Process for producing compatibilized polymer blends

Abstract

A process is provided for producing a compatibilized polymeric blend. A first thermoplastic polymer and a reactive moiety are provided to a progressive melt kneading apparatus. The reactive moiety comprises a first reactive group capable of reacting with the first thermoplastic polymer but not a second polymer and a second reactive group capable of reacting with the second polymer but not the first polymer. The first thermoplastic polymer and the reactive moiety are then melt kneaded so that the first reactive group reacts with the first thermoplastic polymer and the second reactive group is grafted to the first thermoplastic polymer, forming a molten self-compatibilizer. A molten second polymer is then provided. The molten self-compatibilizer is melt kneaded with the molten second polymer so that the second reactive group reacts with the second polymer to form a compatibilized polymeric blend. Also provided are articles formed from the compatibilized polymer blend.

1 . A process for providing a compatibilized polymeric blend composition, comprising:
 providing at least one first thermoplastic polymer, a reactive moiety, an optional initiator, and an optional catalyst to an upstream portion of a first progressive melt kneading apparatus, the reactive moiety comprising a first reactive group capable of reacting with the first thermoplastic polymer but not with a second polymer which is subsequently provided and a second reactive group capable of reacting with the second polymer but not with the first thermoplastic polymer;   melt kneading the first thermoplastic polymer and the reactive moiety so that the first reactive group reacts with the first thermoplastic polymer and grafts the second reactive group to at least one portion of the first thermoplastic polymer, thereby forming a molten self-compatibilizer;   providing at least one molten second polymer to the first progressive melt kneading apparatus; and   melt kneading the molten self-compatibilizer with the molten second polymer at a downstream portion of the first progressive melt kneading apparatus so that the second reactive group reacts with at least one portion of the molten second polymer to form the compatibilized polymeric blend composition   wherein the first thermoplastic polymer comprises ethylene-acrylic esters, ethylene-methacrylic esters; polystyrene; styrene copolymers and terpolymers; styrenic block copolymers; butyl rubber; acrylonitrile butadiene rubber; butadiene rubber; copolymers and terpolymers of butadiene; natural rubber; polyisoprene rubber; polychloroprene; hydrogenated nitrile rubber (HNBR); silicones; or copolymers, block copolymers, blends or combinations thereof.   
     
     
         2 . The process of  claim 1 , further comprising providing an optional initiator, an optional catalyst, or a reaction accelerator to the upstream portion together with the thermoplastic polymer and the reactive moiety. 
     
     
         3 . The process of  claim 2 , wherein the reaction initiator is a free radical initiator, cationic initiator, or anionic initiator. 
     
     
         4 . The process of  claim 1 , wherein the first reactive group and the second reactive group independently comprise a reactive segment selected from the group consisting of carboxyl, anhydride, oxirane, amino, ester, oxazoline, isocyanate, amido, hydroxyl, urethane, silyl, silanol, siloxane, vinyl-terminated silane, vinyl, allyl, acryl, methacryl, diene, and fumaryl. 
     
     
         5 . The process of  claim 1 , wherein only one of the first reactive group and the second reactive group comprises a functional segment having at least one carbon-carbon double bond. 
     
     
         6 . The process of  claim 1 , wherein the first thermoplastic polymer comprises a polyolefin, ethylene copolymer, or ethylene terpolymer. 
     
     
         7 . A compatibilized polymeric blend composition produced according to the process of  claim 1 . 
     
     
         8 . The process of  claim 1 , wherein the molten second polymer is provided from at least one additional melt kneading apparatus into a feed aperture in the first apparatus. 
     
     
         9 . The process of  claim 1 , wherein the molten second polymer is provided from at least one batch mixer into a feed aperture in the first apparatus. 
     
     
         10 . The process of  claim 1 , further comprising the step of adding at least one additive through at least one feed aperture to at least one melt kneading apparatus. 
     
     
         11 . The process of  claim 10 , wherein the additive comprises a short fiber of 10 mm or less selected from the group consisting of glass fiber, ceramic fiber, natural fiber, aramid fiber, mineral fiber, metal fiber, carbon fiber, organic polymer fiber, and combinations thereof. 
     
     
         12 . The process of  claim 1 , further comprising adding at least one roving to the compatibilized polymeric composition. 
     
     
         13 . The process of  claim 12 , wherein the roving is added subsequent to melt kneading the molten self-compatibilizer with the molten second polymer. 
     
     
         14 . The process of  claim 12 , wherein the roving comprises a fiber selected from the group consisting of glass fiber, aramid fiber, ceramic fiber, natural fiber, metal fiber, carbon fiber, organic polymer fiber, and combinations thereof. 
     
