Polycarbonate-ABS moulding materials

Details Polycarbonate-ABS moulding materials Polycarbonate-ABS moulding materials

2000-03-22

2002-07-09

Buttner, David J. (Department: 1712)

Synthetic resins or natural rubbers -- part of the class 520 ser

Synthetic resins

Processes of preparing a desired or intentional composition...

C524S126000, C524S141000, C525S067000, C525S257000, C525S316000

Reexamination Certificate

active

06417256

ABSTRACT:

The present invention relates to polycarbonate-ABS moulding compositions having excellent mechanical properties, in particular an excellent stress cracking behaviour, a high notched impact strength and a high joint line strength.
Polycarbonate-ABS moulding compositions are sufficiently well known (for example, EP-A 363 608, EP-A 345 522, EP-A 640 655).
A specific field of application of these moulding compositions is the production of mouldings having a very. good impact strength. Special graft rubbers prepared by emulsion polymerisation are preferably used in order to obtain or to attain rubber-specific properties in these moulding compositions. The level of the values for the known moulding compositions and of the mouldings produced from them is not always adequate for the production of mouldings having increased impact stress and elastic strain. An increase in the proportion of these graft rubbers prepared by emulsion polymerisation then frequently results in moulding compositions having significant disadvantages as regards their properties (heat deflection temperature, modulus of elasticity).
The object of the present invention is therefore to provide polycarbonate-ABS moulding compositions having excellent mechanical properties, such as an outstanding notched impact strength, an excellent joint line strength, a high modulus of elasticity and a very high stress cracking resistance.
It has now surprisingly been found that the use of particular ABS-polymers leads to polycarbonate-ABS moulding compositions which can be processed to form mouldings having a very good standard of mechanical properties, in particular having an excellent notched impact strength, a high joint line strength, a high modulus of elasticity and an outstanding long-term strength.
The present invention accordingly provides thermoplastic moulding compositions containing
A 1 to 99, preferably 15 to 80, particularly preferably 30 to 70 parts by weight of an aromatic polycarbonate or polyester carbonate and
B 1 to 99, preferably 15 to 80, particularly preferably 30 to 70 parts by weight of at least one graft polymer prepared by solution polymerisation and having a rubber content of from 20 to 50 wt. %, preferably from 22.5 to 45 wt. % and particularly preferably from 25 to 40 wt. %, based on the graft polymer, and an average particle diameter of the rubber phase of from 80 to 600 nm, preferably from 150 to 400 nm and particularly preferably from 200 to 350 nm,
the sum of all the components of the moulding compositions according to the invention amounting to 100 parts by weight.
Component A
Aromatic polycarbonates and/or aromatic polyester carbonates which are suitable according to the invention as component A are known in the literature or can be prepared by methods known in the literature (for the preparation of aromatic polycarbonates, see, for example, Schnell, “Chemistry and Physics of Polycarbonates”, Interscience Publishers, 1964, as well as DE-AS 1 495 626, DE-OS 2 232 877, DE-OS 2 703 376, DE-OS 2 714 544, DE-OS 3 000 610, DE-OS 3 832 396; for the preparation of aromatic polyester carbonates, for example, DE-OS 3 007 934).
Aromatic polycarbonates are prepared, for example, by reaction of diphenols with carboxylic halides, preferably phosgene and/or with aromatic dicarboxylic dihalides, preferably benzenedicarboxylic dihalides, by the phase interface method, optionally using chain stoppers, for example, monophenols and optionally using trifunctional or more than trifunctional branching agents, for example, triphenols or tetraphenols.
Suitable aromatic polycarbonates according to the invention are in particular those based on the diphenols corresponding to formula (I)
wherein
A denotes a single bond, C
1
-C
5
-alkylene, C
1
-C
5
-alkylidene, C
5
-C
6
-cycloalkylidene, —S—, —SO
2
—, —O—, —CO— or C
