METHODS FOR BRANCHING PHA USING THERMOLYSIS

- Metabolix, Inc.

Branched PHA compositions, and related methods and articles are disclosed.

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Description
RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Nos. 61/133,026, filed on Jun. 25, 2008; 61/207,493, filed Feb. 12, 2009; 61/133,023, filed on Jun. 25, 2008; 61/199,817, filed on Nov. 20, 2008; 61/200,619 filed Dec. 2, 2008; 61/203,542 filed Dec. 23, 2008 and 61/166,950 filed Apr. 6, 2009. The entire teachings of the above applications are incorporated herein by reference.

TECHNICAL FIELD

This invention relates to methods of making branched polyhydroxyalkanoate (PHA) compositions. The methods described herein produce more efficient branching, use less branching agent, and result in lower amounts of odiferous decomposition residues in the finished branched PHA polymer. The compositions of branched PHA are useful in applications such as thermoforming, particularly in thermoformed disposable products such as utensils, tubs, bowls, lids, cup lids, yogurt cups, containers, bottles and bottle-like containers, and other container-type items, foams, films, blown films, coatings and the like.

BACKGROUND

Biodegradable plastics are of increasing industrial interest as replacements or supplements for non-biodegradable plastics in a wide range of applications and in particular for packaging applications. One class of biodegradable polymers is the polyhydroxyalkanoates (PHAs), which are linear, aliphatic polyesters that can be produced by numerous microorganisms for use as intracellular storage material. Articles made from the polymers are generally recognized by soil microbes as a food source. There has therefore been a great deal of interest in the commercial development of these polymers, particularly for disposable consumer items. The polymers exhibit good biodegradability and useful physical properties.

Molecular weight, molecular weight distribution, short and long chain branching are the dominating factors influencing processing and key physical properties of any polymeric composition. With molecular weights below certain threshold values it also becomes impossible to provide good melt strength and to achieve required physical properties, e.g., tensile strength or impact resistance.

PHA polymers have quite limited thermal stability, and undergo chain scission by beta-elimination mechanisms at general processing temperatures and conditions. This can reduce the molecular weight quite significantly, and can result in resins with lower than required molecular weights leaving manufacturing or the compounding floor. Commercial utility of PHAs also can be limited in some applications, such as films, coatings and thermoforming, because of the low melt strength or melt elasticity often found in linear polymers. Thus, a need exists to address these shortcomings.

SUMMARY

Disclosed herein are methods of branching polyhydroxyalkanoate (PHA) polymers, by first thermolysing the PHA, and then reacting the thermolysed PHA with a branching agent, such as a peroxide. As used herein, “branched PHA” refers to PHA polymer molecule containing long chain polymers comprising additional polymer chains pendant to or connected to the long chain. Branching on branching via further side chain polymers is also contemplated. This invention also relates to articles, in particular, thermoformed articles made from the branched polymer compositions produced by the methods of the invention.

In one aspect, this invention features a method that includes thermolysing a starting PHA to reduce the molecular weight in a range of 25% to 75% from its starting molecular weight and then reacting the thermolysed PHA with a branching agent (e.g., a free radical initiator, such as peroxide) at a temperature and time sufficient to induce branching. In certain embodiments, the branching agent has a half-life of one third of the reaction time. In particular embodiments, the starting or initial PHA is linear. In still other embodiments, the initial or starting PHA is branched.

The branching methods described herein are useful for providing PHAs with desirable mechanical properties such as melt strength The methods described herein produce compositions containing branched PHA with an increased melt strength compared to the starting PHA. Increasing the melt strength of PHAs is achieved by free-radical-induced cross-linking or branching of the polymer. In one embodiment, the melt strength of the branched PHA greater that 2-20 times the melt strength of the starting polymer when measured at 160° C. and 0.25 rad/sec by torsional melt rheometry.

The resultant branched PHA compositions produced by the methods described herein are processed alone or in combination with PHAs or other materials by a range of polymer processing techniques including injection molding, cast film, cast sheet, thermoforming, blown film, blow molding, foam, fiber spinning or extrusion coating, onto a substrate to form articles. In the case of extrusion coating, preferred substrates are paper or paper board. The branched PHA can also be produced as a pellet for further processing.

The article can be, for example, a film, e.g., a blown film, a blow molded article, a thermoformed article, a profile extruded article, a fiber or a non-woven, a foam product, a coated paper product or a coated paperboard product. The product can be a polymer sheet suitable for use in thermoforming articles. The thermoformed product can be for example, a yogurt cup, a bowl, a lid, a cup lid and the like. In certain preferred embodiments, a thermoformed article is produced using the branched PHA made by the methods described herein.

In any of the methods, articles, or branched PHAs disclosed herein, the branched PHAs can include one or more of the following features.

The branched PHA can have a melt strength of, for example, 2-10 times greater that the starting PHA, such as at 3-15 times greater, or 5-10 times greater.

The branched PHA can have a polydispersity (PD) index greater than the starting PHA.

The branched PHA is characterized by an weight average molecular weight that is at least 1.2 times greater than the weight average molecular weight of the original PHA (herein designated as Mw/Mw,o). More preferably, Mw/Mw,o is at least 1.5 and most preferably at least 2.0. The practical upper limit of Mw/Mw,o is at the limit of polymer gel formation, which can act as imperfections in the PHA formulation. The upper limit of Mw/Mw,o depends on the starting Mw,o in that high molecular weight chains have a greater propensity to form gels. Thus, as the Mw,o increases, the upper limit of Mw/Mw,o will be less. In most cases, the upper limit of Mw/Mw,o is 4.0, more preferably 3.5 and most preferably 3.0.

The synthesis of the branched PHA composition can use a range of 0.001% to 0.5%, for example, 0.2 wt % of a free-radical initiator, or 0.05 wt % free radical initiator of the polymer composition. Alternatively, a range of 0.001% to 0.1% weight is useful.

After synthesis of the branched PHA, the branching agent is essentially all decomposed resulting in a branched PHA containing little or no residual branching agent. The branching agent can be an organic peroxide. Examples of a suitable peroxide include but are not limited to dicumyl peroxide, t-amyl-2-ethylhexyl peroxycarbonate, 1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane, 2,5-bis(t-butylperoxy)-2,5-dimethylhexane, 2,5-dimethyl-di(t-butylperoxy)hexyne-3, di-t-butyl peroxide, benzoyl peroxide, di-t-amyl peroxide, t-butyl cumyl peroxide, n-butyl-4,4-bis(t-butylperoxy)valerate, 1,1-di(t-butylperoxy)-3,3,5-trimethyl-cyclohexane, 1,1-di(t-butylperoxy)cyclohexane, 1,1-di(t-amylperoxy)-cyclohexane, 2,2-di(t-butylperoxy)butane, ethyl-3,3-di(t-butylperoxy)butyrate, 2,2-di(t-amylperoxy)propane, ethyl-3,3-di(t-amylperoxy)butyrate, t-butylperoxy-acetate, t-amylperoxyacetate, t-butylperoxybenzoate, t-amylperoxybenzoate, and di-t-butyldiperoxyphthalate.

The reaction temperature of the thermolysing can be, for example, between 190° C. to 250° C. or for example, thermolysed at a temperature between 200° C. or to 220° C. before the branching reaction step.

The average residence time in the extruder for the reaction, is for example, at least 5 s, at least 30 s, at least 120 s, or at least 240 s.

The choice of a branching agent is based on the experimental conditions for polymer processing and the appropriate branching agent is chosen according to the half life of the branching agent under this processing temperature and conditions, the branching agent is chosen for a half life according to the processing conditions,

The details of one or more embodiments of the invention are set forth in the description below. Other features, objects, and advantages of the invention will be apparent from the description and from the claims.

DETAILED DESCRIPTION

The invention provides methods of making branched polymers by first thermolysing (heat treating) the starting PHA, and then subsequently reacting the starting PHA with a branching agent. As disclosed herein, it has been found that thermolysing a starting PHA polymer to break molecules produces a population of molecules with reactive groups on the ends. The thermolysing proceeds at a temperature until the molecular weight is reduced, e.g., the molecular weight is reduced to between 25% and 75% of the starting PHA, and in a certain embodiments between 40% and 60%, and in other embodiments, the reduction is half of the starting molecular weight. Subsequent reaction with a branching agent, e.g., a free radical initiator, such as a peroxide, creates radicals on the backbone of the linear polymer, which then react, either with each other, or under certain conditions, with the reactive groups on the ends of the thermolysed PHA. The result is a branched PHA, but with the advantage that lower amounts of peroxide can be used, while still obtaining the same level of branching before the peroxide is decomposed by the polymer processing temperatures.

Branched polyhydroxyalkanoates are desirable in that branching can be used to improve the melt strength of PHAs. Melt strength is a rheological property that can be measured a number of ways. One measure is G′, the polymer storage modulus is measured at melt processing temperatures.

Increased melt strength is useful in that it allows the polymers to be formed under a broader temperature range when processed. Broader temperature ranges are desirable for different polymer applications. This property is useful in the production of blown film (i.e., in preventing bubble collapse), thermoformed articles (i.e., preventing or reducing sheet sag during thermoforming), profile extruded articles (i.e., preventing or reducing sag), and foam (i.e., preventing or reducing cell collapse and collapse of the overall foam).

