Abstract: Disclosed are polyester blends that provide improved stress whitening behavior. The blends may be prepared from a polyester having crystallization half-time of at least 5 minutes and a polyester elastomer. The polyesters blends may be extruded or, in the presence of a release additive, calendered to produce film or sheet. Also disclosed are processes for making a film or sheet by extrusion or calendering the above blends and the film or sheet produced therefrom. The polyester blend and the film or sheet produced therefrom also may include plasticizers and/or flame retardants to increase their flexibility and enable their use in commercial applications requiring flame resistance. The film and sheet have excellent appearance and can be used in a wide range of decorative and packaging applications.

Abstract: Disclosed are high clarity films produced from semicrystalline polyesters by calendering. These films unexpectedly develop a higher peak melting point, which leads to higher thermal resistance. The semicrystalline polyesters may be biodegradable. When these calendered films are oriented, they develop unexpectedly high physical strength or clarity in comparison to films that are prepared by conventional techniques.

Abstract: Flame retardant polyester compositions suitable for calendering may be prepared from polyesters having crystallization half time of at least 5 minutes, a plasticizer, a phosphorus-containing flame retardant miscible with the plasticized polyester, and an additive effective to prevent sticking of the polyester to the calendar rolls. Also disclosed are processes for flame retardant films or sheets by calendering the above compositions and the flame retardant films or sheets produced therefrom. These films and sheets have excellent appearance, flexibility, and flame retardancy, and can be used in a wide range of decorative and packaging applications.

Abstract: Polyester compositions that provide a higher throughput in calendering processes may be prepared from a polyester having crystallization half time of at least 5 minutes, an inherent viscosity of about 0.55 to about 0.75 dL/g, a branching monomer, and a release additive. The polyester compositions show a combination of excellent melt strength with good shear response that permits higher calendering line speeds before melt fracture occurs. Also disclosed are processes for film or sheet by calendering the above compositions and the film or sheet produced therefrom. The polyester compositions, film, or sheet also may include plasticizers and/or flame retardants to increase their flexibility and enable their use in commercial applications requiring flame resistance. The film and sheet have excellent appearance and can be used in a wide range of decorative and packaging applications.

Abstract: A film or sheet having a glass transition temperature below about 23° C. and a melting temperature greater than about 120° C. is prepared by first preparing a polyester composition of about 50 to about 95 weight percent of a base copolyester having a melting temperature of less than about 220° C. and exhibiting more than about 1 percent crystallinity after annealing for 2000 minutes at a temperature of which the base copolyester has a maximum crystallization rate; and about 5 to about 50 weight percent of a plasticizer suitable for use with the base copolyester. The polyester composition is formed into a film or sheet. During formation of the film or sheet or afterwards, crystallization is induced to provide a soft and flexible film or sheet.

Abstract: Flame retardant polyester compositions suitable for calendering may be prepared from polyesters having crystallization half time of at least 5 minutes, a plasticizer, a phosphorus-containing flame retardant miscible with the plasticized polyester, and an additive effective to prevent sticking of the polyester to the calendar rolls. Also disclosed are processes for flame retardant films or sheets by calendering the above compositions and the flame retardant films or sheets produced therefrom. These films and sheets have excellent appearance, flexibility, and flame retardancy, and can be used in a wide range of decorative and packaging applications.

Abstract: This invention is directed to a process for preparing an exfoliated, high I.V. polymer-platelet particle nanocomposite comprising the steps of: (i) melt mixing platelet particles with a matrix polymer-compatible oligomeric resin to form an oligomeric resin-platelet particle composite, and (ii) mixing the oligomeric resin-platelet particle composite with a high molecular weight matrix polymer, thereby increasing the molecular weight of the oligomeric resin-platelet particle composite and producing an exfoliated, high I.V. polymer nanocomposite material. The invention also is directed to a nanocomposite material produced by the process, products produced from the nanocomposite material, and a nanocomposite prepared from an oligomeric resin-platelet particle precursor composite.

Abstract: The present invention relates to processes for preparing a nanocomposite comprising: a. preparing an organoclay material by reacting a swellable layered clay with an onium ion represented by Formula (I): wherein i) M is nitrogen or phosphorus, ii) R1 is a straight or branched alkyl group having at least 8 carbon atoms, iii) R2, R3, and R4 are independently selected from organic or oligomeric ligands or hydrogen, and iv) at least one of R2, R3, and R4 comprises an alkylene oxide group having from 2 to 6 carbon atoms or a polyalkylene oxide group, and b. melt mixing the organoclay material with an expanding agent, and c. melt extruding the expanded organoclay and a polymer to provide a nanocomposite.

Abstract: This invention describes the use of organoclays as additives to plasticizers to provide a plasticizer composition, to allow the mixing of the plasticizers with thermoplastic resins in the same process used to convert the resin formulation to finished product. The use of this invention eliminates the need for a preliminary compounding step to incorporate plasticizers into thermoplastics prior to extrusion or molding.

