Us5438086 PDF
Us5438086 PDF
Us5438086 PDF
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US. Patent Aug. 1, 1995 Sheet 2 0f 9 5,438,086
a Control
800.“ 0 Diphosphi're
75
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US. Patent Aug. 1, 1995 Sheet 3 of 9 5,438,086
a Control
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g |200~——
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5 moo-
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3
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TiME (min)
FIG-6
U.S. Patent Aug. 1, 1995 Sheet 4 of 9 5,438,086
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US. Patent Aug. 1, 1995 Sheet 5 0f 9 5,438,086
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FIG-7B
US. Patent Aug. 1, 1995 Sheet 6 of 9 5,438,086
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US. Patent Aug. 1, 1995 Sheet 7 0f 9 5,438,086
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FIG-8B
5,438,086
1 2
coloration, crosslinking, and deterioration of other pol
HYDROLYTICALLY STABLE ymer properties will occur.
PENTAERYTHRITOL DIPHOSPHITES When a free radical is formed, a chain reaction begins
that initiates Spolymeric oxidation. Subsequent reaction
This application is a continuation-in-part of applica 5 of the radical with an oxygen molecule yields a peroxy
tion Ser. No. PCT 93/00499, ?led Jan. 20, 1993 and U.S. radical, which then reacts with an available hydrogen
Ser. No. 08/108,658, ?led Aug. 30, 1993, now U.S. Pat. atom to form an unstable hydroperoxide and another
No. 5,364,895. free radical. In the absence of an antioxidant, these
reactions become self-propagating, and lead to polymer
TECHNICAL FIELD degradation.
The invention described herein pertains generally to There are two basic types of antioxidants, primary
a new class of phosphites, i.e., a bis(aralkylphenyl)pen and secondary. Primary antioxidants intercept and sta
taerythritol diphosphites with improved hydrolytic bilize free radicals by donating active hydrogen atoms.
stability, and their ability to be used as a stabilizer for Hindered phenols and aromatic amines represent the
several polymers, e. g., polypropylene, polyesters, poly 15 two main types of primary antioxidants. Secondary
carbonates, polyamides, polyurethanes, polysulfones, antioxidants prevent formation of additional free radi
polyimides, polyphenylene ethers, styrenic polymers, cals by decomposing the unstable hydroperoxides into a
acrylic polymers, polyacetals, halide-containing poly stable product. Phosphites and thioesters are secondary
mers and copolymers therof. antioxidants that function by decomposing hydroperox
BACKGROUND OF THE INVENTION
20 ides, thus preventing free-radical formation. Secondary
antioxidants are often used along with primary antioxi~
Plastics are used in a myriad of widely diverse appli dants, but can be used alone, especially if they contain a
cations, in automobile parts, in components for houses hindered phenolic group within their structure. To
and buildings, and in packaging from food to electronic gether they decrease the discoloration of the polymer
parts. Plastics would not be able to perform such di 25 and may also regenerate the primary antioxidant.
verse functions without the assistance of a very broad There are several commercially available phosphites
range of plastics additives. Without them, some plastics that are used to stabilize polymer materials against color
would degrade during processing and, over time, the degradation and melt flow degradation. One product
polymers would lose impact strength, discolor, and which has been found to be especially useful is a bis(2,4
become statically charged, to list just a few problems. di-t-butylphenyl)pentaerythritol diphosphite as shown
Additives not only overcome these and other limita by formula (I) described in U.S. Pat. No. 4,305,866 to
tions, but also can impart improved performance prop York, with an initial acid value of ~1.1.
t-Bu
erties to the ?nal product. Another product which has been mentioned in the liter
Formulating with plastics additives has always been a ature is bis(2-t-butyl-4-{a,a’-dimethylbenzyl})pentaery
tricky business. Incorporating additives into a polymer thritol diphosphite as shown by formula (II), described
requires a ?ne balance between the properties of the in U.S. Pat. No. 4,983,657 to Humplik.
