POLYESTERS CONTAINING AN INFRARED ABSORBING MATERIAL

Abstract: Polyesters are disclosed which contain an infrared absorbing material comprising graphite, wherein said polyester is made by the reaction of one or more dicarboxylic acids having from 8 to 40 carbon atoms, or esters thereof, with one of more diols having from 2 to 8 carbon atoms and/or glycol ethers having from 4 to 10 carbon atoms, wherien said graphite is present from 0.1 to 15 parts by weight per million by weight of said polyester and has an average particle size of from 0.1 to 20 mu m, and wherein said polyester has a Hunter a* coordinate value of from -2.0 to +2.0, a Hunter b* coordinate value of from -3.0 to +2.0, and a Hunter L* value of greater than 65 or wherien said polyester is a moulded preform article, having a Hunter a* coordinate value of from -3.0 to +3.0, a Hunter b* coordinate value of from -5.0 to +7.0, and a Hunter L* value of greater than 65, as measured on a moulded bottle preform having a sidewall corss-sectional thickness of about 3.175 mm (0.125 inch). In another embodiment of the invention preformed articles or beverage bottles made of said polyesters are disclosed.

Description: - 1 POLYESTERS CONTAINING AN INFRARED ABSORBING MATERIAL Field of the Invention The present invention relates to polyesters containing an infrared absorbing material. Background of the Invention Many methods have been formulated to reduce infrared radiation heatup times, especially with respect to polyester bottle preforms. Some of these methods comprise the incorporation of sufficient phosphite compounds to chemically reduce indigenous antimony compounds to their elemental state. Other patents have provided for the addition of compounds such as iron oxides and/or anthraquinone dyes. Compounds consisting of carbon black have been added to PET to reduce the infrared heatup times of bottle preforms. U.S. Patents 4,408,004, 4,476,272, and 4,535,118 exemplify the parameters that are necessary for the carbon black to significantly affect heatup rates . The amount of carbon black from these disclosures ranges from 0.1 to 8 parts per million by weight based on the weight of the polyester resin. The two species of carbon black disclosed are channel black and furnace black. One systematic problem with the use of carbon black is the concern about its fine particle size that can easily become airborne during even the slightest process upset. Another problem is the dark hue imparted to objects containing even small amounts of carbon black. Thus, the search for different effective additives other than carbon black have led applicants to the unexpected - 2 - finding that graphite, a different species of carbon than carbon black, unexpectedly outperforms carbon black relative to the balance of properties required in a faster heatup polyester resin. This invention provides a polyester resin composition which yields aesthetically acceptable bottle preforms and minimizes infrared radiation preform heatup time . Brief Description of Invention Polyesters are disclosed which contain an infrared absorbing material, wherein said polyester is made by the reaction of one or more dicarboxylic acids having from 8 to 40 carbon atoms, or esters thereof, with one or more diols having from 2 to 8 carbon atoms and/or glycol ethers having from 4 to 10 carbon atoms, wherein said graphite is present from 0.1 to 15 parts by weight per million by weight of said polyester and has an average particle size from 0.1 to 20 μm, and wherein said polyester has a Hunter a* coordinate value of from -2.0 to +2.0, a Hunter b* coordinate value of from -3.0 to +2.0, and a Hunter L* value of greater than 65 or wherein said polyester is a moulded preform article, having a Hunter a* coordinate value of from -3.0 to +3.0, a Hunter b* coordinate value of from -5.0 to +7.0, and a Hunter L* value of greater than 65, as measured on a moulded bottle preform having a sidewall cross- sectional thickness of about 3.175mm (0.125 inch). In another embodiment of the invention preformed articles or beverage bottles made of said polyesters are disclosed. Detailed Description of the