Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Mixing of two or more solid polymers; mixing of solid...
Reexamination Certificate
1999-02-19
2003-06-17
Short, Patricia A. (Department: 1712)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Mixing of two or more solid polymers; mixing of solid...
C525S437000, C525S450000, C525S534000
Reexamination Certificate
active
06579954
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a thermoplastic resin composition that is excellent in mechanical properties, heat resistance, moldability, molded-article appearance, etc., and a molded article made therefrom.
2. Description of the Related Art
For the object of improving the chemical resistance of an aromatic polyester resin or improving the impact resistance and flowability during mold processing of an aromatic polysulfone resin, various thermoplastic resin compositions comprising an aromatic polyester resin and an aromatic polysulfone resin have been proposed.
For example, JP-B-45-39181, discloses that chemical resistance and thermal-stress brittleness are improved by mixing an aromatic polysulfone resin with an aromatic polycarbonate resin, compared to each resin alone.
JP-B-49-13855 discloses that a composition comprising an aromatic polysulfone resin and an aromatic polycarbonate resin is excellent in heat-deformation resistance compared with ABS resin.
JP-A-54-28361 discloses that a composition comprising an aromatic polycarbonate resin having a weight average molecular weight of larger than 60000, and an aromatic polysulfone resin is improved in chemical resistance and temperature of deflection under load compared with each resin alone.
JP-A-60-51739 discloses that a composition comprising an aromatic polysulfone resin and an aromatic polycarbonate resin having a specific structure is excellent in mechanical properties, and has improved chemical resistance.
However, in these compositions, there have been problems, such that the originally expected physical properties cannot be obtained. These problems have resulted from (1) decomposition of an aromatic polycarbonate resin or an aromatic polyester resin in the production process by melt-kneading, or (2) difficulties encountered in melt-molding operations such as injection molding, extrusion molding, etc. due to a viscosity fall or gas generation accompanying a decomposition.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a thermoplastic resin composition which is excellent in heat resistance and melt-mold processability.
As a result of extensive studies to solve the above problems, the present inventors found that the above object can be attained with using a composition comprising an aromatic polysulfone resin containing only a small amount of alkali metals existing as terminal phenolate and an aromatic polyester resin.
That is, the present invention relates to a thermoplastic resin composition comprising an aromatic polysulfone resin and at least one resin selected from an aromatic polyester resin, wherein the amount of alkali metal which exists in an aromatic polysulfone resin as a terminal phenolate is 50 ppm or less based on the total amount of the aromatic polysulfone resin, and a molded article thereof.
DETAILED DESCRIPTION OF THE INVENTION
The aromatic polyester resins used in the present invention are a polycarbonate resin, a polyalkylene polyarylate resin, a polyarylate resin, and a liquid crystal polyester resin.
The polycarbonate resin is a homopolymer having a repeating unit represented by the following Formula (1), a copolymer thereof, or a mixture containing such a homopolymer and copolymer.
In Formula (1), A is a divalent aromatic group which is the residue of a dihydric phenol as a raw material. A dihydric phenol which can be used in order to manufacture such an aromatic polycarbonate is a single or plural nucleus aromatic compound containing two hydroxyl groups as functional groups attached directly on the aromatic carbon atoms. Examples of such a dihydric phenol include: bisphenol A, bis(4-hydroxyphenyl)methane, 2,2-bis(4-hydroxy-3-methylphenyl)propane, 2,2-(3,5,3′,5′-tetrachloro-4,4′-hydroxyphenyl)propane, 2,2-(3,5,3′,5′-tetrabromo-4,4′-hydroxyphenyl)propane, 1,1-bis(4-hydroxyphenyl)cyclohexane, hydroquinone, resorcinol, biphenyl-4,4′-diol, and the like, although the present invention is not limited thereto.
Use of a homo-polycarbonate or co-polycarbonate using at least 30 mol % bisphenol A as a dihydric phenol is preferable in the present invention.
The polyalkylene polyarylate resin used in the present invention is a polyester synthesized from a dihydric alcohol, or a derivative thereof, and an aromatic dicarboxylic acid, or a derivative thereof, and said polyalkylene polyarylate resin is a homopolymer or copolymer having a repeating unit represented by following Formula (2) or a mixture containing such a homopolymer and copolymer.
