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Polyester compositions containing cyclobutanediol and articles made therefromRelated Patent Categories: Synthetic Resins Or Natural Rubbers -- Part Of The Class 520 Series, Polymer Derived From Nitrile, Conjugated Diene And Aromatic Co-monomers, , From Di- Or Higher Ester Of A Polycarboxylic Acid As Sole Reactant, Or From A Polycarboxylic Acid Or Derivative With A Compound Containing Two Or More Hydroxyl Groups Or Salts Thereof, Two Or More Carboxylic Acid Or Derivatives Or Mixtures ThereofPolyester compositions containing cyclobutanediol and articles made therefrom description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060287479, Polyester compositions containing cyclobutanediol and articles made therefrom. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCES TO RELATED APPLICATIONS [0001] This application claims priority under 35 U.S.C. .sctn.119(e) to U.S. Provisional Application Ser. No. 60/691,567 filed on Jun. 17, 2005, U.S. Provisional Application Ser. No. 60/731,454 filed on Oct. 28, 2005, U.S. Provisional Application Ser. No. 60/731,389, filed on Oct. 28, 2005, U.S. Provisional Application Ser. No. 60/739,058, filed on Nov. 22, 2005, and U.S. Provisional Application Ser. No. 60/738,869, filed on Nov. 22, 2005, U.S. Provisional Application Ser. No. 60/750,692 filed on Dec. 15, 2005, U.S. Provisional Application Ser. No. 60/750,693, filed on Dec. 15, 2005, U.S. Provisional Application Ser. No. 60/750,682, filed on Dec. 15, 2005, and U.S. Provisional Application Ser. No. 60/750,547, filed on Dec. 15, 2005, all of which are hereby incorporated by this reference in their entireties. FIELD OF THE INVENTION [0002] The present invention generally relates to polyester compositions made from terephthalic acid, an ester thereof, or mixtures thereof; 2,2,4,4-tetramethyl-1,3-cyclobutanediol; and 1,4-cyclohexanedimethanol having a certain combination of two or more of high impact strengths, high glass transition temperature (T.sub.g), toughness, certain inherent viscosities, low ductile-to-brittle transition temperatures, good color and clarity, low densities, chemical resistance, hydrolytic stability, and long crystallization half-times, which allow them to be easily formed into articles. BACKGROUND OF THE INVENTION [0003] Poly(1,4-cyclohexylenedimethylene terephthalate (PCT), a polyester based solely on terephthalic acid or an ester thereof and 1,4-cyclohexanedimethanol, is known in the art and is commercially available. This polyester crystallizes rapidly upon cooling from the melt, making it very difficult to form amorphous articles by methods known in the art such as extrusion, injection molding, and the like. In order to slow down the crystallization rate of PCT, copolyesters can be prepared containing additional dicarboxylic acids or glycols such as isophthalic acid or ethylene glycol. These ethylene glycol- or isophthalic acid-modified PCTs are also known in the art and are commercially available. [0004] One common copolyester used to produce films, sheeting, and molded articles is made from terephthalic acid, 1,4-cyclohexanedimethanol, and ethylene glycol. While these copolyesters are useful in many end-use applications, they exhibit deficiencies in properties such as glass transition temperature and impact strength when sufficient modifying ethylene glycol is included in the formulation to provide for long crystallization half-times. For example, copolyesters made from terephthalic acid, 1,4-cyclohexanedimethanol, and ethylene glycol with sufficiently long crystallization half-times can provide amorphous products that exhibit what is believed to be undesirably higher ductile-to-brittle transition temperatures and lower glass transition temperatures than the compositions revealed herein. [0005] The polycarbonate of 4,4'-isopropylidenediphenol (bisphenol A polycarbonate) has been used as an alternative for polyesters known in the art and is a well known engineering molding plastic. Bisphenol A polycarbonate is a clear, high-performance plastic having good physical properties such as dimensional stability, high heat resistance, and good impact strength. Although bisphenol-A polycarbonate has many good physical properties, its relatively high melt viscosity leads to poor melt processability and the polycarbonate exhibits poor chemical resistance. It is also difficult to thermoform. [0006] Polymers containing 2,2,4,4-tetramethyl-1,3-cyclobutanediol have also been generally described in the art. Generally, however, these polymers exhibit high inherent viscosities, high melt viscosities and/or high Tgs (glass transition temperatures) such that the equipment used in industry can be insufficient to manufacture or post polymerization process these materials. [0007] Thus, there is a need in the art for a polymer