Polyketone polymer composition

Abstract: Polymer composition comprising a non-miscible blend of: (1) a linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated hydrocarbon, (2) a mineral filler, and (3) a polyether esteramide polymer, and optionally, (4) an acidic polymer incorporating moieties of an α-olefin, an α,β-ethylenically unsaturated carboxylic acid, and optionally a non-acidic, low molecular weight polymerizable monomer, the acidic polymer optionally having a portion of the carboxylic acid groups neutralized with non-alkali metal, show good dimensional stability while maintaining good strength and impact resistance.

Description: This invention relates to a polyketone polymer composition comprising predominantly a linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated compound and to a process for preparing such a composition. The class of polymers of carbon monoxide and olefin(s) has been known for some time. More recently, the class of linear alternating polymers has become of greater interest because of the greater availability of the polymers in quantity. These polymers, often referred to as polyketones or polyketone polymers, have been shown to be of the repeating formula -CO-(A)- wherein A is the moiety of unsaturated hydrocarbon polymerized through the ethylenic unsaturation. By way of further illustration, when the ethylenically unsaturated hydrocarbon is ethylene the polymer is represented by the repeating formula -CO-(CH₂-CH₂)-. The general process for the more recent production of such polyketone polymers is illustrated by a number of published European Patent Applications including 121,965, 181,014, 213,671, and 257,663. The process typically involves a catalyst composition formed from a compound of a Group VIII metal selected from palladium, cobalt or nickel, the anion of a strong non-hydrohalogenic acid and a bidentate ligand of phosphorus, arsenic or antimony. The resulting polymers are relatively high molecular weight thermoplastics having established utility in the production of shaped articles such as containers for the food and drink industry and internal and external parts for the automotive industry, which articles are produced by processing the polymer according to known methods. For some particular applications it has been found to be desirable to have properties for a polymeric composition which are somewhat different from those of the polyketone polymers. It would be of advantage to retain the more desirable properties of the polyketone polymer and yet improve other properties. These advantages are often obtained through the provision of a polymer blend, but it is not predictable which polymers should be blended with one another in order to obtain the desired effects, the more so as many polymers may interact negatively with each other. Semi-crystalline polymers, such as the polyketone polymer, often suffer from substantial mould shrinkage and high thermal expansion, limiting their utility in applications where dimensional stability is critical. It has now been found that this problem can be solved by adding a mineral filler having a very low thermal expansion coefficient. However, the addition of a mineral filler was found to compromise impact strength, as described in US-A-4851470. This reduction in impact strength can be offset, it was found, by including a second polymer, namely a polyether esteramide polymer in the composition. Moreover, it was found that the inclusion of an acidic polymer containing moieties of an α-olefin and an α,β-ethylenically unsaturated carboxylic acid improved processability. Accordingly, the present invention concerns a polyketone polymer composition comprising a non-miscible blend of: (1) 50-99.4% by weight of a linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated compound, (2) 0.1-45% by weight of a mineral filler, and (3) 0.5-45% by weight of a polyether esteramide polymer, and optionally, (4) 0-10% by weight of an acidic polymer incorporating moieties of an α-olefin, an α,β-ethylenically unsaturated carboxylic acid, and optionally a non-acidic, low molecular weight polymerizable monomer, the acidic polymer optionally having a portion of the carboxylic acid groups neutralized with non-alkali metal. Such blends exhibit improved dimensional stability while exhibiting good strength and impact resistance, relative to the linear alternating polymer with mineral filler alone. The invention furthermore relates to a process for preparing a polyketone polymer composition, characterized by comprising the steps of: mixing a mineral filler with a polyether esteramide polymer to form a premixed polymer blend; and blending the premixed polymer blend with a linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated compound to form a non-miscible polymer blend according to the present invention. Such a process appears to offer advantages over a single step mixing