IMPACT-MODIFIED POLYCARBONATE COMPOSITIONS HAVING A GOOD COMBINATION OF NATURAL COLOR, HYDROLYTIC STABILITY AND MELT STABILITY

• US 20090239991A1
• Filed: 03/17/2009
• Published: 09/24/2009
• Est. Priority Date: 03/22/2008
• Status: Abandoned Application

• Current Assignee: Bayer Materialscience AG (Covestro AG)
• Original Assignee: Bayer Materialscience AG (Covestro AG)
• Inventors: Eichenauer, Herbert, Eckel, Thomas, Seidel, Andreas, Avtomonov, Evgueni
• Application Number:
  US12/405,498
• Publication Number:
  US 20090239991A1
• Time in Patent Office: Days
• US Class Current: 524/504
• CPC Class Codes: C08K 5/092 Polycarboxylic acids
• CPC Class Codes: C08K 5/098 Metal salts of carboxylic acids
• CPC Class Codes: C08K 5/49 Phosphorus-containing compounds C08K5/0091 takes precedence
• CPC Class Codes: C08K 5/523 with hydroxyaryl compounds
• CPC Class Codes: C08L 2201/02 Flame or fire retardant/resistant
• CPC Class Codes: C08L 2205/03 containing three or more polymers in a blend
• CPC Class Codes: C08L 2205/06 having improved processability or containing aids for moulding methods
• CPC Class Codes: C08L 25/12 with unsaturated nitriles
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/24 Graft or block copolymers according to groups C08L51/00, C08L53/00 or C08L55/02; Derivatives thereof
• CPC Class Codes: C08L 51/04 grafted on to rubbers
• CPC Class Codes: C08L 55/02 ABS [Acrylonitrile-Butadiene-Styrene] polymers
• CPC Class Codes: C08L 67/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds C08L67/06 takes precedence
• CPC Class Codes: C08L 69/00 Compositions of polycarbonates; Compositions of derivatives of polycarbonates
• CPC Class Codes: C08L 69/005 Polyester-carbonates

Abstract

The present invention relates to polycarbonate compositions comprising

• • A) from 10 to 99 parts by weight, in each ease based on the sum of components A+B+C, of aromatic polycarbonate and/or aromatic polyester carbonate,
  • B) from 1 to 35 parts by weight, in each case based on the sum of components A+B+C, of rubber-modified graft polymer of
    • B.1 from 5 to 95 wt. % of at least one vinyl monomer on
    • B.2 from 95 to 5 wt. % of one or more graft bases having a glass transition temperature <10° C.,
  • C) from 0 to 40 parts by weight, in each case based on the sum of components A+B+C, of vinyl (co)polymer and/or polyalkylene terephthalate,
  • D) from 0 to 50 parts by weight, in each case based on the sum of components A+B+C, of phosphorus-containing flameproofing agent,
  • E) from 0 to 1.0 part by weight, in each case based on the sum of components A+B+C, of acidic additives, and
  • F) from 0 to 50 parts by weight, in each case based on the sum of components A+B+C, of additives,
  • wherein component B is obtainable by reacting component B.1 with the graft base B.2 by means of emulsion polymerization, with the proviso that in those compositions that are free of components D) and E), the graft polymer dispersion in the spray drying or in the precipitation has a pH value of less than 7,
  • characterized in that there are used in the graft reaction from 0.1 to 5 parts by weight (based on the sum of the parts by weight of the monomers B.1 and of the graft base B.2 that are used=100 parts by weight) of at least one emulsifier selected from the group consisting of alkali, alkaline earth, ammonium and phosphonium salts of a saturated fatty acid having from 10 to 50 carbon atoms, wherein the emulsifier or emulsifiers remains or remain in component B,
    and also to a process for the preparation of these polycarbonate compositions and to the use of the polycarbonate compositions in the production of molded bodies, and to the molded bodies themselves.

Claims

1. A Composition comprising

A) from 10 to 99 parts by weight, in each case based on the sum of components A+B+C, of aromatic polycarbonate and/or aromatic polyester carbonate,

B) from 1 to 35 parts by weight, in each case based on the sum of components A+B+C, of rubber-modified graft polymer of

B.1 from 5 to 95 wt. % of at least one vinyl monomer on

B.2 from 95 to 5 wt. % of one or more graft bases having a glass transition temperature <

10°

C.,

C) from 0 to 40 parts by weight, in each case based on the sum of components A+B+C, of vinyl (co)polymer and/or polyalkylene terephthalate,

D) from 0 to 50 parts by weight, in each case based on the sum of components A+B+C, of phosphorus-containing flameproofing agent,

E) from 0 to 1.0 part by weight, in each case based on the sum of components A+B+C, of acidic additives, and

F) from 0 to 50 parts by weight, in each case based on the sum of components A+B+C, of additives,

wherein component B is obtainable by reacting component B.1 with the graft base B.2 by means of emulsion polymerization,

with the proviso that in a composition that is free of components D) and E), the graft polymer dispersion in the spray drying or in the precipitation has a pH value of less than 7, and wherein, in the graft reaction, there is included from 0.1 to 5 parts by weight (based on the sum of the parts by weight of the monomers B.1 and of the graft base B.2 that are used=100 parts by weight) of at least one emulsifier selected from the group consisting of alkali, alkaline earth, ammonium and phosphonium salts of a saturated fatty acid having from 10 to 50 carbon atoms, and wherein said at least one emulsifier remains in component B.

