Branched block copolymer, process for its preparation and use therefor

Abstract: A branched block copolymer is described, which is represented by the general formula (B₁-T-A-B₂) n X, where B₁ and B₂ are polydiene blocks, A is a polyvinylaromatic block, T is a random copolymer segment composed of units of diene and vinylaromatic monomers, X is a coupling radical having a valence equal to n, and n is an integer of from 3 to 20. Said block copolymer may be used in adhesives to which it imparts an excellent balance of adhesive, cohesive and rheological characteristics as well as resistance to thermooxidation, and in compositions with thermoplastic polymers, resulting in products with improved shock resistance and transparency.

Description: The present invention relates to branched block copolymers, processes for their preparation and the use thereof in adhesive formulations to which they impart an excellent balance of adhesive, cohesive and rheological characteristics as well as resistance to oxidation at elevated temperatures, and in compositions with thermoplastic polymers for the production of articles with improved shock-resistance and transparency. The anionic polymerization of dienic and vinylaromatic monomers in the presence of metal-alkyl and/or metal-aryl catalysts, resulting in so-called "living polymers", is a well-known technique and is described, e.g., by M.Schwarc in "Carbanions, Living Polymers and E1. Transfer Processes", Interscience Publishers, J.Wiley and Sons, New York, 1956. With this living polymer technique it is possible, in particular, to prepare both linear and branched block copolymers, especially block copolymers of polybutadiene and polystyrene such as, for example, those described in US-A-3,078,254, 3,244,644, 3,265,765, 3,280,084, 3,594,452, 3,766,301, 3,937,760, 4,291,139, and EP-A-0 058 952. These block copolymers are widely used, for example, in the fields of adhesives, in compositions with various plastic materials, in the shoe industry, etc. One serious problem with these block copolymers is the difficulty of achieving a good balance of rheological characteristics, mechanical resistance and resistance to thermo-oxidation. For example, the well-known three-block copolymers of the type A-B-A (polystyrene-polybutadiene-polystyrene) normally show satisfactory mechanical characteristics but poor thermo-oxidation resistance. In addition, their rather high viscosity, both in the molten state and in solution, creates problems in the processing and transformation thereof. On the other hand, the known four-block (AB) 2 linear copolymers, containing similar polybutadiene blocks, generally have good rheological but poor mechanical properties. Similar considerations apply for linear multiblock (AB) n copolymers, where n is an integer of higher than 2 and can reach a value of about 10. US-A-4,874,821 describes a linear copolymer with four alternating blocks, B 1 -A 1 -B 2 -A 2 , having defined proportions of blocks and also containing, between blocks B 1 and A 1 , a copolymeric random sequence formed by dienic and vinylaromatic monomer units. This kind of block copolymer is particularly suitable for use in adhesive formulations having good cohesion characteristics and thermo-oxidation stability. Block copolymers are also used in compositions with thermoplastic polymers in order to endow the corresponding manufactured articles with high shock-resistance. The main problems in this field are the poor processability of the corresponding polymer mixtures and the low transparency of the products obtained from these mixtures. There has now been found a special branched block copolymer with satisfactory overall rheological and mechanical characteristics, resistance to thermo-oxidation as well as transparency which is useful in adhesive formulations and which, when mixed with thermoplastic polymers, provides shock-resistant manufactured articles with improved transparency. Accordingly, the present invention provides a branched block copolymer of general formula (I): (B 1 -T-A-B 2 ) n X wherein B 1 and B 2 are polymeric diene blocks (preferably blocks derived