Abstract:
Phenyltetralylbutane (PTB) is used to plasticize polyvinylchloride (PVC) resins. The PTB in one embodiment is prepared by refluxing tetralin an flowing condensed vapors of the tetralin over a bed of strongly acidic catalyst, which may for example be a synthetic acid &#34;Y&#34; type zeolite. In one embodiment, the PTB is used as a secondary plasticizer, with a primary plasticizer such as di(2-ethyl)hexyl phthalate.

Description:
BACKGROUND OF THE INVENTION 
     1-Phenyl-4-(2-tetralyl)butane and 1-phenyl-4-(1-tetralyl)butane, both known as PTB, are known compounds which are obtained by treating 1,2,3,4-tetrahydronaphthalene (tetralin) with a strong acid catalyst: ##STR1## This reaction is discussed in Ber. 57B, 1990 (1924) and in U.S. Pat. No. 3,336,407 where it is pointed out that not only PTB, but other reaction products as well, such as sym-octahydroanthracene (OHA) and sym-octahydrophenanthrene (OHP) are formed. OHA and OHP are known to be plasticizers for polystyrene (U.S. Pat. Nos. 2,289,743 and 2,454,851) but, because of their high volatility they would be of little value for most plasticizer applications in polyvinylchloride (PVC) resins due to unacceptably low levels of permanence resulting from evaporative losses. 
     Alkylbiphenyls (U.S. Pat. No. 2,172,391), cyclohexylbiphenyls (U.S. Pat. No. 4,167,504) and partially hydrogenated terphenyls (U.S. Pat. Nos. 2,155,524 and 2,925,398) represent specific hydrocarbon types which have been said to be useful as vinyl plasticizers. These all have molecular weights in the approximate range of 180 to 240, again imparting to them a volatility too high for acceptable permanence in most PVC formulations. Although chemically quite distinct from the materials of the present invention, these materials are cited as hydrocarbon plasticizers of known compatibility, volatility and plasticization efficiency for the purpose of comparison. 
     STATEMENT OF THE INVENTION 
     In accord with this invention PTB is an effective plasticizer for PVC resins and will be employed either alone as the primary plasticizer or as a secondary plasticizer in conjunction with conventional plasticizers normally used with PVC resins such as di(2-ethyl)hexyl phthalate (DOP). The higher molecular weight of PTB (264) imparts a desired lower volatility and its unique structure combining aromatic, alicyclic and aliphatic segments in a very flexible molecular arrangement is apparently the basis for its improved compatibility. A most striking feature of PTB for PVC plasticization is its combination of high compatibility with vinyl resins and adequate plasticization efficiency. This combination permits PTB to be used at high replacement levels as a secondary plasticizers, and, as indicated, even to be used as a primary plasticizer. The invention embodies PVC resins plasticized with PTB and the process of effecting such plasticization. Also included in the invention is an improved method for making PTB. 
    
    
     REFERENCE TO DRAWINGS 
     FIG. 1 is a graphic display of tensile modululus of the plasticized compositions of the invention. 
     FIG. 2 is a graphic display of tensile strength of the plasticized compositions of the invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     It will be understood that reaction product mixtures as described above may be used as the plasticizer in this invention as long as the PTB content predominates. Because PTB has a higher reactivity toward the highly acidic catalysts needed for this reaction than does tetralin, attempts to increase the conversion of tetralin result in converting PTB to secondary products, mainly OHA and OHP. As a result, the methods for its preparation described by Schroeter in Ber. 57B, 1990 (1924) and Bushick in U.S. Pat. No. 3,336,407 are not particularly well suited for producing PTB in high yield. Therefore, a preferred method for making PTB in high yield for use in this invention involves refluxing tetralin vapors over a bed of a synthetic acidic &#34;Y&#34; type zeolite such as Linde SK-500, Linde LZ-Y82, or any of the more acid types of the Mobile ZFM series of shape selective zeolites. A particularly useful way to do this is to place the catalyst in the thimble of a Soxhlet extraction apparatus or of a simplified version of such an apparatus from which the siphoning action has been eliminated and the tetralin to be reacted is placed in the flask of the extraction apparatus. Alternative techniques using a bed of catalyst through which condensed vapors of the tetralin flows may also be used. In this manner the very reactive PTB has minimal contact with the catalyst and becomes concentrated in the flask. As much as 95% of the tetralin can be converted in this fashion and the product will be comprised of as much as 95% PTB. This mixture can then be distilled under vaccum to remove the small amount of unreacted tetralin and both low and high-boiling by-products to yield a water-white product. 
     Use of the PTB or its mixtures will be in the conventional manner for plasticizing operations and such techniques are well known in the art. When used to replace a portion of the conventional plasticizer about 20% to about 90% of the conventional plasticizer may be replaced with good results. In order to obtain miximum benefit as a replacement plasticizer, about 50% to 90% of the primary plasticizer will be replaced with PTB. The following Tables illustrate the results obtained in various runs for the plasticizing of PVC resin where all or a part of the conventional plasticizer (DOP) is replaced with PTB in varying amounts. 
     
