CA2622032A1 - Aluminum containing polyester polymers having low acetaldehyde generation rates - Google Patents

Aluminum containing polyester polymers having low acetaldehyde generation rates Download PDF

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CA2622032A1
CA2622032A1 CA002622032A CA2622032A CA2622032A1 CA 2622032 A1 CA2622032 A1 CA 2622032A1 CA 002622032 A CA002622032 A CA 002622032A CA 2622032 A CA2622032 A CA 2622032A CA 2622032 A1 CA2622032 A1 CA 2622032A1
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atoms
aluminum
polyester
melt
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CA2622032C (en
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Mary Therese Jernigan
Rodney Scott Armentrout
Kenrick Lyle Venett
Bruce Roger Debruin
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Grupo Petrotemex SA de CV
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
    • C08L67/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/78—Preparation processes
    • C08G63/82—Preparation processes characterised by the catalyst used
    • C08G63/84—Boron, aluminium, gallium, indium, thallium, rare-earth metals, or compounds thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C61/00—Shaping by liberation of internal stresses; Making preforms having internal stresses; Apparatus therefor
    • B29C61/06—Making preforms having internal stresses, e.g. plastic memory
    • B29C61/0608—Making preforms having internal stresses, e.g. plastic memory characterised by the configuration or structure of the preforms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D23/00—Details of bottles or jars not otherwise provided for
    • B65D23/08—Coverings or external coatings
    • B65D23/0807—Coatings
    • B65D23/0814—Coatings characterised by the composition of the material
    • B65D23/0828—Coatings characterised by the composition of the material consisting mainly of paints or lacquers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/02—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/02—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds
    • C08G63/12—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds derived from polycarboxylic acids and polyhydroxy compounds
    • C08G63/16—Dicarboxylic acids and dihydroxy compounds
    • C08G63/18—Dicarboxylic acids and dihydroxy compounds the acids or hydroxy compounds containing carbocyclic rings
    • C08G63/181—Acids containing aromatic rings
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/02—Elements
    • C08K3/08—Metals
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/02—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds
    • C08G63/06—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds derived from hydroxycarboxylic acids
    • C08G63/065—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds derived from hydroxycarboxylic acids the hydroxy and carboxylic ester groups being bound to aromatic rings
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/02—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds
    • C08G63/12—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds derived from polycarboxylic acids and polyhydroxy compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/32—Phosphorus-containing compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/0091—Complexes with metal-heteroatom-bonds

Abstract

A polyester polymer composition containing polyester polymers such as polymers having repeating ethylene terephthalate units, aluminum atoms in an amount of at least 3 ppm based on the weight of the polymer, the polyester polymers having an It.V. of at least 0.72 dL/g obtained through a melt phase polymerization and a residual acetaldehyde level of 10 ppm or less. Also provided are polyester polymer compositions containing polyester polymers and : (i) aluminum atoms (ii) alkaline earth metal atoms or alkali metal atoms or alkali compound residues, and (iii) a catalyst deactivator such as a phosphorus compound. The phosphorus compound is added to the polyester melt either late in the polycondensation or upon remelting a solid polyester polymer. The polyester polymer exhibits good L* brightness, clarity, and low levels of acetaldehyde generated upon melting.

Claims (125)

1. A polyester polymer composition comprising: polyester polymers comprising repeating alkylene arylate units, and aluminum atoms in an amount of at least 3 ppm based on the weight of the polymer, said polymer having an lt.V. of at least 0.72 dL/g obtained through a melt phase polymerization, and a particle residual acetaldehyde level of 10 ppm or less
2. The composition of claim 1, wherein said polymer has repeating units comprising ethylene terephthalate, ethylene naphthalate, or trimethylene terephthalate.
3. The composition of claim 1, wherein said polymer has repeating units of ethylene terephthalate.
4. The composition of claim 3, wherein said composition further comprises alkaline earth metal atoms or alkali metal atoms or alkali compound residues.
5. The composition of claim 4, wherein said composition further comprises phosphorus atoms.
6. The composition of claim 5, wherein said composition further comprises phosphorus atoms added at the end of polycondensation in the melt phase.