CH 0 0 CH (11)
I 3 / \ I 3
I \ / |
CH3 0 0 CH3
t-Bu t-Bu
CH3
CH3
While this phosphonite possesses good thermal and
hydrolytic stability, its oxidative stability is considered 40
as moderate, consistent with the general observation
that the oxidative stability decreases as the number of The invention may take physical form in certain parts
phosphorus-carbon bonds increases. and arrangements of parts, a preferred embodiment of
To date, there still exists a need to 5provide a phos which will be described in detail in the speci?cation and
phite product, based on pentaerythritol, which is slower 45 illustrated in the accompanying drawings which form a
to absorb moisture, thereby maintaining its effectiveness part hereof, and wherein:
for longer periods of time in humid conditions. FIG. 1 is a plot of Yellowness Index as a function of
several phosphites in linear low density polyethylene
SUMMARY OF THE INVENTION
using the following formulations (100 2parts LLPE, 250
In accordance with the present invention, there is ppm CaS+Irganox 1010, and 500 ppm phosphite at
provided more hydrolytically stable bis(aralkylphenyl) 480° F.: (A) base case—no phosphite added; (B) tris
pentaerythritol diphosphites, which are suitable as an (2,4-di-t-butylphenyl)phosphite (formula III); (C) 2,4
antioxidant additive in polyole?ns, particularly polyeth di-t-butylphenyl)pentaerythritol diphosphite (formula
ylene and polypropylene, in polycarbonates, polyesters, I); (D) Sandostab ® PEPQ phosphonate (formula VI);
particularly in polyethylene terephthalate, polyatnides, 55 and (E) bis(2,4-dicumylphenyl)pentaerythritol di
particularly in nylons, polystyrene, impact polystyrene, phosphite (formula V).
polyphenyIene ether, ABS-type graft copolymers, FIG. 2 is a plot of Melt Index vs. the phosphorus
polyurethanes, polysulfone, polyacrylates and halide based additives described previously for FIG. 1;
containing polymers. ' FIG. 3 is a plot of Torque (meter grams) vs. time
It is an object of this invention to provide a thermally (minutes) of the addition of 0.2% of the diphosphite
stable polymer additive of low volatility, which pos described as (E) in FIG. 1 to polybutylene terephthalate
sesses a high thermal decomposition temperature. (PET) in comparison to a control sample with no di
It is another object of this invention to provide a phosphite added;
polymer additive which is resistant to phosphite hydro FIG. 4 is a plot of Yellowness Index vs. time (min
lysis upon exposure to moisture for an extended period 65 utes) using the same comparatives shown for FIG. 3;
of time, thereby remaining granular and free-?owing. FIG. 5 is a plot of Torque (meter grams) vs. time
It is still another object of this invention to maintain (minutes) of the addition of 0.2% of the diphosphite
the Hunter yellowness color index number as low as described as (E) in FIG. 1 to polycarbonate;
5,438,086
5
FIG. 6 is a plot of Yellow Index vs. time (minutes)
using the same comparatives shown for FIG. 5;
FIG. 7A is a 31P NMR spectra of the diphosphite de
scribed as (E) in FIG. 1 run in deuterated benzene at 300
MHZ;
FIG. 7B is an expanded section of the 31P NMR spec
tra shown in FIG. 7;
FIG. 8A is a —P NMR spectra of the diphosphite de
scribed as (E) in FIG. 1 run in deuterated benzene at 300
MHZ;
FIG. 8B is an expanded section of the — P NMR spec
tra shown in FIG. 8;
FIG. 9A is a Fourier Transform Infra-Red (FTIR)
plot of absorbance vs. wavenumbers (cm-1) for the
diphosphite described as (E) in FIG. 1; 15
FIG. 9B is a plot of the same information described for
FIG. 9A for the diphosphite described as (C) in FIG. 1;
and
FIG. 9C is a plot of the same information as that
previously described for FIGS. 9A and 9B for 2,4‘
dicumylphenol.
