# US 12,024,593 B2 · Method of making an acid neutralizing polymer through reactive compounding

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- Number: US 12,024,593 B2
- Document ID: US12024593B2
- Status: Granted
- Kind: B2
- Application number: 17/692,856
- Filed: 2022-03-11
- Published: 2022-09-15
- Granted: 2024-07-02
- Earliest claimed: 2021-03-12
- Assignees: Workers First LLC
- Applicants: Workers First LLC
- Inventors: Matthew James Borowiak, Jr.; Richard Earl Partch; David Geraint Roberts
- Web page: https://patentgrep.com/patent/US12024593B2

## CPC

- C08G 69/48: Polymers modified by chemical after-treatment
- C08K 3/22: of metals
- C08K 5/057: Metal alcoholates {(metal enolates C08K5/0091)}
- C08K 2003/2206: {of calcium, strontium or barium}
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)

## Abstract

A method of making an acid neutralizing polymer includes: a) preparing a first reaction mixture by blending of a polyamide material, a solid strongly basic material, and a halogenated-dimethylalkylamine; b) adding the first reaction mixture to a first compounding machine; c) reacting the first reaction mixture for a time and at a temperature sufficient to produce a first reaction product; d) preparing a second reaction mixture including the polyamide material; e) adding the second reaction mixture to a second compounding machine; f) reacting the second reaction mixture for a time and at a temperature sufficient to produce a second reaction product; g) preparing a third reaction mixture by blending the first reaction mixture and the second reaction mixture; h) adding the third reaction mixture to a third compounding machine; and i) reacting the third reaction mixture for a time and at a temperature sufficient to produce the acid neutralizing polymer.

## Claims

### Claim 1

A method of making an acid neutralizing polymer material, comprising:
a) preparing a first reaction mixture comprising a blend of a first amount of a polyamide material and a quaternary amine salt of a halogenated-dimethylalkylamine having a general chemical formula of (CH3)2N—R—X, wherein R is an alkyl containing 1-12 carbon atoms and X is either chlorine or bromine;
b) adding the first reaction mixture to a first compounding machine;
c) reacting the first reaction mixture for a time and at a temperature sufficient to produce a first reaction product comprising a deprotonated halogenated-dimethylalkylamine;
d) preparing a second reaction mixture comprising a second amount of the polyamide material and a solid, strongly basic material;
e) adding the second reaction mixture to a second compounding machine;
f) reacting the second reaction mixture for a time and at a temperature sufficient to produce a second reaction product comprising a an activated polyamide material;
g) preparing a third reaction mixture comprising a blend of the first reaction product and the second reaction product;
h) adding the third reaction mixture to a third compounding machine; and
i) reacting the third reaction mixture for a time and at a temperature sufficient to produce the acid neutralizing polymer material.

### Claim 2 (depends on 1)

The method of claim 1 further comprising:
j) cooling each of the first reaction product, second reaction product and third reaction product in respective cooling machines.

### Claim 3 (depends on 2)

The method of claim 2 further comprising:
k) reducing a particle size of each of the cooled first reaction product, the cooled second reaction product and the cooled third reaction product in respective size reduction machines.

### Claim 4 (depends on 3)

The method of claim 3 wherein the cooled first reaction product and the cooled second reaction product are size reduced prior to step (g).

### Claim 5 (depends on 1)

The method of claim 1 wherein one or both of the first reaction mixture and the second reaction mixture further comprise a heat stabilizing agent.

### Claim 6 (depends on 1)

The method of claim 1 wherein the first reaction mixture further comprises an acid neutralizing compound.

### Claim 7 (depends on 2)

The method of claim 2 wherein each of the respective cooling machines comprises a pH 10 basic buffer solution bath.

### Claim 8 (depends on 1)

The method of claim 1 wherein the polyamide material comprises nylon 6, nylon 66 or nylon 12.

### Claim 9 (depends on 1)

The method of claim 1 wherein the strongly basic material is potassium tert-butoxide (KOtBu) or calcium hydroxide (Ca(OH)2).

### Claim 10 (depends on 1)

The method of claim 1 wherein the halogenated-dimethylalkylamine is 2-chloro-N,N-dimethylethylamine.

### Claim 11 (depends on 1)

The method of claim 1 wherein the first, second and third compounding machines each comprises one or more twin screw extruders.

### Claim 12 (depends on 1)

The method of claim 1 wherein the first, second and third compounding machines are a single compounding machine.

### Claim 13 (depends on 1)

The method of claim 1 wherein the temperature of the first, second and third compounding machines is between about 194° C.and about 205° C.

### Claim 14 (depends on 3)

The method of claim 3 wherein each of the cooled first reaction product and the cooled second reaction product is sized reduced by pelletizing to a mean particle size of between about 2 and about 8 millimeters.

### Claim 15 (depends on 3)

The method of claim 3 wherein the cooled third reaction product is sized reduced through one or more of the steps of:
i) forming the cooled third reaction product into fibers for weaving into fabric material;
ii) pelletizing the cooled third reaction product for mixing with other polymers; or
iii) pulverizing the cooled third reaction product into a powder.

### Claim 16 (depends on 15)

The method of claim 15 wherein the sized reduced third reaction product is incorporated with a floor mat.