Indian Patents. 265693:CARBON BLACKS AND POLYMERS CONTAINING THE SAME

Title of Invention	CARBON BLACKS AND POLYMERS CONTAINING THE SAME
Abstract	Carbon blacks which are useful in a variety of polymer compounds including ABS compounds are described, as well as methods of making the carbon blacks and polymer compounds. The carbon blacks provide desirable jetness and impact strength, as well as good dispersion in a polymer.

Full Text	CAIffiONBIACKS AND POLYMERS CONTAINING THE SAME BACKGROUND OF THE INVENTION [0001] The pre^nt ixrvcation relates to covd caibon bkcjcs, as weU as polymers containing the carbon blades, and an enhancesnmt in propeardes, sadti as polym^ perfi^nnaace andthelikc. [0002} Caiboxi black is used in a number of polymear compounds, such as those found m aaylonitrlte-butadiotie-styrene (ABS) molding applicationfi. Carbon black-filled polymer compounds, sucb as carbon black-filled ABS and ABS-alloys (blends of ABS vnSx oiQier polynxQ^)> are used in numerous hi^-p«xfonnaiice polymer applications where a balance of coIor» medianica] properties, and siir&ce appearance is preferred. The ^e and amount of carbon black used in Ihepo^er canhavca vai^gefifectoolfaeproperdes ofihe compound. For instance^ increasing Ihe loading of carbon black can improve the cotor (e.g., the compound has higher jetnes$)» but the mechanical properties and/or sur&ce ^jpearance may be degraded with hi^r loadings. Tiicre is a desire m ikt polymer industry to have a caibon biadk that can achieve comparable or better jetness» blue tone, impact str^igth^ and/or sur&ce appearance (smoo&ness) when compounded into a polymer, but at a loadmg ibat is lower than cuxrent conventional loadings* Adiieving equal color at a lower loading can involve u^g a cacbon blacjc with a higher sur&ce area. However> increasing the sur&ce area of carbon black typically causes the carbon blac^ to become difGcuIt to disperse. Furlfa^, poc^ disp^ion of the carbon black reside in a loss of mechanical propeali^ and/or sur&ce appearance* Thus, it would be desirable to d&nlop a hi^-surfkce area carbon black fiaat can be prs&nibly readily (Uspersed in polymers^ sudi as ABS, to attain an accqrtable level of various mechanical properties (such as impact resistance) and sur&ce appearance. SUMMARY OFTHEPRESENT INVENTION [OOftJJ A featare of &c present invention is to provide carbon blacks tbat preferably provide equal color in polymer compounds at a lower loading and yet are diq?erdble to an accqrtable level to maintain mechanical pcc^erdes and surface ^earance. [0004] A fijrther feature of fee present invration is to provide a carbon black vadi when compounded In a polymer, sadh as ABS, provides an acceptable balance of propertiea^ such as jetness^ blue tone^ impact strengths and sur&ce appearance. [0005[ Additional features and advantage? of &e pj:esent inv^on vrill be set fbrth in pait in Ifae des^pti^ that fbltows, and in part v/ill be apparent ^m Ifae desc^riptiQa, or may be leanied l^ practice of &B present invemtioa. The objecdves and ofiber advantages of fee present invention ivtll be realized and attained by means of the elements and combinatiQits particularly pointed 0t3ft in tbe description and upended clums. {000^ To acbieve these and o&er advantSfges, and in accordance wife fee pmposes of the present invmtion, as embo(fied and broadly descmbed berein, fee present invention r^ates to a carbon blade feat is characterized by having: (a) an Iodine munber of fix)m about 150 to about €00 mg/g; (b) a DBF absorption of fiiom about40 to about 90 cc/lOO g; and (c) a nitrogen sur&ce area/statisScal feickness sur&ce area (N2SA/STSA) of fiom about 125 to about L70; and the carbon black fUrther has one or bofe of fee following properties: (d) a jetness as measured by Terlon L of 1.7 or less snd/or (c) a wat^ spreading pressure of 23.0 JAn^ or less- 10007] The presOTt invention fbrfeer relates to a carbon blade feat when compou^ in aoyJonitrile-butadiene-styrene at a loadit^ of 1^ wt% or less based on fee overall weight of the compounded material, results Jn a ccanpounded material having a compound jetness (L) of 4.6 or less and one or bofli of the Mowing diaraoteristics: (a) a compound notched Izod impact sfr^gth of 13,600 J/m^ or greater and/or (b) a compound dispersion rating in a press-but tost of 4.0 or less. [OOOS] Also, tibe pres^ mventian relates to ABS compomids containing one or more types of tiie carbon blacto of the present invention. [0009] Additioxialiy» tixe present invention relates to polymers containing one or more of the carbon blacks of &e present invention. [0010] In addition, the preset invmfon relates to polymer mastezbatcfaes or concentrates containing ODS or more of the carbon blades of the prescsrt invention. [0011] Further, the present invention relactes to methods of making the carbon blacks of the preset invention, as well as makmg the polymer compounds of the present inyenlion. [0012] It is to be understood ^t both tibie foregoing general d^o^ption and &^ detailed description are e?cemplaty and explanatory only and are intended to provide a fbrthear explanation of tiie present invention, as claimed, [0013] The accompanying drawings, which are incozporaled in and constitute a part of this application, illustrate some of ihe embodiments of the present invention and together with the description, serve to explain ihe prmcuples of the present invention. BRIEF DESCRIFnON OF DRAWINGS [0014] Fig. 1 is five photogr^hs showing san^le dispersion ratings DETAILED DESCRIPTION OF THE PRESENT INVENTION [0015] The pres^ invention relates to novel carbon biacks; as welt as methods to make the carbon blades. The present inventi-styraie (ABS). I0pl6] WMi req^ect to the carbon black, tbe carbon black of the present invention has de^rabb morphology mi intei&ciai piop^es that mdke it beneficial in various applications, such as tiie use of the carbon blade in polymer q>pIications like ABS molding ^^lications. [0017] In more det2ul» in at least one embodinaent, the carbon black of fte present invention pTekrMy has one or more of tibie Mowing diree characteristics and preferably has all of the following three dmract^isdcs: (a) an Iodine number of &>m about 150 to about 600 mg/g. Other ranges can include an Iodine number of jSrom about 265 to about 600 m^g, frcxn about 350 mg/g to about 600 mg/g» or from about 400 mg/g to about 600 mg/g; (b) a DBF absozption of from about 40 to about 90 cc/lOOg. OUasr ranges can include from about SO to about 90 cc/lOOg, from about 60 to about 90 cc/lOOg, or from about 70toabout90cc/100g; (c) a ratio of nitrogen sur^ice area/statistical thickness sur&ce area of from about 125 ID about 1.70. Other ranges can include from about 1.30 to about 1-70 or fix»m about 140 to about 1-70. [0018] In addition, in at least one embodiment, the carbon black of frie preseid; invention has one or more of the following additional properties: (d) a jetness value as dettimined by Tearlon L of L7 or less, OSaar ranges can include from about 04 to about 1.7» or from about 0,4 to about I.l; (e) a water spreading pressure value of 23.0 mJ/m^ or less. Other ranges mclude from about 12,0 to about 23.0 mJ/m^ or from about 12.0 to about 21.5 mJ/m^. [0019] With respect to the Iodine number, this number is measured following ASTM D1510, With respect to the DBF absorption, this property is detOTnined following ASTM D2414. Witii respect to tbe nitrogen surface area and ihe statistical tibiokness sur&ce area, these measurements were made following ASTM D6S56 [0020] Wiai respect to the jetaess as determined by Terlon L, this procedure uses a C3ELAB color scale. L is a measure of &e jetness of the carbon black after making an oil-based paste; a lower value is more jet The absolute L* value is used. In detennining jetness, the carbon blade was dried at 125** C for 3 hours and then conditioned in a mixer for 45 seconds. 20 g of Terlon #1 Oil was then added to the lower plate of a Hoover Muller, into which 100 mg of the carbon blade was slowly added witii a spatula. After gathering the matoial in the center of the lower plate, the top plal» was put in place and 4he Hoover MuUer plates spun for 50 revolutions to mix the oil and carbon blade The plates were then opened, and the process of ^fliering ifae material and spinning Ssr 50 revoludons was repeated three more times. The ^tire quantity of the paste was then smoothed onto a glass plate. The 1976 CIELAB L value was measured in four dififerent locations on llie plate usmg a Hunter Labscan XE wifli VSI, using liie following conditions: Mode 0/45, Port Size = 1.2 mches, Area View = 1 inch. UV Filter -= Out, Light Souice « D65 with 10 Observer. The value reported is the median of the four absolute L* values. Simultaneously, the 1976 CIELAB b* value (bluetone) is also measured and recorded by fte Hunter Labscan in an analogous way. [0021] Water ^nreading pressure is a measure of tiie interaciion energy between the caibon black sur&ce and water vapc^. The spreading pressure is measured by observmg the mass inca-ease of a sample as it adsorbs water fi-om a controlled atmosphere. In &e tes^ the relative humidity (RH) of the atmosphere around die sample is mcreased from 0% (pure nitrogen) to --100% (water-saturated mtrogcaa). If the sample and atmosphere are always in equilibrium, the water spreading pressure (TIC) of the sample is defined as: vAere i? is tiie gas constant, T is fte temperature, -4 is the specific suifece area of the sample, T is the amount of adsorbed water on the sample (converted to moles/gm), P is the partial pressure of water in the atmosphere, and Pe is the saturation vapor pressure m the atmosphere. In practice, Hje equilibrium adsorption of water on Ae surfece is measured at cme or (prefisrably) several discrete partial pressures and the integral is estimated by the area under the curve. Alternative measurements of e interfedal prop^es or sur^ be ^ecified, e.g., by not dividing by the surfece area, or ly addmg other mtttfecial properties or surfiaoe energy terms to the water spreading pressure^ or by approximating the integral widi a small number, even possibly as few as one, data points, or nsmg other gases. [0022] The jvocedure for measming the wat^ spreading pressure is detailed m ^'Dynamic Vapor Soiption Using Water, Standard Operating Procedure", rev, 02/08/05 (incozporated in its entirety by reference herein), and is summarized here. Before analysis, 100 mg of the carbon biadk to be analyzed was dried in an oven at 123^ C for 30 minotes-Ader ensuring that the incubator in the Surface Measurement Systems DVSl Instrument (supplied by SMS Instruments, Monarch Beach, California) bad been stable at 25^ C for 2 hours, sample cups were loaded in boft fbt sample and reference chambers. The tai^et RH was set to 0% for 10 minutes to dry the cups and to establish a stable mass baselme. After disdiatging static and taring the balance, (^proTdmately S mg of carbon black was added to the cup in the sample cjiamber Afber sealing the sample chamber, the sample was allowed to equihTsrate at 0% KEi Aflaer equilftxation, ±t initial mass of the sample was recorded, TTie relative humidity of the nitrogen atmosphere was then increased sequentially to levels of approximately 5,10,20,30,40,50,60,70,78,87, and 92% RH, with the system allowed to equilibrate for 20 minutes at each RH level. The mass of water adsozbed at each hmnidity level was recorded, from which water spreadtog pressure was calculated (see above). The measurem^t was done twice on two s^arate samples and the average value is rqfjoited [0025] In anotibw embodiment of the present invention, the present inveotlon rdatcs to c«(rbon black "which is capable of achieving certaJn properties when compounded in ABS foiiowii^ a particular procedure, in more detail, in one raibodiment of the present invention, the carbon black» when compounded in ABS at a carbon black loading of 1.5 wt% or less (for instance, at a carbon black loading of OJ wt% to U oveiEBlI wei^t of the con^unded material, aciuevcs a jetness (in Hie overall compounded material), measured as confound L* of 4,6 or less (othw: jetness values for the compounded material can be e,g., 3.0 to 4,6 or 3-0 to 4.4) and tfie carbon black permits the compounded material to have one or both of the following properties: (a) a COTipound notched izod impact strengfli of 13,600 J/m^ or greater (p&ics ranges include fiom about 13^600 J/m^ to about 18,000 J/m^ frwn about 14,000 to about 17,000 JAn^) and/or (b) a conopound dispersion ra^ in a press-out test of 4.0 or less (oth^ ranges include e,g.» fiom about 1.0 to about 4.0 or dom about 1.0 to about 3.0). The carbcm blade in this embodiment has these properties for at least one carbon blade loading level in diis range of 1,5 WLH or less. [0024] Witii respect to these parameters that tiie carlxm black promotes in an ABS when compounded in the ABS, the following test procedures aie used. [002S] The ABS compounds were produced in a three step compounding procedure (at times referred to as *lhe three step ABS compounding procedure'): First, a 30% SAN masterbstch was prq}ared, which was &en dUuted to 5% with ABS, before being let down to 0.50% to 1,50% Witt) additional ABS in a final mjection molding step. [0026] Masterbatxdx Compound; The SAN masterbatch was prepared by mixing carbon black (CB), lyil 124 SAN (Density -1080 kg/m^ 230'C/3.8kg MFI» 22 ^'lOrnin), and Zinc Stearate (ZnSt) in fiie following prt^rtions by wei^t 30.0% CB, 69-5% SAJST, and 0.5% ZnSt, to give a total mass of the three componwits of 1413 g. The components were mixed in a Banbory JBtemal nuxer (1570 ml) with the following settings: Rotor Speed = Setting 2, lUm Pressure = 3 kg/cm^ Mtial Temperamre =* 70 ^^^ « 90 s, and Feeding Factor " 75%, [00271 5% ABS Compound: lie SAN masterbatch was first ground to remove dust and small particles, 250 g of the SAN masterbatch was then mixed witii 1250 g of Cycolac GPMS500 ABS Pensity - 1050 kg/m^ 220'C/10kg MFI - 24 g/lOmin, 23 "C Notx^ Impact (ISO180/1A) - 18000 J/m^ to produce a 5% ABS compound. This procedure was carried out on a Betol BK32 single screw esdrudw equipped with a disttibutive mixing Wd (cavity transfer mixer (CTM)) to improve it$ dispersive capabilities. The extnkte had the following temperature setting tarn the feeder to the ^fie: Zonel == ISO'^C, Zon^ ^ 185C, Zones - IPO^'C. Zone4 =» 195^C, CIM ^ 210'C, Die 200X, The screw speed was 80 ipm and one pass was used durmg compounding* [0028] 050 -1-50% ABS Compound: The 5% ABS compounds were diluted to tiieir final loading in a Battenfeld BA500/200CD injectionmolding machine. The total mass of material used was 600 g, with the proportions of 5% ABS compound and pure C^obac GPM5500 ABS selected to give the correct final loading. Before mjection, the ABS compounds and the ABS resin were dried for 17 hours at 80C under vacuum. Betwe«i each sample, 500 g of pure ABS was mjected to clean the equipmcait. The esact injection molding parameters depended on the test that the part was to be subjected to (see below): [0029] Q)lor (L) Plaques: 90 x 55 x 2 mm plaques for color analysis were prepared using the followmg temperature settings on the injection molding madiine: Nozzle = 225°Q Zonel « 235C, Zone2 « 250C, Zone3 ^ 250'»C, Mold ^ 60«C. The mjcction speed was 20%» [0030] Izod Impact Bars: 63i x 12.7 x 6,4 mm bars (BO 180 Type 3) for Izod impact testing Wtt^ pr^ared u^ng Ave following tCTiperature settings on the mjection molding machine: Nozzle « 225C, Zonel - 235C, 2oiie2 - 250*C, Zone3 = 250^C, Mold = 25'C. Tlie injeoaon speed was 60%. [0031] Widi respect to Ifae jetness for ^ compound ^ conipound L is an absohite value. L* is a measure of the jetness of tfat