process. The polyketone polymers which are employed as the first component of the blends of the invention are linear alternating copolymers of carbon monoxide and at least one ethylenically unsaturated compound. Suitable ethylenically unsaturated hydrocarbon compounds which are useful as precursors of the polyketone polymers have up to 20 carbon atoms inclusive, preferably up to 10 carbons atoms inclusive, and are aliphatic such as ethylene and other alpha-olefins including propylene, butylene, isobutylene, 1-hexene, 1-octene and 1-dodecene, or are arylaliphatic having an aryl substituent on an otherwise aliphatic molecule, particularly an aryl substituent on a carbon atom of the ethylenic unsaturation. Illustrative of this latter class of ethylenically unsaturated hydrocarbons are styrene, p-methylstyrene, m-propylstyrene and p-ethylstyrene. Preferred polyketone polymers are copolymers of carbon monoxide and ethylene or terpolymers of carbon monoxide, ethylene and a second hydrocarbon of at least three carbon atoms particularly an alpha-olefin such as propylene. The structure of the polyketone polymers is that of a linear alternating polymer and the polymer will contain substantially one molecule of carbon monoxide for each molecule of ethylenically unsaturated hydrocarbon. When terpolymers of carbon monoxide, ethylene and a second hydrocarbon are employed as a blend component in the compositions of the invention, there will suitably be within the terpolymer at least two units incorporating a moiety of ethylene for each unit incorporating a moiety of the second hydrocarbon. Preferably there will be from 10 to 100 units incorporating a moiety of ethylene for each unit incorporating a moiety of the second hydrocarbon. The polymer chain will therefore be represented by the repeating formula wherein G is the moiety obtained by polymerization of the second hydrocarbon through the ethylenic unsaturation and the ratio of y:x is no more than 0.5. In the modification where a copolymer of carbon monoxide and ethylene is employed as a blend component there will be no second hydrocarbon present and the polyketone polymer is represented by the above formula wherein y = 0. When y is other than 0, i.e., terpolymers are employed, the -CO-(CH₂-CH₂)- units and the -CO-(G)- units are found randomly throughout the polymer chain, and ratios of y:x from 0.01 to 0.1 are preferred. The end groups or "caps" of the polymer chain will depend on what materials are present during the production of the polyketone and whether and how the polymer has been purified. The precise properties of the polymer will not depend upon the particular end groups to any considerable extent so that the polymer is fairly represented by the above formula for the polymer chain. Of particular interest are the polyketones of number average molecular weight from 1,000 to 200,000, particularly those of number average molecular weight from 20,000 to 90,000 as determined by gel permeation chromatography. The physical properties of such polymers will depend in part on the molecular weight, whether the polymer is a copolymer or a terpolymer and, in the case of terpolymers the proportion of the second hydrocarbon present. Typical melting points for such polymers are from 175°C to 300°C, preferably from 210°C to 270°C. The polymers have a limiting viscosity number (LVN), measured in a standard capillary viscosity measuring device in m-cresol at 60°C, of from 0.5 to 8, preferably from 0.8 to 4. A method of producing the polyketone polymers which is now becoming conventional is to contact the carbon monoxide and the unsaturated hydrocarbon(s) in the presence of a catalyst composition formed from a palladium compound, the anion of a non-hydrohalogenic acid having a pKa below about 6 and a bidentate phosphorus ligand. The scope of the production of polyketone is extensive but, without wishing to be limited, a preferred palladium compound is a palladium carboxylate, particularly palladium acetate, the preferred anion is the anion of trifluoroacetic acid or para-toluenesulfonic acid, and the preferred bidentate ligand is 1,3-bis(diphenylphosphino)propane or 1,3-bis[di(2-methoxyphenyl)-phosphino]propane. Polymerization is conducted in the gas phase in the substantial absence of reaction diluent or in a liquid phase in the presence of a reaction diluent such as an alkanol, e.g., methanol or ethanol. The reactants are contacted under polymerization conditions in the presence of a catalyst composition by conventional methods such as shaking or stirring in a reaction vessel. Suitable reaction temperatures are from 20°C to 150°C, preferably from 50°C to 135°C. Typical reaction pressures are from 1 bar to 100 bar, more often from 10 bar to 100 bar. Subsequent to reaction the polymer is recovered by decantation or filtration. The polymer product may contain residues of the catalyst composition which are removed, if