DETAILED DESCRIPTION OF THE
INVENTION are more hydrolytically stable than prior art penta
erythritol diphosphites, and therefore require less pre~
Polymer degradation is the deterioration in the physi 25
cautions to be taken in their handling, and are more
cal properties of a polymer caused by chemical reac desirable as additives.
tions involving the backbone of the polymer chain. Specifically, within the pentaerythritol-based di
Symptoms of degradation are yellowing, loss of tensile phosphite of formula (IV), R1, R2, R4, R5, R7, R8, R10
strength, loss of impact strength, changes in melt-?ow, and R11 are selected independently from the group
and poor processability. This degradation can be caused consisting of hydrogen and alkyl radicals of generic
by contamination in the polymer, residual catalyst (po formula CmI-I2m+1 wherein m ranges from 1 to 4; Rn3,
tentially causing depolymerization), temperature, and Rn?, RH9 and R,,12 are selected independently from the
light. Degradation tends to occur under the following group consisting of hydrogen, halogens and alkyl radi
conditions: polymer drying; polymer pelletizing and cals of generic formula CmI-I2m+1 wherein in ranges
compounding; polymer storage and shipment; polymer from 1 to 4, and further wherein n ranges from 0 to 3,
fabrication processing; and during recycling. and the substituent is located at a position ortho, meta or
One technique which ameliorates some of the above para to the bridging methylene radical. The halogens
problems is through the use of an additive, in particular, are preferably selected from the group consisting of
a phosphite additive. One of the problems with the chlorine and bromine and anticipated to impart some
addition of pentaerythritol phosphite stabilizers has 4-0
additional degree of tire retardancy to the polymer.
been their tendency to absorb moisture, thereby de In particular, a preferred embodiment of the inven
creasing the product’s ability to flow freely. Another tion, is a diphosphite in a spiro conformation of formula
problem has been the experience that at high tempera (V), a bis(2,4~dicumylphenyDpentaerythritol diphosph
tures (typically greater than 480° F.), some phosphites
ite,
CH 0 0 on (V)
I 3 / \ i 3
65
are not particularly effective. It has been found, that although depending upon synthetic methods and condi
pentaerythritol-based diphosphites of the invention, tions employed, a minor amount of the cage conforma
shown in genetic form as formula (IV), tion, as is shown below in formula (V ’)
5,438,086
7 8
TABLE I
(V') TGA“) Comparison
TemErature at % of Weight Loss
5 Temp.
T Cc.) T ("0.) T (Q) T (“0.)
Percent Phosphite
C_CH3 weight loss (I) (III) (v) (II)
CH3 CH3 s 250 258 250 314
\C 10 10 275 265 275 332
20 300 282 300 343
CH3 30 315 293 318 350
40 320 297 329 354
0\ 61-120 so 327 303 336 365
CH3 P__0CH2_C_CH2O_P 80 345 318 364 375
15 (DDuPont 2000 TGA using a heating rate of 10‘ C. from room temperature to 800'
H3C—C O CHzO C. under nitrogen
99.49% of the sample , whereas the remainder indicated 40 The acid number was determined by weighing out a
one gram phosphite sample. Approximately 75 ml of
that 0.25% of the sample was of the cage conformation
methylene chloride was neutralized with 0.02N sodium
with 0.26% thiaryl phosphite. butylate to a blue-green endpoint using about 4-6 drops
By using the synthetic procedures outlined in this of a 0.1% bromothymol blue indicator solution. The
application, high purity samples can be obtained. Using 45 neutralized methylene chloride was added to the phos
differential scanning calorimetry to plot heat ?ow vs. phite sample and dissolved. The solution was immedi~
temperature, a melting point of 232.35“ C. was shown, ately titrated with 0.02N sodium butylate to a blue
green endpoint. '
the data of which, when plotted on a Van Hofft plot,
A hydrolytic stability comparison was made between
indicated the purity to be 99.63%. the prior art products, formulas (I) and (II) in compari
Cost and time prohibit real-life testing of stabilizer son to new formula (V), by exposing the 5 g samples of
systems, therefore laboratory tests have been developed the phosphites to 85% relative humidity at about 25° C.
to simulate conditions under which degradation occurs. for various periods of time, and noting when the pow
Thermal gravimetric analysis (TGA) is a sensitive tech 55 der changed its physical characteristics to either non
powdery or became sticky and lumpy. Without being
nique used to follow the weight change of a sample as a
held to any particular theory, it is proposed that the
function of temperature, thereby providing information hydrolytical stability of formula (V) is due to the large
about the thermal stability, volatility and decomposition bulky groups adjacent to the phosphorus. This provides
temperature of the material studied. The test simulates a good deal of steric hindrance to hydrolysis.
conditions which the polymer would experience during TABLE II
manufacturing and compounding. Phosphite Hydrolysisu)
As shown in Table I, TGA scans were used to mea Hours _
t-Bu
HO
t-Bu
(VII)
(2) 0.2% phosphites added to the base
(3) Brabender temperature 200° C. - 100 rpm
As shown in Table III, without the addition of any again, up to a total of ?ve extrusions.