7. The composition of claim 5, wherein the composition contains lithium atoms.
8. The composition of claim 5, wherein the composition contains sodium atoms.
9. The composition of claim 5, wherein the composition contains potassium atoms.
10. The composition of claim 3, wherein the composition contains aluminum atoms in an amount ranging from 3 ppm to 100 ppm based on the weight of the polyester polymer.
11. The composition of claim 10, wherein the composition contains aluminum atoms present in an amount ranging from 5 ppm to 60 ppm based on the weight of the polyester polymer.
12. The composition of claim 3, wherein the composition comprises aluminum atoms and alkali metal atoms comprising lithium atoms, sodium atoms, or potassium atoms, and the amount of aluminum is within a range of 3 ppm to 100 ppm based on the weight of the polyester polymer, and the molar ratio of said alkali metal atoms to aluminum atoms is within a range of 0.1 to 75.
13. The composition of claim 3, wherein the composition comprises aluminum atoms and alkali metal atoms comprising lithium atoms, sodium atoms, or potassium atoms, and the amount of aluminum is within a range of 5 ppm to 60 ppm based on the weight of the polyester polymer, and the molar ratio of said alkali metal atoms to aluminum atoms is within a range of 0.25 to 10.
14. The composition of claim 3, wherein the composition comprises aluminum atoms and alkali metal atoms comprising lithium atoms, sodium atoms, or potassium atoms, and the amount of aluminum is within a range of 5 ppm to 40 ppm based on the weight of the polyester polymer, and the molar ratio of said alkali metal atoms to aluminum atoms is within a range of 0.5 to 5.
15. The composition of claim 11, wherein the alkali metal comprises sodium.
16. The composition of claim 11, wherein the alkali metal comprises lithium.
17. The composition of claim 1, wherein the polyester polymers have an lt.V. of at least 0.76 dL/g obtained in the melt phase polymerization process.
18. The composition of claim 17, wherein the polyester polymers have an lt.V. of at least 0.80 dL/g obtained in the melt phase polymerization process.
19. The composition of claim 18, wherein the polyester polymers have an lt.V. of at least 0.84 dL/g obtained in the melt phase polymerization process.
20. The composition of claim 1, wherein the composition has an acetaldehyde generation rate of 18 ppm or less.
21. The composition of claim 1, wherein the composition has an acetaldehyde generation rate of 13 ppm or less.
22. The composition of claim 1, wherein the composition has an acetaldehyde generation rate of 10 ppm or less.
23. The composition of claim 1, wherein the composition has an acetaldehyde generation rate of 8 ppm or less.
24. The composition of claim 1, wherein the aluminum atoms are derived from aluminum compounds having at least one organic substituent.
25. The composition of claim 1, wherein the aluminum compounds having at least one organic substituent are represented by the formula:

Al[OR]a[OR']b[OR"]c[R''']d wherein R, R', R" are independently an alkyl group, aryl group, acyl group or hydrogen, R"' is an anionic group, and a, b, c, d are independently 0 or positive integers, and a+b+c+d is no greater than 3.
26. The composition of claim 25, wherein the aluminum compound comprises carboxylic acid salts of aluminum, substituted aluminum hydroxides, aluminum alcoholates, or aluminum chelates in which the alkoxy group of an aluminum alcoholate is partially or wholly substituted by a chelating agents.
27. The composition of claim 25, wherein the aluminum compounds comprise aluminum carboxylates, basic aluminum carboxylates or aluminum alkoxides , or a combination thereof.
28. The composition of claim 25, wherein a+b+c+d is equal to 3.
29. The composition of claim 25, wherein the aluminum compounds comprise aluminum carboxylates, basic aluminum carboxylates or aluminum alkoxides , or a combination thereof.
30. The composition of claim 1, wherein the aluminum atoms are obtained from aluminum compounds dispersed or dissolved in a diluent or a carrier reactive with one or more polyester forming ingredients or are contained within a polyester polymer concentrate
31. The composition of claim 1, further comprising alkaline earth metal or alkali metals, wherein the molar ratio of the alkali metal atoms to aluminum atoms is 0.1 to 75.
32. The composition of claim 31, wherein the molar ratio is within a range of 0.5 to 10.
33. The composition of claim 1, wherein the polyester polymer is made without the addition of cobalt to the melt phase process for the manufacture of said polyester polymer.
