WO2015091707A1 - A polymer composition comprising a polyolefin composition and a at least one silanol condensation catalyst - Google Patents

A polymer composition comprising a polyolefin composition and a at least one silanol condensation catalyst Download PDF

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WO2015091707A1
WO2015091707A1 PCT/EP2014/078327 EP2014078327W WO2015091707A1 WO 2015091707 A1 WO2015091707 A1 WO 2015091707A1 EP 2014078327 W EP2014078327 W EP 2014078327W WO 2015091707 A1 WO2015091707 A1 WO 2015091707A1
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polymer composition
polymer
composition according
weight
catalyst
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PCT/EP2014/078327
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French (fr)
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Ola Fagrell
Stefan HELLSTRÖM
Bernt-Åke SULTAN
Perry Nylander
Martin Anker
Kristian Dahlen
Åsa Hermansson
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Borealis Ag
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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/36Sulfur-, selenium-, or tellurium-containing compounds
    • C08K5/41Compounds containing sulfur bound to oxygen
    • C08K5/42Sulfonic acids; Derivatives thereof
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04Homopolymers or copolymers of ethene
    • C08L23/08Copolymers of ethene
    • C08L23/0846Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
    • C08L23/0869Acids or derivatives thereof
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04Homopolymers or copolymers of ethene
    • C08L23/08Copolymers of ethene
    • C08L23/0846Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
    • C08L23/0892Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms containing monomers with other atoms than carbon, hydrogen or oxygen atoms
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/44Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
    • H01B3/441Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from alkenes
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/44Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
    • H01B3/447Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from acrylic compounds
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/44Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
    • H01B3/448Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from other vinyl compounds
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/04Oxygen-containing compounds
    • C08K5/09Carboxylic acids; Metal salts thereof; Anhydrides thereof
    • C08K5/098Metal salts of carboxylic acids
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2203/00Applications
    • C08L2203/18Applications used for pipes
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2310/00Masterbatches

Definitions

  • a polymer composition comprising a polyolefin composition and a at least one silanol condensation catalyst
  • the present invention relates to a new polymer composition, an article, for example, a coating, a wire or a cable, comprising the polymer composition, a process for producing an article and use of the polymer composition.
  • crosslink polymers by means of additives. Crosslinking improves properties of the polymer such as mechanical strength and heat resistance.
  • Polymers normally considered to be thermoplastics, and not crosslinkable, can also be made crosslinkable by introducing crosslinkable groups in the polymer.
  • examples thereof are polymer compositions comprising polyolefms, such as polyethylenes, where silane compounds have been introduced as crosslinkable groups, e.g. by grafting silane compounds onto a prepared polyolefin, or by copolymerisation of an olefin and a silane compound.
  • Such techniques are known e.g. from US4413066, US4297310, US4351876, US4397981, US4446283 and US4456704.
  • crosslinking of polymer compositions comprising hydro lysable silane groups with catalysts is known in the art, see e.g. EP0736065. It is further known that the
  • crosslinking process may advantageously be carried out in the presence of acidic silanol condensation catalysts.
  • the acidic silanol condensation catalysts permit crosslinking of silane-containing polymer compositions already at room temperature (about 20 to 25°C).
  • acidic silanol condensation catalysts which are organic sulphonic acids, or precursors of such acids, are disclosed in, for example,
  • the catalysts may be added as so-called catalyst masterbatches.
  • the catalysts are compounded with a polymer resin (i.e. a carrier resin), and then suitably formed into granular shaped solids, e.g. into pellets.
  • the catalyst masterbatch is then added to the polymer to be crosslinked. Thereby handling of the catalyst is facilitated.
  • a particular polymer composition is surprisingly suitable as carrier resin to a specific silanol condensation catalyst, which catalyst comprises an aryl substituted with one or more alkyl groups.
  • the present invention accordingly provides a polymer composition
  • a polymer composition comprising (a) a polymer portion, and (b) at least one silanol condensation catalyst, wherein each catalyst is selected from: i) a compound of formula I
  • Ar is an 1 to 4 alkyl groups substituted aryl, wherein the aryl is phenyl or naphthyl, and wherein each alkyl group, independently, is a linear or branched alkyl with 10 to 30 carbons, wherein the total number of carbons in the alkyl groups is in the range of 20 to 80 carbons; ii) a derivative of i) selected from the group consisting of an anhydride, an ester, an acetylate, an epoxy blocked ester and an amine salt thereof which is hydro lysable to the corresponding compound of formula I; and iii) a metal salt of i) wherein the metal ion is selected from the group consisting of copper, aluminum, tin and zinc, wherein the polymer portion comprises
  • pellets formed from the polymer composition of the present invention has been shown to have advantageous properties, as, for example, being dry and free flowing, without tendency to stick together and form aggregates, properties which make the pellets easy to handle. Additionally, hereby is a problem free dosing and feeding of pellets to e.g. an extruder also facilitated.
  • the polymer portion of the polymer composition comprises (al) a non-polar polymer composition component in an amount of 0 to 90% by weight, and (a2) a polar component, in an amount of at least 10% by weight, which polar component contains 3 to 30% by weight of a polar comonomer.
  • the non-polar component of the polymer composition may, for example, comprise a non-polar polyolefin, e.g., a non-polar polyethylene, which may be a homo- or copolymer of ethylene, e.g. low density polyethylene or linear low density polyethylene or a copolymer of e.g. ethylene and propylene or a copolymer of ethylene and an alpha olefin where the alpha olefin may be linear or branched.
  • a non-polar polyolefin e.g., a non-polar polyethylene, which may be a homo- or copolymer of ethylene, e.g. low density polyethylene or linear low density polyethylene or a copolymer of e.g. ethylene and propylene or a copolymer of ethylene and an alpha olefin where the alpha olefin may be linear or branched.
  • the polar component of the polymer composition may be selected from the group consisting of ethylene vinyl acetate (EVA), ethylene butyl acrylate (EBA), ethylene tert-butyl methacrylate (ETBMA), ethylene methyl acrylate (EMA), ethylene methyl methacrylate (EMMA), ethylene ethyl acrylate (EEA) and ethylene acrylic acid (EAA).
