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
2001-03-12
2002-06-18
Woodward, Ana (Department: 1711)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Mixing of two or more solid polymers; mixing of solid...
C525S064000
Reexamination Certificate
active
06407167
ABSTRACT:
TECHNICAL FIELD
The present invention relates to a thermoplastic resin composition excellent in impact resistance and molded appearance, containing as constituent components a polycarbonate resin, saturated polyester resin and/or polyester-based elastomer, butadiene-based graft copolymer.
BACKGROUND ART
Regarding a method of improving mechanical features a polycarbonate resin and a polyester resin, various methods have conventionally been suggested. Since impact resistance and the like are poor when they are only combined, JP-B No. 55-9435 suggests, for example, a resin composition composed of a polycarbonate resin, polyester resin and butadiene-based graft copolymer. However, such a resin composition manifests an effect of improving impact resistance only when the formulation of a polycarbonate resin, polyester resin and butadiene-based graft copolymer is restricted in a relatively narrow range, and has poor molded article appearance which causes decrease in glossiness, being able to be improved. Also JP-B No. 62-26343, JP-B No. 62-46578 and JP-B No. 7-5825 suggest resin compositions composed of a polycarbonate resin, polyester resin and butadiene-based graft copolymer, however, an effect of imparting impact resistance and molded appearance can not be necessarily satisfied simultaneously in these compositions.
The present invention has been accomplished in view of such current conditions and an object thereof is to provide a thermoplastic resin composition excellent in impact resistance and molded appearance.
DISCLOSURE OF THE INVENTION
According to the present invention solving the above-mentioned problems, there is provided a thermoplastic resin composition comprising
(A) 4 to 95% by weight of a polycarbonate resin,
(B) 4 to 95% by weight of a saturated polyester resin and/or polyester-based elastomer, and
(C) 1 to 40% by weight of a graft copolymer obtained by graft-polymerizing a monomer or monomer mixture containing at least an aromatic vinyl, alkyl methacrylate or alkyl acrylate in the presence of latex containing a butadiene-based rubber polymer,
wherein the above-mentioned graft copolymer is a copolymer obtained under the following conditions (a) to (c):
(a) the polymerization formulation is composed of 60 to 90% by weight of the above-mentioned butadiene-based rubber polymer and 10 to 40% by weight of the above-mentioned monomer or monomer mixture,
(b) the above-mentioned latex is latex obtained by emulsion-polymerizing 50 to 100% by weight of 1,3-butadiene with 0 to 50% by weight of one or more vinyl-based monomers copolymerized with 1,3-butadiene, and
(c) the above-mentioned latex has a weight-average particle size from 100 to 200 nm, and the ratio d
w
/d
n
of the weight-average particle size to the number-average particle size is 1 or more and 3 or less.
The present invention provides a thermoplastic resin composition excellent in impact resistance and molded appearance, by adopting the constitution as described above.
BEST MODE FOR CARRYING OUT THE INVENTION
A polycarbonate resin, the component (A) in the present invention can be an aromatic polycarbonate resin, and can be a polycarbonate produced using a dihydroxydiphenyl alkane as the main raw material. For example, polycarbonates obtained by a transesterification method or phosgene method using 2,2-(4,4′-dihydroxydiphenyl)propane (bisphenol A) as a dihydroxy component are preferable. Further, part or all of the above-mentioned bisphenol A may be substituted with other 4,4′-dihydroxydiphenyl alkane or 4,4′-dihydroxydiphenylsulfone, 4,4′-dihydroxydiphenyl ether and the like, and two or more of them may also be mixed and used.
The content of the component (A) polycarbonate resin is from 4 to 95% by weight based on 100% by weight of the whole amount of a thermoplastic resin composition of the present invention. By such a content range, a resin composition excellent in impact resistance and molded appearance is obtained.
A saturated polyester resin, the component (B) used in the present invention is a resin obtained by a condensation reaction using an aromatic dicarboxylic acid or ester-forming derivative thereof and alkylene glycol as the main components. Examples of the aromatic dicarboxylic acid include terephthalic acid, isophthalic acid, naphthalenedicarboxylic acid and the like. Examples of the alkylene glycol include ethylene glycol, propylene glycol, tetramethylene glycol, hexamethylene glycol and the like. In addition to them, other dicarboxylic acids and glycols may also be copolymerized in small amount, if necessary. Examples of the preferable saturated polyester resin include polytetramethylene terephthalate, polyethylene terephthalate and a mixture thereof.
A polyester-based elastomer, the component (B) in the present invention is a block copolymer having a polyester segment having high melting point and a polymer segment having low melting point.
The polyester segment having high melting point is a polyester obtained by a condensation reaction of an aromatic dicarboxylic acid with an alkylene glycol. Examples of the aromatic dicarboxylic acid include terephthalic acid, isophthalic acid, naphthalene dicarboxylic acid and the like. Examples of the alkylene glycol include ethylene glycol, propylene glycol, tetramethylene glycol, hexamethylene glycol and the like. In addition to them, other dicarboxylic acids and glycols may also be copolymerized in small amount, if necessary. Examples of the preferable polyester include polytetramethylene terephthalate, polyethylene terephthalate and a mixture thereof.
On the other hand, the polymer segment having low melting point is composed of a polymer having a molecular weight from 400 to 20000 such as a polyalkylene ether glycol, aliphatic polyester and the like. Disclosed as examples of the polyalkylene ether glycol are poly(ethylene oxide) glycol, poly(tetramethylene oxide) glycol, poly(propylene oxide) glycol and a mixture thereof. Examples of the aliphatic polyester include polyesters obtained from an aliphatic dicarboxylic acid having 2 to 12 carbon atoms and an aliphatic glycol having 2 to 10 carbon atoms. Examples of the preferable polymer segment having low melting point include polyethylene adipate, polytetramethylene adipate, polyethylene sebacate, polyneopentyl sebacate, polyhexamethylene azelate, poly-&egr;-caprolactone and the like. The proportion of these polymer segments having low melting point in the polyester-based elastomer is preferably from 2 to 80% by weight.
The total content of the component (B) saturated polyester resin and/or polyester-based elastomer is from 4 to 95% by weight based on 100% by weight of the whole amount of the resin composition. By such a content range, a resin composition excellent in impact resistance and molded appearance is obtained.
A graft copolymer, the component (C) in the present invention is a graft copolymer obtained by graft-polymerizing a monomer or monomer mixture containing at least an aromatic vinyl, alkyl methacrylate or alkyl acrylate in the presence of latex containing a butadiene-based rubber polymer, and this copolymer is obtained under the following conditions (a) to (c).
(a) The polymerization formulation is composed of 60 to 90% by weight of the butadiene-based rubber polymer and 10 to 40% by weight of the monomer or monomer mixture,
(b) The latex is latex obtained by emulsion-polymerizing 50 to 100% by weight of 1,3-butadiene with 0 to 50% by weight of one or more vinyl-based monomers copolymerized with 1,3-butadiene, and
(c) The latex has a weight-average particle size from 100 to 200 nm, and the ratio d
w
/d
n
of the weight-average particle size to the number-average particle size is 1 or more and 3 or less.
By using a graft copolymer satisfying the above-mentioned conditions, a resin composition excellent in impact resistance and molded appearance is obtained.
The latex containing a butadiene-based rubber polymer is composed of a monomer composition containing 50 to 100% by weight of 1,3-butadiene and 0 to 50% by weight of one or more vinyl-based monomers copolymerize
Nakata Akira
Shishido Koichi
Mitsubishi Rayon Co. Ltd.
Oblon & Spivak, McClelland, Maier & Neustadt P.C.
Woodward Ana
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