阅读说明：本技术 用于聚合物的抗酸剂 (Antacids for polymers ) 是由 德米特里厄斯·米克斯 乔斯·M·雷戈 约翰·卡莱维·卡托 阿玛伊娅·蒙托亚-戈尼 米歇尔·倪 于 2019-02-01 设计创作，主要内容包括：本发明提供了具有改善的腐蚀性、颜色稳定性和清晰度的聚合物组合物。还公开了一种制备所述聚合物的方法。所述方法可以包括将酸中和量的无定形硅酸铝掺入到所述聚合物中。所述无定形硅酸铝可以以使得所述聚合物组合物的腐蚀性指数小于6的量存在于所述聚合物中。所述无定形硅酸铝的折射率可以与所述聚合物的折射率相同或基本上相同。(The present invention provides polymer compositions having improved corrosion, color stability and clarity. A method of making the polymer is also disclosed. The method can include incorporating an acid-neutralizing amount of amorphous aluminum silicate into the polymer. The amorphous aluminum silicate can be present in the polymer in an amount such that the polymer composition has a corrosivity index of less than 6. The amorphous aluminum silicate can have a refractive index that is the same as or substantially the same as the refractive index of the polymer.)

1. A method of neutralizing an acid in a polymer, the method comprising contacting the polymer with a neutralizing amount of amorphous aluminum silicate.

2. The method of claim 1, wherein the polymer is a polyolefin.

3. The method of claim 2, wherein the polyolefin is a propylene-based polymer, an ethylene-based polymer, a copolymer of at least one alpha-olefin and a diene, or mixtures thereof.

4. The method of claim 3, wherein the propylene-based polymer is a propylene homopolymer, a propylene copolymer, or mixtures thereof.

5. The process according to claim 4, wherein the propylene copolymer is a propylene random copolymer.

6. The process of claim 5 wherein the propylene copolymer is a copolymer of propylene and at least one alpha-olefin, wherein the alpha-olefin has from 2 to 10 carbon atoms.

7. The method of claim 6, wherein the alpha-olefin is at least one selected from the group consisting of ethylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 4-methyl-1-pentene.

8. The process of claim 5, wherein the propylene copolymer is a heterophasic propylene polymer, wherein the heterophasic propylene polymer comprises a matrix phase and at least one dispersed phase.

9. The method of claim 8, wherein the matrix phase of the heterophasic propylene polymer comprises a propylene homopolymer or a propylene copolymer.

10. The method of claim 3, wherein the ethylene-based polymer is an ethylene homopolymer, an ethylene copolymer, or a mixture thereof.

11. The process of claim 11, wherein the ethylene copolymer is a copolymer of ethylene and at least one alpha-olefin, wherein the alpha-olefin has from 3 to 10 carbon atoms.

12. The method of claim 12, wherein the alpha-olefin is at least one selected from the group consisting of propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 4-methyl-1-pentene.

13. The method of claim 10, wherein the ethylene-based polymer is HDPE or LLDPE.

14. The method of claim 3, wherein the polyolefin is a copolymer of the at least one alpha-olefin and a diene, wherein the alpha-olefin has no more than 20 carbon atoms.

15. The method of claim 1, wherein the amorphous aluminum silicate is an alkali/alkaline earth aluminum silicate.

16. The method of claim 15, wherein the alkali/alkaline earth aluminosilicate comprises at least an alkali metal selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, and mixtures thereof.

17. The method of claim 15, wherein the amorphous alkali/alkaline earth aluminosilicate comprises at least an alkaline earth metal selected from the group consisting of beryllium, magnesium, calcium, strontium, barium, radium, and mixtures thereof.

18. The method of claim 15 wherein the amorphous alkali/alkaline earth aluminosilicate is amorphous sodium magnesium aluminate.

19. The method of claim 18, wherein the amorphous sodium magnesium aluminum silicate comprises magnesium oxide in an amount from 0.5% to about 10% by weight of the total amorphous sodium magnesium aluminum silicate.

