Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Reexamination Certificate
1999-03-03
2001-01-23
Sanders, Kriellion (Department: 1714)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Processes of preparing a desired or intentional composition...
C524S119000, C525S067000
Reexamination Certificate
active
06177492
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to a thermoplastic resin composition. More particularly, it relates to a novel thermoplastic resin composition comprising principally an aromatic polycarbonate and a styrene-based resin and having a good balance of properties such as rigidity and impact resistance and further excellent flame retardancy, and a process for producing thereof.
Aromatic polycarbonate/styrene-based resin compositions, a typical example of which is aromatic polycarbonate/ABS alloys, have been widely used in the art as a material which has good fluidity and high impact resistance. The flame retardants composition comprising such resin compositions have also been popularly used in the field of OA appliances. Regarding the flame-retardant compositions, particularly those comprising a phosphoric flame retardant, the representative ones are disclosed in Japanese Patent Application Laid-Open (KOKAI) Nos. 2-115262 and 2-32154. Also, in the field of OA appliances, especially in applications for specific purposes such as housing, the compositions (and the molded products thereof) are often required to be thin in thickness and high in rigidity and fluidity, and various materials that meet such requirements have been marketed.
However, aromatic polycarbonate resin and styrene-based resin are usually poor in compatibility each other. Therefore, the above-mentioned aromatic polycarbonate styrene-based resin compositions have a problem that in case where molding is conducted under some condition or a molding product having some shape is produced, laminar exfoliation occurs in the produced molding product or the impact resistance of produced molding product tends to reduce.
As a result of the present inventors' earnest studies to solve the above problems, it has been found that a thermoplastic resin composition having mixed therein a specified amount of a melt kneaded resin composition comprising an aromatic polycarbonate, a styrene-based resin, a polyphenylene ether and a saturated polyester has very good compatibility, preferable physical properties and excellent flame retardancy. The present invention has been attained on the basis of the above finding.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a composition remarkably enhanced in aromatic polycarbonate/styrene-based resin compatibility for improving the balance of properties such as rigidity and impact resistance along with flame retardancy of the composition.
To attain the above object, in the first aspect of the present invention, there is provided a thermoplastic resin composition comprising:
(A) 95 to 5 parts by weight of an aromatic polycarbonate,
(B) 5 to 95 parts by weight of a styrene-based resin, and
(C) a melt kneaded resin composition comprising a polyphenylene ether and a saturated polyester,
the amount of component (C) being 1 to 50 parts by weight based on 100 parts by total weight of the components (A) and (B).
In the second aspect of the present invention, there is provided a thermoplastic resin composition comprising:
(A) 95 to 5 parts by weight of an aromatic polycarbonate,
(B) 5 to 95 parts by weight of a styrene-based resin, and
(C) a melt kneaded resin composition comprising a polyphenylene ether and a saturated polyester,
the amount of component (C) being 1 to 50 parts by weight based on 100 parts by total weight of the components (A) and (B), and the component (C) comprising:
(a) 95 to 20 parts by weight of a polyphenylene ether,
(b) 5 to 85 parts by weight of a saturated polyester, the total amount of the components (a) and (b) being 100 parts by weight,
(c) a phosphorous ester compound represented by the following formula (1), the amount of the component (c) being 0.1 to 10 parts by weight based on 100 parts by total weight of the components (a) and (b), and
(d) a phosphoric flame retardant, the amount of the component (d) being 5 to 200 parts by weight based on 100 parts by total weight of the components (a) and (b):
wherein Ar is a C
6
-C
30
aromatic group which may be substituted; n is a number of 1 or 2; R is a C
2
-C
18
alkylene group when n is 1, and a C
4
-C
18
alkyltetrayl group when n is 2; Ar's may be identical or different, and the substituent of Ar and R may contain an oxygen atom, nitrogen atom, sulfur atom or halogen atom.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is described in further detail.
The aromatic polycarbonates usable as component (A) in the present invention are the polycarbonate polymers or copolymers which may be branched and can be obtained by reacting aromatic hydroxyl compounds and a small quantity of polyhydroxyl compounds with phosgene or a carbonic acid diester. These polycarbonate polymers or copolymers may be used by mixing two or more of them.