2. Composition according to claim 1, wherein there are used in the graft reaction, from 0.3 to 2.5 parts by weight (based on the sum of the parts by weight of the monomers B.1 and of the graft base B.2 that are used=100 parts by weight) of at least one emulsifier selected from the group consisting of alkali, alkaline earth, ammonium and phosphonium salts of a saturated fatty acid having from 10 to 50 carbon atoms.

3. Composition according to claim 1, wherein there are used in the graft reaction from 1.5 to 2.5 parts by weight (based on the sum of the parts by weight of the monomers B.1 and of the graft base B.2 that are used=100 parts by weight) of at least one emulsifier selected from the group consisting of alkali, alkaline earth, ammonium and phosphonium salts of a saturated fatty acid having from 10 to 50 carbon atoms.

4. Composition according to claim 1, wherein there is used as emulsifier in the graft reaction at least one selected from the group of the alkali metal salts of the following acids:

capric acid (C₉H₁₉COOH), lauric acid (C₁₁H₂₃COOH), myristic acid (C₁₃H₂₇COOH), palmitic acid (C₁₅H₃₁COOH), margaric acid (C₁₆H₃₃COOH), stearic acid (C₁₇H₃₅COOH), arachic acid (C₁₉H₃₉COOH), behenic acid (C₂₁H₄₃COOH), lignoceric acid (C₂₃H₄₇COOH) and cerotic acid (C₂₅H₅₁COOH).

10. A method for the production of a molded body or semi-finished product comprising utilizing a composition according to claim 1.

11. Molded body comprising a composition according to claim 1.

5. Process for the preparation of an impact-modified polycarbonate molding composition which has an improved natural color along with good hydrolytic stability and processing stability of the impact-modified polycarbonate molding composition, wherein the constituents of said composition comprise:

A) from 10 to 99 parts by weight of aromatic polycarbonate and/or aromatic polyester carbonate,

B) from 1 to 35 parts by weight of rubber-modified graft, polymer of

B.1 from 5 to 95 wt. % of at least one vinyl monomer on

B.2 from 95 to 5 wt. % of one or more graft bases having a glass transition temperature <

10°

C.,

C) from 0 to 40 parts by weight of vinyl (copolymer and/or polyalkylene terephthalate,

D) from 0 to 50 parts by weight, in each case based on the sum of components A+B+C, of phosphorus-containing flameproofing agent,

E) from 0 to 1.0 part, by weight, in each case based on the sum of components A+B+C, of acidic additives, and

F) from 0 to 50 parts by weight, in each case based on the sum of components A+B+C, of additives,

wherein said process comprises mixing said components A-F, either in succession or simultaneously, at a temperature of about 20°

C. or at a higher temperature, and melt compounding and melt extruding at a temperature of from 260°

C. to 300°

C.,

wherein said composition comprises as an impact modifier, a rubber-modified graft polymer (component B), which is prepared by reacting component B.1 with the graft base B.2 by means of emulsion polymerization, wherein

(i) in a first step, the rubber base B.2 is prepared directly in the form of an aqueous dispersion by means of radical emulsion polymerization or is dispersed in water,

(ii) in a second step, a graft reaction of component B.1 with the graft base B.2 is carried out by means of emulsion polymerization, wherein

1) component B.2 is dispersed in water to form a rubber base dispersion,

2) there is provided from 0.1 to 5 parts by weight (based on the sum of the parts by weight of the monomers B.1 and of the graft base B.2 used in the preparation of the graft polymer B=100 parts by weight.) of at least one emulsifier selected from the group consisting of alkali, alkaline earth, ammonium and phosphonium salts of a saturated fatty acid having from 10 to 50 carbon atoms, and there is further provided a monomer according to component B.1 and a radical formers, as well as, optionally, a molecular weight regulator for the rubber base dispersion obtained in step (1),

3) working up by

3.1) spray drying and/or

3.2) by a process comprising the steps

3.2.1) precipitation and

3.2.2) separation of the dispersing water,

with the proviso that, in a composition that is free of components D) and E), the graft polymer dispersion in the spray drying (3.1) or in the precipitation (3.2.1) has a pH value of less than 7,

and wherein the resulting moist graft polymer is not washed with additional water.

6. Process according to claim 5, wherein there is used in the graft reaction, from 0.2 to 2.5 parts by weight (based on the sum of the parts by weight of the monomers B.1 and of the graft base B.2 that are used=100 parts by weight) of at least one emulsifier selected from the group consisting of alkali, alkaline earth, ammonium and phosphonium salts of a saturated fatty acid having from 10 to 50 carbon atoms.

7. Process according to claim 5, wherein there is used in the graft reaction, from 1.5 to 2.5 parts by weight (based on the sum of the parts by weight of the monomers B.1 and of the 3 graft base B.2 that are used=100 parts by weight) of at least one emulsifier selected from the group consisting of alkali, alkaline earth, ammonium and phosphonium salts of a saturated fatty acid having from 10 to 50 carbon atoms.

8. Process according to claim 5, wherein there is used as emulsifier in the graft reaction, at least one selected from the group of the alkali metal salts of the following acids:

capric acid (C₉H₁₉COOH), lauric acid (C₁₁H₂₃COOH), myristic acid (C₁₃H₂₇COOH), palmitic acid (C₁₅H₃₁COOH), margaric acid (C₁₆H₃₃COOH), stearic acid (C₁₇H₃₅COOH), arachic acid (C₁₉H₃₉COOH), behenic acid (C₂₁H₄₃COOH), lignoceric acid (C₂₃H₄₇COOH) and cerotic acid (C₂₃H₅₁COOH).

9. Molded bodies and/or semi-finished product obtainable by the process according to claim 5.