TABLE VI
Multi-Pass Extrusion Stud
melt melt
new") new“) YI(5) YI(5)
base?) Additives 1st 5th 1st 5th
polymer Ca(2) phenol(3) phosphite pass pass pass pass
#1 PP 0.05% 0% 0% 26.9 208.3 4.6 6.7
#2 PP 0.1% 0% 7.0 12.2 4.5 6.3
#3 PP 0.1% (V) 0.05% 5.9 7.8 4.5 5.4
#4 PP 0.1% (I) 0.05% 3.9 4.8 4.0 6.1
#5 PP 0.1% (II) 0.05% 3.5 4.8 4.0 6.1
#6 PP 0.1% (III) 0.05% 6.0 54.6 4.3 5.4
#7 PP 0.1% (V) 0.05% 4.0 5.1 4.0 4.6
#8 PP 0.05% (V) 0.10% 3.9 15.0 4.1 4.4
(“polypropylene (PP) '
calcium stearate
(Dhindered phenol (I-1076 of formula (vn))
(“melt flow (grams/l0 minutes)
<5>Hunter Yellowness Color Index
Schematic l
OH
e3
(I: OH + PCl3 +
CH3 CH3 OH
/
H3C-C C-CH3
(I)
P
0/ \o
+ HQ><:HO
HO HO
O
\l/Na O
/ \
O-P P-O
\ /
O 0
‘EH3
? OH
CH3 CH 3
Na H3 c- 0/
@5
In general, the synthetic procedures used to prepare
the bis(2,4-dicumylphenyl)pentaerythritol diphosphite
@
of formula (V) are shown in Schematics I and II. It is of /ABS or polyester plus some other impact modi?er
course recognized that while only one speci?c embodi— may also be used. Such polymers are available commer
ment is shown, others would be possible. For example, 45 cially or may be made by means well known in the art.
the benzene rings could contain alkyl, typically of C14 However, the diphosphosphites of the invention are
and/or halogen, typically chlorine and bromine, substit particularly useful in thermoplastic polymers, such as
uents, and still be within the spirit of the invention. polyole?ns, polycarbonates, polyesters, polyphenylene
Additionally, the reaction times, temperatures and use ethers and styrenic polymers, due to the extreme tem
of other solvents have not been maximized, the speci?c peratures at which the thermoplastic polymers are often
examples being the best known to the inventors as of the processed and/or used.
