Abstract:
A compound comprising a blend of polypropylene with the reaction product of a functionalized polypropylene and polyether amine in which the polyether amine is grafted onto the functionalized polypropylene in a customary mixing apparatus is disclosed. A process for producing the reaction product of the functionalized polypropylene and the polyether amine by melting with polypropylene in a customary mixing apparatus is also disclosed.

Description:
This application is a continuation of application Ser. No. 08/222,508, filed Apr. 4, 1994, now abandoned, which is a divisional of application Ser. No. 08/090,675, filed Jul. 13, 1993, now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to a novel olefin polymer composed of the reaction product of a functionalized polypropylene and a polyetheramine. This invention also relates to thermoplastic resin blends containing the novel olefin polymer and polypropylene. 
     2. Related Art 
     The in-situ formation of compatibilizers for polyblends is rapidly gaining popularity. In the last few years, more and more cases have been reported where advantage is taken of the presence of reactive groups to form a graft or a block or a random copolymer, which could act as a compatabilizer for a mixture of two or more polymers. The prior art, Process Requirements of the Reactive Compatibilization of Nylon 6/Polypropylene Blends by S. S. Dagli, M. Xanthos and J. A. Biensenberger: Polymer Processing Institute at Stevens Institute of Technology, Hoboken, N.J. 07030 reveals an acrylic acid grafted modified polypropylene used with a blend of nylon-6 and polypropylene. 
     Thermoplastic resin compositions containing polypropylene are well known in the art (e.g. U.S. Pat. No. 5,208,081). U.S. Pat. No. 5,179,164 describes a polypropylene/polyamide composition suitable for producing moldings. The patent describes an ethylene copolymer useful as an adhesion promoter. Moreover, the patent indicates that maleic acid is a suitable monomer for preparing the ethylene copolymer. 
     In addition, maleated polypropylene is commercially available. 
     European patent application 0 367 832 discloses a resin composition containing an olefinic polymer having acid anhydride groups. As in U.S. Pat. No. 5,179,164, the novel compound is blended with a polyamide. 
     Japanese patent 46003838 reveals a maleic anhydride modified polypropylene composition containing triethylamine and polyethylene glycol nonylphenyl ether. Japanese patent 60195120 reveals a molding containing polyethylene, maleic anhydride-grafted polyethylene, and diethylenetriamine. 
     However, the instant invention uses the maleic anhydride in conjunction with polyetheramines which produce unexpected improvements in resin properties. 
     SUMMARY OF THE INVENTION 
     This invention is a compound comprising a blend of polypropylene with the reaction product of a functionalized polypropylene and polyether amine in which the polyether amine is grafted onto the functionalized polypropylene in a customary mixing apparatus. This invention is also a process for producing the reaction product of the functionalized polypropylene and the polyether amine by melting with polypropylene in a customary mixing apparatus. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The blend of polypropylene with the reaction product of maleated polypropylene and polyether amine shows improved paintability, improved impact resistance, and excellent mold flowability over blends of polypropylene and the reaction product of polypropylene and maleated polypropylene. 
     Plastics are increasingly being employed in the production of motor vehicles. Impact-modified PP (polypropylene) has proved to be particularly suitable for applications such as bumpers, spoilers, fenders, side bump strips and the like. Therefore, a thermoplastic resin blend having the improved properties of the instant invention has significant potential commercial usefulness. 
     These resin compositions, according to the present invention, are useful as engineering plastics which are materials for structural members in the fields of transport machines (automobiles, ships and the like), apparatus, tools, electronic appliances, electric appliances, sporting goods, leisure goods and the like; and for connectors, tubes and the like. 
     Suitable polypropylenes are known from polymer chemistry, are described for example in Kunststoff-Handbuch, volume IV, Polyolefine, edited by R. Vieweg, A. Schley and A. Schwarz. Carl Hanser Verlag, Munich, 1969, and are commercially available, so that no details need be given. 
