THERMOPLASTICS

The present invention relates to inorganic pigments treated/coated with at least one non-reactive polysiloxane, methods for producing these coated inorganic pigments, thermoplastics comprising these coated inorganic pigments and methods for the production of these thermoplastics.

Plastics can be divided into the main groups of thermoplastics and thermosets. Polymers that have a flow transition range above the working temperature are known as thermoplastics. Thermoplastics are linear or branched polymers which in principle are flowable above the glass transition temperature (Tg) in the case of amorphous thermoplastics and above the melting point (Tm) in the case of (partly) crystalline thermoplastics. The chain movability is so large that the polymer molecules slide easily over one another and the material reaches the molten state (flow range, polymer melt).

The properties of plastics can be controlled by the use of additives. One group of additives encompasses pigments, e.g. inorganic pigments that are responsible for the coloring. For improved compatibility, inorganic pigments are usually surface- modified. Hence, they are coated to improve the stability of plastic articles or compounds with regard to polymer degradation. The polymer degradation can be e.g. recognized as yellow color of the plastic articles or compounds after applying thermal stress during the extrusion/molding process or thermal stress during the lifetime of the plastic article.

Inorganic pigments can be surface-modified by inorganic coatings. Silicon dioxide and aluminium oxide are commonly used as an inorganic coating of a titanium dioxide pigment, for example. However, inorganic pigments with or without an inorganic coating can still adversely affect plastics, as these pigments often exhibit active sites on their surfaces. In the state of art, it is disclosed to use organic coatings, e.g. antioxidants or octyltriethoxysilanes for inorganic pigments to improve the stability of the plastic materials.

Inorganic pigments are furthermore hygroscopic and thus contain water strongly bound to the surface with its active sites. The high residual moisture content also negatively influences the plastic properties and is regarded to be at least partly responsible for discoloration of the plastic.

Disadvantages of the inorganic pigments having organic coatings according to the state of art are that the organic additives used for coating react with the water traces bound to the pigment surface under condensation of reaction products like hydrogen. Other additives lead e.g. to the formation of alcohol after subsequent thermal treatment. A further disadvantage is that the organic substances used for coating regularly do not meet requirements for materials intended to be in contact with food.

It is an object of the present invention therefore to provide an inorganic pigment that improves the stability of plastic articles or compounds with regard to polymer degradation, that avoids or reduces the formation of reaction products like hydrogen or alcohols during production, storage or application and that allows storage stability also under humid conditions and thus does not have the disadvantages of the known inorganic pigments.

It has now been found that the above-mentioned disadvantages can be dealt with when inorganic pigments are used that are treated with at least one non-reactive polysiloxane of the general Formula I,

Formula I wherein R ¹ to R ⁸ may be the same or different and are selected from the group consisting of C _m H ₂ m+i , wherein m is <10, preferably <6, more preferably <4, and even more preferably m = 1 , 2 or 3, and fluorinated derivatives thereof wherein at least one hydrogen atom is replaced by fluorine, such as CH2CH2CF3, (EO)x, (PO)y and copolymers thereof, wherein EO represents an oxyethylene unit, PO represents an oxypropylene unit and x and y may be the same or different and x + y is in the range of 1 to 50, and

wherein the at least one non-reactive polysiloxane is having a viscosity in the range of 50-3000 mm ² x s ^"1 at 25°C, preferably 100-2000 mm ² x s ^"1 at 25°C, more preferably 150-1000 mm ² x s ^"1 at 25°C (determined according to DIN 51562), and wherein the inorganic pigment coated with at least one non-reactive polysiloxane of the general Formula I has a residual moisture content of less than 1 .0 wt-%, preferably less than 0.5 wt-%, more preferably less than 0.4 wt-%, determined by drying at 160°C to weight constancy.