Physical properties and rheological properties of polymeric materials depend on the molecular weight distribution of the polymer. Producing PHA with desired rheological properties is achieved by the methods described herein. As used herein, “molecular weight” of the polymer can be calculated in a number of different ways. Unless otherwise indicated, “molecular weight,” as it is used herein, refers to weight average molecular weight.

“Number average molecular weight” (Ma) represents the arithmetic mean of the distribution, and is the sum of the products of the molecular weights of each fraction, multiplied by its mole fraction (ΣNi/ΣNi).

“Weight average molecular weight” (Mw) is the sum of the products of the molecular weight of each fraction, multiplied by its weight fraction (ΣNiMi2/ΣiMi). Mw is generally greater than or equal to Mn. One way of increasing the melt strength is by branching the PHA polymer as described by the methods herein. Branching of a starting PHA can be done by exposure of the polymer to heat (e.g., thermolysing) followed by reacting the thermolysed PHA with a branching agents, e.g., peroxides.

Polyhydroxyalkanoates (PHAs)

Polyhydroxyalkanoates are biological polyesters synthesized by a broad range of natural and genetically engineered bacteria as well as genetically engineered plant crops (Braunegg et al., (1998), J. Biotechnology 65: 127-161; Madison and Huisman, 1999, Microbiology and Molecular Biology Reviews, 63: 21-53; Poirier, 2002, Progress in Lipid Research 41: 131-155). These polymers are biodegradable thermoplastic materials, produced from renewable resources, with the potential for use in a broad range of industrial applications (Williams & Peoples, CHEMTECH 26:38-44 (1996)). Useful microbial strains for producing PHAs, include Alcaligenes eutrophus (renamed as Ralstonia eutropha), Alcaligenes latus, Azotobacter, Aeromonas, Comamonas, Pseudomonads, and genetically engineered organisms including genetically engineered microbes such as Pseudomonas, Ralstonia and Escherichia coli.

In general, a PHA is formed by enzymatic polymerization of one or more monomer units inside a living cell. Over 100 different types of monomers have been incorporated into the PHA polymers (Steinbuchel and Valentin, 1995, FEMS Microbiol. Lett. 128: 219-228. Examples of monomer units incorporated in PHAs include 2-hydroxybutyrate, lactic acid, glycolic acid, 3-hydroxybutyrate (hereinafter referred to as 3HB), 3-hydroxypropionate (hereinafter referred to as 3HP), 3-hydroxyvalerate (hereinafter referred to as 3HV), 3-hydroxyhexanoate (hereinafter referred to as 3HH), 3-hydroxyheptanoate (hereinafter referred to as 3HHep), 3-hydroxyoctanoate (hereinafter referred to as 3HO), 3-hydroxynonanoate (hereinafter referred to as 3HN), 3-hydroxydecanoate (hereinafter referred to as 3HD), 3-hydroxydodecanoate (hereinafter referred to as 3HDd), 4-hydroxybutyrate (hereinafter referred to as 4HB), 4-hydroxyvalerate (hereinafter referred to as 4HV), 5-hydroxyvalerate (hereinafter referred to as 5HV), and 6-hydroxyhexanoate (hereinafter referred to as 6HH). 3-hydroxyacid monomers incorporated into PHAs are the (D) or (R) 3-hydroxyacid isomer with the exception of 3HP which does not have a chiral center.

In some embodiments, the starting PHA for use in the methods described herein can be a homopolymer (where all monomer units are the same). Examples of PHA homopolymers include poly 3-hydroxyalkanoates (e.g., poly 3-hydroxypropionate (hereinafter referred to as P3HP), poly 3-hydroxybutyrate (hereinafter referred to as PHB) and poly 3-hydroxyvalerate), poly 4-hydroxyalkanoates (e.g., poly 4-hydroxybutyrate (hereinafter referred to as P4HB), or poly 4-hydroxyvalerate (hereinafter referred to as P4HV)) and poly 5-hydroxyalkanoates (e.g., poly 5-hydroxyvalerate (hereinafter referred to as P5HV)).

In certain embodiments, the starting PHA can be a copolymer (containing two or more different monomer units) in which the different monomers are randomly distributed in the polymer chain. Examples of PHA copolymers include poly 3-hydroxybutyrate-co-3-hydroxypropionate (hereinafter referred to as PHB3HP), poly 3-hydroxybutyrate-co-4-hydroxybutyrate (hereinafter referred to as PHB4HB), poly 3-hydroxybutyrate-co-4-hydroxyvalerate (hereinafter referred to as PHB4HV), poly 3-hydroxybutyrate-co-3-hydroxyvalerate (hereinafter referred to as PHB3HV), poly 3-hydroxybutyrate-co-3-hydroxyhexanoate (hereinafter referred to as PHB3HH) and poly 3-hydroxybutyrate-co-5-hydroxyvalerate (hereinafter referred to as PHB5HV).

By selecting the monomer types and controlling the ratios of the monomer units in a given PHA copolymer a wide range of material properties can be achieved. Although examples of PHA copolymers having two different monomer units have been provided, the PHA can have more than two different monomer units (e.g., three different monomer units, four different monomer units, five different monomer units, six different monomer units). An example of a PHA having 4 different monomer units would be PHB-co-3HH-co-3HO-co-3HD or PHB-co-3-HO-co-3HD-co-3HDd (these types of PHA copolymers are hereinafter referred to as PHB3HX). Typically where the PHB3HX has 3 or more monomer units the 3HB monomer is at least 70% by weight of the total monomers, preferably 85% by weight of the total monomers, most preferably greater than 90% by weight of the total monomers for example 92%, 93%, 94%, 95%, 96% by weight of the copolymer and the HX comprises one or more monomers selected from 3HH, 3HO, 3HD, 3HDd.

The homopolymer (where all monomer units are identical) PHB and 3-hydroxybutyrate copolymers (PHB3HP, PHB4HB, PHB3HV, PHB4HV, PHB5HV, PHB3HHP, hereinafter referred to as PHB copolymers) containing 3-hydroxybutyrate and at least one other monomer are of particular interest for commercial production and applications. It is useful to describe these copolymers by reference to their material properties as follows. Type 1 PHB copolymers typically have a glass transition temperature (Tg) in the range of 6° C. to −10° C., and a melting temperature TM of between 80° C. to 180° C. Type 2 PHB copolymers typically have a Tg of −20° C. to −50° C. and Tm of 55° C. to 90° C.

Preferred Type 1 PHB copolymers have two monomer units have a majority of their monomer units being 3-hydroxybutyrate monomer by weight in the copolymer, for example, greater than 78% 3-hydroxybutyrate monomer. Preferred PHB copolymers for this invention are biologically produced from renewable resources and are selected from the following group of PHB copolymers:

    • PHB3HV is a Type 1 PHB copolymer where the 3HV content is in the range of 3% to 22% by weight of the polymer and preferably in the range of 4% to 15% by weight of the copolymer for example: 4% 3HV; 5% 3HV; 6% 3HV; 7% 3HV; 8% 3HV; 9% 3HV; 10% 3HV; 11% 3HV; 12% 3HV; 13% 3HV; 14% 3HV; and 15% 3HV.
    • PHB3HP is a Type 1 PHB copolymer where the 3-HP content is in the range of 3% to 15% by weight of the copolymer and preferably in the range of 4% to 15% by weight of the copolymer for example: 4% 3HP; 5% 3HP; 6% 3HP; 7% 3HP; 8% 3HP; 9% 3HP; 10% 3HP; 11% 3HP; 12% 3HP; 13% 3HP; 14% 3HP and 15% 3HP.
    • PHB4HB is a Type 1 PHB copolymer where the 4HB content is in the range of 3% to 15% by weight of the copolymer and preferably in the range of 4% to 15% by weight of the copolymer for example: 4% 4HB; 5% 4HB; 6% 4HB; 7% 4HB; 8% 4HB; 9% 4HB; 10% 4HB; 11% 4HB; 12% 4HB; 13% 4HB; 14% 4HB; and 15% 4HB.
    • PHB4HV is a Type 1 PHB copolymer where the 4HV content is in the range of 3% to 15% by weight of the copolymer and preferably in the range of 4% to 15% by weight of the copolymer for example: 4% 4HV; 5% 4HV; 6% 4HV; 7% 4HV; 8% 4HV; 9% 4HV; 10% 4HV; 11% 4HV; 12% 4HV; 13% 4HV; 14% 4HV; 15% 4HV.
    • PHB5HV is a Type 1 PHB copolymer where the 5HV content is in the range of 3% to 15% by weight of the copolymer and preferably in the range of 4% to 15% by weight of the copolymer for example: 4% 5HV; 5% 5HV; 6% 5HV; 7% 5HV; 8% 5HV; 9% 5HV; 10% 5HV; 11% 5HV; 12% 5HV; 13% 5HV; 14% 5 HV; 15% 5HV.
    • PHB3HH is a Type 1 PHB copolymer where the 3HH content is in the range of 3% to 15% by weight of the copolymer and preferably in the range of 4% to 15% by weight of the copolymer for example: 4% 3HH; 5% 3HH; 6% 3HH; 7% 3HH; 8% 3HH; 9% 3HH; 10% 3HH; 11% 3HH; 12% 3HH; 13% 3HH; 14% 3HH; 15% 3HH;
    • PHB3HX is a Type 1 PHB copolymer where the 3HX content is comprised of 2 or more monomers selected from 3HH, 3HO, 3HD and 3HDd and the 3HX content is in the range of 3% to 12% by weight of the copolymer and preferably in the range of 4% to 10% by weight of the copolymer for example: 4% 3HX; 5% 3HX; 6% 3HX; 7% 3HX; 8% 3HX; 9% 3HX; 10% 3HX by weight of the copolymer.
    • Type 2 PHB copolymers have a 3HB content of between 80% and 5% by weight of the copolymer, for example 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%,10% by weight of the copolymer.
    • PHB4HB is a Type 2 PHB copolymer where the 4HB content is in the range of 20% to 60% by weight of the copolymer and preferably in the range of 25% to 50% by weight of the copolymer for example: 25% 4HB; 30% 4HB; 35% 4HB; 40% 4HB; 45% 4HB; 50% 4HB by weight of the copolymer.
    • PHB5HV is a Type 2 PHB copolymer where the 5HV content is in the range of 20% to 60% by weight of the copolymer and preferably in the range of 25% to 50% by weight of the copolymer for example: 25% 5HV; 30% 5HV; 35% 5HV; 40% 5HV; 45% 5HV; 50% 5HV by weight of the copolymer.
    • PHB3HH is a Type 2 PHB copolymer where the 3HH is in the range of 35% to 95% by weight of the copolymer and preferably in the range of 40% to 80% by weight of the copolymer for example: 40% 3HH; 45% 3HH; 50% 3HH; 55% 3HH 60% 3HH; 65% 3HH; 70% 3HH; 75% 3HH; 80% 3HH by weight of the copolymer.
    • PHB3HX is a Type 2 PHB copolymer where the 3HX content is comprised of 2 or more monomers selected from 3HH, 3HO, 3HD and 3HDd and the 3HX content is in the range of 30% to 95% by weight of the copolymer and preferably in the range of 35% to 90% by weight of the copolymer for example: 35% 3HX; 40% 3HX; 45% 3HX; 50% 3HX; 55% 3HX; 60% 3HX; 65% 3HX; 70% 3HX; 75% 3HX; 80% 3HX; 85% 3HX; 90% 3HX; by weight of the copolymer.