The aromatic dihydroxyl compounds usable in the present invention include, for example, 2,2-bis(4-hydroxyphenyl)propane (=bisphenol A), tetramethylbisphenol A, bis(4-hydroxyphenyl)-p-diisopropylbenzene, hydroquinone, resorcinol and 4,4′-dihydroxydiphenyl. Of these compounds, bisphenol A is preferred.
In order to obtain a branched aromatic polycarbonate, a polyhydroxyl compound such as fluoroglycine, 4,6-dimethyl-2,4,6-tri(4-hydroxyphenyl)heptene-2,4,6-dimethyl-2,4,6-tri(4-hydroxyphenyl)heptane, 2,6-dimethyl-2,4,6-tri(4-hydroxyphenyl)heptene-3, 1,3,5-tri(4-hydroxyphenyl)benzene or 1,1,1-tri(4-hydroxyphenyl)ethane, or a polyfunctional compound such as 3,3-bis(4-hydroxyaryl)oxyindole (=isatinbisphenol), 5-chloroisatin, 5,7-dichloroisatin or 5-bromoisatin is used as a part of the aromatic dihydroxyl compound mentioned above in an amount of usually 0.01 to 10% by mole, preferably 0.1 to 2% by mole.
As the aromatic polycarbonate, preferably a polycarbonate polymer derived from 2,2-bis(4-hydroxyphenyl)propane or a polycarbonate copolymer derived from 2,2-bis(4-hydroxyphenyl)propane and other aromatic dihydroxyl compound is used.
The molecular weight of the aromatic polycarbonate used in this invention is preferably in the range of 12,000 to 100,000, more preferably 16,000 to 30,000, especially preferably 18,000 to 23,000, in terms of viscosity-average molecular weight converted from the solution viscosity measured at 25° C. using methylene chloride as solvent.
For adjusting the molecular weight, a monovalent hydroxyl compound such as m- or p-methylphenol, m- or p-propylphenol, p-tert-butylphenol, p-long chain alkyl-substituted phenol or the like is used.
The styrene-based resin used as component (B) in the present invention is a polymer produced by polymerizing a styrene monomer for its main component. Examples of such polymers are homopolymers of styrene monomers, copolymers of styrene monomers and other copolymerizable monomers, and styrene-based graft copolymers produced by copolymerizing the monomers including a styrene monomer in the presence of a rubber component. Examples of the copolymers of styrene monomers and other copolymerizable monomers include AS resins, and examples of the styrene-based graft copolymers include HIPS resins, ABS resins, AES resins and AAS resins. Known polymerization methods such as emulsion polymerization, solution polymerization, suspension polymerization and bulk polymerization can be used for producing the styrene-based resins.
Exemplary of the styrene-based monomers are &agr;-methylstyrene, p-methylstyrene and styrene itself. Of these, styrene is preferred. Examples of the monomers copolymerizable with styrene monomers include vinyl cyanide monomers such as acrylonitrile and methacrylonitrile, (meth)acrylic alkyl esters such as methylacrylate, ethyl acrylate, propyl acrylate, methyl methacrylate and ethyl methacrylate, maleimide and N-phenylmaleimide. Of these, vinyl cyanide monomers and (meth)acrylic alkyl esters are preferred.
The rubber component used for obtaining the styrene-based graft copolymers may, for instance, be diene rubber, acrylic rubber, ethylene/propylene rubber, silicone rubber or the like. Of these, diene rubber and acrylic rubber are preferred.
Examples of the diene rubb
Masuki Tatuya
Miya Shinya
Narita Kenichi
Nishida Koji
Takagi Kiyoji
Conlin David G.
Dike Bronstein, Roberts & Cushman LLP
Hazzard Lisa Swiszcz
Mitsubishi Engineering-Plastics Corporation
Sanders Kriellion
LandOfFree
Thermoplastic resin composition does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Thermoplastic resin composition, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Thermoplastic resin composition will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-2520641