20. The method of claim 1 or 18, wherein the amorphous sodium magnesium aluminum silicate has an average particle size in the range of from about 0.5 μ ι η to about 10.0 μ ι η.

21. The method of claim 1 or 18, wherein the pH of the amorphous sodium magnesium aluminum silicate is in the range of 7 to 12.

22. The method of claim 1 or 15, wherein the amount of the amorphous aluminum silicate in the polymer is an amount sufficient to provide the polymer with a corrosivity index of less than 6.

23. The method of claim 1 or 15, wherein the amount of the amorphous aluminum silicate in the polymer ranges from about 0.005% to about 2.0% by weight of the polymer.

24. The method of claim 15, wherein the amount of the amorphous aluminum silicate in the polymer ranges from about 0.010% to about 1.0% by weight of the polymer.

25. The method of claim 15, wherein the amount of the amorphous aluminum silicate in the polymer ranges from about 0.015% to about 0.8% by weight of the polymer.

26. The method of claim 15, wherein the refractive index of the amorphous alkali aluminosilicate is substantially the same as the refractive index of the polymer.

27. A method of reducing the corrosivity of a polymer comprising an acidic impurity, the method comprising:

an acid-neutralizing amount of amorphous aluminum silicate is incorporated into the polymer to obtain a polymer composition having a corrosivity index of less than 6.

28. The method of claim 27, wherein the polymer is a polyolefin.

29. The method of claim 28, wherein the polyolefin is a propylene-based polymer, an ethylene-based polymer, a copolymer of at least one alpha-olefin and a diene, or mixtures thereof.

30. The method of claim 29, wherein the propylene-based polymer is a propylene homopolymer, a propylene copolymer, or mixtures thereof.

31. The process of claim 30 wherein the propylene copolymer is a propylene random copolymer.

32. The process of claim 30 wherein the propylene copolymer is a copolymer of propylene and at least one alpha-olefin, wherein the alpha-olefin has from 2 to 10 carbon atoms.

33. The method of claim 32, wherein the alpha-olefin is at least one selected from the group consisting of ethylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 4-methyl-1-pentene.

34. The process of claim 30, wherein the propylene copolymer is a heterophasic propylene polymer, wherein the heterophasic propylene polymer comprises a matrix phase and at least one dispersed phase.

35. The method of claim 34, wherein the matrix phase of the heterophasic propylene polymer comprises a propylene homopolymer or a propylene copolymer.

36. The method of claim 29, wherein the ethylene-based polymer is an ethylene homopolymer, an ethylene copolymer, or a mixture thereof.

37. The process of claim 36, wherein the ethylene copolymer is a copolymer of ethylene and at least one alpha-olefin, wherein the alpha-olefin has from 3 to 10 carbon atoms.

38. The method of claim 37, wherein the alpha-olefin is at least one selected from the group consisting of propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 4-methyl-1-pentene.

39. The method of claim 36, wherein the ethylene-based polymer is HDPE or LLDPE.

40. The method of claim 28, wherein the polyolefin is a copolymer of the at least one alpha-olefin and a diene, wherein the alpha-olefin has no more than 20 carbon atoms.

41. The method of claim 27, wherein the amorphous aluminum silicate is an alkali/alkaline earth aluminum silicate.

42. The method of claim 41, wherein the alkali/alkaline earth aluminosilicate comprises at least an alkali metal selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, and mixtures thereof.

43. The method of claim 41, wherein the amorphous alkali/alkaline earth aluminosilicate comprises at least an alkaline earth metal selected from the group consisting of beryllium, magnesium, calcium, strontium, barium, radium, and mixtures thereof.

44. The method of claim 41 wherein the amorphous alkali/alkaline earth aluminosilicate is amorphous sodium magnesium aluminate.

45. The method of claim 44, wherein the amorphous sodium magnesium aluminum silicate comprises magnesium oxide in an amount from 0.5% to about 10% by weight of the total amorphous sodium magnesium aluminum silicate.

46. The method of claim 27 or 44, wherein the amorphous aluminum silicate has a mean particle size in the range of from about 0.5 μm to about 10.0 μm.

