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Blends containing macrocyclic polyester oligomer and high molecular weight polymerRelated Patent Categories: Synthetic Resins Or Natural Rubbers -- Part Of The Class 520 Series, Natural Rubber Compositions Having Nonreactive Materials (dnrm) Other Than: Carbon, Silicon Dioxide, Glass Titanium Dioxide, Water, Hydrocarbon, Halohydrocarbon, Ethylenically Unsaturated Reactant Admixed With A Preformed Reaction Product Derived From: (a) At Least One Polycarboxylic Acid, Ester, Or Anhydride; (b) At Least One Polyhydroxy Compound; And (c) At Least One Fatty Acid Glycerol Ester, Or A Fatty Acid Or Salt Derived From A Naturally Occurring Glyceride, Tall Oil, Or A Tall Oil Fatty Acid, Solid Polymer Derived From At Least One Carboxylic Acid Or Derivative, Solid Polymer Derived From At Least One Lactam; From An Amino Carboxylic Acid Or Derivative; Or From A Polycarboxylic Acid Or Derivative, Solid Polymer Derived From Polyhydroxy Reactant And Polycarboxylic Acid Or Derivative Reactant; Or Derived From Di- Or Higher Ester Of A Polycarboxylic Acid As Sole Reactant, Mixed With O-c(=o)-o-, Hal-c(=o)-o-, Or Hal-c(=o)-hal Containing Reactant Or Polymer Derived Therefrom; Or Wherein Solid Polymer Is Derived From A Hal-c(=o)-hal, O-c(=o)-o-, Or Hal-c(=o)-o-, A Polycarboxylic Acid Or Derivative And A Polyhydroxy ReactantBlends containing macrocyclic polyester oligomer and high molecular weight polymer description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060287440, Blends containing macrocyclic polyester oligomer and high molecular weight polymer. Brief Patent Description - Full Patent Description - Patent Application Claims
PRIOR APPLICATIONS [0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/408,753, filed on Apr. 7, 2003, which is a continuation of U.S. patent application Ser. No. 10/195,853, filed on Jul. 15, 2002, and issued as U.S. Pat. No. 6,639,009, which is a continuation of U.S. patent application Ser. No. 09/754,943, filed on Jan. 4, 2001, and issued as U.S. Pat. No. 6,420,047, which is a continuation-in-part of U.S. patent application Ser. No. 09/535,132, filed on Mar. 24, 2000, and issued as U.S. Pat. No. 6,369,157, which claims benefit of U.S. Provisional Patent Application No. 60/177,727, filed on Jan. 21, 2000, the descriptions of which are incorporated by reference herein in their entirety. This application is related to the commonly-owned U.S. patent application entitled, "Intimate Physical Mixtures Containing Macrocyclic Polyester Oligomer and Filler," by Takekoshi et al., filed under Attorney Docket No. CYC-051, on even date herewith, the description of which is incorporated by reference herein in its entirety. FIELD OF THE INVENTION [0002] This invention relates generally to thermoplastics and articles formed therefrom. More particularly, in certain embodiments, the invention relates to blends of macrocyclic polyester oligomer and high molecular weight polymer. BACKGROUND OF THE INVENTION [0003] Macrocyclic polyester oligomer (macrocyclic oligoester, MPO) has unique properties that makes it attractive as a matrix-forming resin for engineering thermoplastic composites. MPO lends valuable characteristics to polymerized products, for example, high strength, high gloss, and solvent resistance. Furthermore, because certain MPO's melt and polymerize at temperatures well below the melting point of the resulting polymer, polymerization and crystallization can occur virtually isothermally upon melting of the MPO in the presence of an appropriate catalyst. The time and expense required to thermally cycle a tool is favorably reduced, because demolding can take place immediately following polymerization, without first cooling the mold. [0004] MPO generally exhibits low melt viscosity. A low melt viscosity generally provides improved processing flexibility. For example, an MPO with a low melt viscosity can easily impregnate a dense fibrous preform. However, for certain low-pressure processes, such as rotational molding and powder coating, the melt viscosity of MPO may be too low to allow processing with existing process equipment. For example, the water-like viscosity of melted MPO may cause it to leak during rotational molding. In powder coating applications, the low melt viscosity of certain MPO's makes it difficult to control coating area and coating thickness, for example. [0005] Use of a viscosity-enhancing agent along with an MPO during processing is generally not satisfactory, for example, because the agent may not mix well with the MPO, because a separate processing step is generally required to introduce the agent, and because the agent may have a deleterious effect on the properties of the material following polymerization of the MPO. [0006] In addition to