Thermoplastic resin composition, method of preparing the same, and molded part including the same

• US 10,640,638 B2
• Filed: 11/01/2017
• Issued: 05/05/2020
• Est. Priority Date: 11/04/2016
• Status: Active Grant

• Current Assignee: LG Chem Limited (LG Corporation)
• Original Assignee: LG Chem Limited (LG Corporation)
• Inventors: An, Yong Hee, Hwang, Yong Yeon, Oh, Hyun Taek, Ahn, Bong Keun, Kim, Min Jung, Park, Chun Ho, Kang, Eun Soo, Park, Jang Won
• Primary Examiner(s): Mullis, Jeffrey C
• Application Number:
  US16/302,038
• Publication Number:
  US 20190382574A1
• Time in Patent Office: 916 Days
• CPC Class Codes: B29B 9/06 in the form of filamentary material, e.g. combined with extrusion
• CPC Class Codes: B29K 2025/08 Copolymers of styrene, e.g. AS or SAN, i.e. acrylonitrile styrene B29K2055/02 takes precedence
• CPC Class Codes: B29K 2033/12 Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
• CPC Class Codes: B29K 2105/0085 Copolymers
• CPC Class Codes: C08F 212/08 Styrene
• CPC Class Codes: C08F 220/44 Acrylonitrile
• CPC Class Codes: C08F 265/04 on to polymers of esters
• CPC Class Codes: C08J 2333/10 Homopolymers or copolymers of methacrylic acid esters
• CPC Class Codes: C08J 2333/12 Homopolymers or copolymers of methyl methacrylate
• CPC Class Codes: C08J 2425/06 Polystyrene
• CPC Class Codes: C08J 2425/12 with unsaturated nitriles
• CPC Class Codes: C08J 2425/16 Homopolymers or copolymers of alkyl-substituted styrenes
• CPC Class Codes: C08J 2433/20 Homopolymers or copolymers of acrylonitrile C08J2455/02 takes precedence
• CPC Class Codes: C08J 2451/04 grafted on to rubbers
• CPC Class Codes: C08J 3/201 Pre-melted polymers
• CPC Class Codes: C08J 5/18 Manufacture of films or sheets
• CPC Class Codes: C08L 2201/02 Flame or fire retardant/resistant
• CPC Class Codes: C08L 2201/04 Antistatic
• CPC Class Codes: C08L 2201/08 Stabilised against heat, light or radiation or oxydation
• CPC Class Codes: C08L 2205/02 containing two or more polymers of the same C08L -group
• CPC Class Codes: C08L 2205/025 : containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
• CPC Class Codes: C08L 2205/03 : containing three or more polymers in a blend
• CPC Class Codes: C08L 2205/035 : containing four or more polymers in a blend
• CPC Class Codes: C08L 2207/10 : Peculiar tacticity
• CPC Class Codes: C08L 2207/53 : Core-shell polymer
• CPC Class Codes: C08L 25/06 : Polystyrene
• CPC Class Codes: C08L 25/12 : with unsaturated nitriles
• CPC Class Codes: C08L 25/16 : Homopolymers or copolymers of alkyl-substituted styrenes
• CPC Class Codes: C08L 33/062 : Copolymers with monomers not covered by C08L33/06
• CPC Class Codes: C08L 33/12 : Homopolymers or copolymers of methyl methacrylate
• CPC Class Codes: C08L 51/04 : grafted on to rubbers

Abstract

A thermoplastic resin composition with low gloss and improved colorability, pencil hardness and wear resistance has (A) 5 to 35% by weight of a first graft copolymer having an average particle diameter of 50 to 150 nm and containing acrylate rubber as a core; (B) 10 to 40% by weight of a second graft copolymer having an average particle diameter of more than 150 nm and 800 nm or less and containing acrylate rubber as a core; (C) 5 to 15% by weight of an aromatic vinyl compound-vinyl cyanide compound copolymer having a weight average molecular weight of 70,000 to 130,000 g/mol; (D) 20 to 50% by weight of an aromatic vinyl compound-(meth)acrylate compound copolymer having a weight average molecular weight of 65,000 to 100,000 g/mol; and (E) 0.1 to 7% by weight of a syndiotactic polystyrene resin.