compound; a lower value is more jet. To measure fte compound L% sfac 90 X 55 X 2 mm color plaques with the desired loading waie p^ by injection molding as described above. All plaques were inspected to ensure that th^ bad a uniform color on the sur&ce, and to diecd: tot any pips or streaks. Plaques lliat did not meet tiiese criteria were discarded. Each plaque was then tested once £br the 1976 CIELAB L* value with a DATAC01X)R SF600 ^ectrophotocolorimeter, using the following conditions: Calibration Mode - Reflectance, Specular Door - Bxclude4 Visualization -LAV (30 mm), UV * Included, Condition = % R LAV SO E UV inc., Light Source ^ D65 with 10^ Observer^ The value reported is tiie av^age of &e six plaques and is the absolute L value^ not a diderence between the sample and a reforesice. Simuttaneousty, the 1976 CIELAB b'' value (bluctone) of &e compound was measured and recorded by the Datacolor instrument in an analogous way. [0032] W&i tespcct to detamining &e notched Izod impact strength of tiie compounded mat^al, tiie test was generally based on the GSO 180-19S2 standard, but diSbred in the injection molding procecbire of the test bars. The ^st method is described below. [0033] Ten 63 i x 12.7 x 6A mm bars (ISO 180 Type 3) with the desired loading were prepared by iqjection molding as described above. A smgle ixotch (ISO 180 Type A) was then cut in each bar with a notchmg device (CEAST 6530). The sample was loaded with the notch feeing tiic direction of impact and tested wife a 5^ J pendulum-type hammer (CEA.ST 6545/000). If a bar showed bubbles or holes along tiie fifacture point, it was discarded. The measured impact strength of acceptable samples was recorded and the reported value is the average of the ten bars, Un-notched Izod hnpact strcfigft can be measured by following the same procedure but without cutting the notch in the test bar. [0034] 11K dispersion rating in the pres$-out test of &e compoimded material is described below. The disperaon rating is a senii-quaatitative naeasure of carbon black diq^ersion in the compound; a lower vahie equals better [0035J Two 0,3 mg '^buttons" were cut from three different color plaques (pr^andon described above) yielding six buttons. Each button was placed cm a clean microscope slide and covered with anotito slide* The assembly was pressed-out at 210** C for 3 minutes, with enough pressure to obtain a 5 mm button diameter. Each butUm was eicamiaed at 200X and lOOX magnification m a light microscope* A rsSing of 1-5 was Ihen assigned to each button, with 1 corresponding to a good dispersion and 5 to a bad dispersion. In ass^mng tbe dispersion rating, good diversion implies a &w black spots were visible TASTC&S bad dispersion hnplies a lot of blade spots or larger aggregates. More spedlicaUy, the dispersion rating is assigned by counting the number of visible particles greater than 1 fxm in a 651 }jm X 487 pm area under lOOX magnification. The number of particles determmes the dispersion rating: 1 = 0-10 particles, 2 « 11-30 parades, 3 = 31-60 partidcs, 4 = 6M50 particles, 5 ~ more than ISO particles. The cSspersion rating of each sample is the avemge from the six buttons* Figure 1 is photographs showing an example of con^Knmds with dispersion ratings from 1 to 5. [0036] With respect to manufacturing the carbon blades^ the carbon blades can be made as follows. The carbon blacks of flie present invention can be produced in a tubdar &mace reactor similar to those described in U.S. Patent Nos. 6,136,837 and 5,S77j250, incoipor^ed in their entireties by refefKiceheiein, The reactor iUustrated in Figure 1 of4atpalmthas(a) an initial combustion zone, (b) a secondaiy combu^on zon^ (c) a reacfion zone, and (d) a qu«idiingzone» [0037J In the present mvention, a reaction like feat diown in U.S. PatetrtNos, 6,156^837 and 5,877,250 is used wfii Hit adjustmesits described htc&n. In the nutial condaistion zone, £id and an oxidant are mixed and reacted to form aliot combustUm gas stream. Siutable fuels for gen^ating die hot combustion gases include any readily combustible fluid* including natural gas, hydrogen, carbon mon [0038] This zone is followed by a secondary combustion zone, where ti)e hot combustion gases are contacted wi^ a xnixture of alkali salts and a liquid hydrocarbon feedstock &at is readily volatiii2»d. Suitable liquid feedstocks mdude unsaturated hydrocarbons, saturated hydrocarbons, olefins, aromatics, and other hydrocarbons such as karosenes, nscphbal^nes, terpenes^ ethylene tars, and aromatic cycle stoclcs, as wdl as mixtures of all of die above. 7%e foedstock is otteai mjected in a plurality of streams that rapidly mix wi& tiie hot initial combustion gases, causing the carbon black-yieldnig foedstodc to decompose and conv^ to carbon black, h the process of the preset invention, the over^ ra:tio of oxidant to both fuels (including that fai the first zone) is between 0.15 and 0.50 times &e amount of cxsidant needed for stoichiometric combustion. Preferably, ^flje overall ratio is between 025 and 0.40. The concentration of alkali salts in the feedstodc is in the range of 003 to 0,15% by wei^t [0039] In the ttiird zone of the reaction, the mixture of combustion gases and carbon black continues to react as it flows downstream until it reaches the four zone of the reactor, wh^e a quenchmg fluid is mtroduced to stop the reactkm. Suitable quenching fluids include water, a mixture of water and steam, or a mixture of water and air. The ideal location of the quendi (a^ tiuK'efoie Ibie ^dence time of the reaction) d^)ends on the flow rate of Ibe gases'sod &e diameter of the furnace. In geceral, tbie residence time of the reaction ^ould be 10 and 200 ms, and preferably batweem 60 and 150 ms (nuUiseoonds). . [0040] Afier adding the quenching fluid, the mixture is passed to any convc^itional cooling f^^>araius, such as a venturi cooler or a heat exchange, at which point the carbon blade is separated from the gas stream 1^ CDnvexxdonal means such as a precxpitatar> [0042] The carbon blacks used in Ifac polymer compositions of the present invention can optionally be finther treated with a variety of treating ag^its, such as binders and/or surfectents. The treating agents described in aS. Pat Nos, 5,725,650; 5^00,164; 5,872,177; 5,871,706; and 5,747,559, all incorporated herein in their entirety by refeence, can be used in treating flie catbon blades of the present invention. Othar preferred treating a^nts, mcluding surfactants and/or bmders, can be used and bclude, but are not limited to, polyethyleae ^yooU aikylene oxides such as propylene oxides and/or e&ylene oxides^ sodium Iignosul:&te; acetates such as ethyl-vinyl acetates; sorbitan monoolcate and cfliylcne oxide; d6^y\&a^&yttri^^ metbacrylace bind^; copolymers of butadiene and actyionitrile; and the like. Such binders are comm^xaalb^ available from such manufecturers as Union Carbide, Dow, Id, Union Padfic> Wacker/Air Products, foterpolymer Corporation, and B. F. Goodrich.. These bindars are preferably sold nnderthe trade names: Vinnapas LL462, Vinnapas LL870, Vinnapas EAF650, Tween 80, Syntan 1930, Hycar 1561, Hycar 1562, Hycar 1571, Hycar 1572, PEG 1000, PEG 3350, PEG 8000, PEG 20000, PEG 35000, Syx^erottic PE/F38, Synperonic PE/F108» Synperonic PE/P127, and Lignosite^SS. GenOTilty the amount of treatiog ag^t used wi& the catbon blacks of the present invention can be the amounts recited in the above-des(»ibed patents, for instance m an amount of &om about 0.1% to about 50% by weight of the treated cazbon blac^ ^ugh other amounts can be used depending upon fte type of pFcq)erties desired and the pardcuiar treating ag6nt(s) being used. The carbon black used in the polymer compositions of &e present invention can also be modified to form a modified caxbon black having attached at least one organic group. Tlie type of organic group will vaiy depending on the polym^ used as well as on ib& desired p^miance properties. This allows for greater flcTdbility by tailozing the modified carbon blade to the spediic application* [0043] The caibon blacks can be modified using me^ods known to &ose skilled in the art sudi that otganic groups are attached to tiie cait^cm biacL This provides a more stable attadiment of the groups onto the carbon bladi: compaiced to adsorbed groups^ sudi as polymers, sur&ctants, and the like. For example^ the modified cattcxi blacks can be prepai^d using «ie methods described m U.S. Pat Nos. 5,554,739, 5,851^80, 6,042,643, 5,707,432, and 5,837,045, and PCT Publication WO 99>'23174^ the descriptions of vich are fiilly incorporated herem by ref^ence. [0044] Also, for purposes of the present invention, the carbon blade, as defined by its property capabilities when compounded in ABS, can have one or more of the propraties described above wiA respect to lodixie number, DBF abswpdotu nitrogen surfece area/statistical thiokness sutfece area ratio, jetaess, as determined by Terlon L, and/or the watef spreading pressure prop^es. Similarly, Ihe carbon blade properties having Ibe Iodine number, DBF absorpticm, and nitrogen siir&ce area/srtatistical Sickness sur&ce area ratio can have cme or more of the carbon black properties measured ^fin compounded in ABS as descdbed above. [0045] In a furtber embodiment of the present invention, the present invention relates to an ABS compound Aat contains ABS and at least one carbon black of the presmt invention. The present invention fordier relates to an ABS compound that contains ABS and at least one carbon black of the present invention v/herem the ABS compound has the carbon black loading as described above, along with tibte compound jetness, and compound notched ]^od impact strength, as desc^bed above. [0046} b ano&er embodiment of the present invention, the present invesiiion relates to an ABS compound that contains ABS and at least one carbon black of the present invention wherein Ihe ABS compound has the carbon bhick loading as described above, abng with the compound jetnesB as described above and the compound dispersion rating in press-out test as desoribed above, [0047] hi a further embodiment of the present invention, Ihe present invention relates to an ABS compound that contains ABS and at least one carbon black of the present invention, vi:^rein the ABS compound has the carbon black loading as described above, along widi the compound jetaess as described above, the compound notched Izod impact strength as described edjove, and Ihe compound dispersion rating in prcss-out tests as described above. [0048] A further embodiment of the present invention relates to an ABS compound that contains ABS and $t least one carbon black of the present invention, wherein the ABS compound has a compound jetness as described above and a ccnnpound notched Izod impact strength as described above without any limit on the carbon black loading. [0049} An additional embodiment of ^ present invention relates to an ABS compound that contains ABS and at least one carbon blade of the pres^ invention when^ the ABS coni^KTond has the compound jetness as described above and the con:ipound dispersion rating in press-out tests as described above without any limit on the carbon black loading. [0050} A &rther embodiment of the present inv^tion relates to an ABS compound that contains ABS and at least one carbon black of the presexit invention M4I^^ the ABS compound has the compound jetness as described above, tiie compound notched kod impact strength as described above, and the compound dispersion rating in press»out tests as described above, vdtiiout any limi^ on the carbon black loading [0051] Furdiermc^re, in the preset invention^. ^ ABS compound can contain one or more oftter types of poiymers to &nn an ABS alloy as that tarm is understood to those skilled in &e art The ABS compoimd or ABS alloy contains at least one type of carbcm black as described above. Furtibermore, other types of carbon blacks, such as conventional carbon blacks, can fiirther be present, and/or other reinforcing additives can be present Also, otfa^ conventional ingredients Really used in ABS compounds and ABS alloys can fiirflier be preset in the present invention including, but not limited to, otiier conventional components fliat can be used in polymer compositions* [0052] h. a fiirther OTibodiment of the present invention, the present invention relates to a polymer ccmipound that contahis at lea^ one polym^ and at least one carbon black of the prtsent invention. Tie preset in^^ition fiirftier relates to a polymer compound tiiat contains at least one polym^ and at least one carbon blade of Ae present invMtion wherein the polymer compound has the carbon black loading as described above, along with the cOTipound jetness as desadbed above, and the ccanpound notched Izod iir^>act streaigth as descra^ above. [0053] In another embodiment of &e present invention, the prt^eot invention relates to a polym^ compound that oontafns at least one polymer and at least one carbon black of the present invention wherein the pol>tner compound has the carbon blade loading as described above;, along with ^ compound jetness as described above and Ihe compound dispersion rating in p3:essont tests as desoibed above. (0054] In a fijather embodiment of the present invention, the ^-esent invenlion relates to a polymer compound that contains at least one polymer and at least one carbon blade of the present invention, wherein the polymer cc^pound has ibe carbon blade loading as described abov^ along with the compound jetness as described abovQ» the cotqioimd notched Izod impact strength as described above, and the compound dispersicm rating in press^nt tests as described above. [0055] A fiizther embodiment of the present tovention relates to a polymo: compound 1h&t contains at least one polymer and at least one carbon black of the present invention wherein the polymer compound has a compound jetness as described above and a compound notched Izod hnpact strength as described above without any limit on the carbon black loading. [0056] An additional embodiment of the present invention relates to a poiymex compound that oontauis at least one polymer and at least one carbon hlBjck of the present invention wherein the polymo- con^>ound has die compound jetness as described above and the compound diversion rating in pres&^ut tests as described above witfaout any limit on the carbon black loading. [0057] A fiirflner embodiment of the jM-esent mvention relates to a polymer compound that contains at least one polymer and at least one carbon black of the present inv^rtion wheredn the polymer compound has the compound jetness as described above^ the compound notched feod impact strength as described above, and the compound dispersion i^ing in pre$$-out tests as described above» without any limit on &e caiton black loading [00S8] Furdiennore^ in the present invention, the polymer compound can contain one or more types of poI}iners to fonn a polymer alloy as that term is understood to tistose skilled in &e art The polymer compound or polymer alloy contains at least one type of carbon blade as described above. Fnrthennare, o&er types of carbon blades, such as conventional carbon blacks, can &rther be present, along with o&er rdnforcing agents. Also, o&er conventional ingredi^ts typically used in polym^ compounds and polymer alloys can fiirthe* be present in the present invention inctudiiig» but not limited to^ other conventional components that can be used in polymer compositions. (0059J In mcwie detail, the araylonitrile-butadiene-s^ene copolymer type resin to be used in the present inv^tion is one composed mamly of a copolymer having fhrcfi components of aoylonitrile, butadiene and styrenef and a commm>iaIly available product