Polyesters compositions which crystallize rapidly

Claim 2

A thermoplastic composition which crystallizes rapidly, comprising a. a high molecular weight polyalkylene terephthalate which has an intrinsic viscosity of at least about 0.4 dl/g (measured as a 0.5% strength by weight solution in a phenol/tetrachloroethane mixture in a weight ratio of 1:1 at 25° C.) and b. about 0.5 to 30% by weight based on the weight of a. and b. of an esterification product of aliphatic carboxylic acids with 1 to 25 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms, said esterification product being monomeric and free of groups substantially reactive with said high molecular weight polyalkylene terephthalate under injection molding conditions and having a carbon atom to ester bond ratio of between 4 and 14 inclusive of the carbonyl carbon atom.

Claim 3

The composition of claim l, containing about 4 to 30% by weight of the esterification product.

Claim 4

The composition of claim 1 in which the polyalkylene terephthalate has an intrinsic viscosity of at least about 0.8 dl/g.

Claim 5

The composition of claim 1 wherein the esterification product is based on sebacic acid, adipic acid or both.

Claim 6

A process for the production of a composition as claimed in claim 1, in which about 70 to 99.5% by weight of a high-molecular weight polyalkylene terephthalate with an intrinsic viscosity of at least about 0.4 dl/g and about 0.5 to 30% by weight of the esterification product of aliphatic carboxylic acids with 1 to 25 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms, said esterification product having a carbon atom to ester bond ratio of between 4 and 14 inclusive of the carbonyl carbon atom and being monomeric and free of groups substantially reactive with said high molecular weight polyalkylene terephthalate under injection molding conditions, are mixed together and homogenized in the melt.

Claim 7

A process according to claim 5, in which about 70 to 96% by weight of the polyalkylene terephthalate and about 4 to 30% by weight of the esterification product are mixed together and homogenized in the melt.

Claim 8

A process according to claim 5 in which the esterification product of aliphatic carboxylic acids has been produced by esterifying adipic acid or sebacic acid with a monohydric alcohol selected from 2-ethylhexanol, n-butanol, isonanol, benzyl alcohol, and octanol.

Claim 9

The product of the process of claim 7.

Claim 10

A process for increasing the rate of crystallization of a polyethylene terephthalate comprising incorporating therein sufficient esterification product of aliphatic carboxylic acids with 1 to 25 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms to ensure that said polyester when injection molded into molds held at temperatures of less than about 120° C. will have at least about 70% of the crystallinity obtainable by injection molding the polyester alone into molds held at temperatures in excess of 140° C. with mold residence times in excess of sixty seconds.

Claim 11

A process for increasing the rate of crystallization of a polyethylene terephthalate comprising incorporating therein sufficient esterification product of aliphatic carboxylic acids with 1 to 25 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms to ensure that said polyester when injection molded into molds held at temperatures of less than about 120° C. will have at least about 70% of the crystallinity obtainable by injection molding the polyester alone into molds held at temperatures in excess of 140° C. with mold residence times in excess of sixty seconds.

Claim 12

The process of claim 9 wherein the sufficient esterification product is present to ensure that the polyester will have a heat of crystallization of at least about 6 cal/g as molded into a mold colder than about 120° C.

Claim 13

The process of claim 9 wherein the esterification product is derived from an acid having between 1 and 8 carbon atoms.

Claim 14

A highly crystalline thermoplastic composition which crystallizes rapidly comprising a blend of a. a polyalkylene terephthalate based on an acid component of at least about 90 mol % terephthalic acid and a diol component of at least about 90 mol % ethylene glycol, said polymer having an intrinsic viscosity of at least about 0.8 dl/g as measured at 25° C. in a 1:1 phenol tetrachloroethane mixture, and b. about 0.5 to 30 weight % based on the weight of a and b of an esterification product of sebacic or adipic acid with a monohydric alcohol selected from 2-ethylhexanol, n-butanol, isonanol, benzyl alcohol and octanol.

Claim 15

A highly crystalline thermoplastic composition which crystallizes rapidly comprising a blend of a. a polyalkylene terephthalate based on an acid component of at least about 90 mol % terephthalic acid and a diol component of at least about 90 mol % ethylene glycol, said polymer having an intrinsic viscosity of at least about 0.8 dl/g as measured at 25° C. in a 1:1 phenol tetrachloroethane mixture, and b. about 0.5 to 30 weight % based on the weight of a and b of an esterification product of sebacic or adipic acid with a monohydric alcohol selected from 2-ethylhexanol, n-butanol, isonanol, benzyl alcohol and octanol.