47. The method of claim 27 or 44, wherein the pH of the amorphous sodium magnesium aluminum silicate is in the range of 7 to 12.

48. The method of claim 41, wherein the amount of the amorphous aluminum silicate in the polymer is an amount sufficient to provide the polymer with a corrosivity index of less than 1.

49. The method of claim 41, wherein the amount of the amorphous alkali/alkaline earth aluminosilicate in the polymer is in a range from about 0.005 wt% to about 2.0 wt% of the polymer.

50. The method of claim 41, wherein the amount of the amorphous alkali/alkaline earth aluminosilicate in the polymer is in a range from about 0.010% to about 1.0% by weight of the polymer.

51. The method of claim 41, wherein the amount of the amorphous alkali/alkaline earth aluminosilicate in the polymer is in a range from about 0.015 wt% to about 0.5 wt% of the polymer.

52. The method of claim 41, wherein the refractive index of the amorphous alkali/alkaline earth aluminosilicate is substantially the same as the refractive index of the polymer.

53. The method of claim 27, wherein the polymer composition has a clarity of at least about 60% as measured on an IM plate having a thickness of about 1 mm.

54. A polymer composition having reduced corrosivity comprising a polymer comprising an acid impurity and an acid-neutralizing amount of amorphous aluminum silicate.

55. The polymer composition of claim 54, wherein the polymer is a polyolefin.

56. The polymer composition of claim 55, wherein the polyolefin is a propylene-based polymer, an ethylene-based polymer, a copolymer of at least one alpha-olefin and a diene, or mixtures thereof.

57. The polymer composition of claim 56, wherein the propylene-based polymer is a propylene homopolymer, a propylene copolymer, or mixtures thereof.

58. The polymer composition according to claim 57, wherein the propylene copolymer is a propylene random copolymer.

59. The polymer composition of claim 57, wherein the propylene copolymer is a copolymer of propylene and at least one alpha-olefin, wherein the alpha-olefin has from 2 to 10 carbon atoms.

60. The polymer composition of claim 59, wherein the alpha-olefin is at least one selected from the group consisting of ethylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 4-methyl-1-pentene.

61. The polymer composition of claim 57, wherein the propylene copolymer is a heterophasic propylene polymer, wherein the heterophasic propylene polymer comprises a matrix phase and at least one dispersed phase.

62. The polymer composition of claim 61, wherein the matrix phase of the heterophasic propylene polymer comprises a propylene homopolymer or a propylene copolymer.

63. The polymer composition of claim 56, wherein the ethylene-based polymer is an ethylene homopolymer, an ethylene copolymer, or mixtures thereof.

64. The polymer composition of claim 63, wherein the ethylene copolymer is a copolymer of ethylene and at least one alpha-olefin, wherein the alpha-olefin has from 3 to 10 carbon atoms.

65. The polymer composition of claim 64, wherein the alpha-olefin is at least one selected from the group consisting of propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 4-methyl-1-pentene.

66. The polymer composition of claim 65, wherein the ethylene-based polymer is HDPE or LLDPE.

67. The polymer composition of claim 56, wherein the polyolefin is a copolymer of the at least one alpha-olefin and a diene, wherein the alpha-olefin has no more than 20 carbon atoms.

68. The polymer composition of claim 54, wherein the amorphous aluminum silicate is an alkali/alkaline earth aluminum silicate.

69. The polymer composition according to claim 68, wherein the alkali/alkaline earth aluminosilicate comprises at least an alkali metal selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, and mixtures thereof.

70. The polymer composition of claim 68, wherein the amorphous alkali/alkaline earth aluminosilicate comprises at least an alkaline earth metal selected from the group consisting of beryllium, magnesium, calcium, strontium, barium, radium, and mixtures thereof.

71. The polymer composition according to claim 68, wherein the amorphous alkali/alkaline earth aluminosilicate is amorphous sodium magnesium aluminate.

72. The polymer composition of claim 54 or 71, wherein the amorphous aluminum silicate has a mean particle size in the range of from about 0.5 μm to about 10.0 μm.