may be used. For exan\ple» a copolymer obtained by blodc or graft polymerization of at least one monomer selected from an aromatic vinyl monomer and a vinyl cyanide monomer to a diene type rubber, or a blended product with ibt copolymer, may be motioned The diene type rubber is a polymer obtained by polymerizing butadiene as a component, ai)4 examples of which inclixde polybutadiene^ polyiscprene, an acrylomtrik-butadi^ie copolymer and a styrene-butadiene copolymer. The aromatic vinyl monomu' may, for example, be styrene, alpha-meO^ylsfyrene or an alkyl-substituted styrene. l^e vinyl cyaaide monomer m^, for exanq>le, be acrylonitrUe, me^iacrylonitrile or a halogaa-substituted acrylonitrile* Specific examples of the copolymer and the blended product wfti the copolymer include an acxylonitrile-butadiene-styrttne terpolyraer and i^VOTtion, the polymer can be any polymeric compound. PrdferabJyii the polymer b one that is use&l in molding applications, such as a polyoleSn^ a vbylhalide polymer, a vinylidene halide polymer, a peafluwinated polymer, a styrene polymer, an amide polymer, a polycaibonatCj, a polyester, a polyphenyleneorides a polyphenjiene eflier, a poljtetonc, a polyaoetal, a vinyl alcohol polymer, or a polyurethane* Polymws or resms useful in the practice of the invention include PET or polyethylene terephthalate, polystyrene, PBT or polybutyl^e tercphflialate and PBT allays, polypropylene, poIyureSiane, ABS or aoylonitrile-butadijaie-s^ene copolymer, PVC or polyvinyl chloride, polyesters, polycarbonates, PP/PS or polypropylene polystyrene ail su^ as jetaess^ conducdviiy, toughness, 8ti£5iess, smoothness, and tensile properties* [0062] Polymers inchide ^lermoplasdc polyolefins (TPO\ polyeihyirae (P£» sudi as LLDPE, LDEB, HDPE, UHMWra, VLDPEj and mtLDPE), polypropylene, copolymers of ])Olypropyl^t, ettiyleoe propylene rubber (EPR)^ ethylene \|»tjpylene diens terpolymers (such as EFDM), actybnitrile butadiene styrene (ABS), acaylonitrile BPDM s^^rene (AES), polyoxymctfaylene (POM), polyamid^ (PA, such as PA6» PA66, PAll, PA12, and PA46>, polyvinyldiloride (PVCX tetraeflhylHie hcx^ropylene vinylidenefluoride polymers (IHV), p«iluoroalkoxy polymcis (PFA), poljiiexafluc^TOpropyieae (HFPX poJylcetones (PK), ethyiene vinyl alcohol (EVOH), copolyesters, polyuretiianes (PU), polystyrene (PS), polycarbonate (PC), polybutylcne teephthalate (PBT), polyeflijittie taephthalate (PET)j poIypfaeneylKxe cacide (PPO), and polyphenylene efiier (PPE). Prefeired blends include PC/ABS, PC/PBT, PP/EPDM, PP/EPR, PP/PE, PA/PPO, and PPO/PE. [0063] The polymer(s) can be a thennoplastic polymer or a liiestnosettmg polymer. Further, the polymer groq) can be a homqpolyma:, copolymer, terpolymer, and/or a polynxer contairung any tmmber of dsfj^rent ideating unks. Further, ^ polymer groi^ present in the present mvention can be any type of polymer group, such as a random polymer, alternating polymCT, graft polymer, blodc polymer, star-like polymer, and/or comb-iike polymo:* The poller group used in H^ present invention can also be one ^ more poiyblends. The poiymo-group can be an interpeaetrating polymer aetworic (EPNf); simultaneous interpenetrating pobimer network (SIN); or iateapeo^raling elastomeric network (TEN). [0064] Specific examples of polymers include, but are not limited to, linear-high polymers such as polyethylene, poly(vinylchIoridc), polyisobutylai^ polystyz^ne, polycsaproJactam (nylon), polyisoprene, and the like. Other g«ieral classes OF polymers of the present invention are polyamid^ polycarbonates, polyetectrotytes, polyesteis, pplyettiers, (polj1iydroxy)benzenes, pofyimides, polymers conttoiing sulfur (such as polysulfides, (polyph^yleoe) sulfide, and polysulfbnes), polyoiefins, potymethylbenzenes, polystyrene and Styteasi copolymers (ABS included^ acetal poiymeis, acrylic polymers, acrjlonitrile polymers and eopolymer&» polyole(6ns contammg halogen (sudi as polyvinyl chloride and polyvinylidene diloride), fiuoropolymers, ionomeric polymer polymers contaimng ketx>nje group(sX liquid crystal polymers, polyamide-imides, polymers containing olefinic double bond(s) (sudi as polybutadi^ie, polytOcyclopeiitadiKie), polyolefun copolymers, polyph^yl^e oxides, polysiloxan^, poly(vinyl alcohols), poIyuretbanes> ftemioplastic elastomers, and fiie like. The polymer can be a polyoldSn, a polyurdhane» a polysfyreruc> a polyaciylate, a polyamide, a polyester, or mixtures thereof. [0065] Gentt:ally, the poljoneric groups described in Volume 18 of the Encyclopedia of Chemical Technotogy, KIRKOTilMER, (1982), page 328 to p^^ 887, and Modan Plastics Enq^opedia '98, pages B-3 ID B-210, and "Polymers: Structure and Properties" by C.A. Daniels, Technomic Publishing Co^ Lancaster, PA (1989), aU incorporated in flieir endrety herein by re&rcnce, can be used as ihe polymer(s). The polymers can be prepared in a number of ways and sudi ways are known to ftiose skilled in tiie aiL The above referenced KIRK-OTHMER section. Modem Plastics Encyclopedia, and CJu Daniels' reference provide methods in whic^ these polymers can be p!r^)ared [0066] Tltc polymer compositions of the present invention ma^ also mclude suitable additives for their known purposes and amounts. For example, the compositions of the present invention may also include such additives as crosslinking agoits, vulcanizing ^ents, stabilizeiSy pigments, dyes, colorants, metal deactivators, oil extoadei^ lubricants, and/or morganic fillers, and the like. [0067} The polymtt compositions of fte present mvention can be prepared using conventional teohmques such as mixing the various cwuponents togeftier using oommerdally available mixers. The composition may be prepared by bafx^ or continuous mixing processes such as Ihose well known in fte art For example, equipment such as discontinuous btmial mbcers, continuous internal mbcers, reciprocatixig sing^ sorew extrude, twin acd single screw extruder, etc. may be used to mbc the xngre(fient$ of the formulations. Hie carbon black ms^ be btroduced directly into the polymer blend; or the carbon blade may be introduced into one of the polym^s before tfiat polym^ is blended with anodier polymer The compCMieiits of the polym^ compositions of the preseait invention may be mixed and fomied into pellets '&xt fijture use m manu&oturing such materials as articles for automotive applications* (0068] With respect to the amount of carbon black; any amount can be used in the polymer compositions in order to achieve the desired properties. For instance> &csn about 03 wt% to about 50 wt%, based on the overall weight of &e polymer composition, can be used, and more preferably} from about 0.5% to about 10% by wd^ based on the overall weight of the polymer composition* [0069] In a further embodiment of the present invention, the present invexition relates to a mastcrbattA or concentrate containing one or more carbon blacks of the presort inveniion. The masterbatch or concentrate can cont^ one or more polyma:s, sMoh as those descnbed above, along with a masterbatch or concentrate amount of a carbon blade of Ifae present invention. The carbon blade loading can be any suitable amount typically found m masterbatdies or concaitrates, sudi as from about 10 yfi% to about 50 v^ based on the overall wei^ of the mastetbatch or oc^coitrate. [0070] The carbon blacks of the present inventton can be used in any cod use plication where conventional carbon blades are used, e-g., inks, coatings, elastomcrio products, toners, fuel ceUs» tires or parts thereof molded parts> cables or parts thereof and the like, using convmtimal amounts or lower. [0071] The present invention will be fiutha- clarified by the following examples, which are intended to be excmpiaiy of the present invention. EXAMPLES 10072] Ihiee caiboa blacks, identified as 'A", B^ and 'C' of the present ittventkin and having the prq^es set &rdi ux &e Table 1 below, w^e prepared as described above and in Table 1. Tbsst caibon blades are compared to two conmerciaUy available carbon blades from Cabot, designated '"X" and V in the table below, and the analytical data for each of ftese carbon blac^ are set &rdi in the table as well. Using procedures described above, aQ of tiiese carbon blacks were formulated into an ABS CD0q}Oond using the loadmgs indicated in ta& table next to sanq)le idmtification numb^. For instance, carbon black ^OiT vms foonulated widi a caibofi black loading of 0.75% by wei^t of the overall ABS compound^ and carbon black 'X* was also fisrmuiated with a carbon black loadmg of 0,5% by wei^ of tbie overatt compound^ and so on. As a cottxparative» aa ABS compound containing no caibon black whatsoever (indicated as ^^Pure ABS" in ihe table bdow) was analyzed as well. Using the test procedures described above, the various j^by^cal propoiies of the compounded polymas were m^isared, including notched and xm-notxd^ Izod impact strengOi, pre$s-out dispersion ratmg» and jetness (L'^)v using the procedures previously described. As can be seen &om ^e data set forth in the table, the cazbon blac^ oi tbte present izrveniion, when compounded at 0.509^ w^e able to equal or exceed the confound jetaess of carbon bladt X compounded art; 0.75%. Jh addition, the caibon blades of the present invention had a superior imimct strength (both notched and un-^notdhed) and press-out rating when compounded to give equal or better jetness as carbon bladt ^•X', This is not Ihe case fear coniparsfive caibon black W ^iiidi showed a similar jetness to ttie carbon blacks of the prestot invention when compounded at 0.5%, but which showed a pO(^er hnpact strengdt and press-out dispersion rating. The carbon blacks of the present invention have a hi^ sm&ce area and strong jetness but reuxdin relatively easy to disperse. Table 1 [0073] Applicants ^ecificaliy incorporate the entire contents of all cited re&r^ices in Ihis disclosure. Further> when an amount, concentration^ or oflier value or param^^ is given as either a range» preferred rangft^ or a list of upper preferable values and lower preferable values, this i$ to be understood as specifically disclosiog all ranges formed &oni any pair of axQ^ i^yper range limit or preferred value and any lower xange limit or prrfbrred value, regardless of whether ranges are separately disclosed, Where a range of numerical Values i^ recited herein, unless otherwise stated, Ifae range is intmoded to include the endpoints th^«o^ and all hitegers and fiacticHis within (he range. Tt t$ not intended that the scop^ of Ihe inventlcoi be limited to the specific values recited when deSning a range. [0074] Other embodiments of the present invootion will be apparent to those skilled in the art from consideration of the present specification and practice of Ifae presMt invention disclosed herein. It is intoided that the present specification and eacamples be considered as exranplary only with a true scope and spirit of the invention being indicated by &e following claims and equivaloits Ifaereofl WHAT ]S CLAIMED IS: 1. Carbon blade comprising fte foUowing toee characteristics: (a) an Iodine number of fi-om about ISO to about 600 m^g; (b) a DBF absorption of from about 40 to about 90 cc/lOOg; (c) a ratio of nitrogen sur&ce area/stadstical thickness surfece ^rea of fiom ^out 1^5 to about 1.70; and said caibon black has one or more of the following additional properties: (d) a jetness value as detennined by Terlon L* of 1.7 or less; and/or (e) ft water spreading pressure value of 23.0 mJ/m^ or less. 2. Tlie cazbdn black of claim 1» wh^m said bdinc number is from about 265 to about 600mg/g. 3. The carbon black of claim 1, wherrfn said Iodine numba' is from about 350 mg/g to about 600 rng^g* 4. The carbon bla^ of claim 1> wheim said Iodine number is from about 400 mg/g to about 600 mg/g. 5. The carbon black of claim Ij wherwn said DBF absorption is from about 50 to d)OUt 90 cc/100 & 6. The caibon black of claim 1, wherein said DBP absorpticm; is from about 60 to about 90 cc/100 g. 7. Tlie caibon black of claim 1, ^^4ierdn said DBP absorption is from about 70 to about 90 cc/100 g. 8. The carbon black of daim I, wherein said ratio is from about 130 to about 1.70. 9. The carbon black of claim 1, wherein said ratio is from about L40 to about 17.0. 10. The carbon black of claim 1, wherdn said carbon black has said jelness value and said wstear spreading pressure value. 11. The caibon black of claim 1, whotin said jetness value is 6xm. about 0.4 to about 1 J. 12. Tb& carbon black of daim 1, ^eam said j^ess value is from about 0.4 to about 1.1. 13. l%e carbon black of claim l^wheim said watxrspreadmgp 12.0 to about 23,0 mJ/m^ 14. Hie carbon black of claim 1> wber^ said water spreading pressure value is fimi 12.0 to about 21,5 raJ/m^ 15. Carbon black, when coii^wunded in ABS using fte three step ABS compounding procedure at a carbon black loading of 1.5 wt% or less to form a compounded material, based on the aveitdl wei^t of the compounded mat^ial, achieves a compound jetoess in the overall ccsnpounded material, compound L> of 4.6 or less and said caibon black is capable of providing said compounded material to have one or both of the following properties: (a) a compound notched Izod impact strengdi of 13,600 J/m^ or greater; and/or (b) a compound dispersion rating in a press-out test of 4,0 or less. 16. The carbon black of daim 15, wherein said cotupound jetness is from 3,0 to 4.6. 17. The carbon black of claim 15, v^rein said compound jetness value is from 3-0 to 4.4, 18. The carbon black of claim 15, wherein said compound notched Izod impact strength is from about 13,600 J/m^ to about 18,000 J/m^. 19. The carbon black of claim 15, wherein said compoxmd notdbed Izod impact strength is from about 14,000 to about 17,000 J/inl 20. The carbon black of claim 15> wherein said compound dispersion rating is from 1.0 to about 4.0. 21. Hie carbon black of claim 153 wh^n said compound dispo^ion rating is from about 1.0 to about 3.0, 22 An ABS compound comprismg ABS and at least Cfofi carbon black of claim 1. 23. An ABS compound comprismg ABS and at least one carbon black of olaim 1S. 24. A polymer compound comprising at least one polymer and at least one carbon black of claim 1. 23. A polym^ cxonpound convpri^g at least one po}ym^ aad at least cme caibon black of claim 15. 26. An ABS compound compiish^ ABS attd at least c^e carbon black, wherein said ABS compound has a compound jetness in the overall compounded material, as measured as compound L"^, of 4,6 or less and said ABS compound has one or both of the following properties: (a) a compound notched Izod nnpsct strengdi of 13,600 J/m^ or greater; and/or (b) a compound dispersion ratiug in a press-out test of 4.0 or less. 27. The ABS compound of daim 22, wherein said carbon blade is present in an amount from about 0.5% to about 10 wt% by wei^ of the ABS compound* 28. The polym^ compound of claim 24, wherein said caibon black is pres^ in an amount of jfrom about 0.5 wt% to about 10 wt% from the wd^t of the polymer compound, 29. A polymer masterfoatch or concentrate comprising at least one polymer and the carbon black of claim 1, wherein s^d carbon bladk is presait m an amount of from about 10 wt% to about 50 wt% based cm tiie ovoall weight of the polymer mast^battii or concentrate. 30. A polymer masteibatch or concentzat«» comprising at least one polymer and the carbon blade of claim IS, wh^dn s^ carbon black is present in an amount of from about 10 wt^ to about 50 wt^o based on tiie overall wei^ of the polymer masterbatch or oonceniiatB, 31. The carbon black of claim 15^ wherein said compound jdness vahie is from 3.0 to 4.4 and ^d compound notched Lzod impact strengdi is from about 14,000 to about 17^000 J/m^. Dated this 16 day of November 2007