34. The composition of claim 1, wherein the composition contain less than 5 ppm catalytically active titanium atoms.
35. The composition of claim 1, wherein the composition contain less than 3 ppm catalytically active titanium atoms.
36. The composition of claim 1, wherein the polyester polymers are made without the addition of atoms of titanium, cobalt, antimony, or germanium in amounts and forms which are effective to catalyze a polyester melt and increase its lt.V. from a starting point of 0.2 to 0.4 dL/g by 0.1 dL/g or more after 1 hour at 280°C and 0.8 mm Hg.
37. The composition of claim 1, wherein the polyester polymer is made without the addition of any catalyst metal atoms other than one or more sources of aluminum atoms and one or more sources of alkaline earth metal atoms or alkali metal atoms to a melt phase process for making the polyester polymers.
38. The composition of claim 37, further comprising the residues of a catalyst deactivator.
39. The composition of claim 1, further comprising the phosphorus atoms.
40. The composition of claim 39, wherein said phosphorus atoms are obtained from phosphorus compound catalyst deactivators.
41. The composition of claim 39, wherein said phosphorus atoms are obtained from phosphoric acid, phosphorous acid, polyphosphoric acid, pyrophosphoric acid, carboxyphosphonic acids, phosphonic acid derivatives, or each of their salts and esters and derivatives.
42. The composition of claim 41, wherein said phosphorus atoms are obtained from a phosphoric acid composition or their ester derivatives.
43. The composition of claim 42, wherein said phosphoric acid composition comprises 95% phosphoric acid.
44. The composition of claim 31, further comprising phosphorus atoms, wherein the ratio of moles of phosphorus P to the cumulative total moles M of aluminum, alkaline earth metals and alkali metals ranges from 0.1 to 3.
45. The composition of claim 44, wherein the P:M ratio ranges from 0.5 to 1.5.
46. The composition of claim 1, wherein said composition has a degree of crystallinity of at least 30%, an AA generation rate of 20 ppm or less, an L* of at least 60, and an It.V. of at least 0.76 dL/g obtained in a melt phase polymerization.
47. The composition of claim 46, wherein said composition has an AA generation rate of 15 ppm or less,.
48. The composition of claim 1, wherein said composition has a degree of crystallinity of at least 40%,and an AA generation rate of 10 ppm or less, .
49. The composition of claim 1, wherein the polyester polymer comprises:
(a) a carboxylic acid component comprising at least 90 mole% of the residues of terephthalic acid, derivatives of terephthalic acid, naphthalene-2,6-dicarboxylic acid, derivatives of naphthalene-2,6-dicarboxylic acid, or mixtures thereof, and (b) a hydroxyl component comprising at least 90 mole% of the residues of ethylene glycol or 1,3-propanediol, based on 100 mole percent of carboxylic acid component residues and 100 mole percent of hydroxyl component residues in the polyester polymer, and the amount of aluminum is within a range of 3 ppm to 100 ppm based on the weight of the polyester polymer, said composition further comprising alkali metal atoms and phosphorus (P) atoms, and the molar ratio of alkali metal to aluminum is within a range of 0.1 to 10, and the molar ratio of phosphorus to the cumulative moles of aluminum atoms and alkali atoms (P:M) ranges from 0.1 to 3.
50. The composition of claim 39, wherein the polyester polymer comprises (a) a carboxylic acid component comprising at least 95 mole% of the residues of terephthalic acid and derivates of terephthalic acid, and (b) a hydroxyl component comprising at least 95 mole% of the residues of ethylene glycol, based on 100 mole percent of carboxylic acid component residues and 100 mole percent of hydroxyl component residues in the polyester polymer, and the amount of aluminum ranges from 7 ppm to 60 ppm based on the weight of the polyester polymer, and the molar ratio of alkali metal to aluminum atoms is within a range of 0.5 to 5, and the P:M molar ratio ranges from 0.3 to 2.
51. The composition of claim 50, wherein the amount of aluminum ranges from 10 ppm to 40 ppm based on the weight of the polyester polymer, and the molar ratio of alkali metal to aluminum atoms is within a range of 0.5 to 5, and the P:M molar ratio ranges from 0.5 to 1.5.