  • EVA ethylene vinyl acetate
  • EBA ethylene butyl acrylate
  • ETBMA ethylene tert-butyl methacrylate
  • EMA ethylene methyl acrylate
  • EMMA ethylene methyl methacrylate
  • EAA ethylene acrylic acid
  • the polymer composition in accordance with the present invention may be produced by compounding the "at least one" silanol condensation catalyst, i.e.
  • the specific silanol condensation catalyst with the particular polymer portion, and, optionally, together with further suitable additives such as pigments, antioxidants, stabilizers, lubricants, fillers, peroxides, silanes and/or foaming agents.
  • the "at least one" silanol condensation catalyst is comprised in the particular polymer portion in concentrated form, and, optionally, together with the further suitable additives such as pigments, antioxidants, stabilizers, lubricants, fillers, peroxides, silanes and/or foaming agents.
  • the polymer composition is a catalyst masterbatch and the polymer portion constitutes a polymer matrix.
  • said catalyst masterbatch is a mixture which comprises the polymer portion and the "at least one" silanol condensation catalyst, i.e. the compound of formula I, in a concentrated form in said polymer matrix.
  • said catalyst masterbatch may be produced by compounding the "at least one" silanol condensation catalyst and, optionally, any further additives with the polymer portion, wherein the polymer portion constitutes a polymer matrix.
  • the further, optional, additives may, for example, be miscible thermoplastics, antioxidants, stabilizers, lubricants, fillers, peroxides, silanes and/or foaming agents.
  • the catalyst masterbatch in accordance with the present invention may be in a liquid form or a solid form suitably formed into, for example, a powder and/or granular shaped solids, e.g. pellets or granules.
  • a polymer composition wherein the polar component is selected from the group consisting of ethylene vinyl acetate (EVA), ethylene butyl acrylate (EBA), ethylene methyl aery late (EM A), ethylene methyl methacrylate (EMMA), ethylene ethyl acrylate (EE A) and ethylene acrylic acid (EAA).
  • EVA ethylene vinyl acetate
  • EBA ethylene butyl acrylate
  • EM A ethylene methyl aery late
  • EMMA ethylene methyl methacrylate
  • EE A ethylene acrylic acid
  • a polymer composition wherein the polymer portion comprises at least 20, 30 or, alternatively, 50 % by weight of (a2) the polar component.
  • the polymer portion of the polymer composition then comprises (al) a non-polar polymer composition component in amounts of 0 to 80% by weight, 0 to 70% by weight, and 0 to 50%> by weight, respectively.
  • a polymer composition wherein the polymer portion comprises 100 % by weight of (a2) the polar component.
  • the polymer portion of the polymer composition then comprises no (al) a non-polar polymer composition component.
  • a polymer composition wherein the polymer portion comprises more than 50 % by weight of (a2) the polar component.
  • the polymer portion of the polymer composition then comprises (al) a non-polar polymer composition component in amounts of 0 to 50% by weight,
  • a polymer composition wherein the polymer portion comprises at least 55, 60, 65, 75, 80, 85, 90 or, alternatively, 95 % by weight of (a2) the polar component.
  • the polymer portion of the polymer composition then comprises (al) a non-polar polymer composition component in amounts of 0 to 45% by weight, 0 to 40% by weight, 0 to 35% by weight, 0 to 30% by weight, 0 to 25% by weight, 0 to 20% by weight, 0 to 15%) by weight, 0 to 10%> by weight, and 0 to 5% by weight, respectively.
  • the polymer composition of the present invention do also comprise the "at least one", wherein each catalyst is selected from: i) a compound of formula I
  • Ar of the compound of formula I may, besides the "1 to 4 alkyl groups"-substituents, also, optionally, comprise further suitable substituents.
  • Ar is a 1, 2, 3 or 4 alkyl groups substituted aryl, for example, a 2 to 3 alkyl groups substituted aryl, or, e.g.,
  • each alkyl group independently, is a linear or branched alkyl with 10 to 30 carbons, wherein the total number of carbons in the alkyl groups is in the range of 20 to 80 carbons.
  • each alkyl group independently, is a linear alkyl with 10 to 15 carbons, wherein the total number of carbons in the alkyl groups is in the range of 20 to 60 carbons.
  • any two of said alkyl groups may be linked to each other via a bridging group such as an alkylene group.
  • An embodiment of the present invention provides a polymer composition, as described herein, wherein said each silanol condensation catalyst is selected from a) Ci2-alkylated naphthyl sulfonic acids; b) a derivative of a) selected from the group consisting of an anhydride, an ester, an acetylate, an epoxy blocked ester and an amine salt thereof which is hydro lysable to the corresponding compound a); and/or c) a metal salt of a) wherein the metal ion is selected from the group consisting of copper, aluminum, tin and zinc.
  • a further embodiment of the present invention provides a polymer composition, as described herein, wherein said each silanol condensation catalyst is selected from C 12 - alkylated naphthyl sulfonic acids.
  • the silanol condensation catalyst may also be a derivative of the compound of formula I as described herein, wherein said derivative may be converted by hydrolysis to the compound of formula I.
  • the derivative may, for example, be a corresponding acid anhydride of the compound of formula I.
  • the derivative may be a compound of formula I which has been provided with a hydrolysable protective group, as, e.g., an acetyl group.
  • the hydrolysable protective group can be removed by hydrolysis.
  • the polymer composition according to the present invention comprises the "at least one" silanol condensation catalyst in an amount of, for example, 0.0001 to 8 % by weight, 0.0001 to 6 % by weight, 0.001 to 2 % by weight, 0.05 to 1 % by weight, 1 to 8% by weight or 1 to 6 % by weight.
  • the polymer composition according to the present invention further comprises a colour master batch, comprising e.g. Ti0 2 , CaC0 3 , carbon black and/or hindered-amine light stabilizers (HALS).
  • a colour master batch comprising e.g. Ti0 2 , CaC0 3 , carbon black and/or hindered-amine light stabilizers (HALS).
  • the catalyst masterbatch comprises the "at least one" silanol condensation catalyst in an amount of, for example, 0.7 to 8 % by weight, 0.7 to 6 % by, 1 to 8 % by weight or 1 to 6 % by weight.
  • the polymer composition further comprises a crosslinkable polyolefm with hydrolysable silane groups.
  • the crosslinkable polyolefm of the polymer composition may, for example, comprise a polyethylene with hydrolysable silane groups, or the crosslinkable polyolefm may, e.g., consist of a polyethylene with hydrolysable silane groups.