Full Text

CAIffiONBIACKS AND POLYMERS CONTAINING THE SAME
BACKGROUND OF THE INVENTION
[0001] The pre^nt ixrvcation relates to covd caibon bkcjcs, as weU as polymers containing the carbon blades, and an enhancesnmt in propeardes, sadti as polym^ perfi^nnaace andthelikc.
[0002} Caiboxi black is used in a number of polymear compounds, such as those found m aaylonitrlte-butadiotie-styrene (ABS) molding applicationfi. Carbon black-filled polymer compounds, sucb as carbon black-filled ABS and ABS-alloys (blends of ABS vnSx oiQier polynxQ^)> are used in numerous hi^-p«xfonnaiice polymer applications where a balance of coIor» medianica] properties, and siir&ce appearance is preferred. The ^e and amount of carbon black used in Ihepo^er canhavca vai^gefifectoolfaeproperdes ofihe compound. For instance^ increasing Ihe loading of carbon black can improve the cotor (e.g., the compound has higher jetnes$)» but the mechanical properties and/or sur&ce ^jpearance may be degraded with hi^r loadings. Tiicre is a desire m ikt polymer industry to have a caibon biadk that can achieve comparable or better jetness» blue tone, impact str^igth^ and/or sur&ce appearance (smoo&ness) when compounded into a polymer, but at a loadmg ibat is lower than cuxrent conventional loadings* Adiieving equal color at a lower loading can involve u^g a cacbon blacjc with a higher sur&ce area. However> increasing the sur&ce area of carbon black typically causes the carbon blac^ to become difGcuIt to disperse. Furlfa^, poc^ disp^ion of the carbon black reside in a loss of mechanical propeali^ and/or sur&ce appearance* Thus, it would be desirable to d&nlop a hi^-surfkce area carbon black fiaat can be prs&nibly readily (Uspersed in polymers^ sudi as ABS, to attain an accqrtable level of various mechanical properties (such as impact resistance) and sur&ce appearance.

