CRAZE-RESISTANT POLYMODAL LINEAR BLOCK COPOLYMERS WITH RESINOUS TERMINAL BLOCKS

Abstract: Sequential charging of initiator and monomers in a multistage solution polymerization process involving conjugated diene and monovinyl­ aromatic monomers wherein the initial and final charges are monovinylaro­ matic monomer results in the production of polymodal linear block copolymers with terminal resinous blocks. A typical 6-stage charge sequence is as follows: stage 1: (S i ); stage 2: (S i ); stage 3: (B); stage 4: (S i ); stage 5: (B) and stage 6: (S) wherein (S i ) is monovinylaromatic monomer and initiator, (B) is conjugated diene monomer and (S) is monovinylaromatic monomer. At each stage, polymerization is allowed to continue until no free monomer is present. The polymodal block copolymer products comprise high, medium and low molecular weight species designated, respectively, as S₁-S₂-B₁-S₃-B₂-S₄; S₂-B₁-S₃-B₂-S₄; and S₃-B₂-S₄ wherein S₁, S₂, S₃ and S₄ represent, respectively, polyvinylaromatic blocks resulting from polymerization of the first, second, third and fourth charges of monovinylaromatic monomer (stages 1,2,4 and 6); B₁ represents a polydiene block resulting from polymerization of the first charge of conjugated diene monomer (stage 3); and B₂ represents a polydiene block resulting from polymerization of the second charge of conjugated diene monomer (stage 5). The subject copolymers can be fabricated into sheets and molded objects possessing little color, a high degree of transparency and excellent impact resistance. These fabricated products do not craze on being impacted.

Description: Field of the Invention The invention relates to polymodal linear block copolymers with terminal resinous blocks. In another aspect, the invention relates to a method of preparing polymodal linear block copolymers characterized by terminal resinous blocks which involves sequential charging of initiator and monomers to the polymerization zone. Background of the Invention Although substantially transparent and colorless block copolymers have been prepared by a variety of initiator and monomer charge sequences, some of the prior art materials such as described in U.S. 4,080,407 are not entirely satisfactory in regard to impact strength and craze-resistance. Articles fabricated from some of the available block copolymers are quite satisfactory in regard to exhibiting low blueness and a high degree of transparency. However, these articles may also exhibit somewhat low impact strength and a tendency to craze on being impacted. Similar aspects apply to EP-A-0 153 727 which describes 3 modes of a polymerization procedure for producing craze-resistant block copolymers. However, each of the modes described comprises a coupling agent/reaction thereby increasing the number of reaction steps required. Such deficiencies of available block copolymers are evident in packaging applications such as blister packs for bandages and syringes. These transparent colorless packs are intended to display and protect the contents and maintain a sterile atmosphere within the pack. Crazing of these packs due to squeezing during shipping is very undesirable because the crazed packs and their contents are discarded on the presumption that the sterile atmosphere within the pack has been contaminated by an air leak. Thus, there is a need for block copolymers which possess the capacity to impart good impact strength and craze-resistance to transparent colorless manufactured articles, particularly in the packaging field. Invention Thus, it is an object of this invention to provide block copolymers with the capacity to impart good impact strength and craze-resistance to manufactured articles. Another object of this invention is to provide blister packaging possessing craze-resistance and a high degree of transparency. Other aspects, objects and the several advantages of the invention will be apparent to those skilled in the art from the description and the appended claims. In accordance with the present invention, there is provided a process for producing polymodal, craze-resistant, low color, transparent linear block copolymers with terminal resinous blocks by polymerizing under solution polymerization conditions at least one monovinylaromatic monomer containing 8 to 12 carbon atoms and at least one conjugated diene monomer containing 4 to 6 carbon atoms in a ratio of 55 to 95 weight percent monovinylaromatic monomer to 45 to 5 weight percent conjugated diene monomer, in a sequential charge polymerization process, wherein two separate charges consisting of said monovinylaromatic monomer and an organomonoalkali metal initiator precede a separate charge of conjugated diene monomer followed by an additional separate charge of said monovinylaromatic monomer and said initiator before consecutive individual charges of conjugated diene and monovinylaromatic monomers, each monomer charge being polymerized to substantial completion prior to addition of any subsequent charge and wherein said sequential charge polymerization process is carried out in the