Invention During the last 15 to 20 years, PET containers have been used extensively in the sale of beverages. These containers have all but replaced glass, especially in two-litre soft-drink bottles. Polyester beverage bottles such as those used for carbonated soft drinks are generally manufactured via a process comprising injecrion moulding of a "bottle preform" and subsequently blow moulding said bottle preform into the final bottle shape. This process may be run using a single machine, or in two stages, by using an injection moulding machine to produce the bottle preforms, and a blow moulding machine to form the bottles from preforms which have been (re) heated to enhance formability. Many bottle fabricators buy bottle preforms from preform suppliers, and then blow mould the beverage bottles for subsequent sale to commercial bottlers. These bottle fabricators require clear bottle preforms having low (neutral) colour and a high degree of brightness. They also require the fastest possible bottle preform heatup times, to minimize process cycle time and thus maximize bottle production during the blow moulding operation. The PET is usually made by resin manufacturers that sell their resins to converters who, in turn, make PET bottle preforms that are subsequently "blown" into bottles for filling with beverages for sale to the public. In order to form the final bottles, the preforms are heated in the presence of infrared radiation prior to the blowing operation. The preform heatup time is a critical limiting step in determining the number of preforms that can be blown into suitable containers over a certain amount of time. In addition, the final blown bottles must have certain colour and brightness as measured by a spectrocolourimeter . - 4 - Generally, the most common polyesters of this invention are poly (ethylene terephthalate) formed from the approximate 1:1 stoichiometric reaction of terephthalic acid, or its ester, with ethylene glycol. Another common polyester is poly (ethylene naphthalate) formed from the approximate 1:1 stoichiometric reaction of naphthalene dicarboxylic acid, or its ester, with ethylene glycol. It is also understood that an esterification or polycondensation reaction of the carboxylic acid/ester with glycol typically takes place in the presence of a metal catalyst. The preferred metal catalyst is antimony oxide although other metals such as tin and germanium may also be used. The metal catalyst that is selected may result in a quantity of the elemental metal present in the final polymer product. The residual amount of metal, such as antimony, will be present in the final polymer in a quantity of about 50 to 400 parts per million (ppm) based on the weight of the polymer either in an oxidized form or a chemically reduced form. The polymer of this invention may also contain small amounts of phosphorous compounds, such as phosphate, and catalysts such as a cobalt compound, that tends to impart a blue hue. The polyesters can be converted to any form such as films, sheets, containers, fibers, but the preferred form is bottles for holding soft drinks, mineral water, beer, orange ηuice and the like. It has been unexpectedly found that graphite functions as an effective additive to reduce polyester bottle preform heatup time, while maintaining colour and brightness oetter than carbon black. The amount of graphite added to accomplish the desired reduction in - 5 - heatup time is preferably between 0.1 and 15 ppm, more preferably between 0.5 to 10 ppm, and most preferably between 1.0 to 7.0 ppm based on the weight of the polymer. The graphite has a typical average particle size ranging from 0.1 to 20 μm with the preferred size being 1.0 to 10 μm. The graphite can be added at any stage of the polymer preparation such as during the esterification, transesterification, or polycondensation reaction to make the melt phase polymer. The graphite may also be added during any post polymerization melt processing operation. One preferred method of adding the graphite is as a solid masterbatch. In the masterbatch preparation, the graphite is added to a quantity of polyester