resin 14; 2.22 wt. % cobalt neodecanoate; % CHDM
content of the resulting polyester=11 mole % [0182] Results:
brittle strands, "sticks"
[0183] Sample 51: f 69.36% Polyester Polymer Resin 3 and 26.97%
Polyester Polymer Resin 14; 3.67 wt. % cobalt neodecanoate; CHDM
content of the resulting polyester=11 mole % [0184] Results:
brittle strands, "sticks"
[0185] Sample 52: 96.33% Polyester Polymer Resin 14; 3.67 wt. %
cobalt neodecanoate; CHDM content of the polyester=31 mole % [0186]
Results: not as brittle, no sticks, ran better
[0187] Sample 53: production of 4300 lbs of 96.33% Polyester
Polymer Resin 15 (31 mole % CHDM) containing 3.67 wt. % cobalt
neodecanoate on a 92 mm twin-screw extruder. [0188] Results: ran
well enough to qualify for high volume commercial scale production
runs, with few sticks present.
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