desired, by treatment with a solvent or a complexing agent which is selective for the residues. The second component of the non-miscible ternary blends of the invention is a mineral filler, suitably selected from the group consisting of talc, clay, mica, silica, calcium carbonate, wollastonite, franklinite and/or mixtures thereof. Talc is particularly useful herein. The mineral fillers to be used in the non-miscible blends of the invention will customarily be provided by the manufacturer with a coating of a sizing material or a coupling agent, which terms are often used interchangeably. For example, calcium carbonate may be coated with an acidic substance, such as stearic acid. The nature of the sizing or coupling agent will influence the interfacial shear strength of the mineral filler and the polymer matrix, i.e., the degree to which the polymer and filler will adhere. To contribute strength to a polymer blend, the interfacial shear strength will be at least comparable in magnitude to the shear strength of the polymer so that there will be good adhesion between the polymer and the mineral filler. The interfacial shear strength is influenced by the polarity of the polymer so that for some polymers certain sizings or coupling agents work better than others. For the case of blends containing polyketone polymers, a variety of sizings are suitable, particularly sizing designed and provided particularly for use with polar polymers. Sizings are generally characterised by the general nature of the size rather than the specific chemical structures which are often proprietary to the mineral filler manufacturer. Suitable sizings include water emulsions of starch and lubricating oil, aqueous dispersions of surface active materials and lubricants, silicon-containing materials such as vinyl silanes, alkyltrimethoxysilanes, amino silanes and, trimethoxysilanes which may also contain urethane, acrylate or epoxy functionalities, and non-polar hydrocarbons. The mineral filler may aid to reduce and/or control mould shrinkage of the resultant polyketone polymer composition. Physical and thermal properties may be affected by the characteristics of the mineral fillers, such as the shape of the filler particles, the size of the filler particles, the size distribution of the filler particles, the surface area of the filler particles, and the surface preparation (i.e., sizing) of the filler particles. Talc significantly improves the dimensional stability of the polyketone polymer while providing the least reduction in impact strength, relative to other mineral fillers. The third component of the ternary blends of the invention is a polyether esteramide polymer, e.g., a polymer incorporating a polyether portion and at least one other portion which contains ester linkages or amide linkages, or both. The polyether esteramide is a random copolymer or is a block copolymer so long as the polyether, ester and/or amide portions are contained within the polymer molecule. The particular structure of the polyether esteramide polymer will vary and will depend greatly upon the particular way the polyether esteramide polymer is produced. In one modification, the polyether esteramide is suitably produced by reacting (a) one or more compounds selected from omega-aminocarboxylic acids or lactams, the compounds having 10 or more carbon atoms, (b) an alpha,omega-dihydroxy(polyoxyalkylene oxide), particularly an alpha,omega-dihydroxy(polytetrahydrofuran), having an average molecular weight of from 160 to 3000, and (c) an organic dicarboxylic acid. The weight ratio of component (a) to the combination of components (b) and (c) should be from 30:70 to 98:2, based on total polymer. Illustrative of the omega-amino-carboxylic acid and/or lactam of component (a) is caprolactam, lauryllactam, 12-aminododecanoic acid and 11-aminoundecanoic acid. Lauryllactam and 12-aminododecanoic acid are preferred. The diol of component (b) is a dihydroxy-(polyoxyalkylene oxide), particularly an alpha,omega-dihydroxy(polytetrahydrofuran) having a molecular weight of from 500 to 1200. The dicarboxylic acids of component (c) are straight-chain dicarboxylic acids of from 6 to 13 carbon atoms inclusive. Such dicarboxylic acids include adipic acid, subenic acid, sebacic acid and dodecanedioic acid. Dodecanedioic acid is preferred. The polyether esteramide is produced by heating the reactants in the presence of from 2% by weight to 30% by weight of the water, based on component (a) under internal pressure in a closed reactor at 230 to 300°C. After water is removed as steam, the mixture is maintained at 250 to 280°C under normal or reduced pressure in the absence of oxygen. The resulting polymer is a random polymer in which the units of the starting compounds are randomly distributed along the polymer chain. In a second and generally preferred modification, the polyether esteramide is a block copolymer comprising blocks