Claims

1. A thermoplastic resin composition, comprising:

(A) 5 to 35% by weight of a first graft copolymer having an average particle diameter of 50 to 150 nm and containing acrylate rubber as a core;

(B) 10 to 40% by weight of a second graft copolymer having an average particle diameter of more than 150 nm and 800 nm or less and containing acrylate rubber as a core;

(C) 5 to 15% by weight of an aromatic vinyl compound-vinyl cyanide compound copolymer having a weight average molecular weight of 70,000 to 130,000 g/mol;

(D) 20 to 50% by weight of an aromatic vinyl compound-(meth)acrylate compound copolymer having a weight average molecular weight of 65,000 to 100,000 g/mol; and

(E) 0.1 to 7% by weight of a resin selected from syndiotactic polystyrene, a derivative of syndiotactic polystyrene, or a mixture thereof.

2. The thermoplastic resin composition according to claim 1, wherein the acrylate rubbers in parts A and B are alkyl acrylate rubber.

3. The thermoplastic resin composition according to claim 2, wherein the alkyl acrylate rubber is acrylate rubber having an alkyl group having 1 to 10 carbon atoms.

4. The thermoplastic resin composition according to claim 1, wherein the first graft copolymer is obtained by graft-polymerizing 20 to 60% by weight of an aromatic vinyl compound and 5 to 40% by weight of a vinyl cyanide compound onto 30 to 70% by weight of an acrylate rubber core.

5. The thermoplastic resin composition according to claim 1, wherein the second graft copolymer is obtained by graft-polymerizing 20 to 60% by weight of an aromatic vinyl compound and 5 to 40% by weight of a vinyl cyanide compound onto 30 to 70% by weight of an acrylate rubber core.

6. The thermoplastic resin composition according to claim 1, wherein the total content of rubber contained in the first graft copolymer and the second graft copolymer is 10 to 30% by weight with respect to 100% by weight of the total thermoplastic resin composition.

7. The thermoplastic resin composition according to claim 1, wherein a weight ratio of the first graft copolymer to the second graft copolymer is 1:

0.5 to 1;

2.

8. The thermoplastic resin composition according to claim 1, wherein the aromatic vinyl compound-vinyl cyanide compound copolymer is one or more selected from the group consisting of a styrene/acrylonitrile copolymer, an α

-methylstyrene/acrylonitrile copolymer, an α

-methylstyrene/styrene/acrylonitrile copolymer, a styrene/methyl methacrylate copolymer, and a styrene/maleic anhydride copolymer.

9. The thermoplastic resin composition according to claim 1, wherein the aromatic vinyl compound-vinyl cyanide compound copolymer comprises 10 to 50% by weight of a vinyl cyanide compound.

10. The thermoplastic resin composition according to claim 1, wherein the aromatic vinyl compound-(meth)acrylate compound copolymer is obtained by polymerizing 65 to 85% by weight of a (meth)acrylate compound and 15 to 35% by weight of an aromatic vinyl compound.

11. The thermoplastic resin composition according to claim 1, wherein the (meth)acrylate compound is one or more selected from the group consisting of methyl acrylate, ethyl acrylate, methyl methacrylate, ethyl methacrylate, methyl ethacrylate, ethyl ethacrylate, propyl acrylate, isopropyl acrylate, butyl acrylate, propyl methacrylate, isopropyl methacrylate, butyl methacrylate, and isobutyl methacrylate.

12. The thermoplastic resin composition according to claim 1, further comprising one or more additives selected from the group consisting of an anti-dripping agent, a flame retardant, an antimicrobial agent, an antistatic agent, a stabilizer, a release agent, a heat stabilizer, an inorganic additive, a lubricant, an antioxidant, a light stabilizer, a pigment, a dye, and an inorganic filler.

13. The thermoplastic resin composition according to claim 1, wherein, when wear resistance is measured according to JIS K 7204:

1999, the thermoplastic resin composition has a wear resistance value of less than 4.0 mg.

15. A sheet prepared using the composition according to claim 1.

14. A method of preparing a thermoplastic resin composition, comprising:

a step of melt-kneading and extruding a) 5 to 35% by weight of a first graft copolymer having an average particle diameter of 50 to 150 nm and containing acrylate rubber as a core;

b) 10 to 40% by weight of a second graft copolymer having an average particle diameter of more than 150 nm and 800 nm or less and containing acrylate rubber as a core;

c) 5 to 15% by weight of an aromatic vinyl compound-vinyl cyanide compound copolymer having a weight average molecular weight of 70,000 to 130,000 g/mol;

d) 20 to 50% by weight of an aromatic vinyl compound-(meth)acrylate compound copolymer having a weight average molecular weight of 65,000 to 100,000 g/mol; and

e) 0.1 to 7% by weight of a syndiotactic polystyrene resin.