  • the hydrolysable silane groups may be introduced into the polyolefm by
  • crosslinkable polyolefm with hydrolysable silane groups may be obtained by copolymerisation.
  • polyolefm being, for example, polyethylene
  • the copolymerisation may be carried out with an unsaturated silane compound represented by the formula II wherein R 1 is an ethylenically unsaturated alkyl, alkyloxy or (meth)acryloxy alkyl group, R 2 is an aliphatic saturated alkyl group,
  • Y which may be the same or different, is a hydro lysable organic group and q is 0, 1 or 2.
  • unsaturated silane compound are those wherein R 1 is vinyl, allyl, isopropenyl, butenyl, cyclohexanyl or gamma-(meth)acryloxy propyl; Y is methoxy, ethoxy, formyloxy, acetoxy, propionyloxy or an alkyl-or arylamino group; and R 2 , if present, is a methyl, ethyl, propyl, decyl or phenyl group.
  • CH 2 CHSi(OA) 3 (III) wherein A is a alkyl group having 1 to 8 carbon atoms, e.g. 1 to 4 carbon atoms.
  • the silane compound may be, e.g., vinyl trimethoxysilane, vinyl bismethoxyethoxysilane, vinyl triethoxy silane, gamma- (meth)acryloxypropyltrimethoxysilane, gamma(meth)acryloxypropyltriethoxysilane, or vinyl triacetoxy silane.
  • Said copolymerisation may be carried out under any suitable conditions resulting in the copolymerisation of two monomers. Moreover, the copolymerisation may be implemented in the presence of one or more other comonomers which can be copolymerised with the two monomers.
  • Such comonomers include, for example, vinyl carboxylate esters, such as vinyl acetate and vinyl pivalate, alpha-olefms, such as propene, 1-butene, 1-hexane, 1-octene and 4- methyl- 1-pentene, (meth)acrylates, such as methyl(meth)acrylate, ethyl(meth)acrylate and butyl(meth)acrylate, olefmically unsaturated carboxylic acids, such as (meth)acrylic acid, maleic acid and fumaric acid, (meth)acrylic acid derivatives, such as
  • (meth)acrylonitrile and (meth)acrylic amide vinyl ethers, such as vinyl methyl ether and vinyl phenyl ether, and aromatic vinyl compounds, such as styrene and alpha-ethyl styrene.
  • said comonomers may be vinyl esters of monocarboxylic acids having 1-4 carbon atoms, such as vinyl acetate, and/or (meth)acrylate of alcohols having 1-4 carbon atoms, such as methyl(meth)-acrylate.
  • the comonomers butyl acrylate, ethyl acrylate and/or methyl acrylate are disclosed.
  • comonomers such as any of the olefmically unsaturated compounds disclosed herein, may be used in combination.
  • the term "(meth)acrylic acid” is intended to embrace both acrylic acid and methacrylic acid.
  • the comonomer content of the copolymer may amount to 70% by weight of the copolymer, for example, about 0.5 to 35%) by weight, e.g., about 1 to 30% by weight.
  • a graft polymer may have been produced e.g. by any of the two methods described in US3646155 and US4117195, respectively.
  • the polyolefm with hydro lysable silane groups which is comprised in the polymer composition of the present invention, may comprise 0.001 to 15% by weight of silane compound, for example, 0.01 to 5% by weight, e.g., 0.1 to 2% by weight.
  • the polymer composition according to the invention may further comprise various additives, for example, miscible thermoplastics, antioxidants, stabilizers, lubricants, fillers, pigments, peroxides, silanes and/or foaming agents.
  • suitable fillers and/or pigments include Ti0 2 , CaC0 3 , carbon black (e.g. "UV black", i.e. a carbon black that absorbs ultraviolet radiation), huntite, mica, kaolin, aluminium hydroxide (ATH), magnesium dihydroxide (MDH), and Si0 2 .
  • the polymer composition according to the present invention further comprises fillers and/or pigments.
  • fillers and/or pigments may be comprised in the polymer composition according to the present invention in amounts of, for example, 0.01 to 5 wt%, or, e.g., 0.01 to 2 wt%.
  • antioxidant a compound, or a mixture of compounds, may, for example, be used.
  • the antioxidant may, suitably, be neutral or acidic compounds, and which compounds may, suitably, comprise a sterically hindered phenol group or aliphatic sulphur groups.
  • Such compounds are disclosed in EP 1254923 and these are suitable antioxidants for stabilisation of polyolefms containing hydro lysable silane groups which are crosslinked with a silanol condensation catalyst, e.g., an acidic silanol condensation catalyst.
  • a silanol condensation catalyst e.g., an acidic silanol condensation catalyst.
  • Other exemplified antioxidants are disclosed in WO2005003199.
  • the antioxidant may be present in the polymer composition in an amount of from 0.01 to 3 wt%, e.g., 0.05 to 2 wt%, or, e.g., 0.08 to 1.5 wt%.
  • said polymer portion and said "at least one" silanol condensation catalyst may suitably be mixed to produce the polymer composition of the present invention, by compounding a crosslinkable polyolefm together with said catalyst masterbatch and, optionally, one or more additive masterbatches.
  • the, optional, one or more additive masterbatches comprise further additives in concentrated form in their polymer matrices, e.g. polyolefm matrices.
  • the polymer matrices of the, optional, one or more additive masterbatches may comprise, for example, a polyolefm, e.g., a polyethylene, which may be a homo- or copolymer of ethylene, e.g. low density polyethylene, or a polyethylene-methyl-ethyl- butyl- acrylate copolymer containing 1 to 50 percent by weight of the acrylate, or any mixtures thereof.
  • the polymer matrices may comprise high density or medium density polyethylenes.
  • the polymer matrices may comprise bimodal polymers.
  • Said compounding may be performed by any known compounding process, including extruding the final product with a screw extruder or a kneader.
  • one or more of the "at least one" silanol condensation catalyst and the, optional, further additives need not to be added as comprised in masterbatches but may instead be added , e.g. in liquid form, directly to a system for production of the polymer composition of the present invention.
  • the catalyst masterbatch, the additive masterbatch or masterbatches comprise said "at least one" catalyst and, optionally, further additives, respectively, in concentrated form.
  • concentrated form means herein that said "at least one" catalyst and the optional further additives, respectively, have higher concentration in said masterbatches as compared with their concentration in the final crosslinkable polymer composition.