of the polymer components, e.g., blocks of the esteramide component and the polyether component. Such block polyether esteramide polymers are represented by the repeating formula wherein R represents the polyamide moiety illustratively derived from a dicarboxylic polyamide by loss of the two terminal carboxyl groups and R' is the polyoxyalkylene moiety illustratively derived by loss of the two terminal hydroxyl groups from a polyoxyalkylene glycol. The dicarboxylic polyamide is produced by methods known in the art such as polycondensation of one or more lactams and/or omega-aminoacids or by polycondensation of a dicarboxylic acid with a diamine. When the polyamide portion is produced from lactams or aminoacids, it is preferred that the lactam or aminoacid contain a straight-chain alkylene moiety of from 4 to 11 carbon atoms inclusive, as illustrated by caprolactam, lauryllactam, 12-aminododecanoic acid and 11-aminoundecanoic acid. Lauryllactam and 12-aminododecanoic acid are preferred. When the polyamide portion is produced from a diamine and a dicarboxylic acid, the preferred diamines are straight-chain diamines of from 4 to 12 carbon atoms inclusive, particularly hexamethylenediamine and nonamethylenediamine. The preferred dicarboxylic acids have from 4 to 12 carbon atoms inclusive and are illustrated by adipic acid, azelic acid, sebacic acid and dodecanedioic acid. The polyamide portion is produced by contacting the reactants, often in the presence of an excess of dicarboxylic acid to limit the chain length of the polyamide portion. Good results are obtained if the dicarboxylic polyamide has an average molecular weight of from 300 to 15,000, preferably from 800 to 5000. The polyoxyalkylene glycol portion comprises linear or branched polyoxyalkylene glycols wherein the alkylene moiety has at least two carbon atoms, e.g., polyoxyethylene glycol, polyoxypropylene glycol or polyoxytetramethylene glycol as well as copolymers of such glycols. Polyoxytetramethylene glycol is preferred. The average molecular weight of the polyoxyalkylene glycol is suitably from 100 to 6000, but preferably is from 200 to 3000. The weight ratio of the polyoxyalkylene glycol to the dicarboxylic polyamide suitably is from 5:95 to 85:15, based on total polymer, but preferably is from 10:90 to 50:50 on the same basis. The reaction of the polyoxyalkylene glycol portion and the dicarboxylic polyamide portion is conducted in the molten state, e.g., from 100°C to 400°C, in the presence of an alkoxide catalyst which is preferably a zirconium, titanium, or hafnium tetraalkoxide wherein each alkyl independently has up to 24 carbon atoms. The reactant contact is maintained by vigorous agitation, such as by stirring, at a reduced pressure on the order of from (0.05 mm to 5 mm Hg) 6.6-66 Pa. The production of polyether esteramides is well known in the art and is described in more detail in US-4,207,410, in the case of random polymers and in US-4,252,920 in the case of block copolymers. Certain of the polyether esteramides are commercially available. Additionally, a fourth component may optionally be added to these essentially ternary blends. The optional, fourth component of the blends of the invention, present as a minor component if present at all, is an acidic polymer containing moieties of an α-olefin and an α,β-ethylenically unsaturated carboxylic acid, optionally polymerized with a third monomer and optionally having a portion of the carboxylic acid groups neutralized with non-alkali metal. The α-olefin monomer of this optional blend component is an α-olefin of up to 10 carbon atoms inclusive such as ethylene, propylene, 1-butene, isobutylene, 1-octene and 1-decane. Preferred α-olefins are straight chain α-olefins of up to 4 carbon atoms inclusive and most preferred is ethylene. The α-olefin monomer of this optional blend component is present in at least 65% by mole based on total component and is preferably present in at least 80% by mole on the same basis. The ethylenically unsaturated carboxylic acid monomer is an α,β-ethylenically unsaturated carboxylic acid of up to 10 carbon atoms inclusive and is illustrated by acrylic acid, 2-hexenoic acid and 2-octenoic acid. The preferred α,β-ethylenically unsaturated carboxylic acids have up to 4 carbon atoms inclusive. These acids are acrylic acid, methacrylic acid and crotonic acid, of which acrylic acid and methacrylic acid are particularly preferred. The unsaturated acid monomer of the optional fourth blend component is present in an amount from 1% by weight to 35% by weight based on total blend component, but amounts from 5% by mole to 20% by mole on the same basis are preferred. The acidic polymeric optional blend component is suitably a copolymer of the α-olefin and the unsaturated carboxylic acid and in general such copolymers are preferred. On occasion, however, it is useful to incorporate as an optional third monomer