from one or more dienes having 4 to 20, particularly 4 to 12 carbon atoms, such as butadiene and isoprene); A is a polyvinylaromatic block (preferably a block derived from one or more vinylaromatic monomers having 8 to 20 (e.g. 8 to 12) carbon atoms and optionally containing halogen atoms, such as styrene, α-methylstyrene and chloro-substituted derivatives thereof); T is a random copolymer segment formed by dienic and vinylaromatic monomer units; X is a coupling radical derived from a tri- or tetrachloro derivative of silicon, tin and germanium; and n is an integer of from 3 to 4 ; the above copolymer having a weight average molecular weight of from 60,000 to 500,000 (preferably 100,000 to 350,000); an A block content of from 20 to 80% by weight of the total copolymer; a (B 1 +B 2 ) block content of from 20 to 80% by weight of the total copolymer; a weight ratio of blocks B 1 to blocks B 2 of from 0.1 to 1.0; and a T segment content of from 4 to 40% by weight of the total copolymer. In the present invention, the preferred weight ratio in the block copolymer of blocks B 1 to blocks B 2 (which may be derived from the same or different diene(s) and are preferably formed by the same diene(s)) ranges from 0.2 to 0.5, the copolymeric segment T content ranges from 5 to 40% by weight of the block copolymer. It is most preferred that in the block copolymer (I) block A is a polystyrene block and blocks B 1 and B 2 are polybutadiene blocks, the segment T is a random copolymer of butadiene and styrene units in quantities preferably ranging from 10 to 30% by weight of the copolymer, and X represents =Si= or CH 3 Si≡. The branched block copolymer of the present invention is preferably used in accordance with its composition. For instance, copolymers having a low content of vinylaromatic monomer units and a weight ratio of blocks B 2 to blocks B 1 close to unity, are advantageously combined with oils and asphaltic resins to afford adhesive formulations with good adhesion and cohesion characteristics. An example of an adhesive formulation is a hot-melt formulation. Moreover, copolymers with a high content of vinylaromatic monomer units show excellent transparency as well as a high shock-resistance. Therefore these copolymers can advantageously be used either as such or in admixture with common thermoplastic polymers (e.g. in weight ratios of from 9:1 to 1:9) to produce manufactured articles with improved shock-resistance and transparency. Suitable thermoplastic polymers are, e.g., polyolefins such as polyethylene and polypropylene, and particularly polystyrene. Corresponding manufactured articles can be used, e.g., in the packaging industry, especially for food. Furthermore, copolymers of general formula (I) with an A block content of about 30 to 40% by weight and a weight ratio of blocks B 2 to blocks B 1 of about 10:1, when mixed with bitumen, afford manufactured articles showing good high and low temperature resistance. The present invention also comprises processes for the production of the branched block copolymer of general formula (I). More specifically, the process for the preparation of the block copolymer (I) comprises the following successive steps: (a) Polymerization, by means of the living polymer technique, of a mixture of predetermined quantities of diolefin and vinylaromatic monomers until a complete, or almost complete, conversion of the monomers is achieved. Thus, a living copolymer of the type B 1 -T-A is obtained. (b) Addition of a predetermined amount of diene monomer to the copolymer obtained in step (a) and polymerization until a complete, or almost complete, conversion of the added diene monomer is achieved. Thus, a living copolymer of the type B 1 -T-A-B 2 is obtained. (c) Coupling of the living polymeric chains obtained in step (b) by means of a polyfunctional coupling agent. Thereby the branched block copolymer (I), having in its chain the copolymeric segment T, is obtained. (d) Recovery of the branched block copolymer (I) containing the segment T. Using the procedure described above, it is possible to vary the composition and length of the copolymeric