&Parenopenst;O—B—O—CO—D—CO&Parenclosest; Formula (2)
In Formula (2), B is an alkylene group which is a dihydric alcohol residue of the raw material.
As examples of the dihydric alcohol which can be used in order to manufacture the aromatic polyester, ethylene glycol, propylene glycol, butane-1,4-diol, propane-1,3-diol, 2-ethylpropane-1,3-diol, 2,2-dimethylpropane-1,3-diol, pentane-1,5-diol, hexane-1,6-diol, cyclohexane-1,4-dimethanol, 3-ethylpentane-2,4-diol, 2-methylpentane-2,4-diol, and the like are mentioned, although the present invention is not limited thereto. The term “dihydric alcohol derivative” as used herein means a diester, such as an alkyl- or phenyl-diester of the above dihydric alcohol. Also mixtures thereof can be used in the present invention, if so desired.
In Formula (2), D is a divalent aromatic group which is the residue of an aromatic dicarboxylic acid of a raw material. As examples of the aromatic dicarboxylic acid which can be used in order to manufacture such aromatic polyesters, terephthalic acid, isophthalic acid, phthalic acid, biphenyl-4,4′-dicarboxylic acid, naphthalene-2,6-dicarboxylic acid, oxydiphenyl-4,4′-dicarboxylic acid, ethylenedioxyphenyl-4,4′-dicarboxylic acid, thiodiphenyl-4,4′-dicarboxylic acid, and the like are mentioned, although the present invention is not limited thereto. The hydrogen atom of the aromatic nuclei can be optionally substituted with an alkyl group having 1-6 carbon atoms an alkenyl group having 3-10 carbon atoms, a phenyl group or a halogen atom.
Among the polyalkylene polyarylate resin of the present invention there are included: a polyethylene terephthalate resin containing at least 80% by weight, suitably at least 90% by weight of ethylene-glycol unit based on the dihydric alcohol component, and containing at least 80% by weight, suitably at least 90% by weight of terephthalic acid unit based on the aromatic dicarboxylic acid component;
a polybutylene terephthalate resin containing at least 80% by weight, suitably at least 90% by weight of 1,4-butanediol unit based on the dihydric alcohol component, and containing at least 80% by weight, suitably at least 90% by weight of terephthalic acid unit based on the aromatic dicarboxylic acid component; and a polyethylene naphthalate resin containing at least 80% by weight, suitably at least 90% by weight of ethylene-glycol unit based on the dihydric alcohol component, and containing at least 80% by weight, suitably at least 90% by weight of 2,6-naphthalene dicarboxylic acid unit based on the aromatic dicarboxylic acid component.
The polyarylate resin used in the present invention is a polyester synthesized from dihydric phenol or its derivative, and an aromatic dicarboxylic acid, or a derivative thereof, and is a homopolymer or a copolymer having a repeating unit represented by the following Formula (3), and a mixture containing such a homopolymer or copolymer
&Parenopenst;O—E—O—CO—D—CO&Parenclosest; Formula (3)
In Formula (3), E is a divalent aromatic group which is the residue of dihydric phenol of a raw material.
Examples of dihydric phenol which can be used in order to manufacture such a polyarylate resin include: bis(4-hydroxyphenyl)-methane, bis(4-hydroxy-3-methylphenyl)-methane, bis(4-hydroxy-3,5-dichlorophenyl)-methane, bis(4-hydroxy-3,5-dibromophenyl)-methane, bis(4-hydroxy-3,5-difluorophenyl)-methane, bis(4-hydroxyphenyl)-ketone, bis(4-hydroxyphenyl)-sulfide, bis(4-hydroxyphenyl)-sulfone,
Nagashima Tohru
Nakamura Hiroshi
Yoshida Yoshifumi
Birch & Stewart Kolasch & Birch, LLP
Short Patricia A.
Sumitomo Chemical Company Limited
LandOfFree
Aromatic polysulfone resin composition and molded article... does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Aromatic polysulfone resin composition and molded article..., we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Aromatic polysulfone resin composition and molded article... will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-3149995