absence of coupling and employs a 6-stage charge sequence: Stage 1: Initiator and monovinylaromatic monomer (S i ) Stage 2: Initiator and monovinylaromatic monomer (S i ) Stage 3: Conjugated diene monomer (B) Stage 4: Initiator and monovinylaromatic monomer (S i ) Stage 5: Conjugated diene monomer (B) Stage 6: Monovinylaromatic monomer (S). The instant polymodal block copolymers comprise high, medium and low molecular weight species designated, respectively, as S₁-S₂-B₁-S₃-B₂-S₄; S₂-B₁-S₃-B₂-S₄ and S₃-B₂-S₄ wherein S₁, S₂, S₃ and S₄ represent, respectively, polyvinylaromatic blocks resulting from polymerization of the first, second, third and fourth charges of monovinylaromatic monomer (stages 1,2,4 and 6); B₁ represents a polydiene block resulting from polymerization of the first charge of conjugated diene monomer (stage 3); and B₂ represents a polydiene block resulting from polymerization of the second charge of conjugated diene monomer (stage 5). The instant copolymers contain about 55 to 95 preferably 70 to 80 weight percent of monovinylaromatic monomer units and 45 to 5 preferably 30 to 20 weight percent conjugated diene monomer units based on total weight of monomers charged to the polymerization zone. Broad and preferred ranges for practicing the instant process are summarized in Table A. The symbols L, S and B represent, respectively, organomonoalkali metal initiator such as n-butyllithium, monovinylaromatic monomer such as styrene and conjugated diene monomer such as 1,3-butadiene. Monomers The conjugated diene monomers contain 4 to 6 carbon atoms and include 1,3-butadiene, isoprene, 2-ethyl-1,3-butadiene; 2,3-dimethyl-1,3-butadiene and piperylene and mixtures thereof. Presently preferred is 1,3-butadiene. The monovinylaromatic monomers contain 8 to 12 carton atoms and include styrene, alpha-methylstyrene, p-vinyltoluene, m-vinyltoluene, o-vinyltoluene, 4-ethylstyrene, 3-ethylstyrene, 2-ethylstyrene 4-tertbutylstyrene and 2,4-dimethylstyrene and mixtures thereof. Presently preferred is styrene. Polymerization The polymerization process is carried out in a hydrocarbon diluent at any suitable temperature in the range of -10 to 150°C preferably in the range of 0 to 110°C at pressures sufficient to maintain the reaction mixture substantially in the liquid phase. Preferred hydrocarbon diluents include linear and cycloparaffins such as pentane, hexane, octane, cyclohexane and mixtures thereof. Presently preferred is cyclohexane. Small amounts of polar organic compounds such as tetrahydrofuran are required in the hydrocarbon diluent to improve the effectiveness of n-alkyl monoalkali metal initiators such as n-butyllithium. Amounts of tetrahydrofuran to provide from about 0.01 to 1.0 phm (parts per hundred parts of total monomer), preferably 0.02 to 0.1 phm are suitable. The initiators can be any of the organomonoalkali metal compounds of the formula RM wherein R is an alkyl, cycloalkyl or aryl carbanion containing 4 to 8 carbon atoms and M is an alkali metal cation. The presently preferred initiator is n-butyllithium. Suitable amounts of organomonoalkali metal initiator are encompassed by the ranges given in Table A. The polymerization is carried out in the substantial absence of oxygen and water preferably under an inert gas atmosphere. Prior to the termination treatment, the reaction mass contains a very high percentage of living molecules in which an alkali metal cation is positioned at one end of each polymer chain. Impurities in the feed such as water or alcohol reduce the amount of monoalkali metal living polymer in the reaction mass. At the conclusion of the polymerization process, the system is treated as is known in the art with an active hydrogen compound such as water, alcohol, phenols or linear saturated aliphatic mono- and dicarboxylic acids to convert terminal carbon-lithium bonds on the living polymer molecules to carbon-hydrogen bonds resulting in the separation of copolymer. Preferably, the polymer cement, i.e., the polymer in the polymerization solvent, is treated with terminating agents (water and carbon dioxide) and then antioxidants before the solvent is flashed off to increase the solids content. The resinous copolymer products can be and usually are compounded with antioxidants, release agents and the like before fabrication into useful articles such as molded objects and sheeting. The following Examples illustrate my invention. Example I This example described the preparation of invention polymodal linear block copolymers with terminal resinous blocks. Styrene and 1,3-butadiene were copolymerized in a 6-stage process using n-butyllithium initiator. The runs were carried out under nitrogen in a two-gallon jacketed stainless steel reactor. The anhydrous reaction mixtures were stirred continuously during the polymerization process. Termination was effected by the conventional use of carbon dioxide and water. A mixture of Irganox 1076 (0.25 phm) and tris(nonylphenyl)phosphite (TNPP) (1.0 phm) was added prior to isolation of copolymer product. The inventive procedure is summarized