SUMMARY OFTHEPRESENT INVENTION
[OOftJJ A featare of &c present invention is to provide carbon blacks tbat preferably
provide equal color in polymer compounds at a lower loading and yet are diq?erdble to an
accqrtable level to maintain mechanical pcc^erdes and surface ^earance.
[0004] A fijrther feature of fee present invration is to provide a carbon black v*adi when
compounded In a polymer, sadh as ABS, provides an acceptable balance of propertiea^ such as
jetness^ blue tone^ impact strengths and sur&ce appearance.
[0005[ Additional features and advantage? of &e pj:esent inv^on vrill be set fbrth in pait
in Ifae des^pti^ that fbltows, and in part v/ill be apparent ^m Ifae desc^riptiQa, or may be
leanied l^ practice of &B present invemtioa. The objecdves and ofiber advantages of fee present
invention ivtll be realized and attained by means of the elements and combinatiQits particularly
pointed 0t3ft in tbe description and upended clums.
{000^ To acbieve these and o&er advantSfges, and in accordance wife fee pmposes of the
present invmtion, as embo(fied and broadly descmbed berein, fee present invention r^ates to a
carbon blade feat is characterized by having:
(a) an Iodine munber of fix)m about 150 to about €00 mg/g;
(b) a DBF absorption of fiiom about40 to about 90 cc/lOO g; and
(c) a nitrogen sur&ce area/statisScal feickness sur&ce area (N2SA/STSA) of fiom about 125 to about L70; and the carbon black fUrther has one or bofe of fee following properties:
(d) a jetness as measured by Terlon L* of 1.7 or less snd/or
(c) a wat^ spreading pressure of 23.0 JAn^ or less-
10007] The presOTt invention fbrfeer relates to a carbon blade feat when compou^ in aoyJonitrile-butadiene-styrene at a loadit^ of 1^ wt% or less based on fee overall weight of the compounded material, results Jn a ccanpounded material having a compound jetness (L*)

of 4.6 or less and one or bofli of the Mowing diaraoteristics:
(a) a compound notched Izod impact sfr^gth of 13,600 J/m^ or greater and/or
(b) a compound dispersion rating in a press-but tost of 4.0 or less.
[OOOS] Also, tibe pres^ mventian relates to ABS compomids containing one or more
types of tiie carbon blacto of the present invention.
[0009] Additioxialiy» tixe present invention relates to polymers containing one or more of
the carbon blacks of &e present invention.
[0010] In addition, the preset invmfon relates to polymer mastezbatcfaes or concentrates
containing ODS or more of the carbon blades of the prescsrt invention.
[0011] Further, the present invention relactes to methods of making the carbon blacks of
the preset invention, as well as makmg the polymer compounds of the present inyenlion.
[0012] It is to be understood ^t both tibie foregoing general d^o^ption and &^
detailed description are e?cemplaty and explanatory only and are intended to provide a fbrthear
explanation of tiie present invention, as claimed,
[0013] The accompanying drawings, which are incozporaled in and constitute a part of
this application, illustrate some of ihe embodiments of the present invention and together
with the description, serve to explain ihe prmcuples of the present invention.
BRIEF DESCRIFnON OF DRAWINGS
[0014] Fig. 1 is five photogr^hs showing san^le dispersion ratings*
DETAILED DESCRIPTION OF THE PRESENT INVENTION [0015] The pres^ invention relates to novel carbon biacks; as welt as methods to make the carbon blades. The present inventi-styraie (ABS).

I0pl6] WMi req^ect to the carbon black, tbe carbon black of the present invention has de^rabb morphology mi intei&ciai piop^es that mdke it beneficial in various applications, such as tiie use of the carbon blade in polymer q>pIications like ABS molding ^^lications. [0017] In more det2ul» in at least one embodinaent, the carbon black of fte present invention pTekrMy has one or more of tibie Mowing diree characteristics and preferably has all of the following three dmract^isdcs:
(a) an Iodine number of &>m about 150 to about 600 mg/g. Other ranges can include an Iodine number of jSrom about 265 to about 600 m^g, frcxn about 350 mg/g to about 600 mg/g» or from about 400 mg/g to about 600 mg/g;
(b) a DBF absozption of from about 40 to about 90 cc/lOOg. OUasr ranges can include from about SO to about 90 cc/lOOg, from about 60 to about 90 cc/lOOg, or from about 70toabout90cc/100g;
(c) a ratio of nitrogen sur^ice area/statistical thickness sur&ce area of from about 125 ID about 1.70. Other ranges can include from about 1.30 to about 1-70 or fix»m about 1*40 to about 1-70.
[0018] In addition, in at least one embodiment, the carbon black of frie preseid; invention has one or more of the following additional properties:
(d) a jetness value as dettimined by Tearlon L* of L7 or less, OSaar ranges can include from about 0*4 to about 1.7» or from about 0,4 to about I.l;
(e) a water spreading pressure value of 23.0 mJ/m^ or less. Other ranges mclude from about 12,0 to about 23.0 mJ/m^ or from about 12.0 to about 21.5 mJ/m^.
[0019] With respect to the Iodine number, this number is measured following ASTM D1510, With respect to the DBF absorption, this property is detOTnined following ASTM D2414. Witii respect to tbe nitrogen surface area and ihe statistical tibiokness sur&ce area, these measurements were made following ASTM D6S56*

[0020] Wiai respect to the jetaess as determined by Terlon L*, this procedure uses a C3ELAB color scale. L* is a measure of &e jetness of the carbon black after making an oil-based paste; a lower value is more jet The absolute L* value is used. In detennining jetness, the carbon blade was dried at 125** C for 3 hours and then conditioned in a mixer for 45 seconds. 2*0 g of Terlon #1 Oil was then added to the lower plate of a Hoover Muller, into which 100 mg of the carbon blade was slowly added witii a spatula. After gathering the matoial in the center of the lower plate, the top plal» was put in place and 4he Hoover MuUer plates spun for 50 revolutions to mix the oil and carbon blade The plates were then opened, and the process of ^fliering ifae material and spinning Ssr 50 revoludons was repeated three more times. The ^tire quantity of the paste was then smoothed onto a glass plate. The 1976 CIELAB L* value was measured in four dififerent locations on llie plate usmg a Hunter Labscan XE wifli VSI, using liie following conditions: Mode ** 0/45, Port Size = 1.2 mches, Area View = 1 inch. UV Filter -= Out, Light Souice « D65 with 10** Observer. The value reported is the median of the four absolute L* values. Simultaneously, the 1976 CIELAB b* value (bluetone) is also measured and recorded by fte Hunter Labscan in an analogous way.
[0021] Water ^nreading pressure is a measure of tiie interaciion energy between the caibon black sur&ce and water vapc^. The spreading pressure is measured by observmg the mass inca-ease of a sample as it adsorbs water fi-om a controlled atmosphere. In &e tes^ the relative humidity (RH) of the atmosphere around die sample is mcreased from 0% (pure nitrogen) to --100% (water-saturated mtrogcaa). If the sample and atmosphere are always in equilibrium, the water spreading pressure (TIC) of the sample is defined as:
vAere i? is tiie gas constant, T is fte temperature, -4 is the specific suifece area of the

sample, T is the amount of adsorbed water on the sample (converted to moles/gm), P is the partial pressure of water in the atmosphere, and Pe is the saturation vapor pressure m the atmosphere. In practice, Hje equilibrium adsorption of water on Ae surfece is measured at cme or (prefisrably) several discrete partial pressures and the integral is estimated by the area under the curve. Alternative measurements of *e interfedal prop^es or sur^
be ^ecified, e.g., by not dividing by the surfece area, or ly addmg other mtttfecial properties or surfiaoe energy terms to the water spreading pressure^ or by approximating the integral widi a small number, even possibly as few as one, data points, or nsmg other gases. [0022] The jvocedure for measming the wat^ spreading pressure is detailed m ^'Dynamic Vapor Soiption Using Water, Standard Operating Procedure", rev, 02/08/05 (incozporated in its entirety by reference herein), and is summarized here. Before analysis, 100 mg of the carbon biadk to be analyzed was dried in an oven at 123^ C for 30 minotes-Ader ensuring that the incubator in the Surface Measurement Systems DVSl Instrument (supplied by SMS Instruments, Monarch Beach, California) bad been stable at 25^ C for 2 hours, sample cups were loaded in boft fbt sample and reference chambers. The tai^et RH was set to 0% for 10 minutes to dry the cups and to establish a stable mass baselme. After disdiatging static and taring the balance, (^proTdmately S mg of carbon black was added to the cup in the sample cjiamber Afber sealing the sample chamber, the sample was allowed to equihTsrate at 0% KEi Aflaer equilftxation, ±t initial mass of the sample was recorded, TTie relative humidity of the nitrogen atmosphere was then increased sequentially to levels of approximately 5,10,20,30,40,50,60,70,78,87, and 92% RH, with the system allowed to equilibrate for 20 minutes at each RH level. The mass of water adsozbed at each hmnidity level was recorded, from which water spreadtog pressure was calculated (see above). The measurem^t was done twice on two s^arate samples and the average value is rqfjoited* [0025] In anotibw embodiment of the present invention, the present inveotlon rdatcs to

c«(rbon black "which is capable of achieving certaJn properties when compounded in ABS foiiowii^ a particular procedure, in more detail, in one raibodiment of the present invention, the carbon black» when compounded in ABS at a carbon black loading of 1.5 wt% or less (for instance, at a carbon black loading of OJ wt% to U oveiEBlI wei^t of the con^unded material, aciuevcs a jetness (in Hie overall compounded material), measured as confound L* of 4,6 or less (othw: jetness values for the compounded material can be e,g., 3.0 to 4,6 or 3-0 to 4.4) and tfie carbon black permits the compounded material to have one or both of the following properties:
(a) a COTipound notched izod impact strengfli of 13,600 J/m^ or greater (p&ics ranges include fiom about 13^600 J/m^ to about 18,000 J/m^ frwn about 14,000 to about 17,000 JAn^) and/or
(b) a conopound dispersion ra^ in a press-out test of 4.0 or less (oth^ ranges include e,g.» fiom about 1.0 to about 4.0 or dom about 1.0 to about 3.0). The carbcm blade in this embodiment has these properties for at least one carbon blade loading level in diis range of 1,5 WLH or less.
[0024] Witii respect to these parameters that tiie carlxm black promotes in an ABS when
compounded in the ABS, the following test procedures aie used.
[002S] The ABS compounds were produced in a three step compounding procedure (at
times referred to as **lhe three step ABS compounding procedure*'): First, a 30% SAN
masterbstch was prq}ared, which was &en dUuted to 5% with ABS, before being let down
to 0.50% to 1,50% Witt) additional ABS in a final mjection molding step.
[0026] Masterbatxdx Compound; The SAN masterbatch was prepared by mixing
carbon black (CB), lyil 124 SAN (Density -1080 kg/m^ 230'C/3.8kg MFI» 22 ^'lOrnin),
and Zinc Stearate (ZnSt) in fiie following prt^rtions by wei^t 30.0% CB, 69-5% SAJST,
and 0.5% ZnSt, to give a total mass of the three componwits of 1413 g. The components