date of the application. Polymers of monoole?ns and diole?ns, for example
DISCUSSION
would include polypropylene, polyisobutylene, polybu
tene-l, polymethylpentene-l, polyisoprene or polybuta
While the present invention has been directed to just diene, as well as polymers of cycloole?ns, for instance
a few stabilized polymer compositions which are pri of cyclopentene or norbornene, polyethylene (which
marily polyole?ns, polycarbonates, polyesters, etc., optionally can be crosslinked), for example high density
there is no need to limit it to such. In fact, any of the polyethylene (HDPE), low density polyethylene
polymers known in the art, such as polyesters, polyure (LDPE) and linear low density polyethylene (LLDPE)
thanes, polyalkylene terephthalates, polysulfones, 60 may be used. Mixtures of these polymers, for example
polyimides, polyphenylene ethers, styrenic polymers, mixtures of polypropylene with polyisobutylene, poly
polycarbonates, acrylic polymers, polyamides, polyace propylene with polyethylene (for example PP/HDPE),
tals, halide containing polymers and polyole?n homo may also be used. Also useful are copolymers of mono
polymers and copolymers. Additionally included ole?ns and diole?ns with each other or with other vinyl
would be mixtures of different polymers, such as poly 65 monomers, such as, for example, ethylene/propylene,
phenylene ether/styrenic resin blends, polyvinyl LLDPE and its mixtures with LDPE, propylene/bu
chloride/ABS or other impact modi?ed polymers, such tene-l, ethylene/hexene, ethylene/ethylpentene,
as methacrylonitrile containing ABS, and polyester ethylene/heptene, ethylene/octene, propylene/butadi
5,438,086
19 20
ene, isobutylene/isoprene, ethylene/alkyl acrylates, copolymer, vinyl chloride-vinylidene chloride copoly
ethylene/alkyl methacrylates, ethylene/vinyl acetate mer, vinyl chloride-styrene-maleic anhydride ter
(EVA) or ethylene/acrylic acid copolymers (EAA) and copolymer, vinyl chloride-styrene-acrylonitrile copoly
their salts (ionomers) and terpolymers of ethylene with mer, vinyl chloride-isoprene copolymer, vinyl chloride
propylene and a diene, such as hexadiene, dicyclopenta chlorinated propylene copolymer, vinyl chloride
diene or ethylidene-norbomene; as well as mixtures of vinylidene chloride-vinyl acetate tercopolymer, vinyl
such copolymers and their mixtures with polymers chloride-acrylic acid ester copolymers, vinyl chloride
mentioned above, for example polypropylene/ethylene maleic acid ester copolymers, vinyl chloride-methacry
propylene copolymers, LDPE/EVA, LDPE/EAA, lic acid ester copolymers, vinyl chloride-acrylonitrile
LLDPE/EVA and LLDPE/EAA. 10 copolymer and internally plasticized polyvinyl chlo~
Thermoplastic polymers may also include styrenic ride.
polymers, such as polystyrene, poly-(p-methylstyrene), Other useful thermoplastic polymers include homo
poly-(a-methylstyrene), copolymers of styrene or a polymers and copolymers of cyclic ethers, such as poly
methylstyrene with dienes or acrylic derivatives, such alkylene glycols, polyethylene oxide, polypropylene
as, for example, styrene/butadiene, styrene/acryloni oxide or copolymers thereof with bis-glycidyl ethers;
trile, styrene/alkyl methacrylate, styrene/maleic anhy polyacetals, such as polyoxymethylene and those poly
dride, styrene/budadiene/ethyl acrylate, styrene/a oxymethylene with contain ethylene oxide as a come
crylonitrile/methacrylate; mixtures of high impact nomer; polyacetals modi?ed with thermoplastic poly
strength from styrene copolymers and another polymer, urethanes, acrylates or methacrylonitrile containing
such as, for example, from a polyacrylate, a diene poly ABS; polyphenylene oxides and sul?des, and mixtures
mer or an ethylene/propylene/diene terpolymer; and of polyphenylene oxides with polystyrene or polyam
block copolymers of styrene, such as, for example, ides; polycarbonates and polyester-carbonates; polysul
styrene/butadiene/styrene, styrene/isoprene/styrene, fones, polyethersulfones and polyetherketones; and
styrene/ethylene/butylene/styrene or styrene/e polyesters which are derived from dicarboxylic acid
thylene/propylene/styrene. Styrenic polymers may 25 and diols and/or from hydroxycarboxylic acids or the
additionally or alternatively include graft copolymers corresponding lactones, such as polyethylene tere
of styrene or a-methylstyrene such as, for example, phthalate, polybutylene terephthalate, poly-1,4-dime
styrene on polybutadiene, styrene on polybutadiene-sty thyliol-cyclohexane terephthalate, poly-[2,2,4-(4
rene or polybutadiene-acrylonitrile; styrene and acrylo hydroxyphenyl)-propane]terephthalate and polyhy
nitrile (or methacrylonitrile) on polybutadiene; styrene droxybenzoates as well as block copolyetheresters de
and maleic anhydride or maleimide on polybutadiene, rived from polyethers having hydroxyl end groups.
