Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Reexamination Certificate
1999-12-14
2003-09-02
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...
C524S127000, C524S141000
Reexamination Certificate
active
06613820
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to a polycarbonate resin composition. Polycarbonate resins (PC), or polymer alloys produced by blending one of these with a styrene resin, such as an ABS resin (acrylonitrile/butadiene/styrene copolymer), are widely used in electrical and electronic parts, photocopiers, printers, facsimiles, personal computers, notebook and portable computers, and other such office automation equipment, portable telephones and other such communications equipment, and so on.
Products have increasingly needed to be smaller and lighter in these applications in recent years, and novel molding methods have been attempted in an effort to meet these needs. There is also an increasing need for resins that can be molded into thinner articles and can be molded more precisely, and for these resins to have better flame resistance and other such properties.
The addition of glass fibers, talc, carbon fibers, and other such reinforcing agents so as to improve rigidity and dimensional stability has been a common practice in the past in an effort to allow thinner and more precise molding.
The manufacture and use [of these resins] have been surging in Southeast Asia in recent years. In these areas, products are commonly used and stored in an environment of high humidity, and the degradation of physical properties due to the low moisture resistance of the resin in a product is often a cause for concern. It is therefore essential that the moisture resistance of resins used in the above-mentioned products be enhanced.
A polycarbonate resin (PC) or a polymer alloy comprising a blend of a polycarbonate resin and a styrene resin is not generally considered to have high moisture resistance. This is particularly true with a flame resistant resin composition or with a resin composition that has been reinforced with a reinforcing agent such as carbon fibers.
The present applicant has already invented a polycarbonate resin composition having excellent moisture resistance and good flame resistance, and in Japanese Patent Application 10-216487 has applied for a patent for a polycarbonate resin composition containing (A) 1 to 99 weight parts of a polycarbonate resin having a viscosity average molecular weight of 10,000 to 100,000 and (B) 1 to 99 weight parts of (B-1) a copolymer whose structural components are (a) an aromatic vinyl monomer component, (b) a vinyl cyanide monomer component, and (c) a rubber-like polymer and/or (B-2) a copolymer whose structural components are (a) an aromatic vinyl monomer component and (b) a vinyl cyanide monomer component, where the weight average molecular weight of the above-mentioned (B-2) is from 30,000 to 200,000, and where the alkali metal content in each case is no more than 1 ppm, and in which (C) a phosphoric ester compound is added in an amount of 0 to 40 weight parts per combined 100 weight parts of the above-mentioned components (A) and (B).
Problems Which the Invention is Intended to Solve
The present invention provides a polycarbonate resin composition that has superior moisture resistance, good flame resistance, and markedly superior mechanical strength.
Means Used to Solve the Above-Mentioned Problems
The inventors arrived at the following present invention as a result of various investigations aimed at solving the above problems.
Specifically, the present invention is (1) a resin composition containing:
(A) 1 to 99 weight parts of a polycarbonate resin having a viscosity average molecular weight of 10,000 to 100,000 and
(B) 1 to 99 weight parts of a styrene resin, and also containing:
(C) a phosphoric ester compound with an acid value of 1 or less, in an amount of 1 to 40 weight parts per combined 100 weight parts of (A)+(B), and
(D) a reinforcing agent in an amount of 1 to 100 weight parts per combined 100 weight parts of (A)+(B)+(C).
As a result of diligent investigation aimed at further enhancing the impact resistance of the above-mentioned resin composition (1) without lowering its flame resistance, the inventors perfected the present invention of the following preferred aspects upon discovering that the above-mentioned problems can be solved by adding a specific amount of the following (E) compound rubber-based graft copolymer to the above-mentioned resin Composition (1).
Examples of preferred aspects include the following.
(2) The resin composition given in (1) above, further containing (E) a compound rubber-based graft copolymer produced by grafting a vinyl monomer to a compound rubber containing a polyorganosiloxane and a polyalkyl (meth)acrylate, in an amount of 0 to 20 weight parts per combined 100 weight parts of (A)+(B)+(C).