segment T by adding, in the first polymerization step (a), polar compounds, such as ethers and amines, to the reaction system. In particular, the polymerization steps are preferably carried out in an aliphatic and/or cycloaliphatic organic solvent, at temperatures ranging from 30 to 150°C and at a pressure equal to or higher than atmospheric pressure, in the presence of metal-alkyl or metal-aryl catalysts. The most preferred solvents are n-hexane and cyclohexane, while the most preferred reaction temperature ranges from 50 to 100°C and the most preferred catalyst is alkyl lithium wherein the alkyl group preferably contains from 3 to 7 (e.g. 4 to 6) carbon atoms. Said catalyst generally is used in amounts of from 0.025 to 0.20 parts by weight per 100 parts by weight of the total monomers. In the polymerization mixture, polar compounds such as ethers and amines can be present, usually at a maximum concentration of about 0.1% by weight with respect to the solvent. In the coupling step, it is preferable to work at a temperature ranging from 110 to 125°C and in the presence of a coupling agent, selected from the tri- and tetra-chloro derivatives of silicon, tin and germanium. From a practical point of view it is preferred to use silicon tetrachloride and/or CH 3 SiCl 3 as coupling agent. The most preferred diolefin is butadiene and the most preferred vinylaromatic monomer is styrene. After the coupling step, the branched block copolymer can be recovered from the reaction mixture by using conventional techniques such as, e.g., evaporation of the solvent in a vapor stream and subsequent drying of the isolated copolymer. The following examples are to give a more detailed illustration of the present invention without being a limitation thereof. Example 1 (Comparative) 600 g of anhydrous cyclohexane and 15 g of butadiene are charged into a 1 liter reactor under stirring. The temperature of the mixture is brought to 50°C and 0.102 g of sec-butyllithium in a n-hexane solution are then added. After 30 minutes of reaction the temperature of the mass reaches 60°C and the conversion of butadiene is almost complete. 75 g of styrene are then added and after 15 minutes of reaction the temperature of the mixture reaches 78°C and the conversion of styrene is almost complete. 10 g of butadiene are added. After 10 minutes of reaction the temperature of the mixture reaches 85°C and the conversion of butadiene is almost complete. 0.075 g of silicon tetrachloride, in a cyclohexane solution, are finally added and after 5 minutes the coupling reaction of the living chains is practically complete (98% yield). 10 g of triphenyl-nonylphosphite and 0.2 g of pentaerythritol tetrakis (3,3-di-tert-butyl-4-hydroxy-hydrocinnamate) are added to the above polymer solution. The recovery of the polymer is carried out by vapor flow distillation of the solvent and subsequent drying in an oven at 60°C for 24 hours. A block copolymer of the type (B 1 -A-B 2 ) n X where B 1 and B 2 are butadiene blocks, A is a styrene block, X = Si and n = 4 is thus obtained, said copolymer showing the following characteristics: MW 260,000 (weight average molecular weight determined by GPC analysis) Total styrene 75 % (by weight based on the total styrene, determined by IR analysis) Styrene in the blocks 75 % (by weight, determined by decomposition with OsO 4 ) M.F.I. 4 g/10' (Melt Flow Index at 200°C and 5 kg) The mechanical and optical characteristics of the test samples obtained by pressure moulding of the block copolymer at 180°C were as follows: transparency (%): 92 ultimate tensile stress (kJ/cm 2 ) 240 ultimate elongation (%) 15 module (kg/cm 2 ) 9000 Izod notched bar test 3.5 (25°C; kg.cm/cm) M.F.I. (g/10') 9.5 Example 2 6 kg of anhydrous cyclohexane, 250 g of butadiene and 700 g of styrene are charged into a 10 liter steel reaction vessel. The temperature of the mixture is brought to 50°C by means of hot water circulation in the jacket of the vessel and 0.79 g of sec-butyllithium in n-hexane solution are then added. After 25 minutes of reaction, the temperature of the mixture reaches 80°C and the conversion of the monomers is almost complete. 