Poly(butylene-co-adipate terephthalate), method of manufacture, and uses thereof

Abstract

A method for preparing poly(butylene terephthalate-co-adipate) copolymer includes reacting (i) poly(butylene terephthalate-co-adipate) oligomers, wherein the oligomers comprise at least one polymer residue derived from a polyethylene terephthalate component and a quencher, with (ii) a chain extender under conditions sufficient to form the poly(butylene terephthalate-co-adipate) copolymer.

1 - 15 . (canceled) 
     
     
         16 . A poly(butylene terephthalate-co-adipate) copolymer having a melt temperature from 100 to 120° C., wherein
 the copolymer comprises a residue derived from a polyethylene terephthalate component selected from the group consisting of polyethylene terephthalate, polyethylene terephthalate copolymers, and combinations thereof; 
 a residue of a quencher selected from the group consisting of a phosphorus-containing compound, a nitrogen-containing compound, a boron-containing compound, and combinations thereof; and 
 from 0.05 to 1 weight % of a residue of a chain extender selected from the group consisting of isocyanurate, polyisocyanate, isocyanate and combinations thereof, wherein oligomers of poly(butylene terephthalate-co-adipate have been reacted with the chain extender;
 wherein the poly(butylene terephthalate-co-adipate) copolymer has 
 a melting temperature of 100 to 120° C.; 
 a number average molecular weight of at least 30,000 g/mole; 
 an intrinsic viscosity of at least 1.0 deciliter per minute; and 
 a T g  of −30 to −10° C. 
 
 
     
     
         17 . The copolymer of  claim 16 , comprising from 0.05 to 1 mol % of the quencher residue, based on the copolymer. 
     
     
         18 . The copolymer of  claim 16 , wherein residue derived from the polyethylene terephthalate component is selected from ethylene glycol groups, diethylene glycol groups, isophthalic acid groups, and combinations thereof. 
     
     
         19 . The copolymer of  claim 16 , wherein the copolymer comprises less than 10 mole % of ethylene glycol groups, based on poly(butylene terephthalate-co-adipate) copolymer. 
     
     
         20 . The copolymer of  claim 16 , wherein the copolymer comprises less than or equal to 2 mole % of isophthalate groups, based on poly(butylene terephthalate-co-adipate) copolymer. 
     
     
         21 . The copolymer of  claim 16 , wherein the copolymer comprises less than 10 mole % of a combination of ethylene glycol groups and isophthalate groups, based on poly(butylene terephthalate-co-adipate) copolymer. 
     
     
         22 . A composition comprising
 the poly(butylene terephthalate-co-adipate) copolymer of  claim 16 ; and   at least one of   an additive selected from nucleating agents, antioxidants, UV stabilizers, plasticizers, epoxy compounds, melt strength additives, alcohols, acetates, alcohol-acetate copolymers, crosslinkers, anti-aging agents, retrogradation agents, anti-blocking agents, water, odor-controlling agents, and combinations thereof; and   an additional thermoplastic polymer.   
     
     
         23 . The composition of  claim 22 , comprising
 from more than 10 to 59.99 wt. %, based on the total weight of the composition, of the poly(butylene terephthalate-co-adipate) copolymer of  claim 16 ;   from more than 40 to less than 89.99 wt. %, based on the total weight of the composition, of a polymer selected from aliphatic polyesters, aliphatic polycarbonates, starches, aromatic polyesters, cycloaliphatic polyesters, polyesteramides, aromatic polycarbonates, and combinations thereof; and   from 0.01 to 5 wt. %, based on the total weight of the composition, of an additive selected from nucleating agents, antioxidants, UV stabilizers, plasticizers, epoxy compounds, melt strength additives, and combinations thereof;   from 0.01 to 45 wt. %, based on the total weight of the composition, of an additive selected from alcohols, acetates, alcohol-acetate copolymers, and combinations thereof; and   from 0.01 to 2 wt. %, based on the weight of the composition, of an additive selected from crosslinkers, anti-aging agents, retrogradation agents, anti-blocking agents, water, odor-controlling agents, and combinations thereof.   
     
     
         24 . The composition of  claim 23 , wherein the aliphatic polyester is selected from poly(lactic acid)s, poly(hydroxyalkanoate)s, poly(butylene succinate)s, poly(butylene adipate)s, poly(butylene succinate adipate)s, poly(caprolactone)s, and combinations thereof. 
     
     
         25 . An article comprising the composition of  claim 22 . 
     
     
         26 . The article of  claim 25 , wherein the article is a molding, film, fiber, or coating. 
     
     
         27 . (canceled) 
     
     
         28 . The composition of  claim 16 , wherein the quencher is selected from the group consisting of phosphoric acid, phosphorous acid, boric acid, nitrogen containing compound and combinations thereof. 
     
     
         29 . The composition of  claim 16 , wherein the chain extender is selected from the group consisting of mononuclear isocyanate, binuclear isocyanate, trinuclear isocyanate, tetra or higher nuclear isocyanate and their mixtures, diisocyanate selected from the group consisting of tolylene 2,4-diisocyanate, tolylene 2,6-diisocyanate, 2,4′-diphenylmethane diisocyanate, naphthylene-1,5-diisocyanate, xylylene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, and methylenebis (2-isocyanatocyclohexane). 
     
     
         30 . The composition of  claim 16 , wherein the residue derived from a polyethylene terephthalate component is a dihydric alcohol selected from the group consisting of ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, hexylene glycol, 1,3-cyclohexanedimethanol isomers, 1,4-cyclohexanedimethanol isomers, and combinations thereof. 
     
     
         31 . The composition of  claim 16 , wherein the residue derived from a polyethylene terephthalate component comprises a residue selected from the group consisting of dimethyl isophthalate, cyclohexane dimethanol, ethylene glycol, diethylene glycol, triethylene glycol, ethylene glycol groups, diethylene glycol groups, isophthalic acid groups and combinations thereof. 
     
     
         32 . A poly(butylene terephthalate-co-adipate) copolymer having a melt temperature from 100 to 120° C., wherein
 the copolymer comprises a residue derived from a polyethylene terephthalate component selected from the group consisting of polyethylene terephthalate, polyethylene terephthalate copolymers, and combinations thereof, wherein the residue derived from the polyethylene terephthalate component is selected from ethylene glycol groups, diethylene glycol groups, isophthalic acid groups, and combinations thereof; 
 from 0.05 to 1 mol % of a quencher residue, based on the copolymer, wherein the quencher is selected from the group consisting of phosphoric acid, phosphorous acid, boric acid, nitrogen containing compound and combinations thereof, and combinations thereof; and 
 from 0.05 to 1 weight % of a residue of a chain extender selected from the group consisting of isocyanurate, polyisocyanate, isocyanate and combinations thereof, wherein oligomers of poly(butylene terephthalate-co-adipate have been reacted with the chain extender; 
 wherein the poly(butylene terephthalate-co-adipate) copolymer has
 a melting temperature of 100 to 120° C.; 
 a number average molecular weight of at least 30,000 g/mole; 
 an intrinsic viscosity of at least 1.0 deciliter per minute; and 
 a T g  of −30 to −10° C.