GB2336366A - Filled polyethylene compositions - Google Patents

Filled polyethylene compositions Download PDF

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Publication number
GB2336366A
GB2336366A GB9807658A GB9807658A GB2336366A GB 2336366 A GB2336366 A GB 2336366A GB 9807658 A GB9807658 A GB 9807658A GB 9807658 A GB9807658 A GB 9807658A GB 2336366 A GB2336366 A GB 2336366A
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United Kingdom
Prior art keywords
composition
weight
mineral filler
extrusion
particles
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GB9807658A
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GB9807658D0 (en
Inventor
David Anthony Taylor
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Imerys Minerals Ltd
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ECC International Ltd
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Application filed by ECC International Ltd filed Critical ECC International Ltd
Priority to GB9807658A priority Critical patent/GB2336366A/en
Publication of GB9807658D0 publication Critical patent/GB9807658D0/en
Publication of GB2336366A publication Critical patent/GB2336366A/en
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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/01Use of inorganic substances as compounding ingredients characterized by their specific function
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04Homopolymers or copolymers of ethene
    • C08L23/06Polyethene

Abstract

A filled low density polyethylene composition contains from 1% to 50% by weight, based on the total weight of the composition, of a particulate mineral filler which has a particle size distribution such that the weight average equivalent spherical diameter of the particles (d 50 ) is not more than 0.8Ám and not more than 0.5% by weight of the particles have an equivalent spherical diameter larger than 10Ám. The Filler, which may be coated with a hydrophobising agent, is preferably calcium carbonate. The compositions are heated and extruded.