PHAs for use in the methods, compositions and pellets described in this invention are selected from : PHB or a Type 1 PHB copolymer; a PHA blend of PHB with a Type 1 PHB copolymer where the PHB content by weight of PHA in the PHA blend is in the range of 5% to 95% by weight of the PHA in the PHA blend; a PHA blend of PHB with a Type 2 PHB copolymer where the PHB content by weight of the PHA in the PHA blend is in the range of 5% to 95% by weight of the PHA in the PHA blend; a PHA blend of a Type 1 PHB copolymer with a different Type 1 PHB copolymer and where the content of the first Type 1 PHB copolymer is in the range of 5% to 95% by weight of the PHA in the PHA blend; a PHA blend of a Type 1 PHB copolymer with a Type 2 PHA copolymer where the content of the Type 1 PHB copolymer is in the range of 30% to 95% by weight of the PHA in the PHA blend; a PHA blend of PHB with a Type 1 PHB copolymer and a Type 2 PHB copolymer where the PHB content is in the range of 10% to 90% by weight of the PHA in the PHA blend, where the Type 1 PHB copolymer content is in the range of 5% to 90% by weight of the PHA in the PHA blend and where the Type 2 PHB copolymer content is in the range of 5% to 90% by weight of the PHA in the PHA blend.

The PHA blend of PHB with a Type 1 PHB copolymer can be a blend of PHB with PHBP3HP where the PHB content in the PHA blend is in the range of 5% to 90% by weight of the PHA in the PHA blend and the 3HP content in the PHBP3HP is in the range of 7% to 15% by weight of the PHBP3HP.

The PHA blend of PHB with a Type 1 PHB copolymer can be a blend of PHB with PHB3HV where the PHB content of the PHA blend is in the range of 5% to 90% by weight of the PHA in the PHA blend and the 3HV content in the PHB3HV is in the range of 4% to 22% by weight of the PHB3HV.

The PHA blend of PHB with a Type 1 PHB copolymer can be a blend of PHB with PHB4HB where the PHB content of the PHA blend is in the range of 5% to 90% by weight of the PHA in the PHA blend and the 4HB content in the PHB4HB is in the range of 4% to 15% by weight of the PHB4HB.

The PHA blend of PHB with a Type 1 PHB copolymer can be a blend of PHB with PHB4HV where the PHB content of the PHA blend is in the range of 5% to 90% by weight of the PHA in the PHA blend and the 4HV content in the PHB4HV is in the range of 4% to 15% by weight of the PHB4HV.

The PHA blend of PHB with a Type 1 PHB copolymer can be a blend of PHB with PHB5HV where the PHB content of the PHA blend is in the range of 5% to 90% by weight of the PHA in the PHA blend and the 5HV content in the PHB5HV is in the range of 4% to 15% by weight of the PHB5HV.

The PHA blend of PHB with a Type 1 PHB copolymer can be a blend of PHB with PHB3HH where the PHB content of the PHA blend is in the range of 5% to 90% by weight of the PHA in the PHA blend and the 3HH content in the PHB3HH is in the range of 4% to 15% by weight of the PHB3HH.

The PHA blend of PHB with a Type 1 PHB copolymer can be a blend of PHB with PHB3HX where the PHB content of the PHA blend is in the range of 5% to 90% by weight of the PHA in the PHA blend and the 3HX content in the PHB3HX is in the range of 4% to 15% by weight of the PHB3HX.

The PHA blend can be a blend of a Type 1 PHB copolymer selected from the group PHB3HV, PHB3HP, PHB4HB, PHBV, PHV4HV, PHB5HV, PHB3HH and PHB3HX with a second Type 1 PHB copolymer which is different from the first Type 1 PHB copolymer and is selected from the group PHB3HV, PHB3HP, PHB4HB, PHBV, PHV4HV, PHB5HV, PHB3HH and PHB3HX where the content of the First Type 1 PHB copolymer in the PHA blend is in the range of 10% to 90% by weight of the total PHA in the blend.

The PHA blend of PHB with a Type 2 PHB copolymer can be a blend of PHB with PHB4HB where the PHB content in the PHA blend is in the range of 30% to 95% by weight of the PHA in the PHA blend and the 4HB content in the PHB4HB is in the range of 20% to 60% by weight of the PHB4HB.

The PHA blend of PHB with a Type 2 PHB copolymer can be a blend of PHB with PHB5HV where the PHB content in the PHA blend is in the range of 30% to 95% by weight of the PHA in the PHA blend and the 5HV content in the PHB5HV is in the range of 20% to 60% by weight of the PHB5HV.

The PHA blend of PHB with a Type 2 PHB copolymer can be a blend of PHB with PHB3HH where the PHB content in the PHA blend is in the range of 35% to 95% by weight of the PHA in the PHA blend and the 3HH content in the PHB3HH is in the range of 35% to 90% by weight of the PHB3HX.

The PHA blend of PHB with a Type 2 PHB copolymer can be a blend of PHB with PHB3HX where the PHB content in the PHA blend is in the range of 30% to 95% by weight of the PHA in the PHA blend and the 3HX content in the PHB3HX is in the range of 35% to 90% by weight of the PHB3HX.

The PHA blend can be a blend of PHB with a Type 1 PHB copolymer and a Type 2 PHB copolymer where the PHB content in the PHA blend is in the range of 10% to 90% by weight of the PHA in the PHA blend, the Type 1 PHB copolymer content of the PHA blend is in the range of 5% to 90% by weight of the PHA in the PHA blend and the Type 2 PHB copolymer content in the PHA blend is in the range of 5% to 90% by weight of the PHA in the PHA blend.

For example a PHA blend can have a PHB content in the PHA blend in the range of 10% to 90% by weight of the PHA in the PHA blend, a PHB3HV content in the PHA blend in the range 5% to 90% by weight of the PHA in the PHA blend, where the 3HV content in the PHB3HV is in the range of 3% to 22% by weight of the PHB3HV, and a PHBHX content in the PHA blend in the range of 5% to 90% by weight of the PHA in the PHA blend where the 3HX content in the PHBHX is in the range of 35% to 90% by weight of the PHBHX.

For example a PHA blend can have a PHB content in the PHA blend in the range of 10% to 90% by weight of the PHA in the PHA blend, a PHB3HV content in the PHA blend in the range 5% to 90% by weight of the PHA in the PHA blend, where the 3HV content in the PHB3HV is in the range of 3% to 22% by weight of the PHB3HV, and a PHB4HB content in the PHA blend in the range of 5% to 90% by weight of the PHA in the PHA blend where the 4HB content in the PHB4HB is in the range of 20% to 60% by weight of the PHB4HB.

For example a PHA blend can have a PHB content in the PHA blend in the range of 10% to 90% by weight of the PHA in the PHA blend, a PHB3HV content in the PHA blend in the range 5% to 90% by weight of the PHA in the PHA blend, where the 3HV content in the PHB3HV is in the range of 3% to 22% by weight of the PHB3HV, and a PHB5HV content in the PHA blend in the range of 5% to 90% by weight of the PHA in the PHA blend where the 5HV content in the PHB5HV is in the range of 20% to 60% by weight of the PHB5HV.

For example a PHA blend can have a PHB content in the PHA blend in the range of 10% to 90% by weight of the PHA in the PHA blend, a PHB4HB content in the PHA blend in the range 5% to 90% by weight of the PHA in the PHA blend, where the 4HB content in the PHB4HB is in the range of 4% to 15% by weight of the PHB4HB, and a PHB4HB content in the PHA blend in the range of 5% to 90% by weight of the PHA in the PHA blend where the 4HB content in the PHB4HB is in the range of 20% to 60% by weight of the PHB4HB.