under defined conditions to insure that the graphite is dispersed uniformly in the masterbatch. This graphite- loaded polyester masterbatch is then added to the polymerization reactor at the most opportune point of addition, including but not limited to esterification, transesterification, or polycondensation. Another route is the addition of graphite by means of a liquid slurry. A disadvantage of graphite herein is that its greater density makes it more difficult to add to the polyester polymerization reactor as a liquid slurry with a carrier, compared with less dense materials. Alternatively, graphite may be added in a melt-blending extrusion operation, or any other post-polymerization melt processing step. While carbon black and graphite are both forms of carbon, they chemically and structurally display more differences than they have in common. Most significantly, carbon black possesses an amorphous structure while graphite possesses a crystalline structure. The following table exemplifies the very different properties of these two forms of carbon. TABLE 1 TYPICAL PROPERTIES OF GRAPHITE AND CARBON BLACK Property Graphite Carbon Black Particle size of a 1 to 10 μm 0.01 to 0.1 μm single particle Agglomerates Single particles Chains or clusters typically consist and occasionally containing up to of; clusters containing 100 single only a few single particles particles Specific surface 20 rtrVg 25 to 1500 m 2 /g area Structure Crystalline Amorphous Density 2.2 g/cm 3 1.6 to 2.0 g/cm 3 Colour Dark gray Black PH 3 to 9 5 to 6 A crystallographic depiction of the two forms of carbon is shown in Figure 1. It is well recognized by those skilled in the art that the two forms of carbon are not interchangeable when used in industry any more than carbon black is interchangeable with diamond, or diamond dust, another crystalline form of carbon. The colour and brightness of a polyester article can be observed visually, and can also be quantitatively determined by a HunterLab ColourQUEST® Spectrocolourimeter, using reflectance specular included, with a 2° observer angle and a D65 illuminant. - 7 - This instrument uses the 1976 CIE a*, b*, L* designations of colour and brightness determination such that an a* coordinate defines a colour axis wherein plus values are towards the red end of the spectrum and minus values are toward the green end; a b* coordinate, which defines a second colour axis, wherein pl us values are towards the yellow end of the spectrum and minus values are toward the blue end; and an L* coordinate wherein higher values indicate enhanced brightness of the material. Colour and brightness values in preforms tend to differ from values in the correspond raw polyester material . The colour with regard to polyester bottle preforms having a nominal sidewall cross-sectional thickness of about 3.175 mm (0.125 inch) is generally indicated by an a* coordinate value ranging from -3.0 to +3.0, more preferably from -2.0 to +2.0, and most preferably from -1.0 to +1.0; and a b* coordinate value ranging from -5.0 to +7.0, more preferably from -4.0 to +4.0, and most preferably from -3.0 to +3.0. Thus, it is preferred that the bottle preform is essentially neutral or colourless in hue (as measured on a sample having a sidewall cross sectional thickness of about 3.175 mm (0.125 inches) ) . The brightness of the bottle preforms discussed above is measured on the L* coordinate axis wherein higher values denote greater brightness. L* values for the bottle preforms discussed herein should generally be greater than 65.0, more preferably greater than 70.0, and most preferably greater than 75.0 (as measured on a sample having a sidewall cross sectional thickness of about 3.175 mm (0.125 inches)). EXAMPLE The following example demonstrates the unexpected ability of graphite to reduce heatup time while maintaining colour and brightness better than carbon black. A PET resin was prepared by reacting terepnthalic acid and ethylene glycol to make a melt phase polymer, sometimes referred to as a feed polymer. This low molecular weight feed polymer was crystallized and solid state polymerized to prepare a high