52. A bottle preform obtained from the composition of any one of claims 1-51.
53. A polyester composition comprising polyester polymers and:

(i) aluminum atoms (ii) alkaline earth metal atoms or alkali metal atoms or alkali compound residues, and (iii) a catalyst deactivator residue effective to at least partially deactivate the catalytic activity of the combination of said (i) aluminum atoms and (ii) alkaline earth metal atoms or alkali metal atoms or alkali compound residues.
54. The composition of claim 53, wherein said polyester polymer comprises repeating units of ethylene terephthalate.
55. The composition of claim 54, wherein said catalyst deactivator comprises phosphorus atoms.
56. The composition of claim 55, wherein the alkaline earth metal or alkaline metal atoms or alkali compound residues comprise lithium atoms.
57. The composition of claim 55, wherein the amount of aluminum is within a range of 5 ppm to 100 ppm based on the weight of the polyester polymer
58. The composition of claim 57, wherein the It.V. of the polyester composition is at least 0.76 dL/g obtained from a melt phase polycondensation process.
59. The composition of claim 58, wherein the polyester polymer comprises:
(a) a carboxylic acid component comprising at least 80 mole% of the residues of terephthalic acid or derivatives of terephthalic acid, and (b) a hydroxyl component comprising at least 80 mole% of the residues of ethylene glycol, based on 100 mole percent of carboxylic acid component residues and 100 mole percent of hydroxyl component residues in the polyester polymer.
60. The composition of claim 59, wherein the polyester polymer comprises (a) a carboxylic acid component comprising at least 90 mole% of the residues of terephthalic acid and derivates of terephthalic acid, and (b) a hydroxyl component comprising at least 90 mole% of the residues of ethylene glycol, based on 100 mole percent of carboxylic acid component residues and 100 mole percent of hydroxyl component residues in the polyester polymer.
61. The composition of claim 54, wherein the amount of phosphorus ranges from 10 ppm to 300 ppm.
62. The composition of claim 53, wherein the polyester polymers have an It.V. of at least 0.76 dL/g obtained in a melt phase polymerization.
63. The composition of claim 53, having an acetaldehyde generation rate of less than 18 ppm or less.
64. The composition of claim 53, having an acetaldehyde generation rate of 13 ppm or less.
65. The composition of claim 53, having an acetaldehyde generation rate of 10 ppm or less.
66. The composition of claim 53, wherein the aluminum atoms are derived from aluminum compounds represented by the formula:
Al[OR]a[OR']b[OR"]c[R''']d wherein R, R', R" are independently an alkyl group, aryl group, acyl group or hydrogen, R"' is an anionic group, and a, b, c, d are independently 0 or positive integers, and a+b+c+d is no greater than 3.
67. The composition of claim 66, wherein the aluminum organic compound comprises carboxylic acid salts of aluminum, substituted aluminum hydroxides, aluminum alcoholates, or aluminum chelates in which the alkoxy group of an aluminum alcoholate is partially or wholly substituted by a chelating agents.
68. The composition of claim 66, wherein the aluminum compounds comprise aluminum carboxylates, aluminum alcoholate or substituted aluminum hydroxides or a combination thereof.
69. The composition of claim 53, wherein the aluminum atoms are obtained from an aluminum compound dissolved, slurried or dispersed in a diluent or a carrier reactive with one or more polyester forming ingredients or are contained in a solid polyester polymer concentrate.
70. The composition of claim 53, wherein the molar ratio of the alkaline earth metal or alkali metal to aluminum ranges from 0.1:1 to 10:1.
71. The composition of claim 70, wherein the molar ratio of the alkaline earth metal or alkali metal to aluminum is within a range of 1:1 to 5:1.
72. The composition of claim 53, wherein the polyester polymer is made without the addition of cobalt to the melt phase process for the manufacture of said polyester polymer.
73. The composition of claim 53, wherein the composition contain less than 5 ppm catalytic titanium atoms.
74. The composition of claim 53, wherein the polyester polymers are made without the addition after esterification of atoms of titanium, cobalt, antimony, or germanium effective to catalyze a polyester melt and increase its It.V. by 0.1 dL/g or more as measured starting with a polyester polymer It.V. ranging from 0.2 dL/g to 0.4 dL/g, at 1 hour at 280°C
and 0.8 mmHg..