For example a PHA blend can have a PHB content in the PHA blend in the range of 10% to 90% by weight of the PHA in the PHA blend, a PHB4HB content in the PHA blend in the range 5% to 90% by weight of the PHA in the PHA blend, where the 4HB content in the PHB4HB is in the range of 4% to 15% by weight of the PHB4HB, and a PHB5HV content in the PHA blend in the range of 5% to 90% by weight of the PHA in the PHA blend and where the 5HV content in the PHB5HV is in the range of 30% to 90% by weight of the PHB5HV.

For example a PHA blend can have a PHB content in the PHA blend in the range of 10% to 90% by weight of the PHA in the PHA blend, a PHB4HB content in the PHA blend in the range 5% to 90% by weight of the PHA in the PHA blend, where the 4HB content in the PHB4HB is in the range of 4% to 15% by weight of the PHB4HB, and a PHB3HX content in the PHA blend in the range of 5% to 90% by weight of the PHA in the PHA blend and where the 3HX content in the PHB3HX is in the range of 35% to 90% by weight of the PHB3HX.

For example a PHA blend can have a PHB content in the PHA blend in the range of 10% to 90% by weight of the PHA in the PHA blend, a PHB4HV content in the PHA blend in the range 5% to 90% by weight of the PHA in the PHA blend, where the 4HV content in the PHB4HV is in the range of 3% to 15% by weight of the PHB4HV, and a PHB5HV content in the PHA blend in the range of 5% to 90% by weight of the PHA in the PHA blend where the 5HV content in the PHB5HV is in the range of 30% to 90% by weight of the PHB5HV.

For example a PHA blend can have a PHB content in the PHA blend in the range of 10% to 90% by weight of the PHA in the PHA blend, a PHB3HH content in the PHA blend in the range 5% to 90% by weight of the PHA in the PHA blend, where the 3HH content in the PHB3HH is in the range of 3% to 15% by weight of the PHB3HH, and a PHB4HB content in the PHA blend in the range of 5% to 90% by weight of the PHA in the PHA blend where the 4HB content in the PHB4HB is in the range of 20% to 60% by weight of the PHB4HB.

For example a PHA blend can have a PHB content in the PHA blend in the range of 10% to 90% by weight of the PHA in the PHA blend, a PHB3HH content in the PHA blend in the range 5% to 90% by weight of the PHA in the PHA blend, where the 3HH content in the PHB3HH is in the range of 3% to 15% by weight of the PHB3HH, and a PHB5HV content in the PHA blend in the range of 5% to 90% by weight of the PHA in the PHA blend where the 5HV content in the PHB5HV is in the range of 20% to 60% by weight of the PHB5HV.

For example a PHA blend can have a PHB content in the PHA blend in the range of 10% to 90% by weight of the PHA in the PHA blend, a PHB3HH content in the PHA blend in the range 5% to 90% by weight of the PHA in the PHA blend, where the 3HH content in the PHB3HH is in the range of 3% to 15% by weight of the PHB3HH, and a PHB3HX content in the PHA blend in the range of 5% to 90% by weight of the PHA in the PHA blend where the 3HX content in the PHB3HX is in the range of 35% to 90% by weight of the PHB3HX.

For example a PHA blend can have a PHB content in the PHA blend in the range of 10% to 90% by weight of the PHA in the PHA blend, a PHB3HX content in the PHA blend in the range 5% to 90% by weight of the PHA in the PHA blend, where the 3HX content in the PHB3HX is in the range of 3% to 12% by weight of the PHB3HX, and a PHB3HX content in the PHA blend in the range of 5% to 90% by weight of the PHA in the PHA blend where the 3HX content in the PHB3HX is in the range of 35% to 90% by weight of the PHB3HX.

For example a PHA blend can have a PHB content in the PHA blend in the range of 10% to 90% by weight of the PHA in the PHA blend, a PHB3HX content in the PHA blend in the range 5% to 90% by weight of the PHA in the PHA blend, where the 3HX content in the PHB3HX is in the range of 3% to 12% by weight of the PHB3HX, and a PHB4HB content in the PHA blend in the range of 5% to 90% by weight of the PHA in the PHA blend where the 4HB content in the PHB4HB is in the range of 20% to 60% by weight of the PHB4HB.

For example a PHA blend can have a PHB content in the PHA blend in the range of 10% to 90% by weight of the PHA in the PHA blend, a PHB3HX content in the PHA blend in the range 5% to 90% by weight of the PHA in the PHA blend, where the 3HX content in the PHB3HX is in the range of 3% to 12% by weight of the PHB3HX, and a PHB5HV content in the PHA blend in the range of 5% to 90% by weight of the PHA in the PHA blend where the 5HV content in the PHB5HV is in the range of 20% to 60% by weight of the PHB5HV.

The PHA blend can be a blend as disclosed in U.S. Pub. App. No. 2004/0220355, by Whitehouse, published Nov. 4, 2004, which is incorporated herein by reference in its entirety.

Microbial systems for producing the PHB copolymer PHBV are disclosed in U.S. Pat. No. 4,477,654 to Holmes. U.S. Pat. App. Pub 2002/0164729, by Skraly and Sholl describes useful systems for producing the PHB copolymer PHB4HB. Useful processes for producing the PHB copolymer PHB3HH have been described (Lee et al., 2000, Biotechnology and Bioengineering 67: 240-244; Park et al., 2001, Biomacromolecules, 2: 248-254). Processes for producing the PHB copolymers PHB3HX have been described by Matsusaki et al., (Biomacromolecules, 2000, 1: 17-22).

In determining the molecular weight techniques such as gel permeation chromatography (GPC) can be used. In the methodology, a polystyrene standard is utilized. The PHA can have a polystyrene equivalent weight average molecular weight (in daltons) of at least 500, at least 10,000, or at least 50,000 and/or less than 2,000,000, less than 1,000,000, less than 1,500,000, and less than 800,000. In certain embodiments, preferably, the PHAs generally have a weight-average molecular weight in the range of 100,000 to 700,000. For example, the molecular weight range for PHB and Type 1 PHB copolymers for use in this application are in the range of 400,000 daltons to 1.5 million daltons as determined by GPC method and the molecular weight range for Type 2 PHB copolymers for use in the application 100,000 to 1.5 million daltons.

In certain embodiments, the branched PHA can have a linear equivalent weight average molecular weight of from about 150,000 Daltons to about 500,000 Daltons and a polydispersity index of from about 2.5 to about 8.0. As used herein, weight average molecular weight and linear equivalent weight average molecular weight are determined by gel permeation chromatography, using, e.g., chloroform as both the eluent and diluent for the PHA samples. Calibration curves for determining molecular weights are generated using linear polystyrenes as molecular weight standards and a ‘log MW vs elution volume’ calibration method.

Production of Branched PHA

The branching agents for use in the compositions and method described herein include branching agents, also referred to as free radical initiators, e.g., organic peroxides. Peroxides are reactive molecules, and can react with linear PHA molecules or previously branched PHA by removing a hydrogen atom from the polymer backbone or side chain backbone, leaving behind a radical. PHA molecules having such radicals on their backbones are free to combine with each other, creating branched PHA molecules.

When peroxides decompose at processing temperatures, they produce decomposition products and residues, many of which produce noxious odors in the finished polymer. Such odors are unappealing to consumers. In the production of other branched polymers, such as polypropylene, this is less of a problem because branched polypropylene is typically produced at temperatures of 200° C. to 250° C., and the by-products are more readily removed. Polyhydroxyalkanoates, however, are processed at much lower temperatures, and so the by-products are not as efficiently removed. It is therefore desirable to use as little peroxide as possible when producing branched PHAs.

Disclosed herein is a two-step method of branching PHA. It has been found that more efficient branching can be induced in polyhydroxyalkanoate polymers by first thermolysing (i.e., heat treating) the PHA, and then subsequently treating it with a branching agent. This allows less peroxide to be used to achieve branching, thereby reducing the level of undesirable peroxide decomposition products.

During thermolysis, the polyhydroxyalkanoate polymer chains are cleaved, resulting in unsaturated end groups. This thermolysed polymer, with unsaturated end groups, is then reacted with one or more branching agents, such as peroxides. The peroxides remove hydrogen atoms from the polymer backbones, and the resulting radicals are free to react not only with each other, but also the reactive groups on the ends of the PHA that were produced during thermolysis. The result is more efficient branching, because each peroxide-produced radical can not only react with another peroxide produced radical but can also react with the chain end.

For instance, the PHA polymer can be thermolysed, and its molecular weight reduced, for example, by 25% to 75%, by 40% to 60%, or by 50%. A branching agent, e.g., a peroxide, can then be used to branch the polymer and bond multiple polymer molecules together. This is shown in the examples below. Also contemplated is using a starting branched polymer.