73. The polymer composition of claim 54 or 71, wherein the amorphous aluminum silicate has a pH in the range of 7 to 12.

74. The polymer composition of claim 54 or 68, wherein the amount of the amorphous aluminum silicate in the polymer is an amount sufficient to reduce the corrosivity index of the polymer to less than 6.

75. The polymer composition of claim 54 or 68, wherein the amount of the amorphous aluminum silicate in the polymer ranges from about 0.005% to about 2.0% by weight of the polymer.

76. The polymer composition of claim 75, wherein the amount of the amorphous aluminum silicate in the polymer ranges from about 0.010 weight percent to about 1.0 weight percent of the polymer.

77. The polymer composition of claim 75, wherein the amount of the amorphous alkali/alkaline earth aluminosilicate in the polymer is in the range of about 0.015 wt% to about 0.5 wt% of the polymer.

78. The polymer composition of claim 68, wherein the refractive index of the amorphous alkali/alkaline earth aluminosilicate is substantially the same as the refractive index of the polymer.

79. The polymer composition according to claim 71, wherein the polymer composition has a clarity of at least about 60% as measured on an IM plate having a thickness of about 1 mm.

80. An article made from the polymer composition of claim 54.

81. The article of claim 80, wherein the article is at least one selected from the group consisting of fibers, molded articles, extruded profiles, sheets, plates, adhesives, foams, wire coatings, or other manufactured parts.

82. The article of claim 81, wherein the article is a film or sheet or fiber or molded article.

83. The article of claim 82, wherein the article is a film.

Technical Field

The present invention relates to antacids and methods of use thereof. The invention also relates to improved polymer compositions containing antacids, and products formed from the polymer compositions.

Background

Polyolefins such as polypropylene have gained widespread acceptance and use in numerous commercial applications due to their versatility, desirable properties such as excellent mechanical properties and clarity, and generally lower manufacturing costs. Many industries, particularly the packaging industry, utilize these polypropylene materials in a variety of processes, such as extrusion, thermoforming, injection molding, or blow molding, to produce a variety of finished products.

Processes for preparing polyolefins (e.g., polyethylene and polypropylene) typically involve high activity polymerization catalysts, such as ziegler-type catalysts, to produce polymers with acceptable properties without the need for extraction to remove catalyst residues. Catalyst residues remaining in the polymer tend to be acidic and cause problems in processing polyolefins. For example, the presence of acidic species (e.g., in the form of hydrogen chloride) can corrode metal surfaces of polymer processing equipment such as extruders or injection molding equipment.

In addition to the problems associated with polymers described above, acidic residues can cause problems for products made from the polymers. For example, molded products made from polymers may also discolor or deteriorate. Films made from acid-containing polymers may result in poor film clarity or clarity.

To avoid or minimize such detrimental effects on the polymer and products made therefrom, antacids are typically incorporated into the polymer during polymer production to neutralize any acidic residues. An antacid commercially used in the production and processing of polymers, particularly polyolefin polymers and products, is calcium stearate. Generally, calcium stearate or stearic acid (CA) can migrate to the surface of the polymer as a product of neutralizing acidic residues and cause the surface of the polymer to become sticky or greasy. Such materials can also cause smoke in the spinning of the fibers. In addition, migration of stearic acid can result in water retention in raffia and film applications.

Another type of antacid commercially used in the processing or production of polyolefins is hydrotalcite. (see, e.g., U.S. patent No. 4,347,353). However, these materials are generally more expensive than calcium stearate, and they tend to produce increased haze in high definition applications, such as bi-directional polypropylene (BOPP) applications, thus making the film less desirable.

Other known antacids include crystalline zeolites and zinc oxide. In U.S. patent No. 5,510,413, it is disclosed to incorporate a small proportion of synthetic basic crystalline zeolite as an acid acceptor to neutralize or effectively remove the acid component of the unstabilized polymer. U.S. patent No. 4,251,407 discloses the use of zinc oxide as an acid acceptor in polypropylene.