a non-acidic, low molecular weight polymerizable monomer of up to 8 carbon atoms inclusive. Such optional monomer may be another α-olefin such as propylene or styrene when the major α-olefin monomer is ethylene, an unsaturated ester such as vinyl acetate, methyl acrylate or ethyl methacrylate, an unsaturated halohydrocarbon such as vinyl fluoride or vinyl chloride, or an unsaturated nitrile such as acrylonitrile. As previously stated the presence of this third monomer is optional and is not required. Amounts of third monomer up to 5% by mole, based on total optional blend component polymer are satisfactory with amounts up to 3% by mole on the same basis being preferred. Independent of whether the polymer of the optional fourth blend component is a copolymer or a terpolymer, in an optional embodiment of the fourth polymeric blend component a portion of the carboxylic acid groups is neutralized with non-alkali metal. When partially neutralized, this optional blend component is polymeric in form while exhibiting ionic character and is conventionally referred to as a metal ionomer. In the partially neutralized embodiment of the optional polymeric blend component the α-olefin/unsaturated carboxylic acid polymer, with or without the optional third monomer, is reacted with a source of e.g. ionizable zinc, aluminium or magnesium compound sufficient to neutralize from 10% to 90%, preferably from 20% to 80%, of the carboxylic acid groups present in the polymer. Such neutralization, particularly with zinc the preferred metal, results in a uniform distribution of metal throughout the polymer. The ionizable metal compound utilized in the neutralization is a source of complexed or uncomplexed non-alkali metal ions including zinc, aluminium or magnesium ions which are provided in compounds of the type known as metal salts, e.g., uncomplexed metal ion salts such as zinc acetate, zinc chloride or zinc formate, or complexed metal ion salts in which the metal is bonded to two types of groups, at least one of which is readily ionizable and the other is not. Illustrative of such complexed metal ion salts are mixed zinc salts with one weak acid such as oleic acid or stearic acid and one more ionizable acid such as acetic acid or formic acid. In general, neutralization with a complexed non-alkali metal ion is preferred. The optionally partially neutralized polymers employed as the optional polymeric blend component are broadly conventional and many are commercial. The compositions of the invention comprise a major portion of the polyketone polymer with lesser amounts of mineral filler and polyether esteramide. Amounts of polyether esteramide polymer from 0.5% by weight to 45% by weight, based on total blend (components 1, 2, 3 and 4), are satisfactory. Amounts of polyether esteramide from 1% by weight to 20% by weight on the same basis are preferred. Amounts of the mineral filler are from 0.1% by weight to 45% by weight, based on total blend, with amounts from 10% by weight to 40% by weight, being preferred. The amount of the optional fourth polymeric will be up to 10% by weight based on the total polymer blend. Amounts of the optional blend component up to 5% by weight on the same basis are preferred. Accordingly, the composition comprises component (1) in an amount of 50-99.4% by weight, component (2) in an amount of 0.1-45% by weight, component (3) in an amount of 0.5-45% by weight, and component (4) in an amount of 0-10% by weight, based on the total weight of the blend. In particular, the composition comprises component (1) in an amount of 50-89% by weight, component (2) in an amount of 10-40% by weight, component (3) in an amount of 1-20% by weight, and component (4) in an amount of 0-5% by weight, based on the total weight of the blend. The method of producing the non-miscible blend of the polyketone polymer, mineral filler, and polyether esteramide polymer is not material so long as relatively uniform distributions of mineral filler and polyether esteramide polymer throughout the polyketone are obtained. The ternary blend is a non-miscible blend, with the mineral filler and polyether esteramide existing as discrete phases in the polyketone matrix. The blend will therefore not be homogeneous, but good results are obtained when the distributions of the added components are substantially uniform. The method of blending the components is that which is conventional for non-miscible polymeric materials. In one modification the blend components in particulate form are mixed and passed through an extruder to produce the blend as an extrudate. In an alternate modification, the components are blended in a mixing device which exhibits high shear. In a preferred modification, the mineral filler and polyether esteramide polymer are premixed, in an extruder or in a batch mixing device, then the premixed blend is combined with the polyketone polymer, either in a separate