  • the catalyst masterbatch, as described herein may, for example, comprise the "at least one" silanol condensation catalyst in an amount of, for example, 0.7 to 8 % by weight, 0.7 to 6 % by, 1 to 8 % by weight or 1 to 6 % by weight.
  • the catalyst masterbatch or an additive masterbatch when the catalyst masterbatch or an additive masterbatch, as described herein, is compounded with said polymer composition comprising said crosslinkable polyolefm, the catalyst masterbatch or the additive masterbatch may be present in an amount of 1 to 10 wt%, for example, 2 to 8 wt%.
  • the pigment may, for example, be added via a separate additive masterbatch, i.e. a pigment masterbatch, in an amount of 0.01 to 5 % by weight.
  • Said pigment masterbatch can be comprised in the master batch of the present invention, in an amount of 0.2 to 50 % by weight.
  • the present invention do also relate to a process for producing an article, wherein said process comprises use, for example, extrusion, of a polymer composition as described herein. Said extrusion may be performed at a temperature of, for example, 140 to 230 °C.
  • a polymer composition comprising a crosslinked polyolefm, wherein the crosslinked polyolefm is produced by crosslinking the crosslinkable polyolefm comprised in the polymer composition as described herein.
  • a further embodiment of the invention relates to an article, for example, a coating, a wire or a cable, which article comprises the polymer composition as described herein.
  • Still a further embodiment of the present invention relates to use of the polymer composition as described herein.
  • melt flow rate (MFR) is determined according to ISO 1 133 and is indicated in g/10 min.
  • MFR for ethylene polymers is determined at 190°C and with a 2.16 kg load (MFR 2 ).
  • MFR 2 Melt Flow Rate
  • This method is for determining the amount of exudation on the pellet surface of sulphonic acid.
  • Catalyst masterbatches are composed as described Table 1 below.
  • Nacure® CD-2180 i.e. a highly hydrophobic mixture of Ci 2 -alkylated naphthyl sulfonic acids (i.e. silanol condensation catalysts selected from the compound of formula I, as described herein), from King Industries, having an active content of 80% was used. Amounts are given in weight percentages of the total composition.
  • the catalyst carries are a selected from:
  • BAR717 i.e. ethylene butylacrylate copolymer, supplied by Special Polymers Antwerp and with a butyl acrylate content of 17 weight% and a MRF 2 .16 of 7 g/10 min,
  • Exact0210 supplied by DSM with a density of 902 kg/m 3 and a MRF 2 .i 6 of 10 g/lOmin, and
  • the stabiliser is Lowinox CPL, a phenolic stabilizer from Chemtura , and the drying agent is Dynasylan 9116 , HDTMS, hexadecyltrimethoxysilane produced by Evonic.
  • Catalyst masterbatches may be prepared by mixing the components in a Banbury kneader at 130°C for 8 minutes. The compounds may afterwards be pelletized on a Buss kneader.
  • Catalyst MB A Catalyst MB B Catalyst MB C (Comparative (Comparative (Innovative example 1 ) example 2) example 1 )
  • Catalyst MB D Catalyst MB E Catalyst MB F

Abstract

The present invention relates to a polymer composition comprising (a) a polymer portion, and (b) at least one silanol condensation catalyst, wherein each catalyst is selected from: i) a compound of formula (I): ArSO3H or a precursor thereof, wherein Ar is an 1 to 4 alkyl groups substituted aryl, wherein the aryl is phenyl or naphthyl, and wherein each alkyl group, independently, is a linear or branched alkyl with 10 to 30 carbons, wherein the total number of carbons in the alkyl groups is in the range of 20 to 80 carbons; ii) a derivative of i) selected from the group consisting of an anhydride, an ester, an acetylate, an epoxy blocked ester and an amine salt thereof which is hydrolysable to the corresponding compound of formula (I); and iii) a metal salt of i) wherein the metal ion is selected from the group consisting of copper, aluminum, tin and zinc, wherein the polymer portion comprises (a1) a non-polar polymer component in an amount of 0 to 90% by weight, and (a2) a polar component, in an amount of at least 10% by weight, which polar component contains 3 to 30% by weight of a polar comonomer; an article, for example, a coating, a wire or a cable, comprising the polymer composition, a process for producing an article and use of the polymer composition.

Description

A polymer composition comprising a polyolefin composition and a at least one silanol condensation catalyst
Field of invention
The present invention relates to a new polymer composition, an article, for example, a coating, a wire or a cable, comprising the polymer composition, a process for producing an article and use of the polymer composition.
Background
It is known to crosslink polymers by means of additives. Crosslinking improves properties of the polymer such as mechanical strength and heat resistance.
Polymers normally considered to be thermoplastics, and not crosslinkable, can also be made crosslinkable by introducing crosslinkable groups in the polymer. Examples thereof are polymer compositions comprising polyolefms, such as polyethylenes, where silane compounds have been introduced as crosslinkable groups, e.g. by grafting silane compounds onto a prepared polyolefin, or by copolymerisation of an olefin and a silane compound. Such techniques are known e.g. from US4413066, US4297310, US4351876, US4397981, US4446283 and US4456704.
The crosslinking of polymer compositions comprising hydro lysable silane groups with catalysts is known in the art, see e.g. EP0736065. It is further known that the
crosslinking process may advantageously be carried out in the presence of acidic silanol condensation catalysts. The acidic silanol condensation catalysts permit crosslinking of silane-containing polymer compositions already at room temperature (about 20 to 25°C). Examples of such acidic silanol condensation catalysts which are organic sulphonic acids, or precursors of such acids, are disclosed in, for example,
W095/17463, EP1309631, EP1309632 and EP1849816, which documents, and the contents therein, are enclosed herein by reference.
Further, the catalysts may be added as so-called catalyst masterbatches. In these catalyst masterbatches the catalysts are compounded with a polymer resin (i.e. a carrier resin), and then suitably formed into granular shaped solids, e.g. into pellets. The catalyst masterbatch is then added to the polymer to be crosslinked. Thereby handling of the catalyst is facilitated.
Description of the invention
It has now been found that a particular polymer composition is surprisingly suitable as carrier resin to a specific silanol condensation catalyst, which catalyst comprises an aryl substituted with one or more alkyl groups.
