Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Reexamination Certificate
1999-03-18
2001-01-30
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...
C524S238000, C524S240000
Reexamination Certificate
active
06180701
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a resin composition that has excellent wear properties and high flame retardancy and further to a resin molding that is obtainable by melt molding of such composition. In particular, the invention contemplates offering structural materials suited as component parts and casings for use in office automation equipment, household appliances and the like.
2. Description of the Related Art
For its excellent heat resistance, impact resistance and electrical characteristics as well as its good dimensional stability, a polycarbonate resin (hereinafter referred to as a PC resin where needed) has been widely applied to office automation equipment and household appliances especially at their respective portions which are subjected to sliding. Flame retardancy is also required for office automation equipment and household appliances, and therefore, much attention has been focused on making the PC resin nonflammable in nature.
In order to attain nonflammability of the PC resin, one technique is known which is contrived to add to that resin a flame retardant of a bromine type such as biphenyl bromide, tetrabromobisphenol A or the like as disclosed for example at page 242 of “Technique for Nonflammability of High Polymers and its Application” edited by Hitoshi Nishizawa. Another such technique is known in which a phosphate ester compound is incorporated in the PC resin as taught by Japanese Unexamined Patent Publication No. 4-300968.
However, though capable of giving improved flame retardancy to the PC resin, the aforementioned bromine type of flame retardant is liable to evolve dioxins during disposal and incineration of the associated used office automation equipment or household appliance. This eventually invites environmental pollution.
The phosphate ester compound noted above allows the PC resin to be highly flame retardancy but to such an extent that wear properties and impact strength are diminished.
On the other hand, there is proposed a PC-polyolefin resin composition comprised of a PC resin, a polyolefin resin, a modified polyolefin resin and an aminocarboxylic acid as found in Japanese Unexamined Patent Publication No. 8-157664. Such known composition is designed to avoid ply separation or delamination in an effective manner, which defect would be likely to take place when a PC resin and a polyolefin resin are made together into a molded product as by injection molding and because the two resins are, by nature, less compatible with each other. This composition, though highly slidable, is less nonflammable. Moreover, Japanese Examined Patent Publication No. 1-17501 discloses a resin composition comprised of a PC resin and an acrylonitrile-butadiene-styrene copolymer. This type of composition, like the above composition, is excellent in wear properties but unacceptable in flame retardancy.
As is apparent from the foregoing situation of the prior art, no PC type resin compositions have yet been feasible with a proper balance between wear properties and flame retardancy and on an industrial scale.
SUMMARY OF THE INVENTION
For its principal objects, the present invention therefore provides a resin composition that has both excellent wear properties and high flame retardancy, and a resin molding that results from melt molding of such composition.
The present inventors have found that in the case where a polycarbonate resin is incorporated with a compatibilizing agent composed of a modified polyolefin resin and an aminocarboxylic acid and further with a flame retardant composed of a specific phosphate ester, this flame retardant can act not only for flame retardation but also as a sliding agent having a role to render the polycarbonate resin less susceptible to wear at an initial stage of sliding. Thus, it has now been found that when so constituted as to contain a polycarbonate resin, a compatibilizing agent composed of a modified polyolefin resin and an aminocarboxylic acid, and a flame retardant composed of a phosphate ester, a resin composition can be produced having excellent wear properties and high flame retardancy. Those findings have led to the present invention.
More specifically, a first aspect of the present invention provides a resin composition that has excellent wear properties and high flame retardancy, comprising:
(A) a polycarbonate resin;
(B) a modified polyolefin resin;
(C) a compound represented by HOOC—R—NH
2
where R is an alkylene, alkylidene, oligomethylene, phenylene or naphthylene group having 5 or more carbon atoms, wherein each of the phenylene and naphthylene groups may have substituent groups; and
(D) a compound represented by the following formula (1)
where Ar is a phenyl group, Ar′ is at least one functional group selected from the group consisting of a phenylene group, a biphenylene group and a 2,2-propylidene-diphenylene group, wherein each of Ar and Ar′ may have substituent groups, and n is an integer of 0 or above.
In the resin composition according to the first aspect of the invention, it is desired that component (A) be added in an amount of 70 to 97% by weight, component (B) in an amount of 1 to 20% by weight, component (C) in an amount of 0.01 to 5% by weight, and component (D) in an amount of 1 to 10% by weight.
For use as component (B), a polyolefin resin is preferred which has been modified and structured to have polar groups. More preferably, the polar groups are one or more members selected from the group consisting of an acid group such as a carboxylic group, an acid derivative such as an acid anhydride group, and an epoxy group.
A second aspect of the present invention provides a resin composition that has excellent wear properties and high flame retardancy, comprising components (A) to (D) defined above and a polyolefin resin used as component (E).
In the resin composition according to the second aspect of the invention, it is desired that component (A) be added in an amount of 70 to 96% by weight, component (B) in an amount of 1 to 20% by weight, component (C) in an amount of 0.01 to 5% by weight, component (D) in an amount of 1 to 10% by weight, and component (E) in an amount of 1 to 20% by weight.
A third aspect of the present invention provides a resin composition that has excellent wear properties and high flame retardancy, comprising components (A) to (E) defined above and a fluorocarbon resin used as component (F).
In the resin composition according to the third aspect of the invention, it is desired that component (A) be added in an amount of 70 to 96% by weight, component (B) in an amount of 1 to 20% by weight, component (C) in an amount of 0.01 to 5% by weight, component (D) in an amount of 1 to 10% by weight, component (E) in an amount of 1 to 20% by weight, and component (F) in an amount of 0.01 to 2% by weight.
A fourth aspect of the present invention provides a resin composition that has excellent wear properties and high flame retardancy, comprising components (A) to (D) defined above and component (G) that is chosen from a copolymer of an aromatic vinyl compound and a vinyl cyanide compound, a diene rubber, or a graft copolymer of such diene rubber and such copolymer.
In the resin composition according to the fourth aspect of the invention, it is desired that component (A) be added in an amount of 50 to 95% by weight, component (B) in an amount of 1 to 20% by weight, component (C) in an amount of 0.01 to 5% by weight, component (D) in an amount of 1 to 10% by weight, and component (G) in an amount of 2 to 40% by weight.
A fifth aspect of the present invention provides a resin composition that has excellent wear properties and high flame retardancy, comprising components (A) to (D) and components (F) and (G).
In the resin composition according to the fifth aspect of the invention, it is desired that component (A) be added in an amount of 50 to 95% by weight, component (B) in an amount of 1 to 20% by weight, component (C) in an amount of 0.01 to 5% by weight, component (D) in an amount of 1 to 10% by weight, component (F) in an
Eguchi Kunihiko
Ogawa Taichi
Takagi Masato
Takemura Kazuya
Akin Gump Strauss Hauer & Feld L.L.P.
Kawasaki Steel Corporation
Sanders Kriellion
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