Compartmentalized resin pellets

Abstract

Disclosed herein is a resin pellet and a process to make said resin pellet. The resin pellet comprises a major polyester comprising a catalytic titanium compound, and a minor polyester comprising a phosphorus compound. The major polyester is present in a first compartmentalized zone of the resin pellet and the minor polyester is present in a second compartmentalized zone of the resin pellet.

What is claimed is: 
     
         1 . A process for maintaining the catalytic activity of a catalytic titanium compound in a polyester resin during polymerization comprising the steps of:
 A. melt phase polymerizing a first polyester comprising the catalytic titanium compound in the absence of a deactivating amount of a phosphorus compound,   B. solid state polymerizing a second polyester comprising a phosphorus compound,   C. blending the first polyester and the second polyester into an article by melt mixing and making an article,   
       wherein the amount of phosphorus from the phosphorus compound in the second polyester to the amount of titanium from the catalytic titanium compound in the first polyester is in a mole ratio selected from the group consisting of at least 0.1:1.0, at least 0.2:1.0, at least 0.5:1.0, at least 0.7:1.0, and at least 1.0:1.0. 
     
     
         2 . The process of  claim 1 , wherein the second polyester comprises a deactivated titanium compound. 
     
     
         3 . The process of  claim 1 , wherein the titanium from the catalytic titanium compound is present in the first polyester at a level selected from the group consisting of between 2 ppm and 400 ppm, between 2 ppm and 300 ppm, between 2 ppm and 100 ppm, and between 2 ppm and 20 ppm. 
     
     
         4 . The process of  claim 1 , wherein the catalytic titanium compound is selected from the group consisting of titanium alkoxides and their derivatives, titanium complex salts, titanium complexes with hydroxycarboxylic acids, titanium dioxide-silicon dioxide-co-precipitates, and hydrated alkaline or alkaline earth salts-co-titanium dioxide. 
     
     
         5 . The process of  claim 2 , wherein the deactivated titanium compound is selected from the group consisting of titanium alkoxides and their derivatives, titanium complex salts, titanium complexes with hydroxycarboxylic acids, titanium dioxide-silicon dioxide-co-precipitates, and hydrated alkaline or alkaline earth salts-co-titanium dioxide. 
     
     
         6 . The process of  claim 1 , wherein the phosphorus from the phosphorus compound is present in the second polyester at a level selected from the group consisting of between 1 ppm and 20000 ppm, between 1 ppm and 10000 ppm, between 1 ppm and 5000 ppm, between 1 ppm and 1000 ppm, between 1 ppm and 700 ppm, between 1 ppm and 500 ppm, between 1 ppm and 300 ppm, and between 1 ppm and 200 ppm. 
     
     
         7 . The process of  claim 1 , wherein the phosphorus compound is selected from the group consisting of phosphate acids or esters or combinations thereof, phosphite esters, phosphonic acids or esters or combinations thereof, phosphinic acids or esters or combinations thereof, phosphines which do not catalyze the reaction of acetaldehyde with oxygen, phosphine oxide, and phosphorus pentoxide. 
     
     
         8 . The process of  claim 1 , wherein the first polyester and the second polyester are of the same polyester composition. 
     
     
         9 . The process of  claim 1 , wherein solid state polymerizing the second polyester is conducted at a solid state polymerization temperature in a range selected from the group consisting of between 180° C. and 250° C., between 190° C. and 240° C., and between 200° C. and 230° C. 
     
     
         10 . The process of  claim 1 , wherein solid state polymerizing the second polyester is conducted for a solid state polymerization time in a range selected from the group consisting of between 2 hours and 8 hours, between 3 hours and 7 hours, and between 4 hours and 6 hours. 
     
     
         11 . The process of  claim 3 , wherein the catalytic titanium compound is selected from the group consisting of titanium alkoxides and their derivatives, titanium complex salts, titanium complexes with hydroxycarboxylic acids, titanium dioxide-silicon dioxide-co-precipitates, and hydrated alkaline or alkaline earth salts-co-titanium dioxide. 
     
     
         12 . The process of  claim 6 , wherein the phosphorus compound is selected from the group consisting of phosphate acids or esters or combinations thereof, phosphite esters, phosphonic acids or esters or combinations thereof, phosphinic acids or esters or combinations thereof, phosphines which do not catalyze the reaction of acetaldehyde with oxygen, phosphine oxide, and phosphorus pentoxide. 
     
     
         13 . The process of  claim 9 , wherein solid state polymerizing the second polyester is conducted for a solid state polymerization time in a range selected from the group consisting of between 2 hours and 8 hours, between 3 hours and 7 hours, and between 4 hours and 6 hours. 
     
     
         14 . The process of  claim 2 , wherein the first polyester and the second polyester are of the same polyester composition. 
     
     
         15 . The process of  claim 11 , wherein the first polyester and the second polyester are of the same polyester composition. 
     
     
         16 . The process of  claim 12 , wherein the first polyester and the second polyester are of the same polyester composition. 
     
     
         17 . The process of  claim 11 , wherein the phosphorus from the phosphorus compound is present in the second polyester at a level selected from the group consisting of between 1 ppm and 20000 ppm, between 1 ppm and 10000 ppm, between 1 ppm and 5000 ppm, between 1 ppm and 1000 ppm, between 1 ppm and 700 ppm, between 1 ppm and 500 ppm, between 1 ppm and 300 ppm, and between 1 ppm and 200 ppm. 
     
     
         18 . The process of  claim 17 , wherein the phosphorus compound is selected from the group consisting of phosphate acids or esters or combinations thereof, phosphite esters, phosphonic acids or esters or combinations thereof, phosphinic acids or esters or combinations thereof, phosphines which do not catalyze the reaction of acetaldehyde with oxygen, phosphine oxide, and phosphorus pentoxide. 
     
     
         19 . The process of  claim 17 , wherein the first polyester and the second polyester are of the same polyester composition. 
     
     
         20 . The process of  claim 18 , wherein the first polyester and the second polyester are of the same polyester composition.