molecular weight PET base resin. A quantity of 50 ppm masterbatch of either carbon black or graphite was added to the base resin to achieve levels of 1, 3, 5 and 7 ppm as shown in Table 2. TABLE 2 ADDITIVE LEVELS AND REQUIRED WEIGHTS OF MASTERBATCH AND BASE RESIN Additive level, ppm Weight of 50 ppm Weight of base masterbatch, g resin, g 1 54 2670 3 163 2560 5 272 2452 7 381 2342 The base resm/masterbatch mixtures from Table 2 were dried under vacuum at 163°C (325°F) for 18 hours. Thereafter, the dried resin was transferred to a Novotec drying hopper of a Nissei ASB 50T Injection Blow- Moulcmg macnme . The hopper was heated to 163°C (325°F and set for a dew point of -40°C (-40°F) . Typical settings on the Nissei machine used to make the oott_e preforms are set forth m Table 3. - 9 - TABLE 3 PROCESS CONDITIONS FOR BOTTLE PREFORM MANUFACTURE NISSEI ASB-50T MOULDING MACHINE 11.5 sec. INJECTION TIMER, TM-07 6.0 sec. COOLING TIMER, TM-09 260 °C BARREL NOZZLE 260 °C BARREL FRONT 255 °C BARREL MIDDLE 250 °C BARREL REAR 265 °C HOT RUNNER NOZZLE 265 °C HOT RUNNER BLOCK -40 °C CONAIR LIQUID CHILLER 130 R.P.M. SCREW ROTATION YUKEN KOGYO (SK1046) PROGRAM CONTROLLER 90 % SCREW 028.0 mm SHOT SIZE 18 % V1 023 mm X(V1 → V2) 18 % V2 018 mm X(V2 → V3) 15 % V3 15.0 mm S-MONITOR 9 F. DIAL 00.0 mm O-MONITOR 15.0 mm X(P1 → P2) 00 Kgf/cm 2 P1 60 Kgf/cm 2 P2 01.0 sec. TP2 40 Kgf/cm 2 P3 05.0 sec. TP3 9 P. DIAL - 10 - The bottle preforms were heated and blown into bottles in a one-step process on a Cincinnati Milacron Reheat Blow Lab (RHB-L) blow moulding machine. The oven temperature profile, environmental conditions, innate physical properties, and the number of bottle preforms, allowed reheat times to be measured in 4 second intervals, with 42 seconds common to all samples. Reheat of the bottle preforms in the oven was followed by 8 seconds of thermal equilibration at the RHB-L mould/blow position. Bottle preform surface temperatures were recorded with a FLIR System' s Prism DS thermal imaging system from the start of the preform thermal equilibration period to the moment of mould closing. The image of a preform was viewed electronically in six equal sections from just below the thread area to just above the curvature of the base. Each of the sections was visually constrained to a width exclusive of the thickness of the bottle preform walls, as seen in two dimensions. The surface temperature of a preform was then recorded as an average of all the thermal detector readings in the third section down from the top of the preform, just before the mould closing of the RHB-L. Table 4 contains bottle preform heatup data, including temperature differentials, from samples A through I (control) . The table shows bottle preform temperatures at various times in the reheat oven. These data may be linearly regressed and are thus plotted in Figure 2 where the bottle preform temperature at the time of mould closing is plotted against the time spent in the reheat oven. - 11 - Values for the regressed data are also given in Table 4. Because the typical oven heating time for the bottle preforms used in this example, required to blow a bottle with no visible haze, was 42 seconds, the heatup behavior at 42 seconds was routinely compared in order to differentiate one sample from another. The 42-second temperature increases from the control resin are shown in Table 4, and plotted in Figure 3, illustrating the difference in 42-second heatup behavior between graphite and carbon black. While carbon black shows a linear relationship, the effect of graphite appears to plateau above 5 ppm. TABLE 4 tΛ HEATUP RESULTS OF BOTTLE PREFORMS CONTAINING GRAPHITE OR CARBON BLACK GRAPHITE CARBON BLACK CONTROL A B C D E F G H I Graphite, ppm 1 3 5 7 0 Carbon Black, ppm 1 3 5 7 0 Preform Heating Time Temperature (°C) 34 sec. 103.1 100.8 110.9 106.1 n/a 104.5 109.0 109.7 105.6 38 sec. 110.6 113.6 115.9 114.3 108.4 111.0 114.9 117.9 108.3 38 sec. 108.1 114.6 114.4 115.1 107.7 114.1 119.8 117.7 106.4 l\3 38 sec. Average 109.3 114.1 115.2 114.7 108.1 112.5 117.3 117.8 107.3 I 42 sec. 112.9 116.2 118.2 120.4 115.4 119.1 123.1 123.5 110.7 42 sec. 