having low melt viscosities, MPO's are highly friable. This provides certain handling and processing advantages. For example, MPO may be easily crumbled, pulverized, or reduced to powder prior to and/or during processing. The friability of MPO provides a distinct advantage in low-pressure processes such as rotational molding and powder coating, where the form of the MPO prior to melting and polymerization is important. Adding agents to an oligomer to increase its melt viscosity generally results in a less friable mixture, making it difficult to use in processes such as rotational molding and powder coating. [0007] Furthermore, in some applications, polymerization of MPO results in a brittle, highly crystalline material that is not as tough or ductile as desired. Modifying raw materials in order to increase the ductility and/or toughness of the resulting polymer may adversely affect the processibility of the raw materials, for example, by reducing the rate of polymerization. [0008] Therefore, there exists a need for a raw material that is stable and friable under ambient conditions, that polymerizes and crystallizes isothermally, that has a sufficiently high rate of polymerization, and that can be used in low-pressure processes such as rotational molding and powder coating, without modification of existing equipment, to produce a product of sufficient toughness and ductility. SUMMARY OF THE INVENTION [0009] The invention provides blends of macrocyclic polyester oligomer (MPO) with high-molecular-weight polymer and polymerization catalyst as friable, one-part, ready-to-polymerize materials with long shelf life. Components manufactured from these blends exhibit improved ductility and toughness. [0010] Blend materials of the invention are particularly well-suited for use in low-pressure processes such as rotational molding and powder coating, without modification of existing equipment. The presence of the polymer in the blend increases the melt viscosity of the blend without adversely affecting the friability of the blend, without significantly decreasing the rate of polymerization of the blend, and without affecting the ability of the blend to polymerize and crystallize essentially isothermally. Furthermore, the presence of high-molecular-weight polymer in the blend improves the toughness and ductility of the polymerized product. [0011] This combination of attributes is unexpected, for example, because adding a viscosity-enhancing agent to a polymerization reaction mixture typically reduces its rate of polymerization and may unacceptably reduce the friability of the mixture prior to polymerization. [0012] The invention provides methods for preparing the blends in order to adequately disperse the components without prematurely initiating polymerization. Blends prepared according to these methods exhibit long shelf lives and may be stored for weeks, months, or even years prior to use in a manufacturing process. [0013] In one aspect, the invention provides a blend material stable at ambient conditions (at room temperature in air) for at least one week, the blend material including a macrocyclic polyester oligomer (MIPO), a polymerization catalyst, and a polymer. [0014] In one embodiment, the blend material includes a high molecular weight polymer having a weight average molecular weight (M.sub.w) of at least about 5000 (M.sub.w may be lower than 5000 in some embodiments). Preferably, the weight average molecular weight of the polymer is at least about 50,000, and, more preferably, within a range from about 80,000 to about 120,000. Polymers with molecular weights above 120,000 may be used, as well. The polymer may be present in the blend material in an amount up to about 90 weight percent, up to about 75 weight percent, up to about 70 weight percent, up to about 50 weight percent, up to about 30 weight percent, or up to about 20 weight percent, for example, according to the type of MPO, polymer, and/or polymerization catalyst used, as well as the desired properties of the polymerized product. In one embodiment, the polymer is present in the blend in an amount from about 5 weight percent to about 20 weight percent. The polymer may be linear, branched, or cross-linked, and may include one or more polymeric species. In one embodiment, the polymer includes a polyester, a copolyester, a poly(vinyl butyral), and/or an acrylic polymer. The polymer may include a polyacetal, a polyether, an epoxide resin, a polycarbonate, an alkyd resin, and/or a polyallyl ester. More specifically, in one embodiment, the polymer includes one or more of the group consisting of poly(vinyl butyral-co-vinyl alcohol-co-vinyl acetate), poly(butyl methacrylate co-methyl methacrylate), poly[butylene terephthalate-co-poly(alkylene glycol)terephthalate], and poly(ethyl