Thus, the present invention accordingly provides a polymer composition comprising (a) a polymer portion, and (b) at least one silanol condensation catalyst, wherein each catalyst is selected from: i) a compound of formula I
ArS03H (I) or a precursor thereof, wherein
Ar is an 1 to 4 alkyl groups substituted aryl, wherein the aryl is phenyl or naphthyl, and wherein each alkyl group, independently, is a linear or branched alkyl with 10 to 30 carbons, wherein the total number of carbons in the alkyl groups is in the range of 20 to 80 carbons; ii) a derivative of i) selected from the group consisting of an anhydride, an ester, an acetylate, an epoxy blocked ester and an amine salt thereof which is hydro lysable to the corresponding compound of formula I; and iii) a metal salt of i) wherein the metal ion is selected from the group consisting of copper, aluminum, tin and zinc, wherein the polymer portion comprises
(al) a non-polar polymer component in an amount of 0 to 90% by weight, and (a2) a polar component, in an amount of at least 10% by weight, which polar component contains 3 to 30% by weight of a polar comonomer. In accordance with the present invention, by using pellets of the particular polymer portion in the compounding with the specific silanol condensation catalyst, which catalyst comprises an aryl substituted with one or more alkyl groups, there was surprisingly, over time, no apparent sweat out of the catalyst on the compounded catalyst masterbatch surface, not even after being stored in 50°C for 30 days in aluminum bags.
Moreover, pellets formed from the polymer composition of the present invention has been shown to have advantageous properties, as, for example, being dry and free flowing, without tendency to stick together and form aggregates, properties which make the pellets easy to handle. Additionally, hereby is a problem free dosing and feeding of pellets to e.g. an extruder also facilitated.
The polymer portion of the polymer composition comprises (al) a non-polar polymer composition component in an amount of 0 to 90% by weight, and (a2) a polar component, in an amount of at least 10% by weight, which polar component contains 3 to 30% by weight of a polar comonomer.
The non-polar component of the polymer composition may, for example, comprise a non-polar polyolefin, e.g., a non-polar polyethylene, which may be a homo- or copolymer of ethylene, e.g. low density polyethylene or linear low density polyethylene or a copolymer of e.g. ethylene and propylene or a copolymer of ethylene and an alpha olefin where the alpha olefin may be linear or branched.
Further, the polar component of the polymer composition may be selected from the group consisting of ethylene vinyl acetate (EVA), ethylene butyl acrylate (EBA), ethylene tert-butyl methacrylate (ETBMA), ethylene methyl acrylate (EMA), ethylene methyl methacrylate (EMMA), ethylene ethyl acrylate (EEA) and ethylene acrylic acid (EAA). Further, the polymer composition in accordance with the present invention may be produced by compounding the "at least one" silanol condensation catalyst, i.e. the specific silanol condensation catalyst, with the particular polymer portion, and, optionally, together with further suitable additives such as pigments, antioxidants, stabilizers, lubricants, fillers, peroxides, silanes and/or foaming agents. Further, the "at least one" silanol condensation catalyst is comprised in the particular polymer portion in concentrated form, and, optionally, together with the further suitable additives such as pigments, antioxidants, stabilizers, lubricants, fillers, peroxides, silanes and/or foaming agents. In a further embodiment of the present invention, the polymer composition is a catalyst masterbatch and the polymer portion constitutes a polymer matrix.
When the polymer composition in accordance with the present invention is a catalyst masterbatch, said catalyst masterbatch is a mixture which comprises the polymer portion and the "at least one" silanol condensation catalyst, i.e. the compound of formula I, in a concentrated form in said polymer matrix.
Further, when the polymer composition in accordance with the present invention is a catalyst masterbatch, said catalyst masterbatch may be produced by compounding the "at least one" silanol condensation catalyst and, optionally, any further additives with the polymer portion, wherein the polymer portion constitutes a polymer matrix. The further, optional, additives may, for example, be miscible thermoplastics, antioxidants, stabilizers, lubricants, fillers, peroxides, silanes and/or foaming agents.
The catalyst masterbatch in accordance with the present invention may be in a liquid form or a solid form suitably formed into, for example, a powder and/or granular shaped solids, e.g. pellets or granules.
Furthermore, prior to a crosslinking of a polymer, handling of the "at least one" silanol condensation catalyst, i.e. the compound of formula I, may be facilitated when added in concentrated form as the catalyst masterbatch. In an embodiment of the present invention, a polymer composition is disclosed wherein the polar component is selected from the group consisting of ethylene vinyl acetate (EVA), ethylene butyl acrylate (EBA), ethylene methyl aery late (EM A), ethylene methyl methacrylate (EMMA), ethylene ethyl acrylate (EE A) and ethylene acrylic acid (EAA).
In further embodiments of the present invention, a polymer composition is disclosed wherein the polymer portion comprises at least 20, 30 or, alternatively, 50 % by weight of (a2) the polar component.
The polymer portion of the polymer composition then comprises (al) a non-polar polymer composition component in amounts of 0 to 80% by weight, 0 to 70% by weight, and 0 to 50%> by weight, respectively.
In still a further embodiment of the present invention, a polymer composition is disclosed wherein the polymer portion comprises 100 % by weight of (a2) the polar component.
The polymer portion of the polymer composition then comprises no (al) a non-polar polymer composition component.
In a further embodiment of the present invention, a polymer composition is disclosed wherein the polymer portion comprises more than 50 % by weight of (a2) the polar component.
The polymer portion of the polymer composition then comprises (al) a non-polar polymer composition component in amounts of 0 to 50% by weight,
In further embodiments of the present invention, a polymer composition is disclosed wherein the polymer portion comprises at least 55, 60, 65, 75, 80, 85, 90 or, alternatively, 95 % by weight of (a2) the polar component.
The polymer portion of the polymer composition then comprises (al) a non-polar polymer composition component in amounts of 0 to 45% by weight, 0 to 40% by weight, 0 to 35% by weight, 0 to 30% by weight, 0 to 25% by weight, 0 to 20% by weight, 0 to 15%) by weight, 0 to 10%> by weight, and 0 to 5% by weight, respectively.
