# US 10,442,114 B2 · Compartmentalized resin pellets

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- Number: US 10,442,114 B2
- Document ID: US10442114B2
- Status: Granted
- Kind: B2
- Application number: 15/578,878
- Filed: 2016-06-03
- Published: 2019-07-18
- Granted: 2019-10-15
- Earliest claimed: 2015-06-05
- Assignees: APG Polytech, LLC
- Applicants: M & G USA Corporation
- Inventors: Gianluca Ferrari
- Web page: https://patentgrep.com/patent/US10442114B2

## CPC

- B29B 9/12: characterised by structure or composition
- C08G 63/78: Preparation processes
- C08G 63/80: Solid-state polycondensation
- C08G 63/85: Germanium, tin, lead, arsenic, antimony, bismuth, titanium, zirconium, hafnium, vanadium, niobium, tantalum, or compounds thereof {(C08G63/823 takes precedence)}
- C08G 63/916: {Dicarboxylic acids and dihydroxy compounds}
- C08J 3/126: {Polymer particles coated by polymer, e.g. core shell structures}
- C08K 5/51: Phosphorus bound to oxygen
- C08L 67/02: Polyesters derived from dicarboxylic acids and dihydroxy compounds (C08L67/06 takes precedence)
- B29B 9/06: in the form of filamentary material, e.g. combined with extrusion
- B29B 9/065: {under-water, e.g. underwater pelletizers}
- B29B 2009/163: {Coating, i.e. applying a layer of liquid or solid material on the granule}
- B29C 48/04: Particle-shaped (making granules B29B9/00)
- B29C 48/05: Filamentary, e.g. strands
- B29C 48/19: the layers being joined at their edges
- B29C 48/21: the layers being joined at their surfaces
- B29C 48/23: with means for avoiding adhesion of the layers, e.g. for forming peelable layers
- C08G 63/183: Terephthalic acids
- C08J 2367/02: Polyesters derived from dicarboxylic acids and dihydroxy compounds; (C08J2367/06 takes precedence)
- C08J 2467/02: Polyesters derived from dicarboxylic acids and dihydroxy compounds (C08J2467/06 takes precedence)
- C08L 2207/53: Core-shell polymer
- C08L 2310/00: Masterbatches
- B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)

## Abstract

Disclosed herein is a resin pellet and a process to make said resin pellet. The resin pellet comprises a major polyester comprising a catalytic titanium compound, and a minor polyester comprising a phosphorus compound. The major polyester is present in a first compartmentalized zone of the resin pellet and the minor polyester is present in a second compartmentalized zone of the resin pellet.

## Claims

### Claim 1

A process for maintaining the catalytic activity of a catalytic titanium compound in a polyester resin during polymerization comprising the steps of:
A. melt phase polymerizing a first polyester comprising the catalytic titanium compound in the absence of a deactivating amount of a phosphorus compound,
B. manufacturing a compartmentalized pellet comprising a first compartmentalized zone and a second compartmentalized zone wherein the first compartmentalized zone comprises the first polyester and the second compartmentalized zone comprises a second polyester comprising a phosphorus compound,
C. blending the compartmentalized resin pellet into an article by melt mixing and making an article,
wherein the amount of phosphorus from the phosphorus compound to the amount of titanium from the catalytic titanium compound in step A is in a mole ratio selected from the group consisting of at least 0.1:1.0, at least 0.2:1.0, at least 0.5:1.0, at least 0.7:1.0, and at least 1.0:1.0.

### Claim 2 (depends on 1)

The process of claim 1, wherein the second polyester comprises a deactivated titanium compound.

### Claim 3 (depends on 1)

The process of claim 1, wherein the titanium from the catalytic titanium compound is present in the first polyester at a level selected from the group consisting of between 2 ppm and 400 ppm, between 2 ppm and 300 ppm, between 2 ppm and 100 ppm, and between 2 ppm and 20 ppm.

### Claim 4 (depends on 1)

The process of claim 1, wherein the catalytic titanium compound is selected from the group consisting of titanium alkoxides and their derivatives, titanium complex salts, titanium complexes with hydroxycarboxylic acids, titanium dioxide-silicon dioxide-co-precipitates, and hydrated alkaline or alkaline earth salts-co-titanium dioxide.

### Claim 5 (depends on 1)

The process of claim 1, wherein the phosphorus from the phosphorus compound is present in the second polyester at a level selected from the group consisting of between 1 ppm and 20000 ppm, between 1 ppm and 10000 ppm, between 1 ppm and 5000 ppm, between 1 ppm and 1000 ppm, between 1 ppm and 700 ppm, between 1 ppm and 500 ppm, between 1 ppm and 300 ppm, and between 1 ppm and 200 ppm.

### Claim 6 (depends on 1)

The process of claim 1, wherein the phosphorus compound is selected from the group consisting of phosphate acids or esters or combinations thereof, phosphite esters, phosphonic acids or esters or combinations thereof, phosphinic acids or esters or combinations thereof, phosphines which do not catalyze the reaction of acetaldehyde with oxygen, phosphine oxide, and phosphorus pentoxide.

### Claim 7 (depends on 1)

The process of claim 1, wherein the first polyester and the second polyester are of the same polyester composition.

### Claim 8 (depends on 1)

The process of claim 1, wherein the first polyester and the second polyester comprise at least 90% by weight of the compartmentalized pellet.

### Claim 9 (depends on 1)

The process of claim 1, wherein the first compartmentalized zone is a sheath and the second compartmentalized zone is a core.

### Claim 10 (depends on 9)

The process of claim 9, wherein the core is encapsulated by the sheath.

### Claim 11 (depends on 1)

The process of claim 1, wherein the second compartmentalized zone is a sheath and the first compartmentalized zone is a core.

### Claim 12 (depends on 11)

The process of claim 11, wherein the core is encapsulated by the sheath.

### Claim 13 (depends on 1)

The process of claim 1, wherein the first compartmentalized zone is a first layered sheet and the second compartmentalized zone is a second layered sheet.

### Claim 14 (depends on 13)

The process of claim 13, wherein the first layered sheet is next to the second layered sheet.

### Claim 15 (depends on 1)

The process of claim 1, wherein the compartmentalized pellet in step B further comprises a third compartmentalized zone wherein the first compartmentalized zone is a first layered sheet, the second compartmentalized zone is a second layered sheet, the third compartmentalized zone is a third layered sheet, the second polyester is present in the second compartmentalized zone and the first polyester is present in the first compartmentalized zone and the third compartmentalized zone.

### Claim 16 (depends on 15)

The process of claim 15, wherein the second layered sheet is between the first layered sheet and the third layered sheet.

### Claim 17 (depends on 1)

The process of claim 1, wherein the first compartmentalized zone and the second compartmentalized zone are configured in a side-by-side configuration whereby neither compartmentalized zone surrounds the other compartmentalized zone in any plane of the pellet.

### Claim 18 (depends on 1)

The process of claim 1, wherein the first compartmentalized zone is void of any deactivated titanium compound.

### Claim 19 (depends on 1)

The process of claim 1, wherein the first compartmentalized zone is void of any phosphorus compound.