112.8 120.3 120.4 119.0 112.2 118.2 120.5 123.2 113.6 42 sec. Average 112.8 118.3 119.3 119.7 113.8 118.7 121.8 123.4 112.1 46 sec. n/a 120.6 121.7 124.8 n/a 123.3 122.6 129.1 116.1 Regressed Temperature (°C) at 42 sec. 113.2 117.4 118.8 119.7 113.8 118.2 120.6 123.3 111.9 " Regressed Temperature o0 Increase (°C) over the 1.3 5.5 6.9 7.8 1.9 6.3 8.7 11.4 0.0 Control at 42 sec. >0 O © - 13 - TABLE 5 COLOUR AND BRIGHTNESS OF BOTTLE PREFORMS CONTAINING GRAPHITE OR CARBON BLACK GRAPHITE CARBON BLACK CONTROL A B C D E F G H I Graphite, 1 3 5 7 0 Carbon 1 3 5 7 0 Preform a* -0.9 -0.9 - -0.8 -0.8 -0.5 -0.1 +0.5 -0.9 b* 5.9 6.5 6.4 6.7 6.3 7.9 9.9 12.1 5.7 Preform (L*) 78.5 75.3 73. 69.5 78.7 74.1 66.4 57.5 80.5 The colour and brightness difference between graphite and carbon black-loaded bottle preforms is quite significant. The effect of additive concentration on a* colour is seen in Figure 4. Graphite gives essentially no change in a* colour with increasing concentration, whereas carbon black significantly raises a* values with increasing concentration. Figure 5 shows an identical effect on b* colour. It is apparent that graphite has a negligible effect on b* over the range of 1 to 7 ppm, whereas carbon black shows a 100% increase in b* colour over this concentration range. The results for L*, the measure of brightness, are shown in Figure 6. While the relationship between L* and increasing additive concentration is linear for both carbon black and graphite, the latter shows a much less negative slope, indicating that graphite does not produce as dark a bottle preform at equal additive concentrations. This is extremely important to bottle preform suppliers, as bottle fabricators require bright preforms . - 14 - Colour and brightness values (a*, b*, and L*) for bottle preforms illustrated in this example can be found in Table 5.

Claims: 15 - C L A I M S 1. A polyester containing an infrared absorbing material, wherein said polyester is made by the reaction of one or more dicarboxylic acids having from 8 to 40 carbon atoms, or esters thereof, with one or more diols having from 2 to 8 carbon atoms and/or glycol ethers having from 4 to 10 carbon atoms, wherein said graphite is present from 0.1 to 15 parts by weight per million by weight of said polyester and has an average particle size from 0.1 to 20 μm, and wherein said polyester has a Hunter a* coordinate value of from -2.0 to +2.0, a Hunter b* coordinate value of from -3.0 to +2.0, and a Hunter L* value of greater than 65 or wherein said polyester is a moulded preform article, having a Hunter a* coordinate value of from -3.0 to +3.0, a Hunter b* coordinate value of from -5.0 to +7.0, and a Hunter L* value of greater than 65, as measured on a moulded bottle preform having a sidewall cross-sectional thickness of about 3.175mm (0.125 inch). 2. A polyester according to Claim 1, wherein said graphite is present from 1 to 7 parts by weight per million by weight of said polyester and/or has an average particle size from 1 to 10 μm. 3. A polyester according to any one of Claims 1-2, wherein one of said dicarboxylic acids is a phthalic acid and/or naphthalene dicarboxylic acid, or their esters and one of the said glycols is ethylene glycol. 4. A method of making a polyester resin according to Claim 1, wherein graphite is added by means of a solid masterbatch or liquid slurry to said polyester. - 16 - 5. The method of Claim 4, wherein said polyester is made by the reaction of claim 1 in the presence of a metal catalyst in an amount of 50 to 400 ppm based on the weight of the polyester . 6. The method of Claim 5, wherein said metal catalyst comprises an antimony compound, preferably antimony oxide. 7. A preformed article or beverage bottle made of the polyester according to Claim 1.

Inventors: PAZZO NATHAN LYLE, PERKINS WILLIAM GEORGE, SCHIRMER JOSEPH PETER, TUNG WILLIAM CHUNG TSING, PAZZO, NATHAN, LYLE, PERKINS, WILLIAM, GEORGE, SCHIRMER, JOSEPH, PETER, TUNG, WILLIAM, CHUNG, TSING
Applicants: SHELL INT RESEARCH, SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V.
Application year: 1999
Main classification: C08G63
IPC codes: C08K3, C08L67