50 g of butadiene are subsequently added and after 10 minutes of reaction the temperature of the mixture reaches 95°C and the conversion of the butadiene is almost complete. Finally 0.65 g of silicon tetrachloride, dissolved in cyclohexane, are added and after 5 minutes the coupling reaction of the living chains is substantially complete (99.9% yield). Using the same procedure as in example 1, a block copolymer of the type (B 1 -T-A-B 2 ) n X where B 1 and B 2 are butadiene blocks, A is the styrene block, segment T is a random copolymer of diene and styrene units in amounts of 4% by weight with respect to the copolymer, X = Si and n = 4 is recovered, said copolymer having the following characteristics: MW 250,000 Total styrene 70% Styrene in the blocks 50% M.F.I. 5 g/10' 4 kg of the block copolymer obtained as described above are mixed with 4 kg of commerical "crystal" polystyrene having a MW (by GPC) of 250,000. The mass is charged into a twin-screw extruder equipped with a heated jacket and extruded, and the process is repeated twice to yield an intimate mixture. The material is then comminuted to chips having an average diameter of 0.5 cm. The mechanical and optical characteristics of the test samples obtained by pressure moulding of the chips, at 180°C, were as follows: transparency (%): 93 ultimate tensile stress (kJ/cm 2 ) 180 ultimate elongation (%) 70 module (kg/cm 2 ) 10,500 Izod notched bar test 3.6 (25°C; kg.cm/cm) M.F.I. (g/10') 70 Example 3 600 g of anhydrous cyclohexane, 8 g of butadiene and 46 g of styrene are charged into a 1 liter reaction vessel. The temperature of the mixture is brought to 50°C and 0.18 g of sec-butyllithium (2.6 .10 -3 moles) in n-hexane solution are then added. After 25 minutes of reaction, the temperature of the mixture reaches 60°C and the conversion of the monomers is almost complete. 46 g of butadiene are subsequently added and after 10 minutes of reaction the temperature of the mixture reaches 80°C and the conversion of the butadiene is almost complete. Finally 0.15 g of CH 3 SiCl 3 ,dissolved in cyclohexane, are added and after 5 minutes the coupling reaction of the living chains is practically complete (97% yield). Using the same procedure as in example 1, a block copolymer of the type (B 1 -T-A-B 2 ) n X where B 1 and B 2 are butadiene blocks, A is a styrene block, segment T is a random copolymer of butadiene and styrene units in amounts of 5% by weight with respect to the copolymer, X = CH 3 Si and n = 3 is recovered, said copolymer having the following characteristics: MW 100,000 Total styrene 46% Styrene in the blocks 41% M.F.I. 11 g/10' The block copolymer obtained as described above is converted into a hot melt composition containing: The following adhesion characteristics were determined on the above formulation: Polyken tack (g; ASTM 2979) 230 Loop tack (g/2.5 cm; PSTC 5) 230 Peeling (g/2.5 cm; PSTC 1) 2.000 Holding power (g/2.5 cm; PSTC 7) 35 (PSTC = Pressure Sensitive Testing Council) The following thermo-oxidation characteristics were also determined on the above formulation. Period (days) Brookfield viscosity; cps, 180°C 0 12,500 2 18,500 4 23,000 6 26,000 Example 4 3 liters of anhydrous cyclohexane containing 0.03 g of tetrahydrofuran, 100 g of butadiene and 500 g of styrene are charged into a 5 liter stirred steel reactor. The temperature of the mixture is brought to 50°C and 2.0 g of n-butyllithium in n-hexane solution are then added. After 25 minutes of reaction, the temperature of the mixture reaches 65°C and the conversion of the monomers is almost complete. 