Description

2336366 FILLED THERMOPLASTIC COMPOSITIONS The present invention concerns
filled thermoplastic compositions, and, in particular, filled low density polyethylene compositions which are to be formed into products or articles by the process of extrusion.
Articles which can be formed from filled synthetic plastics compositions by the extrusion process include tubes, pipes, ducting for electrical cables, cable sheathing, window frame profiles and the like. It is often found that when a low density polyethylene composition containing a particulate solid filler is formed into a solid article by extrusion, a lip of material derived from the feed composition builds up around the periphery of the aperture(s) of the die. This spoils the surface finish of the extruded article and can also build up to such an extent that it reduces the width of the aperture(s) of the die, and thus alters the dimensions of the extruded article.
According to the present invention in a first aspect there is provi a filled low density polyethylene composition containing from 1-. to 50% by weight, based on the total weight of the composition, of a fine, particulate mineral filler which has a particle size distribution such that the weight average equivalent spherical diameter of the particles (d_,,)) is not more than 0.8gm and not more than 0.5% by weight of the particles have an equivalent spherical diameter larger than 1Ogm.
The particulate mineral filler preferably comprises a calcium carbonate, in either the ground natural or the chemically precipitated form, a kaolinitic clay or a calcined kaolinitic clay. However, the particulate mineral filler may also comprise, for example, talc, mica, alumina, bauxite, alumina trihydrate, silica, titanium dioxide, calcium sulphate, barium sulphate, a silicate of calcium or aluminium, a carbonate or hydroxide of magnesium, or a mixture of any two or more of the above mentioned mineral fillers. In the case of silicates of aluminium and calcium, silica, carbonates and hydroxides of magnesium, calcium sulphate, barium sulphate and titanium dioxide, the mineral may be either in a ground natural, or in a synthetic, form. Where the particulate mineral filler is synthetic, may be, for example, chemically precipitated. The particulate mineral fillers specified above are commonly regarded as "white,, mineral fillers; but the term "white" does not necessarily mean that the mineral has a pure white colour, but that the colour is substantially free of any strong non-white hue.
The particulate mineral filler preferably has a particle size distribution such that at least 90% by weight of the particles have an equivalent spherical diameter smaller than 2gm. The particulate mineral filler should also be substantially free of particles having an equivalent spherical diameter larger than 1Ogm. For example, the mineral filler should preferably not contain more than 0.2% by weight of particles having an equivalent spherical diameter larger than 1Ogm.
The particulate mineral filler is preferably coated with from 0.1% to 5. 0% by weight, eg 0.5% to 3.0%, based on the dry weight of the filler, of a hydrophobising agent, eg one of the agents known in the art. For example, the agent may comprise a compound which can by ionic attraction adhere or attach to the mineral particles and which has at least one saturated or unsaturated hydrocarbon chain having from 8 to 28 carbon atoms.
If the particulate mineral filler has a neutral to alkaline surface reaction, for example calcium carbonate, the hydrophobising agent is preferably an organic carboxylic acid or partially or fully neutralised salt thereof which has at least one saturated or unsaturated hydrocarbon chain having from 8 to 28 carbon atoms. Examples of such acids include unsaturated fatty acids selected from capric acid, lauric acid, montanic acid, myristic acid, palmitic acid, stearic acid, behenic acid, isostearic acid and cerotic acid and mixtures of two or more of these acids. For example so called technical grade stearic acid consists of about 65% by weight stearic acid and about 35% by weight palmitic acid. A hydrophobising agent including at least 60% by weight stearic acid is especially preferred.
If the particulate mineral filler has a neutral to acidic surface reaction, for example kaolinitic clay, the hydrophobising agent preferably has an alkaline reaction, for example a primary, secondary or tertiary amine, or a quaternary ammonium compound, which has at least one saturated or unsaturated hydrocarbon chain having from 8 to 22 carbon atoms. An especially preferred alkaline hydrophobising agent is formed by aminating hydrogenated tallow to give a mixture of primary amines with hydrocarbon chains having from 12 to 20 carbon atoms.
According to the present invention in a second aspect there is provided a method of use of the composition according to the first aspect which includes heating and extruding a material comprising the said composition.
The extrusion may be employed to produce a tube, pipe, ducting, sheathing, or other elongate article or product to be formed into an article having a selected cross-sectional shape formed by an extrusion die or dies. The extrusion die or dies used may have a greatest diameter not greater than 1Omm, eg not greater than Smm.
Heating and extrusion in the method according to the second aspect of the invention may be carried out by a conventional compounder/extruder machine, eg a twin screw compounder/extruder. Extrusion may be carried out simultaneously through multiple extrusion dies.
The composition according to the first aspect of the invention surprisingly and beneficially allows elongate articles and products to be extruded in the method of the second aspect using suitable mineral filler loadings, eg up to 50% by weight, usually up to 35% by weight, of the particulate filler in the thermoplastic composition, without the die lip build up problem experienced in the prior art. This is illustrated later.
Embodiments of the present invention will now be described by way of example with reference to the following illustrative Examples.
EXAMPLE 1 various particulate mineral fillers were incorporated into a low density polyethylene polymer (BOREALIS LE1870) Which contained an antioxidant, and -2 which had a density of 922 kg M and a melt flow rate of 2.0g. per 10 minutes. The melt flow rate was determined according to ASTM Standard No D 1238-79. This rate is a measure of how fast a molten polymer flows under a standard pressure at a standard temperature. The test involves the extrusion of the molten polymer from a dead-weight piston plastometer consisting of a thermostatically controlled heated steel cylinder with a die at the lower end and a weighted piston operating within the cylinder. The total mass of polymer collected during a specified time period is measured and the melt flow rate is expressed as the mass of polymer divided by the time. The pressure used was that exerted by a load of 2.16 kg, and the temperature was 1900C. The time during which the sample of molten polymer was collected was chosen in accordance with the flow properties of the particular polymer under test, and the result was expressed in grams of polymer which flowed out under these conditions in 10 minutes. The amount of filler incorporated in each case was 30% by weight, based on the total weight of the polymer and filler.