                       TABLE I______________________________________Tensile Data For PTB Plasticized PVC Resins                               ModulusTotal             Tensile   % Elon- at 100%Plasti-           Strength  gation  Elong.Run  cizer   % DOP    Ini  A-   Ini- A-   Ini- A-No.  (PHR)   Replaced tial ged  tial ged  tial ged______________________________________1    30      0        3100 2925 275  275  2675 2600                 3025 2900 250  275  2600 2700                 3025 2900 250  225  2600 2675                 3075 2925 250  250  2750 27002    38      21       2975 2825 300  275  2225 2250                 2950 2900 300  275  2125 2350                 2950 2825 275  250  2175 2350                 2900 2825 225  250  2225 24503    50      0        2650 2375 325  275  1550 1450                 2750 2500 375  300  1550 1450                 2650      325       1550                 2625      325       15504    50      40       2675 2625 325  300  1525 1700                 2750 2625 400  275  1500 2000                 2750 2625 375  275  1500 1875                 2650 2650 375  300  1475 19505    60      50       2600 2450 400  375  1200 1350                 2575 2500 475  300  1150 1650                 2525 2625 400  325  1200 1675                 2600 2150 400  200  1225 16506    70      0        2025 2025 375  450   875  775                 2050 2150 400  450   825  825                 1950 2075 375  450   800  775                 2075 2075 400  425   850  8507    70      20       2250 2225 450  450   875  850                 2175 2025 425  400   875  800                 2100 1800 375  275   875  875                 2250 1800 450  300   875  8758    70      40       2325 2150 400  400  1025  925                 2325 2025 450  300  1000 1025                 2275 2I50 425  375  1000 1025                 2400 2175 450  350   950  9759    70      57.1     2275 2250 400  375  1000  950                 2325 2300 425  300  1000 1200                 2300 2275 400  350  1000 1125                 2400 2250 450  350  1000 117510   70      70       2475 2325 450  325  1100 1275                 2400 2500 425  375  1050 1350                 2325 2275 400  300  1075 1300                 2350 2325 450  350  1050 115011   70      80       2300      400       1200                 2300      400       1050                 2275      400       1025                 2250      375       1I2512   70      90       2250      350       1175                 2125      350       1125                 2275      400       1200                 2175      425       110013   70      100      2275      300       1500                 2200      300       1400                 2250      300       1425                 2300      325       135014   80      62.5     2025 2225 400  400   850  925                 2025 2150 400  375   850  950                 2175 2150 425  375   825  975                 2150 2175 425  375   875 1000______________________________________ 
    