in Table I. Referring to the two invention runs in Table I, it is evident that the products were prepared in a 6-stage process involving three portions of styrene and initiator (stages 1,2 and 4), two portions of 1,3-butadiene (stages 3 and 5) and a final portion of styrene (stage 6). This sequence of charging reactants to the polymerization zone results in terminal resinous blocks on high, medium and low molecular weight copolymers in the product. As a result of the sequential charging of initiator in stages 1,2 and 4 (i.e., 3 charges of initiator), the copolymer products in runs 1 and 2 of Table I are referred to as polymodal, viz., trimodal. The term trimodal connotes the production of three molecular weight species: high, medium and low arising by the initiation of new polymer chains in stages 1,2 and 4. Thus, in stage 1, polystyrene chains are initiated by n-butyllithium and propagation continues until no styrene monomer is present resulting ideally in S₁-Li living polymers of comparable molecular weight. The further addition of initiator and styrene in stage 2 results in the initiation of new polystyrene chains and growth of the polystyrene chains initiated in stage 1. After two stages wherein all styrene monomer has been polymerized, the bimodal species can be represented as: S₁-S₂-Li and S₂-Li wherein S denotes polystyrene blocks and subscripts indicate the stage of monomer addition. The addition of 1,3-butadiene in stage 3 results in the incorporation of the conjugated diene into each of the above living polymers to give bimodal copolymers: S₁-S₂-B₁-Li and S₂-B₁-Li wherein S₁ and S₂ are polystyrene blocks and B₁ is a polybutadiene block. In stage 4 additional styrene and n-butyllithium are introduced resulting in the initiation of new polystyrene chains and propagation of the existing S₁-S₂-B₁-Li and S₂-B₁-Li living polymers. After stage 4 wherein all monomer has been polymerized, the trimodal species can be represented as: S₁-S₂-B₁-S₃-Li ; S₂-B₁-S₃-Li and S₃-Li designating high, medium and low molecular weight species. In stages 5 and 6 no additional initiator is charged so that the term trimodal is still appropriate for the copolymers produced. After the incorporation of 1,3-butadiene in stage 5, the trimodal species, i.e., high, medium and low molecular weight, can be represented as: S₁-S₂-B₁-S₃-B₂-Li ; S₂-B₁-S₃-B₂-Li and S₃-B₂-Li . After incorporation of styrene in stage 6, the high, medium and low molecular weight species can be represented, respectively, as: S₁-S₂-B₁-S₃-B₂-S₄-Li ; S₂-B₁-S₃-B₂-S₄-Li and S₃-B₂-S₄-Li . After termination of the polymerization and product recovery, these species can be represented as: S₁-S₂-B₁-S₂-B₂-S₄ ; S₂-B₁-S₃-B₂-S₄ and S₃-B₂-S₄ . Example II This example describes the preparation of linear block copolymers with terminal resinous blocks in accordance with prior art patent U.S. 4,080,407. Styrene and 1,3-butadiene were copolymerized in a 4-stage process using n-butyllithium initiator. The runs were carried out under nitrogen in a two-gallon jacketed stainless steel reactor. The anhydrous reaction mixtures were stirred continuously during the polymerization process. Termination was effected by the conventional use of carbon dioxide and water. The preparation procedure is summarized in Table II. Referring to the control runs in Table II, it is evident that the products were prepared in a 4-stage process involving two portions of styrene and initiator (stages 1 and 2), one portion of 1,3-butadiene (stage 3) and a final portion of styrene (stage 4). This sequence of reactant charges to the polymerization zone results in terminal resinous blocks on each high and low molecular weight species in the product. As a result of the sequential charging of initiator in stages 1 and 2, i.e., two charges of initiator, the copolymer products obtained in runs 1 and 2 of Table II are referred to as polymodal, viz., bimodal in contrast to the trimodal invention copolymers of Example I. The term bimodal connotes the production of high and low molecular weight species arising by the initiation of new polymer chains in stages 1 and 2. Thus, in stage 1, living polystyrene chains are initiated by n-butyllithium and propagation continues until no styrene monomer is present resulting ideally in S₁-Li living polymer chains of comparable molecular weight. The further addition of styrene and initiator (stage 2) results in the initiation of new polystyrene chains and propagation of the living S₁-Li species initiated in stage 1. After two stages wherein all styrene monomer has been polymerized, the bimodal species can be represented as: S₁-S₂-Li and S₂-Li wherein S denotes polystyrene blocks and subscripts indicate the stage of monomer addition. The addition of 1,3-butadiene monomer in stage 3 and the addition of styrene monomer in stage 4 with no additional initiator does not change the modality of the products. In stage 3 the addition of 1,3-butadiene results in the incorporation of the conjugated diene into each of the living polymers to give bimodal copolymers: S₁-S₂-B₁-Li and S₂-B₁-Li