Claim 16

A highly crystalline thermoplastic composition which crystallizes rapidly, comprising a. a high molecular weight polyalkylene terephthalate which has an intrinsic viscosity of at least about 0.4 dl/g (measured as a 0.5% strength by weight solution in a phenol/tetrachloroethane mixture in a weight ratio of 1:1 at 25° C) and b. about 0.5 to 30% by weight based on the weight of a and b of an esterification product of aliphatic carboxylic acids with 1 to 8 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms, said esterification product being monomeric and free of groups substantially reactive with said high molecular weight polyalkylent terephthalate under injection molding conditions.

Claim 17

A highly crystalline thermoplastic composition which crystallizes rapidly, comprising a. a high molecular weight polyalkylene terephthalate which has an intrinsic viscosity of at least about 0.4 dl/g (measured as a 0.5% strength by weight solution in a phenol/tetrachloroethane mixture in a weight ratio of 1:1 at 25° C) and b. about 0.5 to 30% by weight based on the weight of a and b of an esterification product of aliphatic carboxylic acids with 1 to 8 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms, said esterification product being monomeric and free of groups substantially reactive with said high molecular weight polyalkylent terephthalate under injection molding conditions.

Claim 18

A highly crystalline thermoplastic composition which crystallizes rapidly, comprising a. a high molecular weight polyalkylene terephthalate which has an intrinsic viscosity of at least about 0.4 dl/g (measured as a 0.5% strength by weight solution in a phenol-tetrachloroethane mixture in a weight ratio of 1:1 at 25° C.) and b. about 4 to 30% by weight based on the weight of a and b of an esterification product of aliphatic carboxylic acids with 1 to 25 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms, said esterification product having no substituents substantially reactive with said high molecular weight polyalkylene terephthalate under injection molding conditions and being monomeric.

Claim 19

A highly crystalline thermoplastic composition which crystallizes rapidly, comprising a. a high molecular weight polyalkylene terephthalate which has an intrinsic viscosity of at least about 0.4 dl/g (measured as a 0.5% strength by weight solution in a phenol-tetrachloroethane mixture in a weight ratio of 1:1 at 25° C.) and b. about 4 to 30% by weight based on the weight of a and b of an esterification product of aliphatic carboxylic acids with 1 to 25 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms, said esterification product having no substituents substantially reactive with said high molecular weight polyalkylene terephthalate under injection molding conditions and being monomeric.

Claim 20

A process for injection molding a thermoplastic polyester comprising 1. intimately blending a. a polyester at least about 90 mol % of whose acid residues are derived from terephthalic acid and at least 90 mol % of whose alcohol residues are derived from ethylene glycol, said polyester having an intrinsic viscosity of at least about 0.4 dl/g in 1:1 phenol/tetrachloroethane at 25° C., with b. the monomeric esterification product of aliphatic carboxylic acids having between 1 and 25 carbon atoms with alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with between 1 and 20 carbon atoms, said esterification product being free of groups substantially reactive with said polyester under injection molding conditions, and 2. injection molding said blend into molds held at temperatures no more than about 120° C., a sufficient amount of said esterification product being included in the blend to ensure a significant degree of crystallinity to the molded polyester.

Claim 21

A process for injection molding a thermoplastic polyester comprising 1. intimately blending a. a polyester at least about 90 mol % of whose acid residues are derived from terephthalic acid and at least 90 mol % of whose alcohol residues are derived from ethylene glycol, said polyester having an intrinsic viscosity of at least about 0.4 dl/g in 1:1 phenol/tetrachloroethane at 25° C., with b. the monomeric esterification product of aliphatic carboxylic acids having between 1 and 25 carbon atoms with alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with between 1 and 20 carbon atoms, said esterification product being free of groups substantially reactive with said polyester under injection molding conditions, and 2. injection molding said blend into molds held at temperatures no more than about 120° C., a sufficient amount of said esterification product being included in the blend to ensure a significant degree of crystallinity to the molded polyester.

Claim 22

The process of claim 15 wherein sufficient esterification product is used to ensure that the molded polyester has no less than about 70% of the crystallinity obtainable by injection molding the polyester alone into molds held at least about 140° C. with residence times of in excess of about 60 seconds.