extruder or mixing device, or by adding the polyketone polymer downstream into the same extruder. Premixing the mineral filler and polyether esteramide provides improved impact properties, consistent with a hypothesis that the polyether esteramide provides a tough, well-adhering interphase between the polyketone matrix and filler particles. This requires complete wetting of the filler surface by the polyether esteramide, which is facilitated by the premixing technique described above. The blends of the invention may also contain conventional additives such as antioxidants, stabilizers, fire retardant materials, mould release agents and other substances which are added to improve the processability of the polymer components or to improve the properties of the resulting blend. Such additives are added prior to, together with, or subsequent to the blending of the polyketone polymer, mineral filler, and polyether esteramide polymer. The blends of the invention are characterized by improved dimensional stability (relatively low thermal expansion and mould shrinkage), relative to the neat polyketone polymer, and good impact strength, relative to the filled polyketone without the polyether esteramide polymer. The blends are therefore of particular utility where articles are to be produced which require good dimensional stability and impact resistance over a wide temperature range. The blends are processed by conventional methods such as injection moulding and extrusion into sheets, films, plates, fibres and shaped articles. The formed polymer articles find utility in the packaging industry, in the production of shaped containers such as for food or drink, and in the production of external and internal parts for automotive applications, such as automotive body panels. The invention is further illustrated by the following Examples which should not be construed as limiting. Example 1 A. A terpolymer of carbon monoxide, ethylene and propylene was produced in the presence of a catalyst composition formed from palladium acetate, trifluoroacetic acid and 1,3-bis[di(2-methoxyphenyl)phosphino]propane. The terpolymer had a melting point of 220°C and an LVN, measured in m-cresol at 60°C, of 1.7 dl/g. The polyketone polymer contained 1% by weight of a commercial copolymer of ethylene and methacrylic acid as a melt processing aid. B. Various blends of the polyketone terpolymers of paragraph A were prepared to contain 10 to 30% by weight talc filler, and from 0 to 16% by weight PEBAX (trade mark) 2533 elastomer a commercially available polyether esteramide. Specific compositions are provided in Table 1. The blends were prepared in a 30 mm twin screw extruder, operated at 200 RPM and melt temperatures of about 255°C to 265°C. Moulding was performed in a (25 ton) 250 kN injection moulding machine at a temperature of about 265°C. The samples formed were 3.2 mm thick, and they were stored over desiccant prior to testing. Sample H was found to be not processible. C. Impact properties of the "dry as moulded" samples are shown in Table 2. Notched Izod values at 23°C increase steadily with polyether esteramide content, reaching a value of over 2400 g cm/cm at 20% by weight talc and 12% by weight polyether esteramide, and a value of over 3200 g cm/cm at 10% by weight talc and 9% by weight polyether esteramide. Notched Izod values at -29°C exhibit maximums of about 900 g cm/cm at both 20% by weight talc and 8% by weight polyether esteramide, and 10% by weight talc and 9% by weight polyether esteramide. Gardner impact measurements at both 23°C and at -30°C show maximum values for the sample containing 8% by weight polyether esteramide of those containing 20% by weight talc, indicating that this is a particularly preferred composition. The Gardner impact specimen containing 8% by weight polyether esteramide and 20% by weight talc also exhibited ductile, localized failure, which is a desirable property. The two samples containing 10% by weight talc, both with and without polyether esteramide, also demonstrated high Gardner impact at 23°C. D. The tensile properties of the samples are provided in Table 3. The flexural modulus is defined as the secant modulus at 1% strain. The flexural modulus decreases from about 3000 GPa to about 1700 GPa as the polyether esteramide content increases from 0% by weight to 16% by weight. The tensile yield stress also decreases steadily with increasing polyether esteramide content. Some compromise in strength and stiffness occurred with increasing polyether esteramide content, but the effects are not excessive. The ultimate elongation remains relatively unaffected by polyether esteramide content. Example 2 Blends of the polyketone terpolymer of Example 1, paragraph A, were prepared in a manner similar to that of Example 1, paragraph B, to contain 20% by weight talc filler, with and without 8% by weight polyether esteramide elastomer. A (500 ton) 