styrene, acrylonitrile and maleic anhydride or malei Polyamides and copolyamides which are derived
mide on polybutadiene; styrene, acrylonitrile and from diamines and dicarboxylic acids and/or from
methyl methacrylate on polybutadiene, styrene and aminocarboxylic acids or the corresponding lactams,
alkyl acrylates or methacrylates on polybutadiene, sty 35 such as polyamide-4, polyamide-6, polyamide-6/6,
rene and acrylonitrile on ethylene/propylene/diene polyamide-6/l0, polyamide-6/9, polyamide-6/ 12,
terpolymers, styrene and acrylonitrile on polyacrylates polyamide-4/6, polyamide- ll, polyamide- 12, aromatic
or polymethacrylates, styrene and acrylonitrile on polyamides obtained by condensation of m-xylene, di
acrylate/butadiene copolymers, as well as mixtures of amine and adipic acid; polyamides prepared from hexa
with the styrenic copolymers indicated above. methylene diamine and isophthalic and/or terephthalic
Nitrile polymers are also useful in the polymer com acid and optionally an elastomer as modi?er, for exam
position of the invention. These include homopolymers _ ple, poly-2,4,4-trimethylhexamethylene terephthalam
and copolymers of acrylonitrile and its analogs such as ide or poly-m-phenylene isophthalamide may be useful.
methacrylonitrile, such as polyacrylonitrile, acryloni Further copolymers of the aforementioned polyamides
trile/butadiene polymers, acrylonitrile/alkyl acrylate 45 with polyolef'ms, ole?n copolymers, ionomers or chemi
polymers, acrylonitrile/alkyl methacrylate/butadiene cally bonded or grafted elastomers; or with polyethers,
polymers, acrylonitrile/butadiene/styrene (ABS), and such as for instance, with polyethylene glycol, polypro
ABS which includes methacrylonitrile. pylene glycol or polytetramethylene glycols, and poly
Polymers based on acrylic acids, such as acrylic acid, amides or copolyamides modi?ed with EPDM or ABS
methacrylic acid, methyl methacrylate acid and etha may be used.
crylic acid and esters thereof may also be used. Such The resulting stabilized polymer compositions of the
polymers include polymethylmethacrylate, and ABS invention may optionally also contain various conven
type graft copolymers wherein all or part of the tional additives, such as the following:
acrylonitrile-type monomer has been replaced by an (1) Antioxidants
acrylic acid ester or an acrylic acid amide. Polymers 55 (1.1) Alkylated monophenols, for example: 2,6-di-t
including other acrylic-type monomers, such as acro butyl-4-methylphenol, 2-t-butyl-4,6-dimethylphenol,
lein, methacrolein, acrylamide and methacrylamide 2,6-di-t-butyl-4-ethylphenol, 2,6-di-t-butyl-4-n-butyl
may also be used. phenol, 2,6~di-t-butyl-4-butylphenol, 2,6-di-cyclopen
Halogen-containing polymers may also be useful. tyl-4-methylphenol, 2(ct-methylcyclohexyl)-4,6-dirne
These include resins such as polychloroprene, epichlo 60 thylphenol, 2,6-di-octadecyl-4-methylphenol, 2,4,6-tri
rohydrin homopolymers and copolymers, polyvinyl cyclohexylphenol, and 2,6-di-t-butyl-4-methoxymethyl
chloride, polyvinyl bromide, polyvinyl ?uoride, polyvi phenol.
nylidene chloride, chlorinated polyethylene, chlori (1.2) Alkylated hydroquinones, for example, 2,6-di-t
nated polypropylene, ?uorinated polyvinylidene, bro butyl-4—methoxyphenol, 2,5-di-t-butyl-hydroquinone,
minated polyethylene, chlorinated rubber, vinyl chlo 65 2,S-di-t-amyl-hydroquinone, and 2,6—diphenyl-4
ride-vinylacetate copolymer, vinyl chloride-ethylene octadecyloxyphenol.
copolymer, .vinyl chloride-propylene copolymer, vinyl (1.3) Hydroxylated thiodiphenyl ethers, for example,
chloride-styrene copolymer, vinyl chloride-isobutylene 2,2’-thio-bis-(6-t-butyl-4-methylphenol), 2,2’-thio-bis-(4