The polymer composition of the present invention do also comprise the "at least one", wherein each catalyst is selected from: i) a compound of formula I
ArS03H (I) or a precursor thereof, wherein Ar is an 1 to 4 alkyl groups substituted aryl, wherein the aryl is phenyl or naphthyl, and wherein each alkyl group, independently, is a linear or branched alkyl with 10 to 30 carbons, wherein the total number of carbons in the alkyl groups is in the range of 20 to 80 carbons; ii) a derivative of i) selected from the group consisting of an anhydride, an ester, an acetylate, an epoxy blocked ester and an amine salt thereof which is hydro lysable to the corresponding compound of formula I; and iii) a metal salt of i) wherein the metal ion is selected from the group consisting of copper, aluminum, tin and zinc.
Ar of the compound of formula I, may, besides the "1 to 4 alkyl groups"-substituents, also, optionally, comprise further suitable substituents.
In further embodiments of the present invention, Ar is a 1, 2, 3 or 4 alkyl groups substituted aryl, for example, a 2 to 3 alkyl groups substituted aryl, or, e.g.,
a 2 alkyl groups substituted aryl. Further, said aryl is phenyl or naphthyl, e.g. naphthyl. In an embodiment of the present invention, Ar is naphthyl being substituted by, e.g. 2 alkyl groups. Furthermore, each alkyl group, independently, is a linear or branched alkyl with 10 to 30 carbons, wherein the total number of carbons in the alkyl groups is in the range of 20 to 80 carbons.
In a further embodiment of the present invention, each alkyl group, independently, is a linear alkyl with 10 to 15 carbons, wherein the total number of carbons in the alkyl groups is in the range of 20 to 60 carbons.
In still a further embodiment of the present invention, any two of said alkyl groups may be linked to each other via a bridging group such as an alkylene group.
An embodiment of the present invention provides a polymer composition, as described herein, wherein said each silanol condensation catalyst is selected from a) Ci2-alkylated naphthyl sulfonic acids; b) a derivative of a) selected from the group consisting of an anhydride, an ester, an acetylate, an epoxy blocked ester and an amine salt thereof which is hydro lysable to the corresponding compound a); and/or c) a metal salt of a) wherein the metal ion is selected from the group consisting of copper, aluminum, tin and zinc.
A further embodiment of the present invention provides a polymer composition, as described herein, wherein said each silanol condensation catalyst is selected from C12- alkylated naphthyl sulfonic acids.
The silanol condensation catalyst may also be a derivative of the compound of formula I as described herein, wherein said derivative may be converted by hydrolysis to the compound of formula I. The derivative may, for example, be a corresponding acid anhydride of the compound of formula I. Alternatively, the derivative may be a compound of formula I which has been provided with a hydrolysable protective group, as, e.g., an acetyl group. The hydrolysable protective group can be removed by hydrolysis.
In a further embodiment the polymer composition according to the present invention comprises the "at least one" silanol condensation catalyst in an amount of, for example, 0.0001 to 8 % by weight, 0.0001 to 6 % by weight, 0.001 to 2 % by weight, 0.05 to 1 % by weight, 1 to 8% by weight or 1 to 6 % by weight.
In even a further embodiment the polymer composition according to the present invention further comprises a colour master batch, comprising e.g. Ti02, CaC03, carbon black and/or hindered-amine light stabilizers (HALS).
In still a further embodiment wherein the polymer composition is the catalyst masterbatch according to the present invention the catalyst masterbatch comprises the "at least one" silanol condensation catalyst in an amount of, for example, 0.7 to 8 % by weight, 0.7 to 6 % by, 1 to 8 % by weight or 1 to 6 % by weight.
In still a further embodiment of the present invention, the polymer composition further comprises a crosslinkable polyolefm with hydrolysable silane groups.
The crosslinkable polyolefm of the polymer composition may, for example, comprise a polyethylene with hydrolysable silane groups, or the crosslinkable polyolefm may, e.g., consist of a polyethylene with hydrolysable silane groups.
The hydrolysable silane groups may be introduced into the polyolefm by
copolymerisation of, e.g., ethylene monomers with silane group containing comonomers or by grafting, i.e. by chemical modification of the polyolefm by addition of silane groups mostly in a radical reaction. Both techniques are well known in the art.
Moreover, the crosslinkable polyolefm with hydrolysable silane groups may be obtained by copolymerisation. In the case of polyolefm being, for example, polyethylene, the copolymerisation may be carried out with an unsaturated silane compound represented by the formula II
Figure imgf000010_0001
wherein R1 is an ethylenically unsaturated alkyl, alkyloxy or (meth)acryloxy alkyl group, R2 is an aliphatic saturated alkyl group,
Y which may be the same or different, is a hydro lysable organic group and q is 0, 1 or 2.
Special examples of the unsaturated silane compound are those wherein R1 is vinyl, allyl, isopropenyl, butenyl, cyclohexanyl or gamma-(meth)acryloxy propyl; Y is methoxy, ethoxy, formyloxy, acetoxy, propionyloxy or an alkyl-or arylamino group; and R2, if present, is a methyl, ethyl, propyl, decyl or phenyl group.
In even a further embodiment the unsaturated silane compound may be represented by the formula III
CH2=CHSi(OA)3 (III) wherein A is a alkyl group having 1 to 8 carbon atoms, e.g. 1 to 4 carbon atoms.
In further embodiments of the present invention the silane compound may be, e.g., vinyl trimethoxysilane, vinyl bismethoxyethoxysilane, vinyl triethoxy silane, gamma- (meth)acryloxypropyltrimethoxysilane, gamma(meth)acryloxypropyltriethoxysilane, or vinyl triacetoxy silane.
Said copolymerisation may be carried out under any suitable conditions resulting in the copolymerisation of two monomers. Moreover, the copolymerisation may be implemented in the presence of one or more other comonomers which can be copolymerised with the two monomers. Such comonomers include, for example, vinyl carboxylate esters, such as vinyl acetate and vinyl pivalate, alpha-olefms, such as propene, 1-butene, 1-hexane, 1-octene and 4- methyl- 1-pentene, (meth)acrylates, such as methyl(meth)acrylate, ethyl(meth)acrylate and butyl(meth)acrylate, olefmically unsaturated carboxylic acids, such as (meth)acrylic acid, maleic acid and fumaric acid, (meth)acrylic acid derivatives, such as
(meth)acrylonitrile and (meth)acrylic amide, vinyl ethers, such as vinyl methyl ether and vinyl phenyl ether, and aromatic vinyl compounds, such as styrene and alpha-ethyl styrene.
