Vinyl halide polymer impact modifier

Claim 1

A PROCESS FOR MAKING IMPACT MODIFIED POLYVINYL HALIDE POLYMER AND COPOLYMERS COMPRISING THE STEPS: A. FORMING A RUBBERY, FIRST STAGE POLYMER BY EMULSION POLYMERIZATION OF A MONOMER CHARGE OF 70 TO 99.9 WEIGHT PERCENT OF AN ALKYLACRYLATE COMPOUND, THE ESTER MOIETY HAVING TWO TO EIGHT CARBONS; 0 TO 30 WEIGHT PERCENT OF A VINYLAROMATIC MONOMER INTERPOLYMERIZABLE THEREWITH; AND 0.1 TO 10 WEIGHT PERCENT OF A POLYFUNCTIONAL CROSSLINKING MONOMER, WEIGHTS BASED ON THE TOTAL WEIGHT OF THE STEP (A) MONOMER CHARGE, B. ADDING TO THE RESULTING RUBBER POLYMER STAGE PRODUCED IN STEP (A) FROM 70 TO 99.9 WEIGHT PERCENT OF A VINYLAROMATIC MONOMER, AND 0 TO 30 WEIGHT PERCENT OF AN ALKYL ACRYLATE, WHEREIN THE ALKYL GROUP OF SAID ACRYLATE HAD ABOUT 2 TO 8 CARBON ATOMS INTERPOLYMERIZABLE THEREWITH, AND 0.1 TO 10 WEIGHT PERCENT OF A SECOND POLYFUNCTIONAL CROSSLINKING MONOMER WEIGHT BASED ON THE TOTAL WEIGHT OF THE STEP (B) MONOMER CHARGE; AND EMULSION POLYMERIZING THE SECOND MONOMER CHARGE TO FORM A SECOND STAGE POLYMER ON/OR WITHIN THE RUBBERY POLYMER STAGE PRODUCED IN STEP (A); C. ADDING TO THE POLYMER RESULTING FROM STEPS (A) AND (B) A THIRD MONOMER CHARGE OF 80 TO 100 WEIGHT PERCENT OF AN ALKYL METHACRYLATE WHEREIN THE ALKYL GROUPS HAVE 1 TO 4 CARBON ATOMS, AND EMULSION POLYMERIZING THE THIRD MONOMER CHARGE TO FORM A THIRRD STAGE POLYMER ON THE POLYMERS IN STEPS (A) AND (B), AND D. ADDING TO THE RESULTING POLYMER RESULTING FROM STEPS (A), (B) AND (C), AND BASED ON THE WEIGHT OF SAID RESULTING POLYMER, A FOURTH MONOMER CHARGE OF 80 TO 100 WEIGHT PERCENT OF A VINYL HALIDE MONOMER, AND EMULSION POLY: MERIZING THE FOURTH MONOMER CHARGE TO FORM A FOURTH STAGE POLYMER SUBSTANTIALLY ENTANGELED WITHIN THE FIRST AND SECOND STAGES RESULTING FROM STEPS (A) AND (B); WHEREIN THE FIRST STAGE (A) MONOMERS COMPRISE ABOUT 20 T0 45 PARTS, SAID SECOND STAGE (B) MONOMERS COMPRISE ABOUT 20 TO 35 PARTS, SAID THIRD STAGE (C) MONOMERS COMPRISE ABOUT 20 TO 35 PARTS, AND SAID FOURTH STAGE (D) MONOMERS COMPRISE ABOUT 6 TO 90 PARTS; AND WHEREIN THE PARTICLE SIZE OF THE RESULTANT EMULSION POLYMER IS ABOUT 700-1,100 A. E. ADDING THE RESULTING HETEROPOLYMER TO A POLYVINYL HALIDE POLYMER, WHEREBY AN IMPACT RESISTANT THERMOPLASTIC MATERIAL IS FORMED, SAID IMPACT MODIFIED POLYVINYLHALIDE RESIN COMPRISING 98 TO 60 WEIGHT PERCENT OF SAID POLYVINYL HALIDE AND ABOUT 2 TO 40 WEIGHT PERCENT OF THE HETEROPOLYMER.