     Functionalized PP is PP onto which a monomer has been grafted. The usual method of such grafting is by free radical reaction. Suitable monomers for preparing functionalized polypropylene are for example olefinically unsaturated monocarboxylic acids, e.g. acrylic acid or methacrylic acid, and the corresponding tert-butyl esters, e.g. tert-butyl (meth)acrylate, olefinically unsaturated dicarboxylic acids, e.g. fumaric acid, maleic acid, and itaconic acid and the corresponding mono- and/or di-tert-butyl esters, e.g. mono- or di-tert-butyl fumarate and mono- or di-tert-butyl maleate, olefinically unsaturated dicarboxylic anhydrides, e.g. maleic anhydride, sulfo- or sulfonyl-containing olefinically unsaturated monomers, e.g. p-styrenesulfonic acid, 2-(meth)acrylamido-2-methylpropenesulfonic acid or 2-sulfonyl(meth)acrylate, oxazolinyl-containing olefinically unsaturated monomers, e.g. vinyloxazolines and vinyloxazoline derivatives, and epoxy-containing olefinically unsaturated monomers, e.g. glycidyl (meth)acrylate or allyl glycidyl ether. 
     Suitable maleated polypropylene include the following structures: ##STR1## wherein PP is polypropylene. 
     Suitable polyether blocks for the polyetheramine include polyethylene glycol, polypropylene glycol, copolymers of polyethylene glycol and polypropylene glycol, poly(1,2-butylene glycol), and poly(tetramethylene glycol). 
     Suitable polyetheramines include monamines, diamines and triamines, having a molecular weight of from about 150 to 12,000. Suitable monoamines include the polyetheramines sold by Huntsman Corporation under the trademarks JEFFAMINE® M-1000, JEFFAMINE® M-2070, and JEFFAMINE® M-2005. Suitable diamines include the polyetheramines sold by Huntsman Corporation under the trademarks JEFFAMINE® ED-6000, JEFFAMINE® ED-4000, JEFFAMINE® D-2001, JEFFAMINE® D-2000, JEFFAMINE® D-4000, JEFFAMINE® ED-900, JEFFAMINE® ED-600, and JEFFAMINE® D-400. Suitable triamines include the polyetheramines sold by Huntsman Corporation under the trademarks JEFFAMINE® ET-3000, JEFFAMINE® T-3000 and JEFFAMINE® T-5000. A glossary of jeffamine structures is set forth at Table 4. 
     The mixing of the functionalized polypropylene and polyetheramine may be carried out in a customary mixing apparatus including batch mixers, continuous mixers, kneaders, and extruders. 
     Besides the PP/functionalized-PP/polyetheramine structural components according to the invention, the resin composition may, to improve the impact strength, contain impact modifiers, advantageously impact-modifying elastomers. Impact-modifying elastomers for the instant invention are known to a skilled worker. Examples are rubbers based on ethylene, propylene, butadiene, and acrylates, e.g. methacrylates, or mixtures thereof. 
     Suitable impact-modifying elastomers are described for example in Methoden der organischen Chemie (Houben-Weyl), volume XIV/1, Makromolekulare Chemie (Georg-Thieme-Verlag, Stuttgart, 1961), pages 390 to 406, and in the monograph by C. B. Bucknal, Toughened Plastics (Applied Publishers, London, 1977). 
     In addition to the structural components of PP, functionalized-PP, and polyetheramine and any impact modifier contained in a resin composition according to the instant invention, the resin may also contain reinforcing agents and/or additives. The reinforcing agents used may be reinforcing fillers, for example asbestos, carbon or carbon fibers, clay, talc, mica, glass (beads or fibers), and chalk which may be finished with adhesion promoters and/or sizes. 
     The preferred functionalized polypropylene is a maleated polypropylene having the following structure: ##STR2## wherein PP is polypropylene. 
     The preferred monoamines as well as the preferred triamines have a molecular weight of from about 200 to 4000. The preferred diamines have a molecular weight of from about 148 to 6000. 
     The preferred reaction product between the preferred functionalized polypropylene, maleated polypropylene, and the preferred polyetheramine has the following formula: ##STR3## wherein a is from about 5 to 50,000, for b:c from about 0:100 to 100:0, x is from about 1 to 3, and R is an alkyl radical having valence of x. 
     Suitable thermoplastic resin compositions may contain from about 66 to 80 wt % PP, from about 20 to 30 wt % maleated PP and from about 2 to 10 wt % polyetheramine. 
     The preferred customary mixing apparatus is an extruder in which the polyetheramine is grafted onto the maleated polypropylene at from about 175° to 300° C. in the course of a residence time of from about 25 to 300 seconds. Polypropylene is a non-reactive component of the mixing blend. The preferred temperature range is from about 190° to 260° C. 
     Continuous compounding was carried out in a Werner &amp; Pfleiderer 30 mm twin screw extruder (ZSK30) in which the feed sequence was a combined feed in which all the components fed at the same location (hopper of the extruder). 
     The following examples which illustrate the nature of the instant invention are not intended to be limitative. 
     EXAMPLE 1-6 
     Blends of PP, maleated PP (MAL-PP), and JEFFAMINE® M2070 polyetheramine produced in an extruder exhibit characteristics in percent compositions as shown in Table 1 in which the remaining percent is PP: 
     