6
-C
12
-arylene, which may optionally be condensed with other aromatic rings containing hetero atoms,
B independently of one another, denotes halogen, C
1
-C
8
-alkyl, C
6
-C
10
-aryl, preferably chlorine, bromine, phenyl, C
7
-C
12
-aralkyl, for example, benzyl,
x independently of one another, denotes respectively 0, 1 or 2 and
p denotes 1 or 0,
or alkyl-substituted dihydroxyphenylcycloalkanes corresponding to formula (II),
wherein
R
1
and R
2
, independently of one another, denote hydrogen, halogen, preferably chlorine or bromine, C
1
-C
8
-alkyl, preferably C
1
-C
4
-alkyl, for example, methyl, ethyl, C
5
-C
6
-cycloalkyl, C
6
-C
10
-aryl, preferably phenyl, or C
7
-C
12
-aralkyl, preferably phenyl-C
1
-C
4
-alkyl, in particular benzyl,
m is an integer from 4 to 7, preferably 4 or 5,
R
3
and R
4
, individually selectable for each Z and independently of one another, denote hydrogen or C
1
-C
6
-alkyl, preferably hydrogen, methyl or ethyl and
Z denotes carbon, with the proviso that on at least one atom Z, R
3
and R
4
simultaneously denote alkyl, preferably methyl.
Preferred diphenols are hydroquinone, resorcinol, dihydroxydiphenyl, bis(hydroxyphenyl)-C
1
-C
5
-alkanes, bis(hydroxyphenyl)-C
5
-C
6
-cycloalkanes, bis(hydroxyphenyl) ethers, bis(hydroxyphenyl) sulphoxides, bis(hydroxyphenyl) ketones, bis(hydroxyphenyl) sulphones and &agr;,&agr;-bis(hydroxyphenyl)diisopropylbenzenes as well as their ring-brominated and/or ring-chlorinated derivatives.
Particularly preferred diphenols are diphenylphenol, bisphenol A, 2,4-bis(4-hydroxyphenyl)-2-methylbutane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 4,4′-dihydroxydiphenyl sulphide, 4,4′-dihydroxydiphenyl sulphone as well as their di- and tetrabrominated or chlorinated derivatives such as, for example, 2,2-bis(3-chloro-4-hydroxyphenyl)propane, 2,2-bis(3,5-dichloro-4-hydroxyphenyl)propane or 2,2-bis(3,5-dibromo-4-hydroxyphenyl)propane.
2,2-bis(4-hydroxyphenyl)propane (bisphenol A) is preferred in particular.
The diphenols may be used separately or be mixed together in any proportions.
The diphenols are known in the literature or are obtainable by methods known in the literature.
Suitable chain stoppers for the preparation of the thermoplastic, aromatic polycarbonates are, for example, phenol, p-chlorophenol, p-tert. butylphenol or 2,4,6-tribromophenol, also long-chain alkylphenols, such as 4-(1,3-tetramethylbutyl)phenol according to DE-OS 2 842 005 or monoalkylphenol or dialkylphenols having a total of 8 to 20 C atoms in the alkyl substituents, such as 3,5-di-tert. butylphenol, p-isooctylphenol, p-tert. octylphenol, p-dodecylphenol and 2-(3,5-dimethlheptyl)phenol and 4-(3,5-dimethylheptyl)phenol. The quantity of chain stoppers to be used is generally between 0.5 mol-% and 10 mol-%, based on the molar sum of the diphenols used in each case.
The thermoplastic, aromatic polycarbonates have average weight average molecular weights (M
w
, determined, for example, by ultracentrifuge or light-scattering measurement) of from 10,000 to 200,000, preferably 20,000 to 80,000.
The thermoplastic, aromatic polycarbonates may be branched in known manner, and in fact preferably by the incorporation of from 0.05 to 2.0 mol-%, based on the sum of the diphenols used, of ≧trifunctional compounds, for example, those having ≧three phenolic groups.
Both homopolycarbonates and copolycarbonates are suitable. To prepare copolycarbonates as component A) according to the invention, it is also possible to use from 1 to 25 wt. %, preferably 2.5 to 25 wt. % based on the total quantity of diphenols used, of polydiorganosiloxanes having hydroxy-aryloxy end groups. These are known (see, for example, U.S. Pat. No. 3,419,634) or can be prepared by methods known in the literature. The preparation of copolycarbonates containing polydiorganosiloxanes is described, for example, in DE-OS 3 334 782.
Besides the bisphenol A homopolycarbonates, preferred polycarbonates include the copolycarbonates of bisphenol A with up to 15 mol-%, based on the molar sum of diphenols, of diphenols other than those mentioned as being preferred or particularly preferred, and in particular of 2,2-bis(3,5-dibromo-4-hydroxyphenyl)propane.
Aromatic dicarboxylic

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