The filler/polymer mixtures were prepared by placing 2100g of polymer pellets and 900g of dry filler powder (fillers as described later) in a bag and tumbling the components together in a tumbler for a time, usually of a few minutes, which was observed to be sufficient to ensure complete mixing of the polymer pellets and the filler powder.
The characteristics of the particulate mineral fillers which were investigated in the filler/polymer mixtures are set forth in Table I as follows:
Table I
Coating % by wt. of particles Filler Mineral type Compound Amount Mean particle larger smaller (wt.%) diameter (dso) than than lOPM 2pm A (invention) calcium carbonate stearic: acid 3.0 0.4 0.1 99 B (invention) calcium carbonate stearic acid 1.5 0.6 0.1 93 C (invention) calcium carbonate stearic: acid 1.2 0.8 0.2 93 D (invention) calcium carbonate stearic acid 2.7 0.5 0.2 95 E (invention) kaolinitic clay pn 3.0 0.2 0 97 hydrogenated tallow Innine F (comparative) calcium carbonate steanc acid 1.0 1.7 1.0 60 G (comparative) calcium carbonate none 1.2 1.0 72 H (comparative) calcium carbonate stearic: acid 1.0 2.0 1.0 50 I (comparative) calcium carbonate none 2.0 1.9 50 Fillers A and B were prepared by introducing an aqueous suspension containing from 68 to 78-. by weight of a wet-ground natural calcium carbonate into a dry grinding apparatus of the type described in EPA-0681155 (DAG mill). Stearic acid was also introduced in an appropriate amount in the form of a dry flake by means of a solid metering device. Hot air was supplied to the dry grinding apparatus at a rate and at a temperature sufficient to ensure that the temperature of the air leaving the grinding apparatus was at least 800C, which is the melting point of the stearic acid.
Filler D was prepared by blending together 17 parts by weight of Filler A and 3 parts by weight of a filler which was prepared by coating with 1% by weight of stearic acid, based on the weight of dry filler, a calcium carbonate filler which had a particle size distribution such that the mean particle diameter (d5,) was 1.2, 1.09k by weight consisted of particles having an equivalent spherical diameter larger than 1Ogm and 72% by weight consisted of particles having an equivalent spherical diameter smaller than 2pm.
Each polymer/filler mixture was transferred (in turn, each in a separate experiment) to a hopper with a screw discharge which metered the mixture into a Baker Perkins co-rotating twin screw compounding extruder which was operated at a screw speed of from 270 to 280 rpm. The twin barrels of the compounding extruder, had an internal cross section which approximated to the shape of a figure of eight, and the two screws which rotated within these barrels were provided with flights of varying cross section, which were designed to move the polymer/filler mixture along the barrels, and thoroughly to mix the two components of the mixture. The rate at which the mixture was fed into the extruder was adjusted to give an extruder torque reading in the range of from 40 to 60%. The compounding extruder was electrically heated along its operative length, which was about 600 cm, to give a temperature profile of 1800C, 1850C, 1900C, 1950C, 2000C and 2050C, the lowest temperature being maintained at the feed end of the compounder, and the highest temperature at the extrusion end. The plastic polymer/ filler mixture was extruded through two circular dies each of diameter 5 mm and the extruded product was collected. The extrusion process was allowed to continue for a time such that a conveniently measurable quantity of extruded material had built up around the lips of the dies. The extruder was then stopped and the collected extruded product was weighed to give the quantity, Pkg, of polymer/filler mixture which had passed through the extruder during the duration of the test. The material which had built up round the lips of the dies was also carefully removed and weighed to give the quantity w mg. The die lip build-up rate (DBR) was given by the formula:
is DBR (mg/kg) = w / P The die lip build up rates measured for each of the nine filler/polymer mixtures are given in Table II as follows:
Table II
Filler Die lip build-up rate (mg.kg-1) A (invention) 0.9 B (invention) 0.9 C (invention) 1.6 D (invention) 1.0 E (invention) 2.2 F (comparative) 4.4 G (comparative) 5.5 H (comparative) 5.1 I (comparative) 7.4 These results show that the die lip build-up rate can be significantly reduced by using a composition embodying the present invention, ie incorporating fillers A to E.
Example 2
The test described in Example 1 was repeated for each of 16 different plastics compositions which contained one of four different low density polyethylene polymers, and either no filler, or one of three different fillers.
The polymers used were:
Polymer I - the same low density polyethylene polymer as was used in Example 1.
Polymer II - a low density polyethylene polymer which contained an antioxidant, an anti-blocking agent and high slip additives, and which had a -2 density of 923 kg M and a melt flow rate of 3.2g. per 10 minutes (BOREALIS LE4074).
Polymer III - a low density polyethylene polymer -2 which had a density of 922 kg M and a melt flow rate C RT9k) of 2.0g. per 10 minutes (ESCORENEILD100BW) Polymer IV - a low density polyethylene polymer -2 which had a density of 922 kg M and a melt flow rate of 0.75g. per 10 minutes (ESCORENE LD100BW).
The fillers used were:
Filler A (invention) - as in Example 1 Filler H (comparative) - as in Example 1 Filler J (comparative) - a filler which was prepared by coating with 1% by weight of stearic acid, based on the weight of dry filler, a calcium carbonate filler which had a particle size distribution such that the mean particle diameter (d50) was 3. 0, 9. 0% by weight consisted of particles having an equivalent spherical diameter larger than 20 1Ogm and 3396 by weight consisted of particles having an equivalent spherical diameter smaller than 2gm. The results are set forth in Table III as follows:
Table III
Die lip build-up rate (mg.kg-1) Polymer 1 11 111 IV Filler None 0 0.1 0.2 0.9 A (Invention) 0.9 0.9 0.5 1.5 H (comparative) 5.1 4.2 5.4 8.4 J (comparative) 10.9 12.0 7.8 5.8