     
         15 . The process of  claim 1 , further comprising adding a filler selected from the group consisting of a metal oxide, a metal carbonate, a metal sulfate, a metal phosphate, a metal silicate, a metal borate, a metal hydroxide, a silica, a silicate, an aluminate, an alumo-silicate, chalk, talc, dolomite, saw dust, wood flour, milled natural fibers, newsprint, a metal powder, metal-coated inorganic particles, clay, kaolin, industrial ash, concrete powder, cement, wollastonite, and combinations thereof. 
     
     
         16 . The process of  claim 1 , further comprising adding an unmodified polymer or an external compatibilizer after the molten self-compatibilizer is formed. 
     
     
         17 . A process for providing a compatibilized polymeric blend composition, comprising:
 providing at least one first thermoplastic polymer, a reactive moiety, an optional initiator, and an optional catalyst to an upstream portion of a first progressive melt kneading apparatus, the reactive moiety comprising a first reactive group capable of reacting with the first thermoplastic polymer but not with a second polymer which is subsequently provided and a second reactive group capable of reacting with the second polymer but not with the first thermoplastic polymer;   melt kneading the first thermoplastic polymer and the reactive moiety so that the first reactive group reacts with the first thermoplastic polymer and grafts the second reactive group to at least one portion of the first thermoplastic polymer, thereby forming a molten self-compatibilizer;   providing at least one molten second polymer to the first progressive melt kneading apparatus; and   melt kneading the molten self-compatibilizer with the molten second polymer at a downstream portion of the first progressive melt kneading apparatus so that the second reactive group reacts with at least one portion of the molten second polymer to form the compatibilized polymeric blend composition;   wherein the second polymer comprises polyphthalamide; a polyurethane; a polyimide; a polysulfone; a polysulfone; a liquid crystalline polymer (LOP); polyetheretherketone (PEEK); polyphenylsulfone; polyamide-imide; polyolefins, polyolefin copolymers and terpolymers; EVA; ethylene-acrylic ester and ethylene-methacrylic ester; polystyrene; styrene copolymers and terpolymers; styrenic block copolymers; butyl rubber; nitrile rubber; butadiene rubber; copolymers and terpolymers of butadiene; natural rubber; polyisoprene rubber; ethylene-propylene elastomer; polychloroprene; silicone polymer; polysulfide; a vinyl polymer; an acrylic polymer; a fluoropolymer; or copolymers, block copolymers, blends or combinations thereof.   
     
     
         18 . A compatibilized polymeric blend composition produced according to the process of  claim 17 . 
     
     
         19 . A process for providing a compatibilized polymeric blend composition, comprising:
 providing at least one first thermoplastic polymer, a reactive moiety, an optional initiator, and an optional catalyst to an upstream portion of a first progressive melt kneading apparatus, the reactive moiety comprising a first reactive group capable of reacting with the first thermoplastic polymer but not with a second polymer which is subsequently provided and a second reactive group capable of reacting with the second polymer but not with the first thermoplastic polymer;   melt kneading the first thermoplastic polymer and the reactive moiety so that the first reactive group reacts with the first thermoplastic polymer and grafts the second reactive group to at least one portion of the first thermoplastic polymer, thereby forming a molten self-compatibilizer;   providing at least one molten second polymer to the first progressive melt kneading apparatus; and   melt kneading the molten self-compatibilizer with the molten second polymer at a downstream portion of the first progressive melt kneading apparatus so that the second reactive group reacts with at least one portion of the molten second to polymer to form the compatibilized polymeric blend composition;   wherein the second polymer comprises a polyamide; a polyphthalamide; a polyurethane; a polyimide; a polysulfone; a polysulfone; a liquid crystalline polymer (LCP); polyetheretherketone (PEEK); polyphenylsulfone; polyamide-imide; polyolefins, polyolefin copolymers and terpolymers; EVA; ethylene-acrylic ester and ethylene-methacrylic ester; polystyrene; styrene copolymers and terpolymers; styrenic block copolymers; butyl rubber; nitrile rubber; butadiene rubber; copolymers and terpolymers of butadiene; natural rubber; polyisoprene rubber; ethylene-propylene elastomer; polychloroprene; silicone polymer; polysulfide; a vinyl polymer; an acrylic polymer; a fluoropolymer; or copolymers, block copolymers, blends or combinations thereof; and   wherein the compatibilized polymeric blend composition comprises from 5 to 40 wt % of the second polymer.   
     
     
         20 . A compatibilized polymeric blend composition produced according to the process of  claim 19 .