There is a need in the polymer industry for improved antacid compositions that are cost effective and avoid or inhibit the problems associated with antacids currently used in polymer processing and production.

Disclosure of Invention

The present invention satisfies the need in the industry for novel antacids that neutralize acid impurities in polymers. In particular, it has been found that the use of amorphous aluminum silicates as antacids minimizes the adverse effects of acidic residues formed during polymer processing. Unexpectedly, polymer compositions, such as polyolefin polymer compositions, using amorphous aluminum silicates as antacids have improved properties, such as reduced corrosivity and improved color stability, as well as improved clarity and excellent Melt Flow Rate (MFR) stability.

Accordingly, one embodiment of the present invention provides an acid-containing polymer composition having enhanced corrosion, color stability, and clarity properties. The polymer composition can comprise a polymer comprising an acid impurity and an acid-neutralizing amount of amorphous aluminum silicate. In one embodiment, the polymer is a polyolefin.

In one embodiment, the present invention provides a polymer comprising an acid impurity having a corrosivity index of less than 6 and having good color stability. In another embodiment, the amorphous aluminum silicate can have a refractive index that is the same as or substantially the same as the refractive index of the polymer.

Another embodiment of the present invention also provides a process for preparing the polymer composition of the present invention. In general, the method can include incorporating an acid-neutralizing amount of amorphous aluminum silicate into a polymer comprising an acid impurity. In another embodiment, the method can include incorporating amorphous aluminum silicate in an amount sufficient to provide a polymer having a corrosivity index of less than 6.

These and other features and advantages of the present invention will become apparent after a review of the following detailed description of the disclosed embodiments and the appended claims.

Detailed Description

In order that those skilled in the art will better understand the technical aspects of the present disclosure, the present disclosure will be described in more detail with reference to the embodiments.

The following terms used in the present specification and appended claims have the following definitions.

The term "amorphous" refers herein to one or more substances in solid form, which are amorphous or lack long-range order of crystalline character. Generally, in X-ray diffraction, an amorphous solid scatters X-rays in many directions, resulting in a broad range of distributed large projections rather than a high intensity narrow peak of a crystalline solid.

A value modified by "about" is used herein to mean that the value may vary by 10%.

As used herein, the term "corrosivity index" refers to a measure of the likelihood that a composition will cause corrosion or rust on a metal surface, and is measured using the methods described in the examples herein below.

The term "neutralizing amount" is used herein to denote an amount of amorphous antacid sufficient to neutralize all or substantially all of the acidic residues in the polymer. The term "substantially all" is used herein to indicate more than 85%, preferably more than 90%, of all acidic residues in the polymer.

As used herein, the term "polyolefin" includes propylene-based polymers, ethylene-based polymers, copolymers of at least one alpha-olefin and a diene, or mixtures thereof.

As used herein, the term "propylene-based polymer," also referred to as "polypropylene," includes propylene homopolymers, propylene copolymers, or mixtures thereof.

The process of the present invention is a process for neutralizing acids in polymers. The method can include contacting the polymer with a neutralizing amount of amorphous aluminum silicate. The method can further comprise providing amorphous aluminum silicate sufficient to provide a desired corrosivity index. The polymer may be a polyolefin.

In one embodiment, the polyolefin is a propylene-based polymer. Propylene-based polymers that may be used in the present disclosure include, for example, propylene homopolymers. Alternatively, the propylene-based polymer may be a propylene copolymer. Such propylene copolymers may be propylene random copolymers. The propylene copolymer may be a copolymer of propylene and at least one alpha-olefin. The alpha-olefin may have 2 to 10 carbon atoms. In one embodiment, the α -olefin may be at least one selected from the group consisting of ethylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 4-methyl-1-pentene. Exemplary comonomers for making propylene/α -olefin copolymers are C2 to C10 α -olefins; for example, C2, C4, C6, and C8 alpha-olefins. Alternatively, such propylene copolymers may be heterophasic propylene polymers. The heterophasic propylene polymer may, for example, comprise a matrix phase and at least one dispersed phase. The matrix phase of the heterophasic propylene polymer may for example comprise a propylene-based polymer, such as a propylene homopolymer or a propylene copolymer. The propylene copolymer may for example be an impact copolymer polypropylene (PP) with an ethylene-propylene rubber phase or an impact copolymer PP with an alpha-olefin-propylene rubber phase.