Claims (13)

1. A filled low density polyethylene composition containing from 1% to 50% by weight, based on the 5 total weight of the composition, of a fine, particulate mineral filler which has a particle size distribution such that the weight average equivalent spherical diameter of the particles (d50) is not more than 0.8gm and not more than 0.5% by weight of the particles have an equivalent spherical diameter larger than 1Ogm.
2. A composition as claimed in claim 1 and wherein the mineral filler comprises a white mineral filler selected from calcium carbonate, in either the ground natural or the chemically precipitated form, a kaolinitic clay or a calcined kaolinitic clay, talc, mica, alumina, bauxite, alumina trihydrate, silica, titanium dioxide, calcium sulphate, barium sulphate, a silicate of calcium or aluminium, a carbonate or hydroxide of magnesium and mixtures of two or more of any of these minerals.
3. A composition as claimed in claim 1 or claim 2 and wherein the particulate mineral filler consists of particles at least 90k of which have an equivalent spherical diameter of less than 2gm.
4. A composition as claimed in claim 3 and wherein the particulate mineral filler consists of particles of which not more than 0.2% by weight have an equivalent spherical diameter of greater than 1Ogm.
5. A composition as claimed in any one of the preceding claims and wherein the particulate mineral filler is coated with 0.1% to 5.0% by weight, based on the dry weight of the mineral filler, of a hydrophobising agent.
6. A composition as claimed in claim 5 and wherein the mineral filler has a neutral to alkaline surface reaction and the hydrophobising agent comprises an organic carboxylic acid having a hydrocarbon chain having from 8 to 28 carbon atoms or a partially or wholly neutralised salt thereof.
7. A composition as claimed in claim 6 and wherein the mineral filler has a neutral to acidic surface reaction and the hydrophobising agent comprises a primary, secondary or tertiary amine or a quaternary ammonium compound.
8. A composition as claimed in any one of the preceding claims and wherein the mineral filler forms up to 50% by weight of the composition.
9. A method of use of a composition as claimed in any one of the preceding claims which includes heating and extruding a material comprising the said composition.
10. A method as claimed in claim 9 in which the extrusion die or dies used have a greatest diameter of not greater than 1Omm.
11. A method as claimed in claim 9 or claim 10 and wherein the heating and extrusion is carried out in a compounding and extrusion machine.
12. A method as claimed in any one of claims 9 to 11 and wherein the extrusion is carried out through multiple extrusion dies.
13. A method as claimed in any one of claims 9 to 12 wherein the extrusion is carried out by a twin screw extrusion machine.
simultaneously
GB9807658A 1998-04-14 1998-04-14 Filled polyethylene compositions Withdrawn GB2336366A (en)