5000 kN injection moulding machine was used to prepare 17.8 cm x 76.2 cm panels of the blend samples. The melt temperature was 270°C, and mould temperature was 132°C. The panels formed were 2.5 mm and 3.8 mm thick. Gardner impact measurements are shown in Table 4. The results indicate a significant increase in Gardner impact strength when 8% by weight polyether esteramide is included in a talc filled polyketone panel. Example 3 Two identical blends of the polyketone terpolymer of Example 1, paragraph A, were prepared in a manner similar to that of Example 1, paragraph B, to contain 20% by weight talc filler and 12% by weight polyether esteramide elastomer. In the first blend, the components were all dry blended together and compounded in a single pass through the extruder. In the second blend, the talc and polyether esteramide were first compounded together in the appropriate ratio and then this premixed blend was further compounded with the polyketone polymer. The properties of the two blends are compared in Table 5. Although the Izod values do not differ appreciably, the Gardner impact strengths at ambient and at low temperatures are improved by a factor of two as a result of premixing. The elongation to break also increases slightly. The advantage to this strategy is thus clearly demonstrated. EFFECT OF PREMIXING ON PROPERTIES Single Step Property Extrusion Premixed Notched Izod (Room Temp.) 2438 g cm/cm 2157 g cm/cm Notched Izod (-29°C) 858 g cm/cm 899 g cm/cm Gardner Impact (Room Temp.) 2.39 kg.m 4.70 kg.m Gardner Impact (-30°C) 0.31 kg.m 1.18 kg.m Tensile Elongation 75% 91%

Claims: Claims for the following Contracting States : AT, BE, CH, LI, DE, FR, GB, GR, IT, NL, SE Polyketone polymer composition comprising a non-miscible blend of: (1) 50-99.4% by weight of a linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated compound, (2) 0.1-45% by weight of a mineral filler, and (3) 0.5-45% by weight of a polyether esteramide polymer, and optionally, (4) 0-10% by weight of an acidic polymer incorporating moieties of an α-olefin, an α,β-ethylenically unsaturated carboxylic acid, and optionally a non-acidic, low molecular weight polymerizable monomer, the acidic polymer optionally having a portion of the carboxylic acid groups neutralized with non-alkali metal. A polymer composition as claimed in claim 1, characterized in that the component (1) is of the repeating formula wherein G is the moiety of an ethylenically unsaturated hydrocarbon of at least three carbon atoms polymerized through the ethylene unsaturation and the ratio of y to x is no more than 0.5. A polymer composition as claimed in claim 2, characterized in that G is a propylene moiety, and the ratio of y to x is from 0.01 to 0.1. A polymer composition as claimed in any of claims 1-3, characterized in that the component (2) is selected from the group consisting of talc, mica, clay, silica, calcium carbonate, wollastonite, franklinite, and mixtures thereof. A polymer composition as claimed in claim 4, characterized in that the component (2) is talc. A polymer composition as claimed in any of claims 1-5, characterized in that the component (3) is a random polymer of (a) one or more compounds selected from ω-aminocarboxylic acid or lactam of 10 or more carbon atoms, (b) an α,ω-dihydroxy(polyoxyalkylene oxide) of an average molecular weight from 160 to 3000 and (c) a dicarboxylic acid of from 6 to 13 carbon atoms, the weight ratio (a) to (b)+(c) being from 30:70 to 98:2, based on total polyether esteramide polymer. A polymer composition as claimed in claim 6, characterized in that the compound selected from ω-aminocarboxylic acid or lactam is lauryllactam, the dihydroxy(polyoxyalkylene oxide) is α,ω-dihydroxy(polytetrahydrofuran) and the dicarboxylic acid is dodecanedioic acid. A polymer composition as claimed in any of claims 1-5, characterized in that the component (3) is a block copolymer of the repeating formula wherein R is the polyamide moiety derived by loss of the two terminal carboxyl groups from a dicarboxylic polyamide of average molecular weight from 300 to 15000, and R' is the polyoxyalkylene moiety derived by loss of the two terminal hydroxyl groups of a polyoxyalkylene glycol of a molecular weight from 100 to 6000. A polymer composition as claimed in claim 8, characterized in that the polyamide is the product of a straight chain diamine of 4 to 12 carbon atoms inclusive and an excess of straight-chain dicarboxylic acid of 4 to 12 carbon atoms inclusive. A polymer composition as claimed in claim 9, characterized in that the polyoxyalkylene glycol is polyoxytetramethylene glycol. A polymer composition as claimed in any of claims 1-10, characterized in that the component (4) is a non-neutralized copolymer of ethylene and acrylic or methyacrylic acid. A polymer composition as claimed in any of claims 1-10, characterized in that the component (4) has from 10 to 90% of the