75. The composition of claim 53, wherein the polyester polymer is made without the addition of any catalyst metal compound other than one or more aluminum compounds and one or more of alkaline earth metal compounds or alkali metal compounds to a melt phase process for making the polyester polymers.
76. The composition of claim 53 wherein said deactivator residues comprises the residues of acidic phosphorus compounds or their ester derivatives or mixtures thereof.
77. The composition of claim 76, wherein said acidic phosphorus compounds comprise phosphoric acid, pyrophosphoric acid, phosphorous acid, polyphosphoric acid, carboxyphosphonic acids, phosphonic acid derivatives, or each of their salts and esters and derivatives or mixtures thereof.
78. The composition of claim 77, wherein the molar ratio of phosphorus to the cumulative total of aluminum, alkaline earth metals and alkali metals ranges from 0.05:1 to 3.0:1.
79. The composition of claim 78, wherein the molar ratio of phosphorus to the cumulative total of aluminum, alkaline earth metals and alkali metals ranges from 0.5:1 to 2:1.
80. The composition of claim 53, having an AA generation rate of 15 or less, and L* of at least 60, and having an It.V. of at least 0.76 dL/g obtained in a melt phase polymerization.
81. A bottle preform obtained from the composition of any one of claims 53 through 80.
82. The bottle preform of claim 81, wherein the bottle preform has a residual acetaldehyde content of 8 ppm or less.
83. The bottle preform of claim 82, wherein the bottle preform has a residual acetaldehyde content of 6 ppm or less.
84. A continuous process for the manufacture of polyester polymers, comprising adding phosphorus atoms to a polyester melt, said polyester melt containing a) aluminum atoms and b) alkaline earth metal atoms or alkali metal atoms or alkali compound residues, wherein said phosphorus atoms are added to the polyester melt when one or more of the following conditions are satisfied or thereafter and before solidification of the polyester melt:
a) the polyester melt reaches an It.V. of at least 0.50 dL/g or b) vacuum applied to the polyester melt, if any, is at least partially released, or c) if the polyester melt is present in a melt phase polymerization process, adding the phosphorus compound within a final reactor for making the polyester polymer or after the final reactor and before a cutter for cutting the polyester melt, or d) if the polyester melt is present in a melt phase polymerization process, following at least 85% of the time for polycondensing the polyester melt; or e) the It.V. of the polyester melt is within +/- 0.15 dl/g of the It.V.
obtained upon solidification; or f) at a point within 20 minutes or less of solidifying the polyester melt.
85. The process of claim 84, wherein the polyester polymer melt is present in a melt phase process for the manufacture of said polyester polymer.
86. The process of claim 84, wherein the polyester melt is present in a melt processing zone for the manufacture of an article.
87. The process of claim 86, wherein said melt processing zone comprises an extruder barrel.
88. The process of claim 87, wherein said melt processing zone comprises a barrel of an injection molding machine.
89. The process of claim 84, wherein the phosphorus atoms are added to the polyester melt after the polyester melt obtains an It.V. of at least 0.74 dL/g.
90. The process of claim 84, wherein the phosphorus atoms are added to the polyester melt after bringing the pressure in a final reactor to a level of 600 mm Hg or greater and before the polyester melt is solidified.
91. The process of claim 84, wherein the phosphorus atoms are added at a location near or at the end of a final reactor or after the final reactor and before a cutter for cutting the polyester polymer melt into particles.
92. The process of claim 84, wherein the phosphorus atoms are added to a final reactor for polycondensing the polyester melt through a pipe inlet, said phosphorus atoms contained within a portion of the polyester polymer exiting the final reactor and recirculated back to the final reactor.
93. The process of claim 84, wherein the phosphorus atoms are added to the polyester melt following at least 95% of the polycondensation time.
94. The process of claim 84, wherein the phosphorus atoms are added to the polyester melt when the It.V. of the polyester melt is within 0.05 dL/g of the polymer It.V. upon solidification.
95. The process of claim 84, wherein the phosphorus atoms are added to the polyester melt within 10 minutes or less of solidifying the polyester melt.
96. The process of claim 84, wherein the process comprises a melt phase continuous polymerization process having throughput of at least 1 ton/day in a steady state operation.
97. The process of claim 96, wherein the throughput is at least 300 tons/day.
98. The process of claim 84, wherein the reaction time of the polyester melt from an It.V. of 0.40 dL/g through and up to an It.V. in the range of at least 0.68 dL/g is 150 minutes or less.