were mixed in a Banbory JBtemal nuxer (1570 ml) with the following settings: Rotor Speed = Setting 2, lUm Pressure = 3 kg/cm^ Mtial Temperamre =* 70 ^^^
« 90 s, and Feeding Factor " 75%,
[00271 5% ABS Compound: lie SAN masterbatch was first ground to remove dust and small particles, 250 g of the SAN masterbatch was then mixed witii 1250 g of Cycolac GPMS500 ABS Pensity - 1050 kg/m^ 220*'C/10kg MFI - 24 g/lOmin, 23 "C Notx^ Impact (ISO180/1A) - 18000 J/m^ to produce a 5% ABS compound. This procedure was carried out on a Betol BK32 single screw esdrudw equipped with a disttibutive mixing Wd (cavity transfer mixer (CTM)) to improve it$ dispersive capabilities. The extnkte had the following temperature setting tarn the feeder to the ^fie: Zonel == ISO'^C, Zon^ ^ 185*C, Zones - IPO^'C. Zone4 =» 195^C, CIM ^ 210*'C, Die * 200X, The screw speed was 80 ipm and one pass was used durmg compounding*
[0028] 050 -1-50% ABS Compound: The 5% ABS compounds were diluted to tiieir final loading in a Battenfeld BA500/200CD injection*molding machine. The total mass of material used was 600 g, with the proportions of 5% ABS compound and pure C^obac GPM5500 ABS selected to give the correct final loading. Before mjection, the ABS compounds and the ABS resin were dried for 17 hours at 80*C under vacuum. Betwe«i each sample, 500 g of pure ABS was mjected to clean the equipmcait. The esact injection molding parameters depended on the test that the part was to be subjected to (see below): [0029] Q)lor (L*) Plaques: 90 x 55 x 2 mm plaques for color analysis were prepared using the followmg temperature settings on the injection molding madiine: Nozzle = 225°Q Zonel « 235**C, Zone2 « 250*C, Zone3 ^ 250'»C, Mold ^ 60«C. The mjcction speed was 20%»
[0030] Izod Impact Bars: 63i x 12.7 x 6,4 mm bars (BO 180 Type 3) for Izod impact testing Wtt^ pr^ared u^ng Ave following tCTiperature settings on the mjection molding

machine: Nozzle « 225*C, Zonel - 235*C, 2oiie2 - 250**C, Zone3 = 250^C, Mold = 25'C. Tlie injeoaon speed was 60%.
[0031] Widi respect to Ifae jetness for ^ compound ^ conipound L* is an absohite value. L* is a measure of the jetness of tfat compound; a lower value is more jet. To measure fte compound L% sfac 90 X 55 X 2 mm color plaques with the desired loading waie p^ by injection molding as described above. All plaques were inspected to ensure that th^ bad a uniform color on the sur&ce, and to diecd: tot any pips or streaks. Plaques lliat did not meet tiiese criteria were discarded. Each plaque was then tested once £br the 1976 CIELAB L* value with a DATAC01X)R SF600 ^ectrophotocolorimeter, using the following conditions: Calibration Mode - Reflectance, Specular Door - Bxclude4 Visualization -LAV (30 mm), UV * Included, Condition = % R LAV SO E UV inc., Light Source ^ D65 with 10*^ Observer^ The value reported is tiie av^age of &e six plaques and is the absolute L* value^ not a diderence between the sample and a reforesice. Simuttaneousty, the 1976 CIELAB b'' value (bluctone) of &e compound was measured and recorded by the Datacolor instrument in an analogous way.
[0032] W&i tespcct to detamining &e notched Izod impact strength of tiie compounded mat^al, tiie test was generally based on the GSO 180-19S2 standard, but diSbred in the injection molding procecbire of the test bars. The ^st method is described below. [0033] Ten 63 i x 12.7 x 6A mm bars (ISO 180 Type 3) with the desired loading were prepared by iqjection molding as described above. A smgle ixotch (ISO 180 Type A) was then cut in each bar with a notchmg device (CEAST 6530). The sample was loaded with the notch feeing tiic direction of impact and tested wife a 5^ J pendulum-type hammer (CEA.ST 6545/000). If a bar showed bubbles or holes along tiie fifacture point, it was discarded. The measured impact strength of acceptable samples was recorded and the reported value is the average of the ten bars, Un-notched Izod hnpact strcfigft can be measured by following the

same procedure but without cutting the notch in the test bar.
[0034] 11K dispersion rating in the pres$-out test of &e compoimded material is described below. The disperaon rating is a senii-quaatitative naeasure of carbon black diq^ersion in the compound; a lower vahie equals better [0035J Two 0,3 mg '^buttons" were cut from three different color plaques (pr^andon described above) yielding six buttons. Each button was placed cm a clean microscope slide and covered with anotito slide* The assembly was pressed-out at 210** C for 3 minutes, with enough pressure to obtain a 5 mm button diameter. Each butUm was eicamiaed at 200X and lOOX magnification m a light microscope* A rsSing of 1-5 was Ihen assigned to each button, with 1 corresponding to a good dispersion and 5 to a bad dispersion. In ass^mng tbe dispersion rating, good diversion implies a &w black spots were visible TASTC&S bad dispersion hnplies a lot of blade spots or larger aggregates. More spedlicaUy, the dispersion rating is assigned by counting the number of visible particles greater than 1 fxm in a 651 }jm X 487 pm area under lOOX magnification. The number of particles determmes the dispersion rating: 1 = 0-10 particles, 2 « 11-30 parades, 3 = 31-60 partidcs, 4 = 6M50 particles, 5 ~ more than ISO particles. The cSspersion rating of each sample is the avemge from the six buttons* Figure 1 is photographs showing an example of con^Knmds with dispersion ratings from 1 to 5.
[0036] With respect to manufacturing the carbon blades^ the carbon blades can be made as follows. The carbon blacks of flie present invention can be produced in a tubdar &mace reactor similar to those described in U.S. Patent Nos. 6,136,837 and 5,S77j250, incoipor^ed in their entireties by refefKiceheiein, The reactor iUustrated in Figure 1 of4atpalmthas(a) an initial combustion zone, (b) a secondaiy combu^on zon^ (c) a reacfion zone, and (d) a qu«idiingzone» [0037J In the present mvention, a reaction like feat diown in U.S. PatetrtNos, 6,156^837

and 5,877,250 is used wfii Hit adjustmesits described htc&n. In the nutial condaistion zone, £id and an oxidant are mixed and reacted to form aliot combustUm gas stream. Siutable fuels for gen^ating die hot combustion gases include any readily combustible fluid* including natural gas, hydrogen, carbon mon [0038] This zone is followed by a secondary combustion zone, where ti)e hot combustion gases are contacted wi^ a xnixture of alkali salts and a liquid hydrocarbon feedstock &at is readily volatiii2»d. Suitable liquid feedstocks mdude unsaturated hydrocarbons, saturated hydrocarbons, olefins, aromatics, and other hydrocarbons such as karosenes, nscphbal^nes, terpenes^ ethylene tars, and aromatic cycle stoclcs, as wdl as mixtures of all of die above. 7%e foedstock is otteai mjected in a plurality of streams that rapidly mix wi& tiie hot initial combustion gases, causing the carbon black-yieldnig foedstodc to decompose and conv^ to carbon black, h the process of the preset invention, the over^ ra:tio of oxidant to both fuels (including that fai the first zone) is between 0.15 and 0.50 times &e amount of cxsidant needed for stoichiometric combustion. Preferably, ^flje overall ratio is between 025 and 0.40. The concentration of alkali salts in the feedstodc is in the range of 0*03 to 0,15% by wei^t [0039] In the ttiird zone of the reaction, the mixture of combustion gases and carbon black continues to react as it flows downstream until it reaches the four* zone of the reactor, wh^e a quenchmg fluid is mtroduced to stop the reactkm. Suitable quenching fluids include water, a mixture of water and steam, or a mixture of water and air. The ideal location of the quendi

(a^ tiuK'efoie Ibie ^dence time of the reaction) d^)ends on the flow rate of Ibe gases'sod &e diameter of the furnace. In geceral, tbie residence time of the reaction ^ould be 10 and 200 ms, and preferably batweem 60 and 150 ms (nuUiseoonds). .
[0040] Afier adding the quenching fluid, the mixture is passed to any convc^itional cooling f^^>araius, such as a venturi cooler or a heat exchange, at which point the carbon blade is separated from the gas stream 1^ CDnvexxdonal means such as a precxpitatar> [0042] The carbon blacks used in Ifac polymer compositions of the present invention can optionally be finther treated with a variety of treating ag^its, such as binders and/or surfectents. The treating agents described in aS. Pat Nos, 5,725,650; 5^00,164; 5,872,177; 5,871,706; and 5,747,559, all incorporated herein in their entirety by refeence, can be used in treating flie catbon blades of the present invention. Othar preferred treating a^nts, mcluding surfactants and/or bmders, can be used and bclude, but are not limited to, polyethyleae ^yooU aikylene oxides such as propylene oxides and/or e&ylene oxides^ sodium Iignosul:&te; acetates such as ethyl-vinyl acetates; sorbitan monoolcate and cfliylcne oxide;

d6^y\&a^&yttri^^ metbacrylace bind^; copolymers of butadiene and
actyionitrile; and the like. Such binders are comm^xaalb^ available from such manufecturers as Union Carbide, Dow, Id, Union Padfic> Wacker/Air Products, foterpolymer Corporation, and B. F. Goodrich.. These bindars are preferably sold nnderthe trade names: Vinnapas LL462, Vinnapas LL870, Vinnapas EAF650, Tween 80, Syntan 1930, Hycar 1561, Hycar 1562, Hycar 1571, Hycar 1572, PEG 1000, PEG 3350, PEG 8000, PEG 20000, PEG 35000, Syx^erottic PE/F38, Synperonic PE/F108» Synperonic PE/P127, and Lignosite^SS. GenOTilty the amount of treatiog ag^t used wi& the catbon blacks of the present invention can be the amounts recited in the above-des(»ibed patents, for instance m an amount of &om about 0.1% to about 50% by weight of the treated cazbon blac^ ^ugh other amounts can be used depending upon fte type of pFcq)erties desired and the pardcuiar treating ag6nt(s) being used. The carbon black used in the polymer compositions of &e present invention can also be modified to form a modified caxbon black having attached at least one organic group. Tlie type of organic group will vaiy depending on the polym^ used as well as on ib& desired p^miance properties. This allows for greater flcTdbility by tailozing the modified carbon blade to the spediic application*
[0043] The caibon blacks can be modified using me^ods known to &ose skilled in the art sudi that otganic groups are attached to tiie cait^cm biacL This provides a more stable attadiment of the groups onto the carbon bladi: compaiced to adsorbed groups^ sudi as polymers, sur&ctants, and the like. For example^ the modified cattcxi blacks can be prepai^d using «ie methods described m U.S. Pat Nos. 5,554,739, 5,851^80, 6,042,643, 5,707,432, and 5,837,045, and PCT Publication WO 99>'23174^ the descriptions of v*ich are fiilly incorporated herem by ref^ence.
[0044] Also, for purposes of the present invention, the carbon blade, as defined by its property capabilities when compounded in ABS, can have one or more of the propraties