400 g of butadiene are subsequently added and after 10 minutes of reaction the temperature of the mixture reaches 95°C and the conversion of the butatiene is almost complete. Finally 1.31 g of silicon tetrachloride, dissolved in cyclohexane, are added and after 5 minutes the coupling reaction of the living chains is practically complete (98% yield). Using the same procedure as in example 1, a block copolymer of the type (B 1 -T-A-B 2 ) n X were B 1 and B 2 are butadiene blocks, A is a styrene block, segment T is a random copolymer of diene and styrene units in amounts of 18% by weight with respect to the copolymer, X = Si and n = 4 is recovered, said copolymer having the following characteristics: - MW 145,000 - Total styrene 50% - Styrene in the blocks 40% - M.F.I. 12 g/10' 1 kg of the block copolymer obtained as described above is mixed with 3 kg of commerical "crystal" polystyrene having a MW (by GPC) of 250,000 and with 2 kg of high density polyethylene (HDPE). The mixing is carried out in a Banbury mixer at 200°C (3 minute-cycles). The mechanical characteristics of the test samples obtained by injection moulding of the mixture at 195°C were as follows: - ultimate tensile stress (N/mm 2 ) 20 - ultimate elongation (%) 60 - module (N/mm 2 ) 1500 - Izod notched bar test (J/m) 350

Claims: Claims for the following Contracting States : AT, BE, CH, LI, DE, DK, FR, GB, GR, IT, LU, NL, SE Branched block copolymer of general formula (I): (B 1 -T-A-B 2 ) n X wherein: B 1 and B 2 are polydienic blocks; A is a polyvinylaromatic block; T is a random copolymeric segment formed by dienic and vinylaromatic monomer units; X is a coupling radical derived from a tri- or tetrachloro derivative of silicon, tin and germanium; and n is an integer of from 3 to 4; the above copolymer having a weight average molecular weight of from 60,000 to 500,000; an A block content of from 20 to 80% by weight; a (B 1 +B 2 ) block content of from 20 to 80% by weight; a weight ratio of blocks B 1 to blocks B 2 of from 0.1 to 1.0; and a T segment content of from 4 to 40% by weight. Copolymer according to claim 1, wherein the weight ratio of blocks B 1 to blocks B 2 ranges from 0.2 to 0.5; and the copolymeric segment T content ranges from 5 to 40, particularly from 10 to 30% by weight of the total block copolymer. Copolymer according to any one of claims 1 and 2, wherein block A is a polystyrene block and/or blocks B 1 and B 2 both are polybutadiene blocks and/or segment T is a random copolymer block of butadiene and styrene monomer units and/or X is =Si= or CH 3 Si≡. Process for the preparation of the copolymer according to any one of claims 1 to 3, comprising: (a) polymerization, by means of the living polymer technique, of a mixture of diolefin and vinylaromatic monomer up to the complete, or almost complete, conversion of the monomers; (b) addition of diene monomer to the copolymer obtained in step (a) and continuation of the polymerization up to the complete, or almost complete, conversion of the added diene monomer; and (c) coupling of the living polymeric chains obtained in step (b) by means of a polyfunctional coupling agent. Process according to claim 4, wherein the polymerization steps are carried out in an aliphatic or cycloaliphatic organic solvent at a temperature of from 30 to 150°C and atmospheric or superatmospheric pressure in the presence of metal-alkyl and/or metal-aryl catalysts. Process according to claim 5, wherein the solvent is n-hexane and/or cyclohexane, the reaction temperature ranges from 50 to 100°C, the catalyst is a C 3 -C 7 -alkyl-lithium and said catalyst is used in amounts of from 0.025 to 0.20 parts by weight per 100 parts by weight of the total monomers. Process according to any one of claims 4 to 6, wherein the coupling step is carried out at a temperature of from 110 to 125°C in the presence of coupling agents selected from tri- and tetra-chloro derivatives of silicon, tin and germanium, and particularly is selected from SiCl 4 and CH 3 SiCl 3 . Process according to any one of claims 4 to 7, wherein the diolefin is butadiene and/or the vinylaromatic monomer is styrene. Adhesive composition, comprising copolymers according to any one of claims 1 to 3. Polymeric composition, comprising the copolymers according to any one of claims 1 to 3 and thermoplastic polymer, particularly polyethylene, polypropylene and/or polystyrene. Claims for the following Contracting State : ES Process for the preparation of a branched block copolymer of general formula (I): (B 1 -T-A-B 2 ) n X wherein: B 1 and B 2 are polydienic blocks; A is a polyvinylaromatic block; T is a random copolymeric segment formed by dienic