Claim 23

The process of claim 16 wherein the polyester consists essentially of terephthalic acid residues and ethylene glycol residues.

Claim 24

The process of claim 15 wherein sufficient esterification product is used to ensure that the molded polyester has a heat of crystallization of no less than about 6 cal/g.

Claim 25

An improved process for forming injection molded articles comprising 1. intimately blending a. a polyester at least about 90 mol % of whose acid residues are derived from terephthalic acid and at least 90 mol % of whose alcohol residues are derived from ethylene glycol, said polyester having an intrinsic viscosity of at least about 0.4 dl/g in 1:1 phenol/tetrachloroethane at 25° C., with b. the monomeric esterification product of an aliphatic carboxylic acid having between 1 and 25 carbon atoms with alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with between 1 and 20 carbon atoms, said esterification product being free of groups substantially reactive with said polyester under injection molding conditions, and 2. injection molding said blend with mold temperatures less than about 120° C. and with mold residence times significantly less than those required when molding the same part from the polyester alone, the amount of aliphatic acid ester and the residence time being sufficient to ensure at least about 70% of the crystallinity obtainable by molding the polyester alone with mold temperatures no less than about 140° C. and residence times in excess of 60 seconds.

Claim 26

An improved process for forming injection molded articles comprising 1. intimately blending a. a polyester at least about 90 mol % of whose acid residues are derived from terephthalic acid and at least 90 mol % of whose alcohol residues are derived from ethylene glycol, said polyester having an intrinsic viscosity of at least about 0.4 dl/g in 1:1 phenol/tetrachloroethane at 25° C., with b. the monomeric esterification product of an aliphatic carboxylic acid having between 1 and 25 carbon atoms with alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with between 1 and 20 carbon atoms, said esterification product being free of groups substantially reactive with said polyester under injection molding conditions, and 2. injection molding said blend with mold temperatures less than about 120° C. and with mold residence times significantly less than those required when molding the same part from the polyester alone, the amount of aliphatic acid ester and the residence time being sufficient to ensure at least about 70% of the crystallinity obtainable by molding the polyester alone with mold temperatures no less than about 140° C. and residence times in excess of 60 seconds.

Claim 27

A thermoplastic composition which crystallizes rapidly consisting essentially of a. a high molecular weight polyalkylene terephthalate which has an intrinsic viscosity of at least about 0.4 dl/g (measured as a 0.5% strength by weight solution in a phenol/tetrachloroethane mixture in a weight ratio of 1:1 at 25° C.), b. about 0.5 to 30% by weight based on the weight of a. and b. of an esterification product of aliphatic carboxylic acids with 1 to 25 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms, said esterification product being monomeric and free of groups substantially reactive with said high molecular weight polyalkylene terephthalate unde injection molding conditions and having a carbon atom to ester bond ratio of between 4 and 14 inclusive of the carbonyl carbon atom, and c. up to about 1 wt. % of nucleating agent.

Claim 28

A thermoplastic composition which crystallizes rapidly consisting essentially of a. a high molecular weight polyalkylene terephthalate which has an intrinsic viscosity of at least about 0.4 dl/g (measured as a 0.5% strength by weight solution in a phenol/tetrachloroethane mixture in a weight ratio of 1:1 at 25° C.), b. about 0.5 to 30% by weight based on the weight of a. and b. of an esterification product of aliphatic carboxylic acids with 1 to 25 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms, said esterification product being monomeric and free of groups substantially reactive with said high molecular weight polyalkylene terephthalate unde injection molding conditions and having a carbon atom to ester bond ratio of between 4 and 14 inclusive of the carbonyl carbon atom, and c. up to about 1 wt. % of nucleating agent.

Claim 29

A glass reinforced thermoplastic composition which crystallizes rapidly, consisting essentially of a. a high molecular weight polyethylene terephthalate which has an intrinsic viscosity of at least 0.4 dl/g (measured as a 0.5% strength by weight solution in a phenol/tetrachloroethane mixture in a weight ratio of 1:1 at 25° C.), b. about 0.5 to 30% by weight based on the weight of a. and b. of an esterification product of aliphatic carboxylic acids with 1 to 25 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms, said esterification product being monomeric and free of groups substantially reactive with said high molecular weight polyalkylene terephthalate under injection molding conditions and having a carbon atom to ester bond ratio of between 4 and 14 inclusive of the carbonyl carbon atom, c. a reinforcing amount of glass fibers, and d. up to about 1 wt. % of nucleating agent.