In certain embodiments, the branched PHA can be prepared as follows. First a PHA is thermolysed (heat treated) at elevated temperature to break the polymer chains. For example, a PHA (either linear or branched) is heated at an elevated temperature (e.g., from 170° C. to about 220° C., or from about 190° C. to about 220° C. for a sufficient period of time (e.g., from 0.5 minutes to 3.0 minutes) before it is mixed with a free radical initiator. Typically, this temperature is higher than the temperature used in the subsequent branching reaction. Without wishing to be bound by any theory, it is believed that certain PHA polymer chains are cleaved during the thermal treatment and terminal reactive groups are produced (during the subsequent branching reaction, these terminal reactive groups will facilitate the formation of branching by reacting with radical sites on other PHA molecules which are formed when the free radical initiator is added to the polymer). As a result of this chain cleavage, the thermally treated PHA has a lower weight average molecular weight than it did before heat treatment.

Because the thermally treated PHA (e.g., thermolysed PHA) already contains terminal reactive groups when the branching initiator is added, this method can be used to prepare PHAs with a high degree of branching.

The thermolysed PHA is then mixed with the requisite quantity of a free radical initiator by a suitable means. The mixing step can preferably be carried out under the conditions that the initiator does not undergo substantial decomposition. The branching reaction is then carried out by exposing the mixture to a temperature above the melting temperature of the PHA and the decomposition temperature of the initiator for a sufficient period of time. Without wishing to be bound by any theory, it is believed that decomposition of the initiator forms free radicals, which react with PHA molecules to generate radical sites on the polymer backbone. A branched PHA can then be formed by a coupling reaction between these radical sites on PHA molecules with other such radical sites, or the reactive groups at the broken ends of the linear molecules that were created during the thermolysis step.

Typically, the reaction time is sufficient for branching between polymer molecules while substantially all of the branching agent decompose. For example, the reaction time should at least three times the half-life of the initiator at the reaction temperature. The branched PHA thus prepared contains a minimal amount of residual initiator and possesses improved stability and reproducibility. Typically, the branched PHA has a higher degree of branching and weight average molecular weight than the initial PHA. For example, the branched PHA can have a weight average molecular weight of least about 1.2 times as high as that of the linear PHA. The branched PHA has a G′ of about 2 to 20 times that of the starting PHA.

Both the thermolysis step and the branching reaction are performed as two separate steps, for example, the PHA can be thermolysed and extruded, and then combined with the branching agent in a separate run.

Alternatively, both steps can be performed in a single extruder in different subsequent zones. For instance, the thermolysing step can be done in an extruder, and when the PHA is sufficiently thermolysed, the branching agent may be added to conduct the branching step. That is, the thermolysing step and the branching step are separate in time.

Both steps can also be performed in separate zones in the extruder. For instance, the thermolysis step can be performed in one zone of an extruder, and the branching agent can then be added as the thermolysed PHA enters another zone of the extruder.

Branching Agents

Branching agents also referred to as free radical initiators are selected from any suitable initiator known in the art, such as organic peroxides, azo-dervatives (e.g., azo-nitriles), peresters, and peroxycarbonates. Suitable peroxides for use in the present invention include, but are not limited to, organic peroxides, for example dialkyl organic peroxides such as 2,5-dimethyl-2,5-di(t-butylperoxy)hexane, 2,5-bis(t-butylperoxy)-2,5-dimethylhexane (available from Akzo Nobel as TRIGANOX 101), tert-butylperoxy-2-ethylhexylcarbonate (available from Akzo Nobel as TRIGANOX 117), tert-amylperoxy-2-ethylhexylcarbonate (available from Akzo Nobel as TRIGANOX 131), n-butyl-4,4-di-(tert-butylperoxy)valerate (available from Akzo Nobel as TRIGANOX 17), 2,5-dimethyl-di(t-butylperoxy)hexyne-3, di-t-butyl peroxide, dicumyl peroxide (DCP, DiCuP), benzoyl peroxide, di-t-amyl peroxide, t-amylperoxy-2-ethylhexylcarbonate (TAEC), t-butyl-2-ethylhexyl peroxycarbonate, t-butyl cumyl peroxide, n-butyl-4,4-bis(t-butylperoxy)valerate, 1,1-di(t-butylperoxy)-3,3,5-trimethyl-cyclohexane, 1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane (CPK), 1,1-di(t-butylperoxy)cyclohexane, 1,1-di(t-amylperoxy)-cyclohexane, 2,2-di(t-butylperoxy)butane, ethyl-3,3-di(t-butylperoxy)butyrate, 2,2-di(t-amylperoxy)propane, ethyl-3,3-di(t-amylperoxy)butyrate, t-butylperoxy-acetate, t-amylperoxyacetate, t-butylperoxybenzoate (TBPB), t-amylperoxybenzoate, di-t-butyldiperoxyphthalate, and the like. Combinations and mixtures of peroxides can also be used. Examples of free radical initiators include those mentioned herein, as well as those described in, e.g., Polymer Handbook, 3rd Ed., J. Brandrup & E. H. Immergut, John Wiley and Sons, 1989, Ch. 2. Irradiation (e.g., e-beam or gamma irradiation) can also be used to generate PHA branching.

Additives

In certain embodiments, various additives is added to the branched PHA described above. Examples of these additives include antioxidants, pigments, UV stabilizers, fillers, plasticizers, nucleating agents, and radical scavengers.

Optionally, an additive is included in the thermoplastic composition. The additive is any compound known to those of skill in the art to be useful in the production of thermoplastics. Exemplary additives include, e.g., plasticizers (e.g., to increase flexibility of a thermoplastic composition), antioxidants (e.g., to protect the thermoplastic composition from degradation by ozone or oxygen), ultraviolet stabilizers (e.g., to protect against weathering), lubricants (e.g., to reduce friction), pigments (e.g., to add color to the thermoplastic composition), flame retardants, fillers, reinforcing, mold release, and antistatic agents. It is well within the skilled practitioner's abilities to determine whether an additive should be included in a thermoplastic composition and, if so, what additive and the amount that should be added to the composition.

In poly-3-hydroxybutyrate compositions, for example, plasticizers are often used to change the glass transition temperature and modulus of the composition, but surfactants may also be used. Lubricants may also be used, e.g., in injection molding applications. Plasticizers, surfactants and lubricants may all therefore be included in the overall blend. In certain embodiments, the compositions and methods of the invention include one or more surfactants. Surfactants are generally used to de-dust, lubricate, reduce surface tension, and/or densify.

One or more lubricants can also be added to the compositions and methods of the invention Lubricants are normally used to reduce sticking to hot processing metal surfaces and can include polyethylene, paraffin oils, and paraffin waxes in combination with metal stearates. Other lubricants include stearic acid, amide waxes, ester waxes, metal carboxylates, and carboxylic acids. Lubricants are normally added to polymers in the range of about 0.1 percent to about 1 percent by weight, generally from about 0.7 percent to about 0.8 percent by weight of the compound. Solid lubricants is warmed and melted before or during processing of the blend.

Nucleating Agents

For instance, an optional nucleating agent is added to the branched PHA to aid in its crystallization. Nucleating agents for various polymers are simple substances, metal compounds including composite oxides, for example, carbon black, calcium carbonate, synthesized silicic acid and salts, silica, zinc white, clay, kaolin, basic magnesium carbonate, mica, talc, quartz powder, diatomite, dolomite powder, titanium oxide, zinc oxide, antimony oxide, barium sulfate, calcium sulfate, alumina, calcium silicate, metal salts of organophosphates, and boron nitride; low-molecular organic compounds having a metal carboxylate group, for example, metal salts of such as octylic acid, toluic acid, heptanoic acid, pelargonic acid, lauric acid, myristic acid, palmitic acid, stearic acid, behenic acid, cerotic acid, montanic acid, melissic acid, benzoic acid, p-tert-butylbenzoic acid, terephthalic acid, terephthalic acid monomethyl ester, isophthalic acid, and isophthalic acid monomethyl ester; high-molecular organic compounds having a metal carboxylate group, for example, metal salts of such as: carboxyl-group-containing polyethylene obtained by oxidation of polyethylene; carboxyl-group-containing polypropylene obtained by oxidation of polypropylene; copolymers of olefins, such as ethylene, propylene and butene-1, with acrylic or methacrylic acid; copolymers of styrene with acrylic or methacrylic acid; copolymers of olefins with maleic anhydride; and copolymers of styrene with maleic anhydride; high-molecular organic compounds, for example: alpha-olefins branched at their 3-position carbon atom and having no fewer than 5 carbon atoms, such as 3,3 dimethylbutene-1,3-methylbutene-1,3-methylpentene-1,3-methylhexene-1, and 3,5,5-trimethylhexene-1; polymers of vinylcycloalkanes such as vinylcyclopentane, vinylcyclohexane, and vinylnorbornane; polyalkylene glycols such as polyethylene glycol and polypropylene glycol; poly(glycolic acid); cellulose; cellulose esters; and cellulose ethers; phosphoric or phosphorous acid and its metal salts, such as diphenyl phosphate, diphenyl phosphite, metal salts of bis(4-tert-butylphenyl)phosphate, and methylene bis-(2,4-tert-butylphenyl)phosphate; sorbitol derivatives such as bis(p-methylbenzylidene) sorbitol and bis(p-ethylbenzylidene) sorbitol; and thioglycolic anhydride, p-toluenesulfonic acid and its metal salts. The above nucleating agents may be used either alone or in combinations with each other. In particular embodiments, the nucleating agent is cyanuric acid. In certain embodiments, the nucleating agent can also be another polymer (e.g., polymeric nucleating agents such as PHB).

