Thermoplastic and thermoset polymer compositions

Claim 2

A thermoplastic or thermoset polymer composition comprising thermoplastic or thermoset matrix polymer and, dispersed therein, from 0.1 to 40% by weight of the total composition of substantially spherical polymer particles having an average of from 2 to 15 micrometers and a particle size distribution such that at least 90% by weight of the particles fall within ± 20% of the average particle diameter; subject to the proviso that when said polymer composition is a light-scattering composition based on a thermoplastic polymer matrix and the spherical polymer particles comprise from 0.1 to 10% of the total composition weight, the spherical polymer particles are not core/shell polymers having a core of rubbery alkyl acrylate polymer, the alkyl group having from 2 to 8 carbon atoms, copolymerised with 0 or up to 5% crosslinker and 0 or up to 5% graftlinker (based on the total weight of the core) and a refractive index ( ) within ± 0.2 units of, but preferably no closer than ± 0.003 units to, the refractive index of the matrix polymer, and one or more polymer shells, the outermost of which is compatible with the matrix polymer, which shell(s) comprises 5 to 40% of the weight of the particles.

Claim 3

A thermoplastic or thermoset polymer composition as claimed in Claim 1, wherein said thermoplastic or thermoset matrix polymer is substantially amorphous.

Claim 4

A thermoplastic or thermoset polymer composition as claimed in Claim 2, wherein said spherical polymer particles comprise only a single polymeric phase and have a refractive index ( ) within ± 0.2 units of, but preferably no closer than ± 0.003 units to, the refractive index of the matrix polymer.

Claim 5

A thermoplstic or thermoset polymer composition as claimed in Claim 2, wherein said spherical polymer particles comprise core/shell polymer having a core polymer which has a refractive index (no 5 ) within ± 0.2 units of, but preferably no closer than ± 0.003 units to, the refractive index of the matrix polymer.

Claim 6

A thermoplastic or thermoset polymer composition as claimed in Claim 3 or Claim 4, wherein said single polymeric phase or said core polymer is a rubbery alkyl acrylate polymer, the alkyl group having from 2 to 8 carbon atoms, copolymerised with 0 or up to 10% crosslinker and 0 or up to 10% graftlinker (based on the total weight of the single polymeric phase or the core).

Claim 7

A thermoplastic or thermoset polymer composition as claimed in Claim 1 or Claim 2, wherein said spherical polymer particles comprise 0.1 to 10% by weight of the total composition.

Claim 8

A thermoplastic or thermoset polymer composition as claimed in any one of Claims 1, 2 or 6, wherein said spherical polymer particles comprise only a single polymeric phase.

Claim 9

A thermoplastic or thermoset polymer composition as claimed in any one of Claims 1, 2 or 6, wherein said spherical polymer particles comprise core/shell polymer.

Claim 10

A thermoplastic or thermoset polymer composition as claimed in Claim 8, wherein said core/shell polymer comprises a polymeric core phase and one or more polymeric shell phases, the outermost of which is compatible with the matrix polymer, which shell phase or phases comprise from 5 to 40% of the weight of the particles.

Claim 11

A thermoplastic or thermoset polymer composition as claimed in Claim 6, 8 or 9 when dependent on Claim 2, wherein said single polymeric phase or the polymeric core phase of the core/shell polymer has a refractive index (np 5 ) within ± 0.003 units of the refractive index of the matrix polymer.

Claim 12

A thermoplastic or thermoset polymer composition as claimed in any one of Claims 7 to 10, wherein said single polymeric phase or said core polymer is a rubbery alkyl acrylate polymer, the alkyl group having from 2 to 8 carbon atoms, copolymerised with 0 or up to 10% crosslinker and 0 or up to 10% graftlinker (based on the total weight of the single polymeric phase or the core polymer).

Claim 13

A process for preparing a thermoplastic or thermoset polymer composition comprising thermoplastic, or thermoset matrix polymer and substantially spherical polymer particles, comprising only a single polymeric phase, said single phase polymer particles having an average diameter of from 2 to 15 u.m and a particle size distribution such that at least 90% by weight of the particles fall within ± 20% of the average particle diameter, wherein the process comprises: A) polymerizing a first aqueous emulsion of one or more monomers which, when polymerized, produce a particulate composition comprising polymer particles; B) 1. swelling the particles of the particulate composition produced in A), or if appropriate the particles of B2), with one or more monomers, and

Claim 14

A process for preparing a thermoplastic or thermoset polymer composition comprising thermoplastic, or thermoset matrix polymer and substantially spherical polymer particles, comprising only a single polymeric phase, said single phase polymer particles having an average diameter of from 2 to 15 u.m and a particle size distribution such that at least 90% by weight of the particles fall within ± 20% of the average particle diameter, wherein the process comprises: A) polymerizing a first aqueous emulsion of one or more monomers which, when polymerized, produce a particulate composition comprising polymer particles; B) 1. swelling the particles of the particulate composition produced in A), or if appropriate the particles of B2), with one or more monomers, and

Claim 15

polymerizing the swelling monomer within the particles until all of the monomers have been polymerized, steps B1 and B1 being repeated, if necessary, until at least 90% by weight of the particles of the particulate composition fall within ± 20% of a desired size, in which case such particles are to be referred to as single phase polymer particles, and blending said single phase polymer particles, in an amount of 0.1 to 40% by weight of the total composition, with said matrix polymer.