                       TABLE 1______________________________________Example   1      2       3     4     5     6______________________________________% MAL-PP  20             30% Polyetheramine     0      2       4     0     2     4FM, psi   284K   255K    226K  289K  256K  201KStY, psi  8660   7980    7030  8750  7830  6170TE, %     8      16      10    4     13    5TSt, psi  4990   4770    4280  5000  4630  3720NI, ftlb/in     0.161  0.220   0.386 0.123 0.139 0.220UnI, ftlb/in     12     14      10    10    14    5______________________________________ where: FM  flexural modulus StY  stress at yield TE  Tensile elongation TSt  tensile strength NI  notched izod impact UnI  unnotched izod impact. 
    
     EXAMPLES 7-10 
     Table 2 reveals the effects of JEFFAMINE® M-2070 polyetheramine (M) as compared to JEFFAMINE® ED-2001 polyetheramine (ED) in which either is blended with from about 76 to 78 wt % of PP, and from about 20 wt % of MAL-PP in an extruder. 
     
                       TABLE 2______________________________________Example        7       8        9     10______________________________________Polyetheramine Type          M       ED       M     ED% Polyetheramine          2                4FM, psi        255K    246K     226K  230KStY, psi       7980    7730     7030  7140TE, %          16      10       10    16TSt, psi       4770    4560     4280  4420NI, ftlb/in    14      15       10    18UnI, ftlb/in   14      15       10    18______________________________________ where: FM  flexural modulus StY  stress at yield TE  Tensile elongation TSt  tensile strength NI  notched izod impact UnI  unnotched izod impact. 
    
     EXAMPLES 11-17 
     Table 3 reveals the percent paint adhesion of various compositions of PP, maleated PP, and the JEFFAMINE® polyetheramines indicated relative to a control sample wherein the blends were produced in an extruder. 
     
                       TABLE 3______________________________________Ex-am-         MAL-                   Paint  Con-ple  PP     PP      Polyetheraime Type                              Adhesion                                     trol______________________________________11   76%    20%     4% JEFFAMINE ® M-1000                              62%     2%12   76%    20%     4% JEFFAMINE ® ED-6000                              28%     4%13   74%    20%     6% JEFFAMINE ® ED-6000                              46%     4%14   74%    20%     6% JEFFAMINE ® 4000                              40%     4%15   74%    20%     6% JEFFAMINE ® M-2070                              77%    21%16   72%    20%     8% JEFFAMINE ® M-2070                              40%    21%17   72%    20%     8% JEFFAMINE ® ED-2001                              68%    21%______________________________________ 
    
     TABLE 4 
     GLOSSARY 
     JEFFAMINE® M-1000 Polyetheramines ##STR4## 
     JEFFAMINE® M-2070 and JEFFAMINE® M-2005 Polyetheramines ##STR5## where R=H, CH 3 , m is from about 3 to 32, and n is from about 10 to 32. 
     JEFFAMINE® D-2000, JEFFAMINE ® D-4000, and JEFFAMINE® D-400 Polyetheramines ##STR6## where x is about 33 for D-2000, x is about 68 for D-4000 and x is about 5.6 for D-400. 
     JEFFAMINE® ED-600, JEFFAMINE® ED-900, JEFFAMINE® ED-2001, JEFFAMINE® ED-4000, and JEFFAMINE® ED-6000 Polyetheramines ##STR7## where b is about 8.5 and a+c is about 2.5 for ED-600, b is about 15.5 and a+c is about 2.5 for ED-900, b is about 40.5 and a+c is about 2.5 for ED-2001, b is about 86.0 and a+c is about 2.5 for ED-4000, and b is about 132.0 and a+c is about 3.0 for ED-6000. 
     JEFFAMINE® T-3000 and JEFFAMINE® T-5000 Polyetheramines ##STR8## where x+y+z=50 for T-3000 and x+y+z=83 for T-5000. 
     JEFFAMINE® ET-3000 Polyetheramine ##STR9## where x+y+z=57 and a+b+c=4.