wherein S₁ and S₂ are polystyrene blocks and B₁ is a polybutadiene block. In stage 4 additional styrene without initiator is charged so that the term bimodal is still appropriate for the copolymers produced. After all of the styrene monomer has been incorporated, the bimodal species (high and low molecular weight) can be represented, respectively, as: S₁-S₂-B₁-S₃-Li and S₂-B₁-S₃-Li wherein S denotes polystyrene blocks, B₁ denotes a polydiene-derived block and the subscripts indicate the stage of monomer addition. After termination of the polymerization and product recovery, these species can be represented as: S₁-S₂-B₁-S₃ and S₂-B₁-S₃ . The copolymer species present in the Example I products (inventive) and the copolymer species present in the Example II products (prior art) can be compared as below: Example III This example compares the properties exhibited by test samples of trimodal invention copolymers with the properties of test samples prepared from bimodal control copolymers. The invention copolymers were prepared by the procedure summarized in Table I of Example I. The control copolymers were prepared in accordance with U.S. 4,080,407 (see Table II in Example II). The comparative results are shown in Table III. Referring to the summary of properties in Table III, it is evident that the trimodal inventive copolymers were clearly superior to the control copolymers in regard to impact strength and craze-resistance. The invention copolymers exhibited craze-resistance on being impacted whereas the control copolymers did not exhibit this property. The Gardner impact values for the invention copolymers were in the range of 110 to 120 in-lbs whereas the impact values for the control copolymers were in the range of 35 to 40 in-lbs. In regard to blueness and % Haze, the control copolymers and invention copolymers were comparable. Reasonable variations and modifications of the present invention which will become apparent to those skilled in the art can be made in this invention without departing from the spirit and scope thereof.

Claims: A process for producing polymodal, craze-resistant, low color, transparent linear block copolymers with terminal resinous blocks by polymerizing under solution polymerization conditions at least one monovinylaromatic monomer containing 8 to 12 carbon atoms and at least one conjugated diene monomer containing 4 to 6 carbon atoms in a ratio of 55 to 95 weight percent monovinylaromatic monomer to 45 to 5 weight percent conjugated diene monomer, in a sequential charge polymerization process, characterized in that two separate charges consisting of said monovinylaromatic monomer and an organomonoalkali metal initiator precede a separate charge of conjugated diene monomer followed by an additional separate charge of said monovinylaromatic monomer and said initiator before consecutive individual charges of conjugated diene and monovinylaromatic monomers, each monomer charge being polymerized to substantial completion prior to addition of any subsequent charge, wherein said sequential charge polymerization process is carried out in the absence of coupling and employs a 6-stage charge sequence: Stage 1: Initiator and monovinylaromatic monomer (S i ) Stage 2: Initiator and monovinylaromatic monomer (S i ) Stage 3: Conjugated diene monomer (B) Stage 4: Initiator and monovinylaromatic monomer (S i ) Stage 5: Conjugated diene monomer (B) Stage 6: Monovinylaromatic monomer (S). The process of claim 1 characterized by employing ranges of monomer additions and of organomonoalkali metal initiator added at each stage: wherein L represents organomonoalkali metal initiator, B represents conjugated diene monomer, S represents monovinylaromatic monomer, phm represents parts by weight per 100 parts by weight of total monomers and mhm represents grammillimoles per 100 grams of total monomers. The process of claim 2 characterized by employing ranges of monomer additions and of organomonoalkali metal initiator added at each stage: The process of any of the preceding claims characterized by employing 1,3-butadiene as said conjugated diene monomer. The process of any of the preceding claims characterized by employing styrene as said monovinylaromatic monomer. The process of any of the preceding claims characterized by employing n-butyllithium as said organomonoalkali metal initiator. The process of any of the preceding claims characterized in that in stage 1 the charge includes 0.01 to 1.0 parts by weight of tetrahydrofuran based on the total amount of monomers charged. The process of any of the preceding claims characterized by employing a ratio of 70 to 80 weight percent of monovinylaromatic monomer units to 30 - 20 weight percent of conjugated diene monomer units. The polymodal linear block copolymers with terminal resinous blocks obtainable by the process of any of claims 1 to 8. The use of the copolymers of claim 9 for making blister packs.

Inventors: KITCHEN, ALONZO GENE
Applicants: PHILLIPS PETROLEUM COMPANY
Application year: 1987
Main classification: C08F297
IPC codes: C08F297, C08F4