In another embodiment, the polyolefin is an ethylene-based polymer. Ethylene-based polymers that may be used in the present disclosure include ethylene homopolymers, such as High Density Polyethylene (HDPE). Alternatively, the ethylene-based polymer may be an ethylene copolymer, for example, High Density Polyethylene (HDPE), Medium Density Polyethylene (MDPE), or Linear Low Density Polyethylene (LLDPE). The ethylene copolymer may be a copolymer of ethylene and at least one alpha-olefin. The alpha-olefin may have 3 to 10 carbon atoms. In one embodiment, the α -olefin may be at least one selected from the group consisting of propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 4-methyl-1-pentene.

In yet another embodiment, the polyolefin is a copolymer of at least one alpha-olefin and a diene. The alpha-olefin comonomer may have no more than 20 carbon atoms. For example, the alpha-olefin comonomer may preferably have 3 to 10 carbon atoms, and more preferably 3 to 8 carbon atoms. Exemplary alpha-olefin comonomers include, but are not limited to, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 4-methyl-1-pentene.

The particular manner in which the polyolefin is produced is not limited herein. The polymers may suitably be produced by a gas phase process. Alternatively, the polymer may be produced in a liquid phase or slurry phase process. The polymerization may be carried out in a continuous, semi-continuous or batch mode, and the polymerization system may comprise other species known in the art, such as molecular hydrogen.

The particular manner in which the polymer is contacted with the desired amount of amorphous aluminum silicate is not limited herein. In one embodiment, the polymer may be mixed with amorphous aluminum silicate to form a homogeneous or heterogeneous mixture of polymers. In a preferred process, amorphous aluminum silicate/polymer blends can be mixed using an extruder or mixing device operating under high shear.

Amorphous aluminosilicates (also known as aluminosilicates) useful in the present invention are derived from alumina (Al)₂O₃) And silicon dioxide (SiO)₂) The compound of (1). The amorphous aluminum silicate can be an amorphous alkali/alkaline earth aluminosilicate further comprising an alkali metal and an alkaline earth metal. The alkali metal may be selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, francium, and mixtures thereof. In one embodiment, the alkali metal is sodium.

The amorphous alkali/alkaline earth aluminosilicate may further comprise at least an alkaline earth metal selected from the group consisting of beryllium, magnesium, calcium, strontium, barium, radium and mixtures thereof. In one embodiment, the alkaline earth metal is magnesium.

In a preferred embodiment, the amorphous alkali/alkaline earth aluminosilicate is amorphous sodium magnesium aluminate. The magnesium content in the aluminium silicate, in the form of magnesium oxide (MgO), may vary depending on the amount of acid groups in the polymer to be neutralized. In one embodiment, the magnesium oxide content ranges from about 0.5% to about 10% by weight of the total amorphous sodium magnesium aluminum silicate. In a preferred embodiment, the magnesium oxide content ranges from 1.0% to about 9.0% by weight of the total amorphous sodium magnesium aluminum silicate. In a most preferred embodiment, the magnesium oxide content ranges from 1.5% to about 8.0% by weight of the total amorphous sodium magnesium aluminum silicate.

Generally, the amorphous aluminum silicates have average particle sizes in the range of about 0.2 μm to about 10.0 μm, preferably about 0.5 μm to 5 μm. The pH of the amorphous aluminum silicate may be in the range of 7.0 to 13.0, preferably in the range of 8.0 to 12.0, and more preferably in the range of 9.0 to 11.0.

In one embodiment, the refractive index of the amorphous aluminum silicate may be the same or substantially the same as the refractive index of the polymer. By "substantially the same" is meant herein that the absolute difference of the two refractive indices is equal to or less than 1.5% of the refractive index of the polymer. Preferably, the absolute difference of the two refractive indices is equal to or less than 1.0% of the refractive index of the polymer.