In still further embodiments of the present invention, said comonomers may be vinyl esters of monocarboxylic acids having 1-4 carbon atoms, such as vinyl acetate, and/or (meth)acrylate of alcohols having 1-4 carbon atoms, such as methyl(meth)-acrylate.
In even further embodiments of the present invention, the comonomers: butyl acrylate, ethyl acrylate and/or methyl acrylate are disclosed.
Two or more comonomers, such as any of the olefmically unsaturated compounds disclosed herein, may be used in combination. The term "(meth)acrylic acid" is intended to embrace both acrylic acid and methacrylic acid. The comonomer content of the copolymer may amount to 70% by weight of the copolymer, for example, about 0.5 to 35%) by weight, e.g., about 1 to 30% by weight.
If a graft polymer is used, it may have been produced e.g. by any of the two methods described in US3646155 and US4117195, respectively.
The polyolefm with hydro lysable silane groups, which is comprised in the polymer composition of the present invention, may comprise 0.001 to 15% by weight of silane compound, for example, 0.01 to 5% by weight, e.g., 0.1 to 2% by weight.
The polymer composition according to the invention may further comprise various additives, for example, miscible thermoplastics, antioxidants, stabilizers, lubricants, fillers, pigments, peroxides, silanes and/or foaming agents. Examples of suitable fillers and/or pigments include Ti02, CaC03, carbon black (e.g. "UV black", i.e. a carbon black that absorbs ultraviolet radiation), huntite, mica, kaolin, aluminium hydroxide (ATH), magnesium dihydroxide (MDH), and Si02. In still a further embodiment the polymer composition according to the present invention further comprises fillers and/or pigments.
Furthermore, said fillers and/or pigments may be comprised in the polymer composition according to the present invention in amounts of, for example, 0.01 to 5 wt%, or, e.g., 0.01 to 2 wt%. As antioxidant, a compound, or a mixture of compounds, may, for example, be used.
The antioxidant may, suitably, be neutral or acidic compounds, and which compounds may, suitably, comprise a sterically hindered phenol group or aliphatic sulphur groups. Such compounds are disclosed in EP 1254923 and these are suitable antioxidants for stabilisation of polyolefms containing hydro lysable silane groups which are crosslinked with a silanol condensation catalyst, e.g., an acidic silanol condensation catalyst. Other exemplified antioxidants are disclosed in WO2005003199.
Moreover, the antioxidant may be present in the polymer composition in an amount of from 0.01 to 3 wt%, e.g., 0.05 to 2 wt%, or, e.g., 0.08 to 1.5 wt%.
In accordance with the present invention said polymer portion and said "at least one" silanol condensation catalyst may suitably be mixed to produce the polymer composition of the present invention, by compounding a crosslinkable polyolefm together with said catalyst masterbatch and, optionally, one or more additive masterbatches.
Further, the, optional, one or more additive masterbatches comprise further additives in concentrated form in their polymer matrices, e.g. polyolefm matrices.
The polymer matrices of the, optional, one or more additive masterbatches may comprise, for example, a polyolefm, e.g., a polyethylene, which may be a homo- or copolymer of ethylene, e.g. low density polyethylene, or a polyethylene-methyl-ethyl- butyl- acrylate copolymer containing 1 to 50 percent by weight of the acrylate, or any mixtures thereof. Furthermore, the polymer matrices may comprise high density or medium density polyethylenes. Further, the polymer matrices may comprise bimodal polymers.
Said compounding may be performed by any known compounding process, including extruding the final product with a screw extruder or a kneader.
Alternatively, one or more of the "at least one" silanol condensation catalyst and the, optional, further additives, need not to be added as comprised in masterbatches but may instead be added , e.g. in liquid form, directly to a system for production of the polymer composition of the present invention.
The further, optional, additives may be as already described herein.
Further, the catalyst masterbatch, the additive masterbatch or masterbatches comprise said "at least one" catalyst and, optionally, further additives, respectively, in concentrated form. The wording "concentrated form" means herein that said "at least one" catalyst and the optional further additives, respectively, have higher concentration in said masterbatches as compared with their concentration in the final crosslinkable polymer composition. In a further embodiment of the present invention the catalyst masterbatch, as described herein, may, for example, comprise the "at least one" silanol condensation catalyst in an amount of, for example, 0.7 to 8 % by weight, 0.7 to 6 % by, 1 to 8 % by weight or 1 to 6 % by weight.
Further in accordance with the present invention, when the catalyst masterbatch or an additive masterbatch, as described herein, is compounded with said polymer composition comprising said crosslinkable polyolefm, the catalyst masterbatch or the additive masterbatch may be present in an amount of 1 to 10 wt%, for example, 2 to 8 wt%. If a pigment is used in the polymer composition, the pigment may, for example, be added via a separate additive masterbatch, i.e. a pigment masterbatch, in an amount of 0.01 to 5 % by weight. Said pigment masterbatch can be comprised in the master batch of the present invention, in an amount of 0.2 to 50 % by weight.
The present invention do also relate to a process for producing an article, wherein said process comprises use, for example, extrusion, of a polymer composition as described herein. Said extrusion may be performed at a temperature of, for example, 140 to 230 °C.
In a further embodiment of the present invention a polymer composition is disclosed, wherein the polymer composition comprises a crosslinked polyolefm, wherein the crosslinked polyolefm is produced by crosslinking the crosslinkable polyolefm comprised in the polymer composition as described herein.
A further embodiment of the invention relates to an article, for example, a coating, a wire or a cable, which article comprises the polymer composition as described herein.
Still a further embodiment of the present invention relates to use of the polymer composition as described herein.
The following examples illustrate, but intend not to limit, the present invention.
Examples
1. Methods a. Melt Flow Rate The melt flow rate (MFR) is determined according to ISO 1 133 and is indicated in g/10 min. The MFR for ethylene polymers is determined at 190°C and with a 2.16 kg load (MFR2). b. Methanol wash, exudation test
This method is for determining the amount of exudation on the pellet surface of sulphonic acid.
100 g pellets were extracted in 100 ml methanol at room temperature for 5 minutes under magnetic stirring. The extracts were analyzed with HPLC and the exudation of sulphonic acid was obtained by referencing versus a reference spectra for the used sulphonic acid. c. Pellet Stickyness test
For the agglomeration tests, 50 g pellets of each catalyst masterbatch were heat sealed in aluminium bags and put in air circulating oven for seven days at 50 °C.