The inorganic pigments according to the present invention provide a surface, on which the active sites are mostly covered by the at least one non-reactive polysiloxane accompanied by a low residual moisture content. Due to the treating or coating, the inorganic pigments show reduced hygroscopic properties, which seem to be responsible for an improved storage stability, and the treatment leads to an improved stability of plastic articles containing these coated pigments. The low residual moisture content and the coverage of the active sites seem to be responsible for reduced polymer degradation, which is measured as yellow color of the plastics due to thermal stress during the extrusion/molding process or during the lifetime of the plastic article containing the inorganic pigment. Other impacts on the properties of the plastics, which are impaired by polymer degradation like mechanical strength, will also be reduced.

The inorganic pigment can be coated either with one kind of non-reactive polysiloxanes or with a mixture of different kinds of non-reactive polysiloxanes of the general Formula I as shown above. Preferably, R ¹ to R ⁸ , in the at least one non-reactive polysiloxane of the general Formula I, may be the same or different and are selected from the group consisting of CmH _2m +i, wherein m is <6, more preferably <4, and even more preferably m = 1 or 2. Even more preferably, the at least one non-reactive polysiloxane is polydimethylsiloxane, most preferably a FDA-approved polydimethylsiloxane, e.g. M350, which is a polydimethylsiloxane having a viscosity of 350 mm ² x s ^"1 at 25°C. These polydimethylsiloxanes meet the regulations for materials intended to have contact with foods which are thus in line with EU No 10/201 1 .

The at least one polysiloxanes is preferably present in an amount of 0.1 and 10 wt- %, preferably between 1 and 8 wt-%, more preferably between 3 and 6 wt-% of the coated inorganic pigment, calculated on the total weight of the coated pigment according to carbon analysis after drying at 160°C to weight constancy. It has been found that the degradation properties of the coated inorganic pigment according to the present invention rapidly decreases with an increasing amount of the at least one non-reactive polysiloxane. However, amounts of the at least one non-reactive polysiloxane of more than 3 % per weight only slightly decreases the degradation properties further.

The inorganic pigment according to the present invention can be any inorganic pigment, however, the inorganic pigment is preferably selected from the group consisting of titanium dioxide, barium sulfate, zinc oxide and lithopone or mixtures thereof, more preferably the inorganic pigment is titanium dioxide, most preferably rutile.

The inorganic pigment according to the present invention can be organically or inorganically surface-modified with further compounds before treating with the at least one non-reactive polysiloxane of the general Formula I. According to the present invention, the inorganic pigment can also be pretreated with a reactive siloxane like MH-15 having reactive Si-H moieties or other reactive polysiloxanes having Si-OR moieties in order to additionally silanize the surface of the pigment particles. In one exemplary embodiment, the inorganic pigment is a titanium dioxide pigment being treated with hydrated inorganic precursors of silicon dioxide and/or aluminium oxide and then treated with at least one non-reactive polysiloxane of the general Formula I.

In one embodiment, the coated pigment comprises reactive groups selected from -Si-H, or -Si-OR in an amount of less than 0.1 wt.-%, preferably less than 0.01 wt.-% calculated on the total weight of the coated pigment and the added amount of organic additive after drying at 160°C to weight constancy. Thus, almost no reaction products like hydrogen or alcohols during production, storage or application are formed.

Accordingly, the present invention also provides a method for producing a coated inorganic pigment according to the present invention comprising the step of treating an inorganic pigment with at least one non-reactive polysiloxane of the general Formula I or mixtures thereof,

Formula I wherein R ¹ to R ⁸ may be the same or different and are selected from the group consisting of

C _m H ₂ m+i , wherein m is <10, preferably <6, more preferably <4, and even more preferably m = 1 , 2 or 3, and fluorinated derivatives thereof wherein at least one hydrogen atom is replaced by fluorine, such as CH ₂ CH ₂ CF ₃ ,

(EO)x, (PO)y and copolymers thereof, wherein EO represents an oxyethylene unit, PO represents an oxypropylene unit and x and y may be the same or different and x + y is in the range of 1 to 50, and wherein the at least one non-reactive polysiloxane is having a viscosity in the range of 50-3000 mm ² x s ^"1 at 25°C, preferably 100-2000 mm ² x s ^"1 at 25°C, more preferably 150-1000 mm ² x s ^"1 at 25°C (in line with DIN 51562). The treating step is preferably carried out at a temperature in the range of 100°C to 450°C, more preferably at a temperature in the range of 250°C to 400 °C. Due to the elevated temperature, the water is driven out of the inorganic pigment and the surface of the inorganic pigment with its active sites is covered by the at least one non-reactive polysiloxane.