carboxylic acid groups neutralized with zinc, aluminium or magnesium. A polymer composition as claimed in any one of claims 1-12, characterized in that it comprises component (1) in an amount of 5089% by weight, component (2) in an amount of 10-40% by weight, component (3) in an amount of 1-20% by weight, and component (4) in an amount of 0-5% by weight, based on the total weight of the blend. Process for preparing a polyketone polymer composition, characterized by comprising the steps of: mixing a mineral filler with a polyether esteramide polymer to form a premixed polymer blend; and blending the premixed polymer blend with a linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated compound to form a non-miscible polymer blend as claimed in claim 1. Claims for the following Contracting State : ES Process comprising forming a non-miscible blend, which process comprises mixing (1) 50-99.4% by weight of a linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated compound, (2) 0.1-45% by weight of a mineral filler, and (3) 0.5-45% by weight of a polyether esteramide polymer, and optionally, (4) 0-10% by weight of an acidic polymer incorporating moieties of an α-olefin, an α,β-ethylenically unsaturated carboxylic acid, and optionally a non-acidic, low molecular weight polymerizable monomer, the acidic polymer optionally having a portion of the carboxylic acid groups neutralized with non-alkali metal. Process as claimed in claim 1, characterized in that the component (1) is of the repeating formula wherein G is the moiety of an ethylenically unsaturated hydrocarbon of at least three carbon atoms polymerized through the ethylene unsaturation and the ratio of y to x is no more than 0.5. Process as claimed in claim 2, characterized in that G is a propylene moiety, and the ratio of y to x is from 0.01 to 0.1. Process as claimed in any of claims 1-3, characterized in that the component (2) is selected from the group consisting of talc, mica, clay, silica, calcium carbonate, wollastonite, franklinite, and mixtures thereof. Process as claimed in claim 4, characterized in that the component (2) is talc. Process as claimed in any of claims 1-5, characterized in that the component (3) is a random polymer of (a) one or more compounds selected from ω-aminocarboxylic acid or lactam of 10 or more carbon atoms, (b) an α,ω-dihydroxy(polyoxyalkylene oxide) of an average molecular weight from 160 to 3000 and (c) a dicarboxylic acid of from 6 to 13 carbon atoms, the weight ratio (a) to (b)+(c) being from 30:70 to 98:2, based on total polyether esteramide polymer. Process as claimed in claim 6, characterized in that the compound selected from ω-aminocarboxylic acid or lactam is lauryllactam, the dihydroxy(polyoxyalkylene oxide) is α,ω-dihydroxy(polytetrahydrofuran) and the dicarboxylic acid is dodecanedioic acid. Process as claimed in any of claims 1-5, characterized in that the component (3) is a block copolymer of the repeating formula wherein R is the polyamide moiety derived by loss of the two terminal carboxyl groups from a dicarboxylic polyamide of average molecular weight from 300 to 15000, and R' is the polyoxyalkylene moiety derived by loss of the two terminal hydroxyl groups of a polyoxyalkylene glycol of a molecular weight from 100 to 6000. Process as claimed in claim 8, characterized in that the polyamide is the product of a straight chain diamine of 4 to 12 carbon atoms inclusive and an excess of straight-chain dicarboxylic acid of 4 to 12 carbon atoms inclusive. Process as claimed in claim 9, characterized in that the polyoxyalkylene glycol is polyoxytetramethylene glycol. Process as claimed in any of claims 1-10, characterized in that the component (4) is a non-neutralized copolymer of ethylene and acrylic or methyacrylic acid. Process as claimed in any of claims 1-10, characterized in that the component (4) has from 10 to 90% of the carboxylic acid groups neutralized with zinc, aluminium or magnesium. Process as claimed in any one of claims 1-12, characterized in that it comprises mixing component (1) in an amount of 50-89% by weight, component (2) in an amount of 10-40% by weight, component (3) in an amount of 1-20% by weight, and component (4) in an amount of 0-5% by weight, based on the total weight of the blend. Process for preparing a polyketone polymer composition as claimed in any one of claims 1-13, characterized by comprising the steps of: mixing a mineral filler with a polyether esteramide polymer to form a premixed polymer blend; and blending the premixed polymer blend with a linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated compound.

Inventors: GEORGE ERIC RICHARD, MACHADO JOSEPH MICHAEL, GEORGE, ERIC RICHARD, MACHADO, JOSEPH MICHAEL
Applicants: SHELL INT RESEARCH, SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V.
Application year: 1990
Main classification: C08L73
IPC codes: C08L77, C08L71, C08K3, C08L23, C08L73