After the bags have been condition in 2 h at room temperature they were gently opened. The stickiness of the pellets and the propensity to form agglomerates of pellets were visualized and determined.
2. Materials
Catalyst masterbatches are composed as described Table 1 below. Nacure® CD-2180, i.e. a highly hydrophobic mixture of Ci2-alkylated naphthyl sulfonic acids (i.e. silanol condensation catalysts selected from the compound of formula I, as described herein), from King Industries, having an active content of 80% was used. Amounts are given in weight percentages of the total composition. The catalyst carries are a selected from:
BAR717, i.e. ethylene butylacrylate copolymer, supplied by Special Polymers Antwerp and with a butyl acrylate content of 17 weight% and a MRF2.16 of 7 g/10 min,
Exact0210 supplied by DSM with a density of 902 kg/m3 and a MRF2.i6 of 10 g/lOmin, and
LE1806 supplied by Borealis having a density of 923 kg/m3 and a MRF2.i6 of 2.1 g/10 min.
The stabiliser is Lowinox CPL, a phenolic stabilizer from Chemtura , and the drying agent is Dynasylan 9116 , HDTMS, hexadecyltrimethoxysilane produced by Evonic. Catalyst masterbatches may be prepared by mixing the components in a Banbury kneader at 130°C for 8 minutes. The compounds may afterwards be pelletized on a Buss kneader.
Table 1
Catalyst MB A Catalyst MB B Catalyst MB C (Comparative (Comparative (Innovative example 1 ) example 2) example 1 )
EXACT0210 83.3
LE1806 83.3 71.2
BAR717 12.1
Nacure CD-2180 6.3 6.3 6.3
Stabilizers 6.4 6.4 6.4
3 3 3
Drying agent Catalyst MB D Catalyst MB E Catalyst MB F (Innovative example (Innovative example (Innovative 2) 3) example 4)
EXACT0210
LE1806 41.65 12.1
BAR717 41.65 71.2 83.3
Nacure CD-2180 6.3 6.3 6.3
Stabilizers 6.4 6.4 6.4
3 3 3
Drying agent
The results from the methanol wash test are given in Table 2 and the results from the agglomeration test in Table 3.
Table 2
Figure imgf000017_0001
Catalyst MB D Catalyst MB E Catalyst MB F
(Innovative (Innovative (Innovative example 2) example 3) example 4)
Exudation of
sulphonic acid 180 180 130 (ppm) Table 3
Figure imgf000018_0001
Figure imgf000018_0002
The results from table 2 and 3 show a much lower exudation of sulphonic acid and free flowing pellets in the innovative examples where a polar polymer component is present in the composition.

Claims

Claims
1. A polymer composition comprising (a) a polymer portion, and (b) at least one silanol condensation catalyst, wherein each catalyst is selected from: i) a compound of formula I
ArS03H (I) or a precursor thereof, wherein
Ar is an 1 to 4 alkyl groups substituted aryl, wherein the aryl is phenyl or naphthyl, and wherein each alkyl group, independently, is a linear or branched alkyl with 10 to 30 carbons, wherein the total number of carbons in the alkyl groups is in the range of 20 to 80 carbons; ii) a derivative of i) selected from the group consisting of an anhydride, an ester, an acetylate, an epoxy blocked ester and an amine salt thereof which is hydro lysable to the corresponding compound of formula I; and iii) a metal salt of i) wherein the metal ion is selected from the group consisting of copper, aluminum, tin and zinc, characterized in that the polymer portion comprises (al) a non-polar polymer component in an amount of 0 to 90% by weight, and (a2) a polar component, in an amount of at least 10% by weight, which polar component contains 3 to 30% by weight of a polar comonomer.
2. A polymer composition according to claim 1 , wherein the polymer
composition is a catalyst masterbatch and the polymer portion constitutes a polymer matrix.
3. A polymer composition according any of claims 1 to 2, wherein the polar component is selected from the group consisting of ethylene vinyl acetate (EVA), ethylene butyl acrylate (EBA), ethylene methyl acrylate (EM A), ethylene methyl methacrylate
(EMMA), ethylene ethyl acrylate (EE A) and ethylene acrylic acid (EAA).
4. A polymer composition according to any of claims 1 to 3, wherein the polymer portion comprises at least at least 50% by weight of the polar component.
5. A polymer composition according to any of claims 1 to 4, wherein Ar is naphthyl.
6. A polymer composition according to any of claims 1 to 5, wherein each catalyst is selected from a) Ci2-alkylated naphthyl sulfonic acids; b) a derivative of a) selected from the group consisting of an anhydride, an ester, an acetylate, an epoxy blocked ester and an amine salt thereof which is hydro lysable to the corresponding compound a); and/or c) a metal salt of a) wherein the metal ion is selected from the group consisting of copper, aluminum, tin and zinc.
7. A polymer composition according to any of claims 1 to 6, wherein the polymer composition comprises the "at least one" silanol condensation catalyst in an amount of 0.0001 to 8 wt%.
8. A polymer composition according to any of claims 1 to 7, which further comprises a colour master batch, comprising e.g. Ti02, CaC03, carbon black and/or hindered-amine light stabilizers (HALS).
9. A polymer composition according to any of claims 1, 3 to 8, wherein the polymer composition further comprises a crosslinkable polyolefm with hydro lysable silane groups.
10. A polymer composition according to claim 9, wherein the crosslinkable polyolefm with hydro lysable silane groups comprises a polyethylene with hydro lysable silane groups.
11. A polymer composition according to any of claims 1, 3 to 10, wherein the polyolefm with hydro lysable silane groups comprises 0.001 to 15% by weight of silane compound.
12. A polymer composition according to any of claims 1, 3 to 1 1, which comprises a crosslinked polyolefin, wherein the crosslinked polyolefin is produced by crosslinking the crosslinkable polyolefin comprised in the polymer composition according to any of claims 6 to 11.
13. An article, for example, a coating, a wire or a cable, comprising the polymer composition, according to any of claims 1 to 12.
14. A process for producing an article, wherein said process comprises use, for example, extrusion, of a polymer composition according to any of claims 1 to 12.
15. Use of a polymer composition according to any of claims 1 to 12.
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