Abstract: A film or sheet having a glass transition temperature below about 23° C. and a melting temperature greater than about 120° C. is prepared by first preparing a polyester composition of about 50 to about 95 weight percent of a base copolyester having a melting temperature of less than about 220° C. and exhibiting more than about 1 percent crystallinity after annealing for 2000 minutes at a temperature of which the base copolyester has a maximum crystallization rate; and about 5 to about 50 weight percent of a plasticizer suitable for use with the base copolyester. The polyester composition is formed into a film or sheet. During formation of the film or sheet or afterwards, crystallization is induced to provide a soft and flexible film or sheet.

Abstract: This invention is directed to a process for preparing an exfoliated, high I.V. polymer-platelet particle nanocomposite comprising the steps of: A process for preparing an exfoliated, high I.V. polymer-platelet particle nanocomposite comprising the steps of: (i) melt mixing platelet particles with an oligomeric polyamide resin to form an oligomeric resin-platelet particle composite, and (ii) mixing the oligomeric resin-platelet particle composite with a high molecular weight matrix polyamide having diamine and diacid repeat units, thereby increasing the molecular weight of the oligomeric resin-platelet particle composite and producing an exfoliated, high I.V. polymer nanocomposite material. The invention also is directed to a nanocomposite material produced by the process, products produced from the nanocomposite material, and a nanocomposite prepared from an oligomeric resin-platelet particle precursor composite.

Abstract: The present invention relates to a composition comprising (i) a layered clay material that has been cation-exchanged with an organic cation salt represented by Formula (I): wherein M is nitrogen or phosphorous, X− is a halide, hydroxide, or acetate anion, R1 is a straight or branched alkyl group having at least 8 carbon atoms, and R2, R3, and R4 are independently hydrogen or a straight or branched alkyl group having 1 to 22 carbon atoms; and (ii) at least one expanding agent, wherein the cation-exchanged clay material contains platelet particles and the expanding agent separates the platelet particles. The present invention also relates to a composite comprising a polymer having dispersed therein a composition of this invention. Preferred polymers for use in the composite include polyesters. The composite of the present invention shows vastly improved platelet separation as evidenced by higher than previously reported basal spacing.

Abstract: The present invention relates to processes for preparing a nanocomposite comprising:

Abstract: This invention is directed to a process for preparing an exfoliated, high I.V. polymer-platelet particle nanocomposite comprising the steps of: (i) melt mixing platelet particles with a matrix polymer-compatible oligomeric resin to form an oligomeric resin-platelet with a high molecular weight matric polymer, thereby increasing the molecular weight of the oligomeric resin-platelet particle composite and producting an exfoliated, high I.V. polymer nanocomposite material. The invention also is directed to a nanocomposite material producted by the process, producted produced from the nanocomposite material, and a nanocomposite prepared from an oligomeric resin-platelet particle precursor composite.

Abstract: This invention relates to novel multilayer formed articles including, but not limited to containers such as bottles, tubes, pipes, preforms and films (including oriented films such as biaxially oriented) comprising a melt processible resin having dispersed therein a platelet filler. The multilayer formed articles have improved barrier while maintaining excellent clarity. More particularly, the multilayer structures of the present invention display haze values of less than about 2% and carrier resins which are substantially free from platelet particles having a diameter greater than about 15 microns.

Abstract: The present invention relates to a polyester-platelet particle composite comprising at least one polyester having dispersed therein a platelet particle dispersion comprising chalcogen or platelet particles and at least one water dissipatible polymer.

Abstract: This invention relates to novel multilayer formed articles including, but not limited to containers such as bottles, tubes, pipes, preforms and films (including oriented films such as biaxially oriented) comprising a melt processible resin having dispersed therein a platelet filler. The multilayer formed articles have improved barrier while maintaining excellent clarity. More particularly, the multilayer structures of the present invention display haze values of less than about 2% and carrier resins which are substantially free from platelet particles having a diameter greater than about 15 microns.

Abstract: The present invention relates to polyester-platelet particle composite comprising; at least one polyester having dispersed therein a platelet particle dispersion comprising about 0.01 to about 25 weight percent platelet particles and at least one water dissipatible polymer in a concentration which is at least about 1 part water dissipatible polymer to 1 part said polyester wherein said platelet particles primarily comprise individual platelet particles and tactoids. The composites of the present invention are prepared by dispersing at least one clay material in a water dissipatible polymer to form a platelet particle dispersion; introducing said platelet particle dispersion to a polyester and extrusion mixing said dispersion and polyester.

Abstract: The present invention relates to a composition comprising a polymer having dispersed therein at least one layered clay material which has been cation exchanged with an organic cation salts represented by Formula I: ##STR1## wherein M represents either nitrogen or phosphorous; X.sup.- represents an anion selected from the group consisting of halogen, hydroxide, or acetate anions, preferably chloride and bromide; R.sub.1 is selected from the group consisting of straight and branched alkyl groups having at least 8 carbon atoms; R.sub.2, R.sub.3, and R.sub.4 are independently selected from straight or branched alkyl groups having 1 to four carbon atoms; and at least one expanding agent which is compatible with said polymer. Preferred polymers include polyesters. The compositions of the present invention show vastly improved platelet separation as evidenced by higher than previously reported basal spacing.