having a combination of two or more properties chosen from at least one of the following: toughness, high glass transition temperatures, high impact strength, hydrolytic stability, chemical resistance, long crystallization half-times, low ductile to brittle transition temperatures, good color and clarity, lower density and/or thermoformability of polyesters while retaining processability on the standard equipment used in the industry. SUMMARY OF THE INVENTION [0008] It is believed that certain compositions formed from terephthalic acid or an ester thereof, or mixtures thereof; 1,4-cyclohexanedimethanol; and 2,2,4,4-tetramethyl-1,3-cyclobutanediol with certain monomer compositions, inherent viscosities and/or glass transition temperatures are superior to polyesters known in the art and to polycarbonate with respect to one or more of high impact strengths, hydrolytic stability, toughness, chemical resistance, good color and clarity, long crystallization half-times, low ductile to brittle transition temperatures, lower specific gravity and/or thermoformability. These compositions are believed to be similar to polycarbonate in heat resistance and are still processable on the standard industry equipment. [0009] In one aspect, the invention relates to a polyester composition comprising at least one polyester which comprises: [0010] (a) a dicarboxylic acid component comprising: [0011] i) 70 to 100 mole % of terephthalic acid residues; [0012] ii) 0 to 30 mole % of aromatic dicarboxylic acid residues having up to 20 carbon atoms; and [0013] iii) 0 to 10 mole % of aliphatic dicarboxylic acid residues having up to 16 carbon atoms; and [0014] (b) a glycol component comprising: [0015] i) 40 to 65 mole % of 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues; and [0016] ii) 35 to 60 mole % of 1,4-cyclohexanedimethanol residues, [0017] wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %; and [0018] wherein the inherent viscosity of the polyester is from 0.5 to 0.68 dL/g as determined in 60/40 (wt/wt) phenol/tetrachloroethane at a concentration of 0.5 g/100 ml at 25.degree. C. [0019] In one aspect, the invention relates to a polyester composition comprising at least one polyester which comprises: [0020] (a) a dicarboxylic acid component comprising: [0021] i) 70 to 100 mole % of terephthalic acid residues; [0022] ii) 0 to 30 mole % of aromatic dicarboxylic acid residues having up to 20 carbon atoms; and [0023] iii) 0 to 10 mole % of aliphatic dicarboxylic acid residues having up to 16 carbon atoms; and [0024] (b) a glycol component comprising: [0025] i) 40 to 65 mole % of 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues; and [0026] ii) 35 to 60 mole % of 1,4-cyclohexanedimethanol residues, [0027] wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %; [0028] wherein the inherent viscosity of the polyester is 0.68 dL/g or less as determined in 60/40 (wt/wt) phenol/tetrachloroethane at a concentration of 0.5 g/100 ml at 25.degree. C.; and optionally, wherein one or more branching agents is added, but when the branching agent is added, it is added prior to or during the polymerization of the polyester. [0029] In one aspect, the invention relates to a polyester composition comprising at least one polyester which comprises: [0030] (a) a dicarboxylic acid component comprising: [0031] i) from 70 to 100 mole % of terephthalic acid residues; [0032] ii) 0 to 30 mole % of aromatic dicarboxylic acid residues having up to 20 carbon atoms; and [0033] iii) 0 to 10 mole % of aliphatic dicarboxylic acid residues having up to 16 carbon atoms; and [0034] (b) a glycol component comprising: [0035] i) 40 to 65 mole % of 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues; and [0036] ii) 35 to 60 mole % of 1,4-cyclohexanedimethanol residues, and [0037] (c) branching agent residues; [0038] wherein the total mole % of the dicarboxylic acid component is 100 mole %, and the total mole % of the glycol component is 100 mole %; and [0039] wherein the inherent viscosity of the polyester is from 0.5 to 1.2 dL/g as determined in 60/40 (wt/wt) phenol/tetrachloroethane at a concentration of 0.5 g/100 ml at 25.degree. C. In one embodiment, the branching agent is added before or during polymerization of the polymer. [0040] In one aspect, the invention relates to a polyester composition comprising: [0041] (I) at least one polyester which comprises: [0042] (a) a dicarboxylic acid component comprising: [0043] i) 70 to 100 mole % of terephthalic acid residues; [0044] ii) 0 to 30 mole % of aromatic dicarboxylic acid residues having up to 20 carbon atoms; and [0045] iii) 0 to 10 mole % of aliphatic dicarboxylic acid residues having up to 16 carbon atoms; and Continue reading about Polyester compositions containing cyclobutanediol and articles made therefrom... 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