The treating step can also be carried out as a two-step or multi-step process in which the at least one non-reactive polysiloxane of the general Formula I is added to the pigment in several steps which stages might be interrupted each by a milling or kneading step.

By the method according to the invention, it is possible to produce coated inorganic pigments preferably selected from the group consisting of titanium dioxide, barium sulfate, zinc oxide and lithopone, preferably titanium dioxide, more preferably rutile, or mixtures thereof.

In one embodiment, the inorganic pigment is used in a pre-dried form having a residual moisture content of less than 1 wt-%, preferably less than 0.5 wt-%, more preferably less than 0.4 wt-%, determined by drying at 160°C to weight constancy. In case of a pre-dried inorganic pigment, an elevated temperature during the treating of the inorganic pigment with at least one non-reactive polysiloxane of the general Formula I is not mandatory. Thus, according to the present invention, it is possible to treat the inorganic pigment thermally until a residual moisture content of less than 1 .0 wt-%, preferably less than 0.5 wt-%, more preferably less than 0.4 wt-%, determined by drying at 160°C to weight constancy, is achieved, followed by treating the obtained inorganic pigment with the at least one non-reactive polysiloxane of the general Formula I. However, due to the hygroscopic properties of the inorganic pigment itself, it has to be ensured that, in the period between the thermal treatment and the treating of the inorganic pigment with at least one non- reactive polysiloxane of the general Formula I, the moisture content does not increase over the limit as required.

Consequently, in case the step of treating an inorganic pigment with at least one non-reactive polysiloxane of the general Formula I is carried out at elevated temperatures, it is possible to use an inorganic pigment as starting material that has a higher moisture content. The elevated temperatures leads to evaporation of the water, which is directly replaced by the at least on non-reactive polysiloxane. According to the invention, the step of treating the inorganic pigment with said at least one non-reactive polysiloxane of the general Formula I is carried out for less than 12 h, preferably less than 6 h, more preferably less than 4h, most preferably between 0.25 to 2 h. The thermal treatment can also be applied by microwave heating. By using microwaves, the drying-time can significantly be reduced to a few minutes, but may lead to a deterioration of the color value b. Therefore, applying microwave heating should be carried out under conditions with controlled energy impact. In a further embodiment, the treating comprises milling and/or kneading. In one embodiment, only a partial amount of the at least one non-reactive polysiloxane is added to the inorganic pigment before the milling step and/or kneading step, wherein the remaining amount of the at least one non-reactive polysiloxane is added during the further process. Such a partitioning of the at least one non- reactive polysiloxane is particularly preferred if a steam jet mill is used for milling and leads to increased yields of the coated inorganic pigment.

In a further embodiment of the invention, the inorganic pigment is crushed down to a size of less than 1 mm, preferably to a size of less than 0,8 mm, more preferably to less than 0,6 mm, before being treated with the at least one non-reactive polysiloxane. In a preferred embodiment, the at least one non-reactive polysiloxane is used in an amount that a coated inorganic pigment comprising between 0.1 and 10 wt-%, preferably between 1 and 8 %, more preferably between 3 and 6 % of the at least one polysiloxane, referred to the total weight of the treated pigment after drying at 160°C to weight constancy and calculated in accordance with a carbon analysis, is obtained.

Preferably, the method of the present invention comprises the step of adding at least one additive having reactive groups selected from silane-(Si-H) or C1 -C12- alkoxy-siloxanes. Such coated inorganic pigments provide an further improved thermal stability. The silane-(Si-H) can be added before, together or after the addition of the non-reactive polysiloxane.