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Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2355462A (en) * 1999-10-21 2001-04-25 Raj Chandrakant Mehta Polyethylene plastics compositions and a method of moulding plastics products
CN102241846A (en) * 2011-04-18 2011-11-16 刘立文 Calcium sulfate whisker modified high density polyethylene composite material and preparation method thereof
US20120118886A1 (en) * 2009-02-13 2012-05-17 Toyo Aluminium Kabushiki Kaisha Multilayer body and container
CN102796314A (en) * 2012-09-03 2012-11-28 上海清远管业科技有限公司 Masterbatch special for buried polyethylene drainage pipeline
EP2722368A1 (en) 2012-10-16 2014-04-23 Omya International AG Process of controlled chemical reaction of a solid filler material surface and additives to produce a surface treated filler material product
EP2770017A1 (en) 2013-02-22 2014-08-27 Omya International AG New surface treatment of white mineral materials for application in plastics
EP2843005A1 (en) 2013-08-26 2015-03-04 Omya International AG Earth alkali carbonate, surface modified by at least one polyhydrogensiloxane
EP2975078A1 (en) 2014-08-14 2016-01-20 Omya International AG Surface-treated fillers for breathable films
CN106467615A (en) * 2016-08-18 2017-03-01 徐英豪 The application in plastic pipe of barium sulfate and titanium white compound powder
EP3176204A1 (en) 2015-12-02 2017-06-07 Omya International AG Surface-treated fillers for ultrathin breathable films
EP3415570A1 (en) 2017-06-14 2018-12-19 Omya International AG Process for preparing a surface treated filler material product with mono-substituted succinic anhydride(s) and a mixture of aliphatic linear or branched carboxylic acids comprising stearic acid
EP3628705A1 (en) 2018-09-28 2020-04-01 Omya International AG Process for preparing a coarse surface treated filler material product
EP3753980A1 (en) 2019-06-17 2020-12-23 Omya International AG Caco3 coated with maleic anhydride grafted polyethylene and/or maleic anhydride grafted polypropylene and at least one hydrophobizing agent
US11708478B2 (en) 2016-07-19 2023-07-25 Omya International Ag Use of mono-substituted succinic anhydride

Citations (3)

* Cited by examiner, † Cited by third party
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GB1026113A (en) * 1963-11-28 1966-04-14 Shell Int Research Polymer compositions and the production of articles therefrom
EP0000084A1 (en) * 1977-06-07 1978-12-20 SOLVAY & Cie (Société Anonyme) Use of alpha-polyolefin compositions for extrusion
WO1994004606A2 (en) * 1992-08-24 1994-03-03 Gaia Research L.P. Chemically degradable polyolefin films

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1026113A (en) * 1963-11-28 1966-04-14 Shell Int Research Polymer compositions and the production of articles therefrom
EP0000084A1 (en) * 1977-06-07 1978-12-20 SOLVAY & Cie (Société Anonyme) Use of alpha-polyolefin compositions for extrusion
WO1994004606A2 (en) * 1992-08-24 1994-03-03 Gaia Research L.P. Chemically degradable polyolefin films