(3) The resin composition given in (2) above, containing (E) in an amount of 1 to 10 weight parts.
(4) The resin composition given in any of (1) to (3) above, wherein the amount of alkali metal contained in (B) is 1 weight ppm or less.
(5) The resin composition given in any of (1) to (3) above, wherein the amount of alkali metal contained in (B) is 0.5 weight ppm or less.
(6) The resin composition given in any of (1) to (3) above, wherein the amount of alkali metal contained in (B) is 0.1 weight ppm or less.
(7) The resin composition given in any of (1) to (6) above, wherein the alkali metal contained in (B) is sodium and/or potassium.
(8) The resin composition given in any of (1) to (7) above, wherein (B) is one more types of resin selected from the group consisting of HIPS (high impact polystyrene), ABS resin (acrylonitrile/butadiene/styrene copolymer), AES resin (acrylonitrile/ethylene/propylene/styrene copolymer), ACS resin (acrylonitrile/chlorinated polyethylene/styrene copolymer), and AAS resin (acrylonitrile/acrylic elastomer/styrene copolymer).
(9) The resin composition given in any of (1) to (8) above, wherein the viscosity average molecular weight of (A) is 10,000 to 40,000.
(10) The resin composition given in any of (1) to (9) above, wherein (C) is contained in an amount of 3 to 30 weight parts.
(11) The resin composition given in any of (1) to (9) above, wherein (C) is contained in an amount of 5 to 20 weight parts.
(12) The resin composition given in any of (1) to (11) above, further containing
(F) an epoxy-based stabilizer in an amount of 0.01 to 10 weight parts per combined 100 weight parts of (A)+(B).
(13) The resin composition given in (12) above, wherein (F) is contained in an amount of 0.1 to 0.5 weight parts.
(14) The resin composition given in (12) or (13) above, wherein the epoxy-based stabilizer (F) is 3,4-epoxycyclohexylmethyl-3′,4′-epoxycyclohexane carboxylate.
(15) The resin composition given in any of (1) to (14) above, wherein the polycarbonate resin (A) is manufactured by melt polymerization.
(16) The resin composition given in any of (1) to (15) above, wherein the reinforcing agent (D) is at least one type of agent selected from the group consisting of talc, glass fibers, carbon fibers, glass flakes, milled glass, wollastonite, potassium titanate, calcium carbonate, barium sulfate, and mica.
(17) The resin composition given in any of(1) to (16) above, further containing (G) 0.01 to 3 weight parts of a fluorinated polyolefin per combined 100 weight parts of (A)+(B).
DETAILED DESCRIPTION OF THE INVENTION
The polycarbonate resin (A) used in the present invention is an aromatic polycarbonate made by a known phosgene process or melt process. Polycarbonate resins such as this are discussed, for example, in Japanese Laid-Open Patent Applications 63-215763 and 2-124,934. Examples of the diphenol used as a raw material include 2,2-bis(4-hydroxyphenyl)propane (known as bisphenol A); 2,2-bis-(3,5-dibromo-4-hydroxyphenyl)propane; 2,2-bis(3,5-dimethyl-4-hydroxyphenyl)cyclohexane; 1,1-bis(3,5-dimethyl-4-hydroxyphenyl)cyclohexane; 1,1-bis(4-hydroxyphenyl)decane; 1,4-bis(4-hydroxyphenyl)propane; 1,1-hydroxyphenyl)cyclo dodecane; 1,1-bis(3,5-dimethyl-4-hydroxyphenyl)cyclododecane; 4,4-dihydroxydiphenyl ether; 4,4-thiodiphenol; 4,4-dihydroxy-3,3-dichlorodiphenyl ether; and 4,4-dihydroxy-2,5-dihydroxyphenyl ether. Exam
Choate Kim
Fujiguchi Tomohide
Itoi Hideyuki
Saito Akihiro
Sawano Yuzuru
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