The present invention further provides a thermoplastic comprising the inorganic pigment of the present invention.

Thermoplastics which can be used in the process of the invention include thermoplastically workable plastics having pronounced entropy-elastic properties. Thermoplastics also include all plastics consisting of linear or thermolabile cross- linked polymer molecules, for example polyolefins, vinyl polymers, polyesters, polyacetals, polycarbonates, also polyurethanes, ionomers, and thermoplastic elastomers such as acrylnitrile-butadiene-styrene (ABS), polyamide (PA), polylactate (PLA), polymethylmethacrylate (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polyethylene (PE), polypropylene (PP), polystyrene (PS), polyether etherketone (PEEK), polyvinylchloride (PVC), PBT polybutylene terephthalate as well as baking enamels for powder coating.

Preferably, the thermoplastic comprises polycarbonate. The present invention further provides a method for the production of a thermoplastic comprising adding a pigment according to the present invention to a thermoplastic polymer, mixing the polymer mixture and subjecting the obtained polymer mixture to a plastics forming process, preferably an injection molding process, a compression molding process, a pressing process or an extrusion process.

Preferably, the polymer mixture is dried at a temperature in the range of 80°C to 200°C for 1 -10 h before the plastics forming process.

In a preferred embodiment, the plastic production process is carried out at a temperature in the range of 200°C to 450°C, preferably in the range of 280°C to 370°C.

The attached Figures 1 to 4 illustrate the Lightness L ^* and Color b ^* values obtained for the samples as prepared in Examples 1 to 4, respectively.

Experimental Part

Measuring methods

The methods for determining properties of the coated pigments are as follows.

A mixture of 5% of the coated pigment in Makrolon 3108 powder is dried for 5 hours at 120°C. The dried mixture is processed on an Arburg 221 injection moulder at 300°C and 350°C, respectively giving white polycarbonate plates. The optical properties Lightness L ^* and color b ^* (according to the CIELab color system) of the moulded plates are determined with a Hunterlab UltraScan VIS spectrophotometer applying a light source D 65 using a 10° observer with gloss included.

The content of the organic coating on a pigment is determined by carbon analysis of the pigment using an ELTRA CS2000 analyzer and calculation of the total organic coating out of it according to the share of carbon in the organic applied. For this purpose, the probe is combusted at 1 100°C in an oxygen stream and the formed CO ₂ is passed through in an infrared cell for detection.

The water content of the particles, especially after drying, can be calculated making use of the Karl-Fischer titration method. The content of reactive groups such as -Si-H moieties is measured by alkaline hydrolysis and volumetric determination of the formed hydrogen gas. The particle size of the particles is determined by sieving analysis.

All weight percentages refer to the total weight of the treated pigment after drying to weight constancy at 160°C. Such drying can be carried under air or protective atmosphere.

The invention is further illustrated by the following Examples 1 to 4 which are further illustrated in the attached Figures 1 to 4 referring to the respective Example of the same number. Example 1

A)

Micronized rutile titanium dioxide pigment treated with alumina (RKB3) was dried at 130°C. The dry residue was crushed to particles having a diameter below 1 mm. These particles were sprayed with 0.5 wt-% M350 (20 g M350/4 kg dry residue) and heated for 1 h at 350°C in a rotary kiln. Subsequently, the particles were treated in a steam jet mill (steam/product relation 3.0, 20 kg/h entry-, 40 kg/h mill- steam), whereby just a low dust formation was observed. The milled product (5.14 kg) was homogenized in a Lodige mixer, whereby further 200 g M350 (3.9%) was added. Approximately 5.3 kg of an inorganic pigment coated with a non- reactive polysiloxane and a residual moisture content of 0.6 % according to the present invention was obtained.