Cited By (27)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2355462A (en) * 1999-10-21 2001-04-25 Raj Chandrakant Mehta Polyethylene plastics compositions and a method of moulding plastics products
US20120118886A1 (en) * 2009-02-13 2012-05-17 Toyo Aluminium Kabushiki Kaisha Multilayer body and container
US9327879B2 (en) * 2009-02-13 2016-05-03 Toyo Aluminium Kabushiki Kaisha Multilayer body and container
CN102241846A (en) * 2011-04-18 2011-11-16 刘立文 Calcium sulfate whisker modified high density polyethylene composite material and preparation method thereof
CN102796314A (en) * 2012-09-03 2012-11-28 上海清远管业科技有限公司 Masterbatch special for buried polyethylene drainage pipeline
EP2722368A1 (en) 2012-10-16 2014-04-23 Omya International AG Process of controlled chemical reaction of a solid filler material surface and additives to produce a surface treated filler material product
WO2014060286A1 (en) 2012-10-16 2014-04-24 Omya International Ag Process of controlled chemical reaction of a solid filler material surface and additives to produce a surface treated filler material product
US11530313B2 (en) 2012-10-16 2022-12-20 Omya International Ag Process of controlled chemical reaction of a solid filler material surface and additives to produce a surface treated filler material product
US10066086B2 (en) 2013-02-22 2018-09-04 Omya International Ag Surface treatment of white mineral materials for application in plastics
EP2770017A1 (en) 2013-02-22 2014-08-27 Omya International AG New surface treatment of white mineral materials for application in plastics
WO2014128087A1 (en) 2013-02-22 2014-08-28 Omya International Ag New surface treatment of white mineral materials for application in plastics
US10465074B2 (en) 2013-08-26 2019-11-05 Omya International Ag Earth alkali carbonate, surface modified by at least one polyhydrogensiloxane
US9783682B2 (en) 2013-08-26 2017-10-10 Omya International Ag Earth alkali carbonate, surface modified by at least one polyhydrogensiloxane
EP2843005A1 (en) 2013-08-26 2015-03-04 Omya International AG Earth alkali carbonate, surface modified by at least one polyhydrogensiloxane
US10287407B2 (en) 2014-08-14 2019-05-14 Omya International Ag Surface-treated fillers for breathable films
EP2975078A1 (en) 2014-08-14 2016-01-20 Omya International AG Surface-treated fillers for breathable films
US10941279B2 (en) 2015-12-02 2021-03-09 Omya International Ag Surface-treated fillers for ultrathin breathable films
EP3176204A1 (en) 2015-12-02 2017-06-07 Omya International AG Surface-treated fillers for ultrathin breathable films
US11708478B2 (en) 2016-07-19 2023-07-25 Omya International Ag Use of mono-substituted succinic anhydride
CN106467615A (en) * 2016-08-18 2017-03-01 徐英豪 The application in plastic pipe of barium sulfate and titanium white compound powder
EP3415570A1 (en) 2017-06-14 2018-12-19 Omya International AG Process for preparing a surface treated filler material product with mono-substituted succinic anhydride(s) and a mixture of aliphatic linear or branched carboxylic acids comprising stearic acid
US11441037B2 (en) 2017-06-14 2022-09-13 Onya International Ag Process for preparing a surface treated filler material product with mono-substituted succinic anhydride(s) and a mixture of aliphatic linear or branched carboxylic acids comprising stearic acid
WO2018229061A1 (en) 2017-06-14 2018-12-20 Omya International Ag Process for preparing a surface treated filler material product with mono-substituted succinic anhydride(s) and a mixture of aliphatic linear or branched carboxylic acids comprising stearic acid
WO2020064968A1 (en) 2018-09-28 2020-04-02 Omya International Ag Process for preparing a coarse surface treated filler material product
EP3628705A1 (en) 2018-09-28 2020-04-01 Omya International AG Process for preparing a coarse surface treated filler material product
EP3753980A1 (en) 2019-06-17 2020-12-23 Omya International AG Caco3 coated with maleic anhydride grafted polyethylene and/or maleic anhydride grafted polypropylene and at least one hydrophobizing agent
WO2020254112A1 (en) 2019-06-17 2020-12-24 Omya International Ag CaCO3 COATED WITH MALEIC ANHYDRIDE GRAFTED POLYETHYLENE AND/OR MALEIC ANHYDRIDE GRAFTED POLYPROPYLENE AND AT LEAST ONE HYDROPHOBIZING AGENT

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