99. The process of claim 98, wherein the reaction time is 90 minutes or less.
100. The process of claim 84, wherein the It.V. of the polyester melt upon solidification is between 0.82 dL/g and 0.92 dL/g prior to adding the phosphorus atoms.
101. The process of claim 84, wherein vacuum is applied in a final polycondensation reactor at a pressure between 0. 5 and 1.0 torr and at a temperature between 270°C to 285°C.
102. The process of claim 84, wherein the polyester polymer comprises:
(a) a carboxylic acid component comprising at least 80 mole% of the residues of terephthalic acid or derivatives of terephthalic acid, and (b) a hydroxyl component comprising at least 80 mole% of the residues of ethylene glycol, based on 100 mole percent of carboxylic acid component residues and 100 mole percent of hydroxyl component residues in the polyester polymer.
103. Finished polyester polymer particles having an average It.V. of at least 0.74 dL/g obtained in a melt phase polymerization and a residual acetaldehyde level of 5 ppm or less, wherein said particles have a degree of crystallinity of at least 30% and contain aluminum atoms in an amount of at least 10 ppm based on the weight of the polyester polymer.
104. The particles of claim 103, contained in a shipping container.
105. The particles of claim 103, containing a nonzero amount of alkaline earth metal atoms or alkali metal atoms, and a nonzero amount of phosphorus atoms.
106. The particles of claim 105, wherein the acetaldehyde generation rate of said particles is less than 15 ppm.
107. The particles of claim 106, wherein the particles have an acetaldehyde generation rate of less than 10 ppm.
108. The particles of claim 105, wherein the particles have an L* brightness of at least 60.
109. The particles of claim 108, having an L* brightness of at least 73.
110. The particles of claim 103, wherein the particles lack organic acetaldehyde scavengers.
111. The particles of claim 103, wherein the particles are not solid state polymerized.
112. The particles of claim 103, wherein the particles are fed to an injection molding machine for converting the particles into articles.
113. The particles of claim 112, wherein the particles are molded into bottle preforms.
114. The particles of claim 113, wherein the particles are molded into preforms at a temperature in a range of 280°C to 290°C with a melt residence time of 2 minutes or less, wherein the preforms have an L*
brightness of 65 or more.
115. An article obtained by feeding pellets to a melt processing zone, melting the pellets to form a polyester melt, and forming an article from the polyester melt, wherein said pellets having an It.V. of at least 0.72 dL/g and have not been solid state polymerized, said pellets comprising polyester polymers and:
a) aluminum atoms; and b) alkaline earth atoms or alkali metal atoms or alkali compound residues; and c) phosphorus atoms wherein said article has an acetaldehyde level of less than 11 ppm.
116. The article of claim 115, wherein said article is a bottle preform.
117. The article of claim 116, wherein the bottle preform is made without the addition of organic acetaldehyde scavengers.
118. The article of claim 116, wherein the It.V. of the pellets is at least 0.76 dL/g.
119. The article of claim 115, wherein the acetaldehyde level is 7 ppm or less.
120. The article of claim 115, wherein the pellets contain phosphorus atoms in an amount of at least 20 ppm.
121. The article of claim 115, wherein the article has an L* of at least 70.
122. The article of claim 115, wherein the acetaldehyde level is 4 ppm or less.
123. A continuous process for the manufacture of polyester polymers, comprising adding phosphorus atoms to a polyester melt, said polyester melt containing a) aluminum atoms and b) alkaline earth metal atoms or alkali metal atoms or alkali compound residues, wherein said phosphorus atoms are added to a final polycondensation reactor, wherein the melt exits said final polycondensation reactor through a conduit, a portion of the melt is taken from the conduit as a slipstream, the phosphorus atoms are added to the slipstream to produce a phosphorus containing slipstream, and the phosphorus containing slipstream is added to melt in the final polycondensation reactor.
124. The process of claim 123, wherein the phosphorus containing slipstream is distributed within the final reactor through a distributor plate.
125. The process of claim 124, wherein the distributor plate has te an inlet to receive the phosphorus containing slipstream, said slipstream flowing through a plurality of channels in the plate and exiting through the channel outlets into the final reactor..
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