methacrylate co-glycidyl methacrylate). In one embodiment, the polymer includes polyethylene, either with or without at least one additional polymeric species. For example, an additional polymeric species may be used with polyethylene as a compatibilizer between the MPO (or its polymerization product) and the polyethylene. [0015] The blend material has a higher viscosity than the macrocyclic polyester oligomer. In one embodiment, the viscosity of the blend is from about 5 times to about 5000 times the viscosity of the macrocyclic polyester oligomer. In one embodiment, the viscosity of the blend material at about 190.degree. C. is at least about 100 centipoise (cP), and preferably, is within a range from about 100 cP to about 100,000 cP. Preferably, the blend material is friable. [0016] The blend material includes a catalyst, yet is stable at ambient conditions for at least about one week. More preferably, the blend material is stable at least about one month, or at least about one year without requiring refrigeration and without requiring storage in the absence of oxygen. The catalyst preferably includes a tin compound and/or a titanate compound, and is preferably present in the blend in an amount from about 0.01 to about 10.0 mole percent per monomeric unit of the MPO. [0017] The blend material includes a macrocyclic polyester oligomer (MPO). In one embodiment, the MPO includes a plurality of species. Species of MPO may differ from one another in the type and/or number of structural repeat units (i.e. monomeric units) contained. In one embodiment, the MPO includes a butylene terephthalate unit and an ethylene terephtlialate unit. In one embodiment, the MPO includes about 95 mole percent butylene terephthalate units and about 5 mole percent ethylene terephthalate units. [0018] In another aspect, the invention provides a method for preparing a friable blend material that is stable at ambient conditions for at least about one week, the method including the step of contacting an MPO, a polymer, and a polymerization catalyst at a temperature at which the MPO at least partially melts. In one embodiment, the MPO is at least partially melted prior to the contacting step. The MPO may be fully melted prior to the contacting step. [0019] The contacting step may be performed in any number of stages. For example, in one embodiment, the method includes (a) contacting the MPO and the polymer at a first temperature where the MPO melts or at least temporarily remains melted, thereby forming a mixture of MPO and polymer; (b) cooling the mixture of MPO and polymer to a second temperature; and (c) adding the polymerization catalyst to the mixture. In one embodiment, the MPO is melted and mixed with polymer at a first temperature, then the mixture is cooled to a second temperature, at which point the polymerization catalyst is added. Here, the catalyst is added at a lower temperature in order to prevent (or reduce) premature polymerization of the MPO. In one embodiment, the step of contacting the MPO and polymer is performed at a first temperature from about 130.degree. C. to about 250.degree. C. In one embodiment, the MPO and polymer mixture is cooled to a temperature from about 10.degree. C. to about 50.degree. C. below the first temperature. The method may further include the step of solidifying the blend of the MPO, polymer, and polymerization catalyst and/or processing the blend to form a powder. [0020] In yet another aspect, the invention provides a method for polymerizing an MPO, the method including the steps of: (a) providing a blend material that is stable at ambient conditions for at least one week, the blend material including an MPO, a polymerization catalyst, and a polymer; and (b) heating the blend material to polymerize the MPO. The blend material is preferably friable prior to the heating step. This provides improved handling and processibility, for example, in low-pressure processing methods. The method may be implemented as part of a manufacturing process including, for example, a rotational molding process, a powder coating process, a low-pressure molding process, a gas-assist molding process, a short-shot molding process, a co-injection molding process, a reaction-injection molding process, a blow molding process, a thermoforming process, or combinations thereof. Continue reading about Blends containing macrocyclic polyester oligomer and high molecular weight polymer... Full patent description for Blends containing macrocyclic polyester oligomer and high molecular weight polymer Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Blends containing macrocyclic polyester oligomer and high molecular weight polymer patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. 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