Amorphous aluminum silicates can be prepared using any conventional method. For example, amorphous aluminosilicates (such as sodium magnesium aluminium silicate) can be prepared by a precipitation process using sodium silicate, aluminium chloride or sodium aluminate, magnesium chloride and a mineral acid (such as sulphuric acid) in a manner similar to that described in GB925001, US3798046, US3909286, US4339421 or EP 07001534.

Amorphous aluminosilicates are incorporated or blended into polymers containing acid impurities in acid-neutralizing amounts. In one embodiment, the amount of amorphous alkali/alkaline earth aluminosilicate incorporated into the polymer may be in the range of about 0.005 wt.% to about 2.0 wt.% of the polymer, preferably in the range of about 0.010 wt.% to about 1.0 wt.% of the polymer, and more preferably in the range of about 0.015 wt.% to about 0.8 wt.% of the polymer.

In another embodiment, the amount of amorphous alkali/alkaline earth aluminosilicate incorporated into the polymer may be an amount sufficient to reduce the corrosivity index of the polymer to less than 6, preferably less than 3, and more preferably less than 1.

In addition to the amorphous alumino-silicate antacid, the polymer compositions of the present invention may include additional components, including other polymer components, as well as ingredients or additives conventionally used in the art for a variety of purposes in polymer compositions, such as dyes, pigments, fillers, antioxidants, secondary antioxidants, antistatic agents, slip agents (e.g., erucamide), mold release agents, nucleating agents (polymeric and non-polymeric), UV stabilizers, antiblocking agents, and flameproofing agents, and the like. Typically these additional components will be used in conventional amounts, depending on the intended use of the polymer composition.

The particular manner in which the amorphous aluminum silicate and optional additional components are incorporated into the polymer is not limited herein. Any conventional method of mixing the polymer with amorphous aluminum silicate may be used herein. In one embodiment, the polymer is mixed with a neutralizing amount of amorphous aluminum silicate by an extruder or mixing device operating under high shear to form a homogeneous or heterogeneous mixture of polymer and amorphous aluminum silicate. In one embodiment, the polymer is mixed with amorphous aluminum silicate in the molten state. In another embodiment, the mixture of polymer and amorphous aluminum silicate is heated to melt the polymer. The molten mixture is then mixed as described herein above to form a homogeneous or heterogeneous mixture. In yet another embodiment, the polymer and amorphous aluminum silicate may be dissolved in a suitable solvent to form a solution or dispersion, which may then be cast and dried to form the polymer composition.

The polymer compositions of the present invention have enhanced corrosion, color stability and clarity properties. Unexpectedly, the polymer composition exhibits increased corrosivity as evidenced by a corrosion index of less than 6, preferably less than 3, and more preferably less than 1. The polymer composition also exhibits increased clarity. Typically, the clarity of the polymer composition is at least about 60%, preferably at least about 65%, as measured on an Injection Molded (IM) plate having a thickness of about 1 mm. Details of measuring the clarity of the polymer composition are further described in the examples below.

The polymer compositions of the present invention can be processed to provide a variety of products conventionally made with polymers. Such products may include, for example, articles such as films, fibers, molded articles, extruded profiles, sheets, plates, adhesives, foams, wire coatings, or other manufactured parts. Articles prepared from the polymer composition can be prepared according to conventional methods such as extrusion, blow molding, cast film processing, or injection molding. In one embodiment, the article is a film or a fiber.

Articles prepared using the polymer/antacid compositions according to the present invention have reduced acidic residues that may be harmful to processing equipment. Furthermore, articles that require clear or transparent polymer compositions exhibit improved clarity.

The description of various embodiments of the present invention has been presented for purposes of illustration but is not intended to be exhaustive or limited to the disclosed embodiments. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terms used herein were chosen to best explain the principles of the embodiments, to improve upon the practical applications or techniques available on the market, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.

Hereinafter, the present invention will be described in more detail with reference to examples. However, the scope of the present invention is not limited to the following examples.