described above wiA respect to lodixie number, DBF abswpdotu nitrogen surfece area/statistical thiokness sutfece area ratio, jetaess, as determined by Terlon L*, and/or the watef spreading pressure prop^es. Similarly, Ihe carbon blade properties having Ibe Iodine number, DBF absorpticm, and nitrogen siir&ce area/srtatistical Sickness sur&ce area ratio can have cme or more of the carbon black properties measured ^*fin compounded in ABS as descdbed above.
[0045] In a furtber embodiment of the present invention, the present invention relates to an ABS compound Aat contains ABS and at least one carbon black of the presmt invention. The present invention fordier relates to an ABS compound that contains ABS and at least one carbon black of the present invention v/herem the ABS compound has the carbon black loading as described above, along with tibte compound jetness, and compound notched ]^od impact strength, as desc^bed above.
[0046} b ano&er embodiment of the present invention, the present invesiiion relates to an ABS compound that contains ABS and at least one carbon black of the present invention wherein Ihe ABS compound has the carbon bhick loading as described above, abng with the compound jetnesB as described above and the compound dispersion rating in press-out test as desoribed above,
[0047] hi a further embodiment of the present invention, Ihe present invention relates to an ABS compound that contains ABS and at least one carbon black of the present invention, vi:^rein the ABS compound has the carbon black loading as described above, along widi the compound jetaess as described above, the compound notched Izod impact strength as described edjove, and Ihe compound dispersion rating in prcss-out tests as described above. [0048] A further embodiment of the present invention relates to an ABS compound that
contains ABS and $t least one carbon black of the present invention, wherein the ABS compound has a compound jetness as described above and a ccnnpound notched Izod impact

strength as described above without any limit on the carbon black loading.
[0049} An additional embodiment of ^ present invention relates to an ABS compound
that contains ABS and at least one carbon blade of the pres^ invention when^ the ABS
coni^KTond has the compound jetness as described above and the con:ipound dispersion
rating in press-out tests as described above without any limit on the carbon black loading.
[0050} A &rther embodiment of the present inv^tion relates to an ABS compound that
contains ABS and at least one carbon black of the presexit invention M4I^^ the ABS
compound has the compound jetness as described above, tiie compound notched kod
impact strength as described above, and the compound dispersion rating in press»out tests as
described above, vdtiiout any limi^ on the carbon black loading*
[0051] Furdiermc^re, in the preset invention^. ^ ABS compound can contain one or
more oftter types of poiymers to &nn an ABS alloy as that tarm is understood to those
skilled in &e art The ABS compoimd or ABS alloy contains at least one type of carbcm
black as described above. Furtibermore, other types of carbon blacks, such as conventional
carbon blacks, can fiirther be present, and/or other reinforcing additives can be present
Also, otfa^ conventional ingredients Really used in ABS compounds and ABS alloys can
fiirflier be preset in the present invention including, but not limited to, otiier conventional
components fliat can be used in polymer compositions*
[0052] h. a fiirther OTibodiment of the present invention, the present invention relates to
a polymer ccmipound that contahis at lea^ one polym^ and at least one carbon black of the
prtsent invention. Tie preset in^^ition fiirftier relates to a polymer compound tiiat contains
at least one polym^ and at least one carbon blade of Ae present invMtion wherein the
polymer compound has the carbon black loading as described above, along with the
cOTipound jetness as desadbed above, and the ccanpound notched Izod iir^>act streaigth as descra^ above.

[0053] In another embodiment of &e present invention, the prt^eot invention relates to a
polym^ compound that oontafns at least one polymer and at least one carbon black of the
present invention wherein the pol>tner compound has the carbon blade loading as described
above;, along with ^ compound jetness as described above and Ihe compound dispersion
rating in p3:ess*ont tests as desoibed above.
(0054] In a fijather embodiment of the present invention, the ^-esent invenlion relates to
a polymer compound that contains at least one polymer and at least one carbon blade of the
present invention, wherein the polymer cc^pound has ibe carbon blade loading as described
abov^ along with the compound jetness as described abovQ» the cotqioimd notched Izod
impact strength as described above, and the compound dispersicm rating in press^nt tests as
described above.
[0055] A fiizther embodiment of the present tovention relates to a polymo: compound
1h&t contains at least one polymer and at least one carbon black of the present invention
wherein the polymer compound has a compound jetness as described above and a
compound notched Izod hnpact strength as described above without any limit on the carbon
black loading.
[0056] An additional embodiment of the present invention relates to a poiymex
compound that oontauis at least one polymer and at least one carbon hlBjck of the present
invention wherein the polymo- con^>ound has die compound jetness as described above and
the compound diversion rating in pres&^ut tests as described above witfaout any limit on
the carbon black loading.
[0057] A fiirflner embodiment of the jM-esent mvention relates to a polymer compound
that contains at least one polymer and at least one carbon black of the present inv^rtion
wheredn the polymer compound has the compound jetness as described above^ the compound notched feod impact strength as described above, and the compound dispersion

i^ing in pre$$-out tests as described above» without any limit on &e caiton black loading* [00S8] Furdiennore^ in the present invention, the polymer compound can contain one or more types of poI}iners to fonn a polymer alloy as that term is understood to tistose skilled in &e art The polymer compound or polymer alloy contains at least one type of carbon blade as described above. Fnrthennare, o&er types of carbon blades, such as conventional carbon blacks, can &rther be present, along with o&er rdnforcing agents. Also, o&er conventional ingredi^ts typically used in polym^ compounds and polymer alloys can fiirthe* be present in the present invention inctudiiig» but not limited to^ other conventional components that can be used in polymer compositions.
(0059J In mcwie detail, the araylonitrile-butadiene-s^ene copolymer type resin to be used in the present inv^tion is one composed mamly of a copolymer having fhrcfi components of aoylonitrile, butadiene and styrenef and a commm>iaIly available product may be used. For exan\ple» a copolymer obtained by blodc or graft polymerization of at least one monomer selected from an aromatic vinyl monomer and a vinyl cyanide monomer to a diene type rubber, or a blended product with ibt copolymer, may be motioned The diene type rubber is a polymer obtained by polymerizing butadiene as a component, ai)4 examples of which inclixde polybutadiene^ polyiscprene, an acrylomtrik-butadi^ie copolymer and a styrene-butadiene copolymer. The aromatic vinyl monomu' may, for example, be styrene, alpha-meO^ylsfyrene or an alkyl-substituted styrene. l^e vinyl cyaaide monomer m^, for exanq>le, be acrylonitrUe, me^iacrylonitrile or a halogaa-substituted acrylonitrile* Specific examples of the copolymer and the blended product wfti the copolymer include an acxylonitrile-butadiene-styrttne terpolyraer and
i^VOTtion, the polymer can be any polymeric compound. PrdferabJyii the polymer b one that is use&l in molding applications, such as a polyoleSn^ a vbylhalide polymer, a vinylidene halide polymer, a peafluwinated polymer, a styrene polymer, an amide polymer, a polycaibonatCj, a polyester, a polyphenyleneorides a polyphenjiene eflier, a poljtetonc, a polyaoetal, a vinyl alcohol polymer, or a polyurethane* Polymws or resms useful in the practice of the invention include PET or polyethylene terephthalate, polystyrene, PBT or polybutyl^e tercphflialate and PBT allays, polypropylene, poIyureSiane, ABS or aoylonitrile-butadijaie-s^ene copolymer, PVC or polyvinyl chloride, polyesters, polycarbonates, PP/PS or polypropylene polystyrene ail
su^ as jetaess^ conducdviiy, toughness, 8ti£5iess, smoothness, and tensile properties* [0062] Polymers inchide ^lermoplasdc polyolefins (TPO\ polyeihyirae (P£» sudi as LLDPE, LDEB, HDPE, UHMWra, VLDPEj and mtLDPE), polypropylene, copolymers of ])Olypropyl^t, ettiyleoe propylene rubber (EPR)^ ethylene |»tjpylene diens terpolymers (such as EFDM), actybnitrile butadiene styrene (ABS), acaylonitrile BPDM s^^rene (AES), polyoxymctfaylene (POM), polyamid^ (PA, such as PA6» PA66, PAll, PA12, and PA46>, polyvinyldiloride (PVCX tetraeflhylHie hcx^ropylene vinylidenefluoride polymers (IHV), p«iluoroalkoxy polymcis (PFA), poljiiexafluc^TOpropyieae (HFPX poJylcetones (PK), ethyiene vinyl alcohol (EVOH), copolyesters, polyuretiianes (PU), polystyrene (PS), polycarbonate (PC), polybutylcne teephthalate (PBT), polyeflijittie taephthalate (PET)j poIypfaeneylKxe cacide (PPO), and polyphenylene efiier (PPE). Prefeired blends include PC/ABS, PC/PBT, PP/EPDM, PP/EPR, PP/PE, PA/PPO, and PPO/PE.
[0063] The polymer(s) can be a thennoplastic polymer or a liiestnosettmg polymer. Further, the polymer groq) can be a homqpolyma:, copolymer, terpolymer, and/or a polynxer contairung any tmmber of dsfj^rent ideating unks. Further, ^ polymer groi^ present in the present mvention can be any type of polymer group, such as a random polymer, alternating polymCT, graft polymer, blodc polymer, star-like polymer, and/or comb-iike polymo:* The poller group used in H^ present invention can also be one ^ more poiyblends. The poiymo-group can be an interpeaetrating polymer aetworic (EPNf); simultaneous interpenetrating pobimer network (SIN); or iateapeo^raling elastomeric network (TEN). [0064] Specific examples of polymers include, but are not limited to, linear-high polymers such as polyethylene, poly(vinylchIoridc), polyisobutylai^ polystyz^ne, polycsaproJactam (nylon), polyisoprene, and the like. Other g«ieral classes OF polymers of the present invention are polyamid^ polycarbonates, polyetectrotytes, polyesteis, pplyettiers, (polj1iydroxy)benzenes, pofyimides, polymers conttoiing sulfur (such as polysulfides,

(polyph^yleoe) sulfide, and polysulfbnes), polyoiefins, potymethylbenzenes, polystyrene and Styteasi copolymers (ABS included^ acetal poiymeis, acrylic polymers, acrjlonitrile polymers and eopolymer&» polyole(6ns contammg halogen (sudi as polyvinyl chloride and polyvinylidene diloride), fiuoropolymers, ionomeric polymer polymers contaimng ketx>nje group(sX liquid crystal polymers, polyamide-imides, polymers containing olefinic double bond(s) (sudi as polybutadi^ie, polytOcyclopeiitadiKie), polyolefun copolymers, polyph^yl^e oxides, polysiloxan^, poly(vinyl alcohols), poIyuretbanes> ftemioplastic elastomers, and fiie like. The polymer can be a polyoldSn, a polyurdhane» a polysfyreruc> a polyaciylate, a polyamide, a polyester, or mixtures thereof.
[0065] Gentt:ally, the poljoneric groups described in Volume 18 of the Encyclopedia of Chemical Technotogy, KIRKOTilMER, (1982), page 328 to p^^ 887, and Modan Plastics Enq^opedia '98, pages B-3 ID B-210, and "Polymers: Structure and Properties*" by C.A. Daniels, Technomic Publishing Co^ Lancaster, PA (1989), aU incorporated in flieir endrety herein by re&rcnce, can be used as ihe polymer(s). The polymers can be prepared in a number of ways and sudi ways are known to ftiose skilled in tiie aiL The above referenced KIRK-OTHMER section. Modem Plastics Encyclopedia, and CJu Daniels' reference provide methods in whic^ these polymers can be p!r^)ared
[0066] Tltc polymer compositions of the present invention ma^ also mclude suitable additives for their known purposes and amounts. For example, the compositions of the present invention may also include such additives as crosslinking agoits, vulcanizing ^ents, stabilizeiSy pigments, dyes, colorants, metal deactivators, oil extoadei^ lubricants, and/or morganic fillers, and the like.
[0067} The polymtt compositions of fte present mvention can be prepared using conventional teohmques such as mixing the various cwuponents togeftier using oommerdally available mixers. The composition may be prepared by bafx^ or continuous mixing processes

such as Ihose well known in fte art For example, equipment such as discontinuous btmial mbcers, continuous internal mbcers, reciprocatixig sing^ sorew extrude, twin acd single screw extruder, etc. may be used to mbc the xngre(fient$ of the formulations. Hie carbon black ms^ be btroduced directly into the polymer blend; or the carbon blade may be introduced into one of the polym^s before tfiat polym^ is blended with anodier polymer* The compCMieiits of the polym^ compositions of the preseait invention may be mixed and fomied into pellets '&xt fijture use m manu&oturing such materials as articles for automotive applications* (0068] With respect to the amount of carbon black; any amount can be used in the polymer compositions in order to achieve the desired properties. For instance> &csn about 03 wt% to about 50 wt%, based on the overall weight of &e polymer composition, can be used, and more preferably} from about 0.5% to about 10% by wd^ based on the overall weight of the polymer composition*
[0069] In a further embodiment of the present invention, the present invexition relates to a mastcrbattA or concentrate containing one or more carbon blacks of the presort inveniion. The masterbatch or concentrate can cont^ one or more polyma:s, sMoh as those descnbed above, along with a masterbatch or concentrate amount of a carbon blade of Ifae present invention. The carbon blade loading can be any suitable amount typically found m masterbatdies or concaitrates, sudi as from about 10 yfi% to about 50 v^ based on the overall wei^ of the mastetbatch or oc^coitrate.
[0070] The carbon blacks of the present inventton can be used in any cod use plication where conventional carbon blades are used, e-g., inks, coatings, elastomcrio products, toners, fuel ceUs» tires or parts thereof molded parts> cables or parts thereof and the like, using convmtimal amounts or lower.
[0071] The present invention will be fiutha- clarified by the following examples, which are intended to be excmpiaiy of the present invention.