and vinylaromatic monomer units; X is a coupling radical derived from a tri- or tetrachloro derivative of silicon, tin and germanium, and n is an integer of from 3 to 4; the above copolymer having a weight average molecular weight of from 60,000 to 500,000; an A block content of from 20 to 80% by weight; a (B 1 +B 2 ) block content of from 20 to 80% by weight; a weight ratio of blocks B 1 to blocks B 2 of from 0.1 to 1.0; and a T segment content of from 4 to 40% by weight, comprising: (a) polymerization, by means of the living polymer technique, of a mixture of diolefin and vinylaromatic monomer up to the complete, or almost complete, conversion of the monomers; (b) addition of diene monomer to the copolymer obtained in step (a) and continuation of the polymerization up to the complete, or almost complete, conversion of the added diene monomer; and (c) coupling of the living polymeric chains obtained in step (b) by means of a polyfunctional coupling agent. Process according to claim 1, wherein the weight ratio of blocks B 1 to blocks B 2 ranges from 0.2 to 0.5; and the copolymeric segment T content ranges from 5 to 40, particularly from 10 to 30% by weight of the total block copolymer Process according to any one of claims 1 and 2, wherein block A is a polystyrene block and/or blocks B 1 and B 2 both are polybutadiene blocks and/or segment T is a random copolymer block of butadiene and styrene monomer units and/or X is =Si= or CH 3 Si≡. Process according to claim 1, wherein the polymerization steps are carried out in an aliphatic or cycloaliphatic organic solvent at a temperature of from 30 to 150°C and atmospheric or superatmospheric pressure in the presence of metal-alkyl and/or metal-aryl catalysts. Process according to claim 4, wherein the solvent is n-hexane and/or cyclohexane, the reaction temperature ranges from 50 to 100°C, the catalyst is a C 3 -C 7 -alkyl-lithium and said catalyst is used in amounts of from 0.025 to 0.20 parts by weight per 100 parts by weight of the total monomers. Process according to any one of claims 1 to 5, wherein the coupling step is carried out at a temperature of from 110 to 125°C in the presence of coupling agents selected from tri- and tetra-chloro derivatives of silicon, tin and germanium, and particularly is selected from SiCl 4 and CH 3 SiCl 3 . Process according to any one of claims 1 to 6, wherein the diolefin is butadiene and/or the vinylaromatic monomer is styrene. Branched block copolymer of general formula (I): (B 1 -T-A-B 2 ) n X wherein: B 1 and B 2 are polydienic blocks; A is a polyvinylaromatic block; T is a random copolymeric segment formed by dienic and vinylaromatic monomer units; X is a coupling radical derived from a tri- or tetrachloro derivative of silicon, tin and germanium, and n is an integer of from 3 to 4; the above copolymer having a weight average molecular weight of from 60,000 to 500,000; an A block content of from 20 to 80% by weight; a (B 1 +B 2 ) block content of from 20 to 80% by weight; a weight ratio of blocks B 1 to blocks B 2 of from 0.1 to 1.0; and a T segment content of from 4 to 40% by weight. Copolymer according to claim 8, wherein the weight ratio of blocks B 1 to blocks B 2 ranges from 0.2 to 0.5; and the copolymeric segment T content ranges from 5 to 40, particularly from 10 to 30% by weight of the total block copolymer. Copolymer according to any one of claims 8 and 9, wherein block A is a polystyrene block and/or blocks B 1 and B 2 both are polybutadiene blocks and/or segment T is a random copolymer block of butadiene and styrene monomer units and/or X is =Si= or CH 3 Si≡. Adhesive composition, comprising copolymers according to any one of claims 8 to 10. Polymeric composition, comprising the copolymers according to any one of claims 8 to 10 and thermoplastic polymer, particularly polyethylene, polypropylene and/or polystyrene.

Inventors: CUSTRO SERGIO, ZAZZETTA ALESSANDRO DR, CUSTRO, SERGIO, ZAZZETTA, ALESSANDRO, DR.
Applicants: ENICHEM ELASTOMERS, ENICHEM ELASTOMERI S.R.L.
Application year: 1991
Main classification: C08F297
IPC codes: C08L23, C09J153, C08L53, C08L51, C08L25, C08F297