In certain embodiments, the nucleating agent is selected from: cyanuric acid, carbon black, mica talc, silica, boron nitride, clay, calcium carbonate, synthesized silicic acid and salts, metal salts of organophosphates, and kaolin. In particular embodiments, the nucleating agent is cyanuric acid.

In various embodiments, where the nucleating agent is dispersed in a liquid carrier, the liquid carrier is a plasticizer, e.g., a citric compound or an adipic compound, e.g., acetylcitrate tributyrate (Citroflex A4, Vertellus, Inc., High Point, N.C.), or DBEEA (dibutoxyethoxyethyl adipate), a surfactant, e.g., Triton X-100, TWEEN-20, TWEEN-65, Span-40 or Span 85, a lubricant, a volatile liquid, e.g., chloroform, heptane, or pentane, a organic liquid or water.

In other embodiments, the nucleating agent is aluminum hydroxy diphosphate or a compound comprising a nitrogen-containing heteroaromatic core. The nitrogen-containing heteroaromatic core is pyridine, pyrimidine, pyrazine, pyridazine, triazine, or imidazole.

In particular embodiments, the nucleating agent can include aluminum hydroxy diphosphate or a compound comprising a nitrogen-containing heteroaromatic core. The nitrogen-containing heteroaromatic core is pyridine, pyrimidine, pyrazine, pyridazine, triazine, or imidazole. The nucleant can have a chemical formula selected from the group consisting of

and combinations thereof, wherein each R1 is independently H, NR2R2, OR2, SR2, SOR2, SO2R2, CN, COR2, CO2R2, CONR2R2, NO2, F, Cl, Br, or I; and each R2 is independently H or C1-C6 alkyl.

Another nucleating agent for use in the compositions and methods described herein are milled as described in PCT/US2009/041023, filed Apr. 17, 2009, which is incorporated by reference in its entirety. Briefly, the nucleating agent is milled in a liquid carrier until at least 5% of the cumulative solid volume of the nucleating agent exists as particles with a particle size of 5 microns or less. The liquid carrier allows the nucleating agent to be wet milled. In other embodiments, the nucleating agent is milled in liquid carrier until at least 10% of the cumulative solid volume, at least 20% of the cumulative solid volume, at least 30% or at least 40%-50% of the nucleating agent can exist as particles with a particle size of 5 microns or less, 2 microns or less or 1 micron or less. In alternative embodiments, the nucleating agents is milled by other methods, such as jet milling and the like. Additionally, other methods is utilized that reduce the particle size.

The cumulative solid volume of particles is the combined volume of the particles in dry form in the absence of any other substance. The cumulative solid volume of the particles is determined by determining the volume of the particles before dispersing them in a polymer or liquid carrier by, for example, pouring them dry into a graduated cylinder or other suitable device for measuring volume. Alternatively, cumulative solid volume is determined by light scattering.

Applications for Branched Polymers

The branched PHA compositions and produced by the methods described herein can be used to create, without limitation, a wide variety of useful products, e.g., automotive, consumer durable, construction, electrical, medical, and packaging products. For instance, the polymeric compositions can be used to make, without limitation, films (e.g., packaging films, agricultural film, mulch film, erosion control, hay bale wrap, slit film, food wrap, pallet wrap, protective automobile and appliance wrap, etc.), golf tees, caps and closures, agricultural supports and stakes, paper and board coatings (e.g., for cups, plates, boxes, etc.), thermoformed products (e.g., trays, containers, lids, yoghurt pots, cup lids, plant pots, noodle bowls, moldings, etc.), housings (e.g., for electronics items, e.g., cell phones, PDA cases, music player cases, computer cases and the like), bags (e.g., trash bags, grocery bags, food bags, compost bags, etc.), hygiene articles (e.g., diapers, feminine hygiene products, incontinence products, disposable wipes, etc.), coatings for pelleted products (e.g., pelleted fertilizer, herbicides, pesticides, seeds, etc.), injection moldings (writing instruments, utensils, disk cases, etc.), solution and spun fibers and melt blown fabrics and non-wovens (threads, yarns, wipes, wadding, disposable absorbent articles, etc.), blow moldings (deep containers, bottles, etc.) and foamed articles (cups, bowls, plates, packaging, etc.).

Thermoforming is a process that that uses films or sheets of thermoplastic. The polymeric composition made by the methods herein is processed into a film or sheet. The sheet of polymer is then placed in an oven and heated. When soft enough to be formed, the sheet is transferred to a mold, formed and shaped.

During thermoforming, when the softening point of a semi-crystalline polymer is reached, the polymer sheet begins to sag. The window between softening and droop is usually narrow. It can therefore be difficult to move the softened polymer sheet to the mold quickly enough. Branching the polymer as described herein increases melt strength of the polymer so that the sheet is more readily processed and maintains its structural integrity. Measuring the sag of a sample piece of polymer when it is heated is therefore a way to measure the relative size of this processing window for thermoforming.

Because the branched polymers described herein have increased melt strength and increased processability, they are easier to convert to film or sheet form. They are therefore excellent candidates for thermoforming. Molded products can include a number of different product types and, for example, can include products such as disposable spoons, forks and knives, tubs, bowls, lids, cup lids, yogurt cups, and other containers, bottles and bottle-like containers, etc.

Blow molding, which is similar to thermoforming and is used to produce deep draw products such as bottles and similar products with deep interiors, also benefits from the increased elasticity and melt strength and reduced sag of the branched polymer compositions described herein.

The branched PHA compositions described herein can be provided in any suitable form convenient for an intended application. For example, branched PHA can be provided in pellet for to subsequently produce films, coatings, moldings or other articles, or the films, coatings, moldings and other articles can be made directly as the branched PHA is produced. For instance, the articles can be made from a starting linear or branched PHA by reactive extrusion, in which the thermolysis and the branching are done in-process, and where portions of the extrusion temperature and the residence time are sufficient for the thermolysis and branching steps. These steps can then be followed immediately by either extrusion of the PHA in pellet form (for production at another time into finished articles), or processing (such as by molding) of the branched PHA into finished articles immediately.

The specific examples below are to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever. Without further elaboration, it is believed that one skilled in the art can, based on the description herein, utilize the present invention to its fullest extent. All publications cited herein are hereby incorporated by reference in their entirety.

EXAMPLES Testing Methods Measurement of Molecular Weight of Polymers

Molecular weight (either weight-average molecular weight (Mw) or number-average molecular weight (Mn)) of PHA is estimated by gel permeation chromatography (GPC) using, e.g., a Waters Alliance HPLC System equipped with a refractive index detector. The column set is, for example, a series of three PLGel 10 micrometer Mixed-B (Polymer Labs, Amherst, Mass.) columns with chloroform as mobile phase pumped at 1 ml/min. The column set is calibrated with narrow distribution polystyrene standards.

The PHA sample is dissolved in chloroform at a concentration of 2.0 mg/ml at 60C. The sample is filtered with a 0.2 micrometer Teflon syringe filter. A 50 microliter injection volume is used for the analysis.

The chromatogram is analyzed with, for example, Waters Empower GPC Analysis software. Molecular weights and PD are reported as polystyrene equivalent molecular weights.

Measurement of Polydispersity (PD)

The polydispersity index (PD, or PDI) is a measure of the distribution of molecular mass in (individual molecular masses) a given polymer sample. It is calculated from the weight average molecular weight (Mw) divided by the number average molecular weight (Mn). The PD has a value always greater than 1, but as the polymer chains approach uniform chain length, the PDI approaches unity (i.e., 1). It is therefore useful as a measure of the distribution of chain lengths in a polymer sample.

Measuring G′ Using Torsional Melt Rheometry

Torsional rheometry can be used to measure the melt strength of a polymer. For purposes of simplicity, G′ will be used herein, measured at an imposed frequency of 0.25 rad/s as a measure of “melt strength” (unless otherwise indicated). Higher G′ translates to higher melt strength.

All oscillatory rheology measurements are performed using a TA Instruments AR2000 rheometer employing a strain amplitude of 1%. First, dry pellets (or powder) are molded into 25 mm diameter discs that are about 1200 microns in thickness. The disc specimens are molded in a compression molder set at about 165° C., with the molding time of about 30 seconds. These molded discs are then placed in between the 25 mm parallel plates of the AR2000 rheometer at 160° C. A gap of 800-900 microns is used, depending on the normal forces exerted by the polymer. The melt density of PHB is determined to be about 1.10 g/cm3 at 160° C.; this value is used in all the calculations. Specifically, the specimen disc is loaded on the parallel plate rheometer set at 160° C.

During the frequency sweep performed at 160° C., the following data are collected as a function of measurement frequency: |η*| or complex viscosity, G′ or elastic modulus (elastic or solid-like contribution to the viscosity) and G″ or loss modulus (viscous or liquid-like contribution to the viscosity).

As used herein, G′ measured at an imposed frequency of 0.25 rad/s (unless otherwise indicated) is used as a measure of “melt strength.” Higher G′ translates to higher melt strength.