Claim 16

polymerizing the swelling monomer within the particles until all of the monomers have been polymerized, steps B1 and B1 being repeated, if necessary, until at least 90% by weight of the particles of the particulate composition fall within ± 20% of a desired size, in which case such particles are to be referred to as single phase polymer particles, and blending said single phase polymer particles, in an amount of 0.1 to 40% by weight of the total composition, with said matrix polymer.

Claim 17

A process as claimed in Claim 12 wherein the polymerization of step A) is conducted under conditions that form the emulsion polymer as an easily swellable oligomer, preferably conditions including the presence of a chain-transfer moderator, for example a mercaptan.

Claim 18

A process as claimed in Claim 12 or 13, wherein one or more polymerizations of step B-2) are conducted under conditions that form a readily swellable oligomer from the swelling monomer, preferably conditions including the presence of a chain-transfer moderator, for example a mercaptan.

Claim 19

A process as claimed in any one of Claims 12, 13 or 14, wherein said single phase polymer particles comprise a rubbery alkyl acrylate polymer, the alkyl group having from 2 to 8 carbon atoms, copolymerised with 0 or up to 10% crosslinker and 0 or up to 10% graftlinker (based on the total weight of the particles).

Claim 20

A process as claimed in any one of claims 12 to 15. wherein said matrix polymer is substantially amorphous.

Claim 21

A process as claimed in Claim 16, wherein said single phase polymeric particles have a refractive index ( ) within ± 0.2 units of the refractive index of the matrix polymer.

Claim 22

Use of substantially spherical polymer particles in the formation of a light-scattering and/or reduced-gloss finish thermoplastic or thermoset polymer composition comprising a thermoplastic or thermoset matrix polymer and said spherical polymer particles, wherein said particles have an average diameter of from 2 to 15 u.m, a particle size distribution such that at least 90% by weight of the particles fall within 20% of the average particle diameter; subject to the proviso that when said polymer composition is a light-scattering composition based on a thermoplastic polymer matrix and the spherical polymer particles comprise from 0.1 to 10% of the total composition weight, the spherical polymer particles are not core/shell polymers having a core of rubbery alkyl acrylate polymer, the alkyl group having from 2 to 8 carbon atoms, copolymerised with 0 or up to 5% crosslinker and 0 or up to 5% graftlinker (based on the total weight of the core) and a refractive index (no 5 ) within ± 0.2 units of, but preferably no closer than ± 0.003 units to, the refractive index of the matrix polymer, and one or more polymer shells, the outermost of which is compatible with the matrix polymer, which shell(s) comprises 5 to 40% of the weight of the particles.

Claim 23

Use of substantially spherical polymer particles in the formation of a light-scattering and/or reduced-gloss finish thermoplastic or thermoset polymer composition comprising a thermoplastic or thermoset matrix polymer and said spherical polymer particles, wherein said particles have an average diameter of from 2 to 15 u.m, a particle size distribution such that at least 90% by weight of the particles fall within 20% of the average particle diameter; subject to the proviso that when said polymer composition is a light-scattering composition based on a thermoplastic polymer matrix and the spherical polymer particles comprise from 0.1 to 10% of the total composition weight, the spherical polymer particles are not core/shell polymers having a core of rubbery alkyl acrylate polymer, the alkyl group having from 2 to 8 carbon atoms, copolymerised with 0 or up to 5% crosslinker and 0 or up to 5% graftlinker (based on the total weight of the core) and a refractive index (no 5 ) within ± 0.2 units of, but preferably no closer than ± 0.003 units to, the refractive index of the matrix polymer, and one or more polymer shells, the outermost of which is compatible with the matrix polymer, which shell(s) comprises 5 to 40% of the weight of the particles.

Claim 24

Use, in sheet or moulded form, of a thermoplastic or thermoset polymer composition as claimed in any one of Claims 1 to 11, or as prepared in Claims 12 to 17, as, or as a component of, a luminaire, a rear projection screen for e.g. television or film viewing, a decoration, an illuminated sign, a skylight, a lighting fixture, greenhouse glazing, a light box, a drafting table, an automotive part, e.g. a sun-roof or a cover for automotive lights, an artistic application, an antiglow screen for a CTR unit or a twin-wall glazing.