Claim 30

A glass reinforced thermoplastic composition which crystallizes rapidly, consisting essentially of a. a high molecular weight polyethylene terephthalate which has an intrinsic viscosity of at least 0.4 dl/g (measured as a 0.5% strength by weight solution in a phenol/tetrachloroethane mixture in a weight ratio of 1:1 at 25° C.), b. about 0.5 to 30% by weight based on the weight of a. and b. of an esterification product of aliphatic carboxylic acids with 1 to 25 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms, said esterification product being monomeric and free of groups substantially reactive with said high molecular weight polyalkylene terephthalate under injection molding conditions and having a carbon atom to ester bond ratio of between 4 and 14 inclusive of the carbonyl carbon atom, c. a reinforcing amount of glass fibers, and d. up to about 1 wt. % of nucleating agent.

Claim 31

A thermoplastic composition which crystallizes rapidly consisting essentially of a. a high molecular weight polyalkylene terephthalate which has an intrinsic viscosity of at least about 0.4 dl/g (measured as a 0.5% strength by weight solution in a phenol/tetrachloroethane mixture in a weight ratio of 1:1 at 25° C.), b. about 0.5 to 30% by weight based on the weight of a. and b. of an esterification product of aliphatic carboxylic acids with 1 to 25 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms, said esterification product being monomeric and free of groups substantially reactive with said high molecular weight polyalkylene terephthalate under injection molding conditions and having a carbon atom to ester bond ratio of between 4 and 14 inclusive of the carbonyl carbon atom, c. up to about 1 wt. % of nucleating agent, and d. about 2 to 20% by weight, based on the weight of the molding composition, of flameproofing agent.

Claim 32

A thermoplastic composition which crystallizes rapidly consisting essentially of a. a high molecular weight polyalkylene terephthalate which has an intrinsic viscosity of at least about 0.4 dl/g (measured as a 0.5% strength by weight solution in a phenol/tetrachloroethane mixture in a weight ratio of 1:1 at 25° C.), b. about 0.5 to 30% by weight based on the weight of a. and b. of an esterification product of aliphatic carboxylic acids with 1 to 25 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms, said esterification product being monomeric and free of groups substantially reactive with said high molecular weight polyalkylene terephthalate under injection molding conditions and having a carbon atom to ester bond ratio of between 4 and 14 inclusive of the carbonyl carbon atom, c. up to about 1 wt. % of nucleating agent, and d. about 2 to 20% by weight, based on the weight of the molding composition, of flameproofing agent.

Claim 33

A glass reinforced thermoplastic composition which crystallizes rapidly, consisting essentially of a. a high molecular weight polyethylene terephthalate which has an intrinsic viscosity of at least 0.4 dl/g (measured as a 0.5% strength by weight solution in a phenol/tetrachloroethane mixture in a weight ratio of 1:1 at 25° C.), b. about 0.5 to 30% by weight based on the weight of a. and b. of an esterification product of aliphatic carboxylic acids with 1 to 25 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms, said esterification product being monomeric and free of groups substantially reactive with said high molecular weight polyalkylene terephthalate under injection molding conditions and having a carbon atom to ester bond ratio of between 4 and 14 inclusive of the carbonyl carbon atom, c. a reinforcing amount of glass fibers, d. up to about 1 wt. % of nucleating agent, and e. about 2 to 20% by weight relative to the molding composition, of flameproofing agent.

Claim 34

A glass reinforced thermoplastic composition which crystallizes rapidly, consisting essentially of a. a high molecular weight polyethylene terephthalate which has an intrinsic viscosity of at least 0.4 dl/g (measured as a 0.5% strength by weight solution in a phenol/tetrachloroethane mixture in a weight ratio of 1:1 at 25° C.), b. about 0.5 to 30% by weight based on the weight of a. and b. of an esterification product of aliphatic carboxylic acids with 1 to 25 carbon atoms and alcohols selected from aliphatic, cycloaliphatic and araliphatic alcohols with 1 to 20 carbon atoms, said esterification product being monomeric and free of groups substantially reactive with said high molecular weight polyalkylene terephthalate under injection molding conditions and having a carbon atom to ester bond ratio of between 4 and 14 inclusive of the carbonyl carbon atom, c. a reinforcing amount of glass fibers, d. up to about 1 wt. % of nucleating agent, and e. about 2 to 20% by weight relative to the molding composition, of flameproofing agent.