Example 1 Effect of Heat Treatment on Branching

Experiments were carried out to demonstrate the effect of the thermolysis step on the branching of poly(3-hydroxybutyrate-co-8%-3-hydroxyvalerate) (“PHBV8”) with t-butylperoxybenzoate (TBPB; from R.T. Vanderbilt Co., Norwalk Colo. Specifically, PHBV8 was thermolysed by heating at 210° C. in a single screw extruder (1 inch screw diameter, Welex Inc, Blue Bell, Pa.) operating at 40 RPM, resulting an average residence time of about 1.6 minutes, which reduced its weight average molecular weight to 263,000 from 458,000. The thermolysed PHBV8 as well as the original PHBV8 were then each mixed with 0%, 0.15%, or 0.30% (by weight) of the peroxide TBPB, and fed into a single screw extruder operating at 165° C. and 30 RPM, with an average residence time of about 2 minutes. At 165° C., CPK has a half-life of about 0.3 minutes. The molecular weights of the branched polymers obtained from the extruder were determined by GPC and shown in Table 1, below. Mw/Mw,0 is the molecular weight of the peroxide-treated polymer, divided by the Mw of the corresponding starting or initial polymer that was not peroxide-treated.

TABLE 1 Effect of thermolysis on molecular weights of branched PHA polymers. Wt % Peroxide Peroxide Thermolysed Mw PD Mw/Mw, o TBPB 0 Y 263,000 2.4 1.0 TBPB 0.15 Y 343,000 3.2 1.3 TBPB 0.30 Y 525,000 4.1 2.0 TBPB 0 N 458,000 2.3 1.0 TBPB 0.15 N 536,000 2.9 1.2 TBPB 0.30 N 616,000 4.4 1.3 TBPB 0.45 N 666,000 3.9 1.5

In both cases, increases in branching are observed as indicated by the increase in the weight average molecular weight ratio, Mw/Mw,o. Clearly, the increase in molecular weight, and hence the amount of branching, is greater for the thermolysed PHBV8 as indicated by the greater values of Mw/Mw,o at comparable levels of peroxide.

Example 2 Branching of PHA Polymers with TAEC

Branched PHAs were prepared using poly(3-hydroxybutyrate-co-8%-3-hydroxyvalerate) (“PHBV8”) and poly(3-hydroxybutyrate-co-7%-4-hydroxybutyrate) (“PHB7”) as the starting materials, and branching them with t-amylperoxy-2-ethylhexylcarbonate (TAEC). As measured by GPC, the PHBV8 starting polymer had a weight average molecular weight of 734,850 and a number average molecular weight of 288,571 g/mol. The PHB7 starting polymer had a weight average molecular weight of 505,000 and a number average molecular weight of 207,000 g/mol.

The PHBV8 and PHB7 were thermolysed by heating at 210° C. in a single screw extruder (1 inch screw diameter, Welex Inc, Blue Bell, Pa.) operating at 40 RPM, resulting an average residence time of about 1.6 minutes. The thermolysed PHBV8 had a weight average molecular weight of about 220,000 Daltons and a polydispersity (PD) index of about 2.7, while the PHB7 was 214,000 Daltons and had a PD of 8.4. Subsequently, the PHBV8 was mixed with 0.30, 0.45, or 0.60 wt % and the PHB7 was mixed with 0.40 wt % t-amylperoxy-2-ethylhexylcarbonate (TAEC). The mixtures were fed into the same extruder operating at 165° C. and 30 RPM, having an average residence time of about 2 minutes. TAEC has a half-life of about 0.3 minutes at 165° C. The molecular weights of the branched polymers obtained from the extruder were determined by gel permeation chromatography (GPC). Also calculated were the ratios of the weight average molecular weight of the branched PHA over the weight average molecular weight of the starting PHA. This data is provided in Table 2, below.

TABLE 2 Molecular Weights of PHA Polymers Thermolysed and Branched with TAEC. Polymer Wt % TAEC Mw PD Mw/Mw, o PHBV8 0 220,000 2.7 1.0 PHBV8 0.30 380,000 3.6 1.7 PHBV8 0.45 600,000 5.7 2.8 PHBV8 0.60 600,000 8.4 2.8 PHB7 0 214,000 2.6 1.0 PHB7 0.40 475,000 4.0 2.2

Unexpectedly, the branched polymer obtained from the mixture containing 0.30 wt % TAEC had a weight average molecular weight of about 380,000 Daltons and a polydispersity index of about 3.8. The branched polymer obtained from the mixture containing 0.45 wt % TAEC had a weight average molecular weight of about 600,000 Daltons and a polydispersity index of about 5.8. The branched polymer obtained from the mixture containing 0.60 wt % TAEC had a weight average molecular weight of about 600,000 Daltons and a polydispersity index of about 7.0. The column Mw/Mw,o shows the normalized increase in weight average molecular weight.

These results show that branching occurred, as evidenced by the increase in both the weight average molecular weight and polydispersity. Additionally, the level of molecular weight increase (Mw/Mw,o) is similar for PHBV8 and PHB7 at comparable levels of TAEC, indicating that the co-monomer component has a negligible effect on the branching reaction.

Example 3 Branching of PHA Polymers with TBPB and CPK

Other initiators were tested for their capability in inducing branching. Poly(3-hydroxy butyrate-co-11%-4-hydroxybutyrate) (PHB11) with a weight average molecular weight of 559,000 and a number average molecular weight of 278,000 was thermolysed under similar conditions as in Example 1, to a weight average molecular weight of about 270,000 Daltons. The polymer was then branched with t-butylperoxybenzoate (TBPB; Varox TBPB from R.T. Vanderbilt Co., Norwalk, Conn.) and 1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane (CPK; Varox 231 from R.T. Vanderbilt Co., Norwalk, Conn.) at levels of 0.15 and 0.30 wt %. The extruder was maintained at 165° C. For CPK, the extruder was operated at 60 RPM with an average residence time of about 1 minute. At 165° C., the half-life of CPK is about 0.3 minutes. For TBPB, the extruder was operated at 10 RPM with an average residence time of about 4.5 minutes. At 165° C., the half-life of TBPB is about 1 minute. The molecular weights of the branched polymers obtained from the extruder were determined by GPC as shown in Table 3, below.

TABLE 3 Molecular weights of PHA Polymers Thermolysed and Branched with TBPB and CPK. Peroxide Wt % Peroxide Mw PD Mw/Mw, o TBPB 0 270,000 2.0 1.0 TBPB 0.15 489,000 2.8 1.8 TBPB 0.30 537,000 3.2 2.0 CPK 0 267,000 2.6 1.0 CPK 0.15 315,000 2.6 1.2 CPK 0.30 382,000 2.6 1.4

When CPK was used as an initiator, the branched polymer obtained from thermolysed PHB11 had a weight average molecular weight up to 2.0 times as high as the starting polymer with TBPB peroxide. Similarly, CPK peroxide effectively increases the weight average molecular weight.

These results show that various peroxides can be used effectively if the decomposition temperature and residence time for the branching reaction is commensurate with the rate of decomposition (half-life) of the peroxide.

Example 4 Effect of Branching on Melt Strength

Rheological measurements were carried out to determine the effect of branching on the melt strength of PHA copolymer. The samples of PHB11 from Example 3 that were branched using TBPB peroxide were analyzed further, by dynamic melt rheology at 160° C. using a Rheometrics RSA parallel plate rheometer. The (G′) measured at 0.25 sec−1 was used an a measure of melt strenght of the branched polymer. The results are shown in Table 5, below.

TABLE 5 Effect of Branching on Melt Strength. Sample Mw PD Mw/Mw, o G' (Pa) 1 270,000 2.0 1.0 19.3 2 489,000 2.8 1.8 2094 3 537,000 3.2 2.0 3752

The branched polymer obtained from the mixture without TBPB peroxide had a melt strength of about 19 Pa at 0.25 rad/s. The branched polymer obtained from the mixture containing 0.15 wt % TBPB had a melt strength of nearly 2100. The branched polymer obtained from the mixture containing 0.30 wt % TBPB had a melt strength of about 3800 Melt strength (G′) is another measure of polymer branching, and confirms that the polymer is being branched.

Other than in the examples herein, or unless otherwise expressly specified, all of the numerical ranges, amounts, values and percentages, such as those for amounts of materials, elemental contents, times and temperatures of reaction, ratios of amounts, and others, in the following portion of the specification and attached claims may be read as if prefaced by the word “about” even though the term “about” may not expressly appear with the value, amount, or range. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains error necessarily resulting from the standard deviation found in its underlying respective testing measurements. Furthermore, when numerical ranges are set forth herein, these ranges are inclusive of the recited range end points (i.e., end points may be used). When percentages by weight are used herein, the numerical values reported are relative to the total weight.

Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of “1 to 10” is intended to include all sub-ranges between (and including) the recited minimum value of I and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10. The terms “one,” “a,” or “an” as used herein are intended to include “at least one” or “one or more,” unless otherwise indicated.

Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.

All of the features disclosed in this specification may be combined in any combination. Each feature disclosed in this specification may be replaced by an alternative feature serving the same, equivalent, or similar purpose. Thus, unless expressly stated otherwise, each feature disclosed is only an example of a generic series of equivalent or similar features.

From the above description, one skilled in the art can easily ascertain the essential characteristics of the present invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. Thus, other embodiments are also within the scope of the following claims.

While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.

Claims

1. A method of branching a starting biologically-produced polyhydroxyalkanoate polymer (PHA), comprising the steps of:

a) thermolysing the starting PHA to reduce its molecular weight between 25% and 75% from its starting molecular weight, and
b) reacting the thermolyzed PHA from step a) with a branching agent, thereby forming a branched PHA, wherein the branching agent is a peroxide.