EXAMPLES 10072] Ihiee caiboa blacks, identified as 'A", *B^ and 'C' of the present ittventkin and having the prq^es set &rdi ux &e Table 1 below, w^e prepared as described above and in Table 1. Tbsst caibon blades are compared to two conmerciaUy available carbon blades from Cabot, designated '"X" and *V in the table below, and the analytical data for each of ftese carbon blac^ are set &rdi in the table as well. Using procedures described above, aQ of tiiese carbon blacks were formulated into an ABS CD0q}Oond using the loadmgs indicated in ta& table next to sanq)le idmtification numb^. For instance, carbon black ^OiT vms foonulated widi a caibofi black loading of 0.75% by wei^t of the overall ABS compound^ and carbon black 'X* was also fisrmuiated with a carbon black loadmg of 0,5% by wei^ of tbie overatt compound^ and so on. As a cottxparative» aa ABS compound containing no caibon black whatsoever (indicated as ^^Pure ABS" in ihe table bdow) was analyzed as well. Using the test procedures described above, the various j^by^cal propoiies of the compounded polymas were m^isared, including notched and xm-notxd^ Izod impact strengOi, pre$s-out dispersion ratmg» and jetness (L'^)v using the procedures previously described. As can be seen &om ^e data set forth in the table, the cazbon blac^ oi tbte present izrveniion, when compounded at 0.509^ w^e able to equal or exceed the confound jetaess of carbon bladt **X** compounded art; 0.75%. Jh addition, the caibon blades of the present invention had a superior imimct strength (both notched and un-^notdhed) and press-out rating when compounded to give equal or better jetness as carbon bladt ^•X*', This is not Ihe case fear coniparsfive caibon black * W ^iiidi showed a similar jetness to ttie carbon blacks of the prestot invention when compounded at 0.5%, but which showed a pO(^er hnpact strengdt and press-out dispersion rating. The carbon blacks of the present invention have a hi^ sm&ce area and strong jetness but reuxdin relatively easy to disperse.

Table 1

[0073] Applicants ^ecificaliy incorporate the entire contents of all cited re&r^ices in Ihis disclosure. Further> when an amount, concentration^ or oflier value or param^^ is given as either a range» preferred rangft^ or a list of upper preferable values and lower preferable values, this i$ to be understood as specifically disclosiog all ranges formed &oni any pair of axQ^ i^yper range limit or preferred value and any lower xange limit or prrfbrred value, regardless of whether ranges are separately disclosed, Where a range of numerical Values i^ recited herein, unless otherwise stated, Ifae range is intmoded to include the endpoints th^«o^ and all hitegers and fiacticHis within (he range. Tt t$ not intended that the scop^ of Ihe inventlcoi be limited to the specific values recited when deSning a range.
[0074] Other embodiments of the present invootion will be apparent to those skilled in the art from consideration of the present specification and practice of Ifae presMt invention disclosed herein. It is intoided that the present specification and eacamples be considered as exranplary only with a true scope and spirit of the invention being indicated by &e following claims and equivaloits Ifaereofl

WHAT ]S CLAIMED IS:
1. Carbon blade comprising fte foUowing toee characteristics:
(a) an Iodine number of fi-om about ISO to about 600 m^g;
(b) a DBF absorption of from about 40 to about 90 cc/lOOg;
(c) a ratio of nitrogen sur&ce area/stadstical thickness surfece ^rea of fiom ^out 1^5 to about 1.70; and said caibon black has one or more of the following additional properties:
(d) a jetness value as detennined by Terlon L* of 1.7 or less; and/or
(e) ft water spreading pressure value of 23.0 mJ/m^ or less.

2. Tlie cazbdn black of claim 1» wh^m said bdinc number is from about 265 to about 600mg/g.
3. The carbon black of claim 1, wherrfn said Iodine numba' is from about 350 mg/g to about 600 rng^g*
4. The carbon bla^ of claim 1> wheim said Iodine number is from about 400 mg/g to about 600 mg/g.
5. The carbon black of claim Ij wherwn said DBF absorption is from about 50 to d)OUt 90 cc/100 &
6. The caibon black of claim 1, wherein said DBP absorpticm; is from about 60 to about 90 cc/100 g.
7. Tlie caibon black of claim 1, ^^4ierdn said DBP absorption is from about 70 to about 90 cc/100 g.
8. The carbon black of daim I, wherein said ratio is from about 130 to about 1.70.
9. The carbon black of claim 1, wherein said ratio is from about L40 to about 17.0.
10. The carbon black of claim 1, wherdn said carbon black has said jelness value and said wstear spreading pressure value.
11. The caibon black of claim 1, whotin said jetness value is 6xm. about 0.4 to about 1 J.

12. Tb& carbon black of daim 1, ^eam said j^ess value is from about 0.4 to about 1.1.
13. l%e carbon black of claim l^wheim said watxrspreadmgp
12.0 to about 23,0 mJ/m^
14. Hie carbon black of claim 1> wber^ said water spreading pressure value is fimi 12.0
to about 21,5 raJ/m^
15. Carbon black, when coii^wunded in ABS using fte three step ABS compounding
procedure at a carbon black loading of 1.5 wt% or less to form a compounded material,
based on the aveitdl wei^t of the compounded mat^ial, achieves a compound jetoess in the
overall ccsnpounded material, compound L*> of 4.6 or less and said caibon black is capable
of providing said compounded material to have one or both of the following properties:
(a) a compound notched Izod impact strengdi of 13,600 J/m^ or greater; and/or
(b) a compound dispersion rating in a press-out test of 4,0 or less.

16. The carbon black of daim 15, wherein said cotupound jetness is from 3,0 to 4.6.
17. The carbon black of claim 15, v^rein said compound jetness value is from 3-0 to 4.4,
18. The carbon black of claim 15, wherein said compound notched Izod impact strength is from about 13,600 J/m^ to about 18,000 J/m^.
19. The carbon black of claim 15, wherein said compoxmd notdbed Izod impact strength is from about 14,000 to about 17,000 J/inl
20. The carbon black of claim 15> wherein said compound dispersion rating is from 1.0 to about 4.0.
21. Hie carbon black of claim 153 wh^n said compound dispo^ion rating is from about 1.0 to about 3.0,
22* An ABS compound comprismg ABS and at least Cfofi carbon black of claim 1.
23. An ABS compound comprismg ABS and at least one carbon black of olaim 1S.
24. A polymer compound comprising at least one polymer and at least one carbon black of

claim 1.
23. A polym^ cxonpound convpri^g at least one po}ym^ aad at least cme caibon black of
claim 15.
26. An ABS compound compiish^ ABS attd at least c^e carbon black, wherein said ABS
compound has a compound jetness in the overall compounded material, as measured as
compound L"^, of 4,6 or less and said ABS compound has one or both of the following
properties:
(a) a compound notched Izod nnpsct strengdi of 13,600 J/m^ or greater; and/or
(b) a compound dispersion ratiug in a press-out test of 4.0 or less.
27. The ABS compound of daim 22, wherein said carbon blade is present in an amount
from about 0.5% to about 10 wt% by wei^ of the ABS compound*
28. The polym^ compound of claim 24, wherein said caibon black is pres^ in an amount of jfrom about 0.5 wt% to about 10 wt% from the wd^t of the polymer compound,
29. A polymer masterfoatch or concentrate comprising at least one polymer and the carbon black of claim 1, wherein s^d carbon bladk is presait m an amount of from about 10 wt% to about 50 wt% based cm tiie ovoall weight of the polymer mast^battii or concentrate.
30. A polymer masteibatch or concentzat«» comprising at least one polymer and the carbon blade of claim IS, wh^dn s^ carbon black is present in an amount of from about 10 wt^ to about 50 wt^o based on tiie overall wei^ of the polymer masterbatch or oonceniiatB,
31. The carbon black of claim 15^ wherein said compound jdness vahie is from 3.0 to 4.4
and ^d compound notched Lzod impact strengdi is from about 14,000 to about 17^000 J/m^.
Dated this 16 day of November 2007

Documents:

5193-CHENP-2007 AMENDED CLAIMS 07-01-2015.pdf

5193-CHENP-2007 AMENDED CLAIMS 18-02-2015.pdf

5193-CHENP-2007 AMENDED PAGES OF SPECIFICATION 07-01-2015.pdf

5193-CHENP-2007 CORRESPONDENCE OTHERS 03-07-2014.pdf

5193-CHENP-2007 CORRESPONDENCE OTHERS 13-02-2015.pdf

5193-CHENP-2007 CORRESPONDENCE OTHERS 13-08-2014.pdf

5193-CHENP-2007 EXAMINATION REPORT REPLY RECEIVED 07-01-2015.pdf

5193-CHENP-2007 CORRESPONDENCE OTHERS. 18-02-2015.pdf

5193-chenp-2007-abstract.pdf

5193-chenp-2007-assignement.pdf

5193-chenp-2007-claims.pdf

5193-chenp-2007-correspondnece-others.pdf

5193-chenp-2007-description(complete).pdf

5193-chenp-2007-drawings.pdf

5193-chenp-2007-form 1.pdf

5193-chenp-2007-form 26.pdf

5193-chenp-2007-form 3.pdf

5193-chenp-2007-form 5.pdf

5193-chenp-2007-pct.pdf

5739-2007_FORM 3.pdf

5739-2007_Petition 137 Annex Form 3.pdf

5739-2007_Petiton 137-POR.pdf

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Patent Number

265693

Indian Patent Application Number

5193/CHENP/2007

PG Journal Number

11/2015

Publication Date

13-Mar-2015

Grant Date

05-Mar-2015

Date of Filing

16-Nov-2007

Name of Patentee

CABOT CORPORATION

Applicant Address

TWO SEAPORT LANE, SUITE 1300, BOSTON, MASSACHUSETTS 02210-2019.

Inventors:

#	Inventor's Name	Inventor's Address
1	GREEN, MARTIN C	119 STEELE LANE, BOXBOROUGH, MA 01719
2	MOESER, GEOFFREY, D	19 HAROLD AVENUE, READING, MA 01867, USA.
3	BROWN, STEVEN, E	111 DENNISTON DRIVE, NEW WINDSOR, NY 12553, USA.
4	REZNEK, STEVEN, R	781 STRAWBERRY HILL ROAD, CONCORD, MA 01742, USA.

PCT International Classification Number

C08K 3/04

PCT International Application Number

PCT/US2006/018723

PCT International Filing date

2006-05-16

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1	11/130,838	2005-05-17	U.S.A.