B)

Micronized rutile titanium dioxide pigment treated with alumina (RKB3) was dried at 130°C. The dry residue was crushed to particles having a diameter below 1 mm. These particles were sprayed with 0.5 wt-% M350 (20 g M350/4 kg dry residue). The particles were treated in a steam jet mill (steam/product relation 3.0, 20kg/h entry-, 40 kg/h mill-steam). The milled product (5.51 kg) was homogenized in a Lodigemischer, whereby further 200 g M350 (3.6%) was added. The product was heated for 1 h at 350°C in a rotary kiln. Approximately 5.51 kg of an inorganic pigment coated with a non-reactive polysiloxane and a residual moisture content of 0.3 % according to the present invention was obtained as granulate having an particle diameter of approximately 1 -2 mm.

C)

Micronized rutile titanium dioxide pigment treated with alumina (RKB3) was dried at 130°C. The dry residue was crushed to particles having a diameter below 1 mm. These particles were sprayed with 3 wt-% M350 (120 g M350/4 kg dry residue) and heated for 1 h at 350°C in a rotary kiln. The product (8.02 kg) was milled in a steam jet mill (steam/product relation 3.0, 20 kg/h entry-, 40 kg/h mill-steam) Approximately 6.03 kg of an inorganic pigment coated with a non-reactive polysiloxane and a residual moisture content of 0.4 % according to the present invention was obtained.

The following processes include mixing of polycarbonate powder Macrolon 3108 (PC) and the obtained pigment powder (5 %) of Examples 1 . A), B) and C), respectively, drying of the mixture at 120°C for 5h and subsequently subjecting the mixture an injection moulding process at 300 and 350°C. Optical properties of polycarbonate (PC) plates containing the pigments according to examples A)-C) were analyzed and shown in Figure 1 .

Example 2

Optical properties of polycarbonate (PC) plates containing pigments RFK3 with organic treatment M350 (Example 2 A) and octyltriethoxysilane (Example 2 B), respectively, and subsequent thermal treatment at 350°C (0.5h) before injection moulding were analyzed. The following processes include the mixing of polycarbonate powder Macrolon 3108 (PC) and the pigment powder (5% referred to the weight of the ) containing M350 and octyltriethoxysilane, respectively, drying of the mixture at 120°C for 5h and subsequently subjecting the mixture an injection moulding process at 300 and 350°C. The resulting plates were analyzed regarding optical properties Lightness L ^* and colour b ^* . M350, compared to octyltriethoxysilane, leads to higher L ^* and lower b ^* values at test temperatures 300 and 350°C as and shown in Figure 2. Example 3

Optical properties of PC plates containing pigments RKB3 with increasing amount of organic treatment M350 with 0,0, 2,0, 3,0 and 4% (Examples 3 A) - 3 D), respectively, and subsequent thermal treatment at 350°C followed by an injection moulding process were analyzed.

The injection moulding process includes mixing polycarbonate powder Macrolon 3108 (PC) and the pigment powder (5%), drying of the mixture at 120°C for 5h and subsequently subjecting the mixture an injection moulding process at 300 and 350°C, respectively. The resulting plates were analyzed regarding optical properties Lightness L ^* and colour b ^* and shown in Figure 3. An increasing amount of organic treatment increases L ^* and decreases colour b ^* at test temperatures 300 and 350°C, respectively.

Example 4

Optical properties of PC plates containing pigments RKB3 with organic treatment M350 (3%, Example 4 A)) and subsequent thermal treatment at 350°C and microwave (1 min. 800W/50g, Example 4 B)), respectively, followed by an injection moulding process were analyzed. The injection moulding process includes mixing of polycarbonate powder Macrolon 3108 (PC) and the pigment powder (5%), drying of the mixture at 120°C for 5h and subsequently subjecting the mixture an injection moulding process at 300 and 350°C, respectively. The resulting plates were analyzed regarding optical properties Lightness L ^* and colour b ^* and shown in Figure 4. Microwave heating leads to higher L ^* and higher b ^* at test temperatures 300 and 350°C, compared to thermal treatment at 350°C.