2. A process for producing a branched polyhydroxyalkanoate (PHA), comprising: thereby producing a branched PHA, wherein the branching agent is a peroxide.

providing an initial PHA;
thermolysing the initial PHA to reduce its molecular weight and produce PHA with reactive ends, wherein the thermolysis is conducted at a temperature for a sufficient time that the weight average molecular weight of the PHA with reactive ends is from about 25% to about 75% of the weight average molecular weight of the initial PHA; and
treating the PHA with reactive ends with a branching agent at a reactive temperature for a reaction time to provide for cross-linking between molecules of PHA with reactive ends, to produce a branched PHA;

3. The method of claim 1, wherein the PHA thermolysed in step a) is linear.

4. The method of claim 1, wherein the PHA thermolysed in step a) is branched.

5. The method of claim 1, wherein the PHA molecular weight is reduced in step a) by at least 50% from its starting molecular weight.

6. The method of claim 1, wherein the PHA molecular

weight is reduced in step a) by at least 40% from its starting molecular weight.

7. The method of claim 1, wherein the thermolysing occurs at a temperature of 190° C. to 250° C.

8. The method of claim 1, wherein the thermolysing occurs at a temperature of 190° C. to 220° C.

9. The method of claim 1, wherein the residence time for thermolysing occurs for 0.1 minutes to 1.6 minutes.

10. The method of claim 1, wherein the thermolysing and reacting with a branching agent occur in separate zones inside an extruder.

11. The method of claim 1, wherein the peroxide is selected from: dicumyl peroxide, t-amyl-2-ethylhexyl peroxycarbonate, t-butyl-2-ethylhexyl peroxycarbonate, 1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane, 2,5-bis(t-butylperoxy)-2,5-dimethylhexane, 2,5-dimethyl-di(t-butylperoxy)hexyne-3, di-t-butyl peroxide, benzoyl peroxide, di-t-amyl peroxide, t-butyl cumyl peroxide, n-butyl-4,4-bis(t-butylperoxy)valerate, 1,1-di(t-butylperoxy)-3,3,5-trimethyl-cyclohexane, 1,1-di(t-butylperoxy)cyclohexane, 1,1-di(t-amylperoxy)-cyclohexane, 2,2-di(t-butylperoxy)butane, ethyl-3,3-di(t-butylperoxy)butyrate, 2,2-di(t-amylperoxy)propane, ethyl-3,3-di(t-amylperoxy)butyrate, t-butylperoxy-acetate, t-amylperoxyacetate, t-butylperoxybenzoate, t-amylperoxybenzoate, di-t-butyldiperoxyphthalate, tert-butylperoxy-2-ethylhexylcarbonate, tert-amylperoxy-2-ethylhexylcarbonate, and n-butyl-4,4-di-(tert-butylperoxy)valerate.

12. (canceled)

13. The method of claim 1, wherein the concentration of branching agent is between 0.001 to 0.5% by weight of the PHA or between 0.01 to 0.1% by weight of the PHA.

14. (canceled)

15. The method of claim 1, wherein the melt strength (G′) of the branched PHA is greater than the melt strength of the starting PHA as measured at 0.25 rad/sec at 160° C.

16. The method of claim 15, wherein the melt strength of the branched PHA is at least twice to about 20 times that of the starting PHA.

17. The method of claim 15, wherein the melt strength of the branched PHA is at least five to 15 times that of the starting PHA.

18. The method of claim 1, wherein the branched PHA has a molecular weight greater than the starting PHA.

19. The method of claim 1, wherein, the biologically-produced polyhydroxyalkanoate polymer is a poly(3-hydroxybutyrate) homopolymer, a poly(3-hydroxybutyrate-co-4-hydroxybutyrate), a poly(3-hydroxybutyrate-co-3-hydroxyvalerate), a poly(3-hydroxybutyrate-co-5-hydroxyvalerate), or a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate;

a poly(3-hydroxybutyrate) homopolymer, a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with 5% to 15% 4-hydroxybutyrate content, a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with 5% to 22% 3-hydroxyvalerate content, a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with 5% to 15% 5-hydroxyvalerate content, or a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with 3% to 15% 3-hydroxyhexanoate content;
a polymer blend of a) a poly(3-hydroxybutyrate) homopolymer blended with b) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate); a) a poly(3-hydroxybutyrate) homopolymer blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyvalerate); a) a poly(3-hydroxybutyrate) homopolymer blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate); a) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyvalerate); a) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) or a) a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate);
a polymer blend of a) a poly(3-hydroxybutyrate) homopolymer blended with b) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 5% to 15% 4-hydroxybutyrate content; a) a poly(3-hydroxybutyrate) homopolymer blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content; a) a poly(3-hydroxybutyrate) homopolymer blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content; a) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 5% to 15% 4-hydroxybutyrate content blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content; a) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with 5% to 15% 4-hydroxybutyrate content blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content or a) a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content;
a polymer blend of a) a poly(3-hydroxybutyrate) homopolymer blended with b) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b); a) a poly(3-hydroxybutyrate) homopolymer blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b); a) a poly(3-hydroxybutyrate) homopolymer blended to with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) and the weight of polymer a) is 5% to 95% of the and polymer b a a oly(3-hydroxybutyrate-co-4-hydroxbutyrate) blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b); a) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) blended with b) a poly(3-hydroxbutrate-co-3-hdroxhexanoate) and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b); or a) a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b); wherein the weight of polymer a) is 20% to 60% of the combined weight of polymer a) and polymer b) and the weight of polymer b) is 40% to 80% of the combined weight of polymer a) and polymer b);
a polymer blend of a) poly(3-hydroxybutyrate) homopolymer blended with b) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content; a) a poly(3-hydroxybutyrate) homopolymer blended with b) a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate content; a) a poly(3-hydroxybutyrate) homopolymer blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content; a) poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 5% to 15% 4-hydroxybutyrate content blended with b) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content; a) poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 5% to 15% 4-hydroxybutyrate content blended with b) a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate content; a) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with 5% to 15% 4-hydroxybutyrate content blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content; a) a poly(3-hydroxybutyrate-co-3-hydroxvvalerate) with a 5% to 22% 3-hydroxyvalerate content blended with b) poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content; a) a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content blended with b) a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate content; a) a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content; a) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content blended with b) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content; a) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content blended with b) a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate; or a) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content;
a polymer blend of a) a poly(3-hydroxybutyrate) homopolymer blended with b) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b); a) a poly(3-hydroxybutyrate) homopolymer blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate content and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b); a) a poly(3-hydroxybutyrate) homopolymer blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b);
a copolymer blend of a) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 5% to 15% 4-hydroxybutyrate content blended with b) poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b);a) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 5% to 15% 4-hydroxybutyrate content blended with b) poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate and the weigt of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b); a) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 5% to 15% 4-hydroxybutyrate content blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b);
a copolymer blend of a) a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content blended with b) poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b); a) a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content blended with b) a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b); a) a poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 5% to 22% 3-hydroxyvalerate content blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b);
a copolymer blend of a) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content blended with b) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20-50% 4-hydroxybutyrate content and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b); a) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content blended with b) a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b); or a) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 3% to 15% 3-hydroxyhexanoate content blended with b) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) having a 5%-50% 3-hydroxyhexanoate content and the weight of polymer a) is 5% to 95% of the combined weight of polymer a) and polymer b); wherein the weight of polymer a) is 20% to 60% of the combined weight of polymer a) and polymer b) and the weight of polymer b is 40% to 80% of the combined weight of polymer a) and polymer b).

20-27. (canceled)

28. The method of claim 1, wherein the biologically-produced polyhydroxyalkanoate is further blended with polymer c) a poly(3-hydroxybutyrate-co-4-hydroxybutyrate) with a 20% to 50% 4-hydroxybutyrate content; a poly(3-hydroxybutyrate-co-5-hydroxyvalerate) with a 20% to 50% 5-hydroxyvalerate content or c) a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) with a 5% to 50% 3-hydroxyhexanoate content.

29-30. (canceled)

31. The method of claim 28, wherein the weight of polymer c) is 5% to 95% of the combined polymer weight of polymer a), polymer b) and polymer c) or the weight of polymer c is 5% to 40% of the combined polymer weight of polymer a), polymer b) and polymer c).

32. (canceled)

33. An article comprising the branched polymer made by the method of claim 1.

34. The article of claim 33, wherein the article is a utensil, tub, bowl, lid, cup lid, yogurt cup, container, bottle, bottle-like containers, or other container-type items.

35. A thermoformed article comprising a branched PHA produced by branching a starting polyhydroxyalkanoate polymer (PHA), comprising the steps of:

a) thermolysing the starting PHA to reduce its molecular weight between 25% and 75% from its starting molecular weight,
b) reacting the thermolysed PHA from step a) with a branching agent at a temperature above the decomposition temperature of the branching agent, thereby forming a branched PHA, and
c) extruding and thermoforming the branched PHA into an article.

36. The article of claim 35, wherein the article is a utensil, tub, bowl, lid, cup lid, yogurt cup, container, bottle, bottle-like containers, or other container-type items.

37. (canceled)

38. An article comprising the branched polymer of claim 19.

39. The article of claim 38, wherein the article is thermoformed.

Patent History
Publication number: 20110293865
Type: Application
Filed: Jun 19, 2009
Publication Date: Dec 1, 2011
Applicant: Metabolix, Inc. (Cambridge, MA)
Inventors: Allen R. Padwa (Worcester, MA), Yelena Kann (Marblehead, MA)
Application Number: 13/000,959