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Home Nonmetallic Processes Compatibilization-of-hydroxyl-containing-fillers-and-thermoplastic-polymers

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 Compatibilization of hydroxyl-containing fillers and thermoplastic polymers

Details
Inventors: Gaylord, Norman G.;
Assignee: Champion International Corporation (Stamford, CT)
Primary Examiner: Derrington; James H.
Assistant Examiner:
Attorney, Agent or Firm: Roylance, Abrams, Berdo & Kaul

Hydroxyl-containing filler reinforced thermoplastic polymers, such as polyolefins, are disclosed having improved physical properties such as impact strength, break strength and flexural modulus. The filler is compatibilized with a thermoplastic polymer containing labile atoms by mixing the two together in the presence of a coupling agent, such as maleic anhydride and a free radical initiator such as a peroxide catalyst. In a preferred embodiment, clay is coated with polyethylene by mixing the two in the presence of a peroxide catalyst and maleic anhydride and the coated filler is then compounded with additional polyethylene. In another preferred embodiment, a filler is coated with a polyolefin having a high melt index and the coated filler is then compounded with a polyolefin having a lower melt index. Also disclosed are various means for molding the compatibilized composites of this invention.

DETAILED DESCRIPTION I claim: 1.
A process for compatibilizing a hydroxyl group containing inorgaic filler with a thermoplastic polymer having labile atoms which provide sites for the formation of free radicals which comprises mixing said filler and said thermoplastic polymer in the presence of an ethylenically unsaturated carboxylic acid or anhydride and a free radical catalyst under conditions which will generate free radicals on the thermoplastic polymer and which will permit the acid or anhydride to react simultaneously with the thermoplastic polymer and the hydroxyl group containing filler, whereby said acid or anhydride reacts with and couples said thermoplastic polymer and said hydroxyl group containing filler to provide a filled thermoplastic polymer composition.
2.
A process as defined in claim 1 wherein said free radical catalyst is a peroxide compound which will initiate the homopolymerization of maleic anhydride.
3.
A process as defined in claim 1 wherein said free radical catalyst is a peroxide compound which has a half-life of up to about 30 minutes at the temperature at which said mixing occurs.
4.
A process as defined in claim 1 wherein said thermoplastic polymer is a polyolefin.
5.
A process as defined in claim 4 wherein said ethylenically unsaturated carboxylic acid or anhydride is maleic anhydride or maleic acid.
6.
A process according to claim 5 wherein said polyolefin is high density polyethylene.
7.
A process as defined in claim 5 wherein said filler is clay.
8.
A process as defined in claim 5 wherein said filler material and said polyolefin are mixed with from about 2 to 30% by weight of maleic anydride and from about 0.
5 to 10% by weight of a peroxide catalyst.
9.
A process as defined in claim 5 wherein said filler and said thermoplastic polymer are mixed together before being mixed with said ethylenically unsaturated carboxylic acid or anhydride and said free radical catalyst.
10.
A process as defined in claim 5 wherein said hydroxyl group containing filler is glass



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