     
                       TABLE II______________________________________Tensile Date For PTB Plasticized PVC Resins                                ModulusTotal             Tensile   % Elon-  at 100%Plasti-           Strength  gation   Elong.Run  cizer   % DOP    Ini- A-   Ini- A-    Ini- A-No.  (PHR)   Replaced tial ged  tial ged   tial ged______________________________________1    40      0        3075 3125 300  275   2000 2500                 3200 2950 325  225   2050 23002    40      100      3225 4250 275  &lt;100  2425 --                 3100 4550 225  &lt;100  2400 --3    50      0        2300 2600 250  300   1425 1525                 2800 2625 375  300   1425 15004    50      20       2825 2800 350  300   1475 1700                 2945 2800 400  300   1500 18255    50      100      3000 4125 325  75    2000 --                 --   4650 --   100   --   40506    55      11       2650 2275 375  225   1250 1475                 2825 2775 400  300   1450 16757    55      27       2750 2925 425  275   1250 2075                 2775 2850 425  275   1450 2I008    60      0        2375 2275 425  250    950 1400                 2475 2325 425  250   1100 15009    60      20       2525 2650 425  275   1050 1900                 2400 2800 400  300   1100 195010   60      50       2650 2900 400  275   1300 2200                 2650 2950 400  275   1295 220011   60      100      2650 4275 325  50    1625 --                 2550 3675 300  50    1625 --12   65      11       2250 2300 425  325    975 2225                 2350 2250 425  325    975 215013   65      27       2125 2100 325  300   1000 2100                 2000 2300 325  325    950 225014   70      20       2250 2350 450  375    850 2175                 2200 2250 450  375    875 2025______________________________________ 
    
     
                       TABLE III______________________________________Non-Tensile Data For PTB Plasticized PVC ResinsTotalPlasticizer     % DOP    Hardness      Volatility(PHR)     Replaced Initial   Aged  (%)______________________________________30        0        91.0      88.3  0.5038        21       83.3      83.4  1.8040        0        81.3      80.0  1.1640        100      82.6      90.3  6.7550        0        76.5      72.7  1.3950        20       74.6      70.7  3.0950        40       78.5      70.5  3.1550        100      79.0      90.3  7.0055        11       72.6      61.3  1.9855        27       71.6      71.3  2.6960        0        69.6      68.3  1.0160        20       70.6      67.3  2.2260        50       70.5      71.0  3.9260        100      76.7      86.7  4.6565        11       71.7      66.7  1.3865        27       67.6      68.3  1.9970        0        66.0      61.7  2.2970        20       65.8      63.6  2.5470        40       68.7      64.7  3.8670        57.1     69.3      66.0  5.3070        70       69.6      67.6  6.3180        62.75    65.3      62.7  5.83______________________________________ 
    
     The above data is best evaluated by reference to the graphic displays of FIG. 1 and FIG. 2. 
     These figures provide a graphic display of the way the key tensile properties (ultimate tensile strength, elongation at break and tensile modulus at 100 percent elongation) are distributed over a broad range of PVC formulations incorporating the hydrocarbon plasticizer phenyltetralylbutane. Data is given for PVC plasticized with DOP in which amounts of the DOP varying from 0 to 100 percent have been replaced by PTB and for amounts of total plasticizer (combined DOP and PTB) varying from 30 to 80 parts per hundred parts by weight of PVC resin. Thus, the data at 70 PHR and 70 percent replacement are for a formulation containing 100 parts PVC resin, 28 parts DOP and 42 parts PTB. As long as the plasticizer remains fully compatible with the resin at the level used, the tensile modulus at 100 percent elongation (FIG. 1) provides a good indication of the plasticization efficiency of the plasticizer; the lower the value at a given loading, the softer and more flexible is the formulation. By comparing the values for formulations plasticized by DOP along (0 percent replacement) with those of formulations containing PTB, it is seen that the values increase steadily as the amount of DOP replaced by PTB increases. This shows that PTB is less efficient as a plasticizer than DOP. However, the rather small increases in tensile modulus as shown by the numbers in the boxes (especially at replacements below 50 percent) indicates that the plasticization efficiency of PTB is not notably inferior to that of DOP. 
     FIG. 2 displays the tensile strength and elongation at break of the same PVC formulations represented in FIG. 1. The constancy of these values over the total range of replacement of DOP by PTB is good indication of the compatibility of PTB and DOP-PTB mixtures with PVC resin in these formulations and other more qualitative tests corroborate the good efficiency of PTB as a PVC plasticizer. Thus, the appearance, feel, lack of color, and other general qualitative properties all establish the good compatibility and plasticization efficiency of PTB for PVC.