Thermoplastic Resin Composition and Molded Article Using the Same

• US 20150005435A1
• Filed: 04/09/2014
• Published: 01/01/2015
• Est. Priority Date: 06/28/2013
• Status: Active Grant

• Current Assignee: Lotte Advanced Materials Co., Ltd. (Lotte Chemical Corporation)
• Original Assignee: Cheil Industries Incorporated
• Inventors: PARK, Ji-Eun, KIM, Ja-Yoon, HONG, Chang-Min, BAN, Kyun-Ha
• Granted Patent: US 9,783,668 B2
• Time in Patent Office: Days
• US Class Current: 524/504
• 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 25/12 with unsaturated nitriles
• CPC Class Codes: C08L 25/14 with unsaturated esters
• CPC Class Codes: C08L 33/12 Homopolymers or copolymers of methyl methacrylate
• CPC Class Codes: C08L 51/003 grafted on to macromolecular compounds obtained by reactions only involving unsaturated carbon-to-carbon bonds C08L51/04, C08L51/06 take precedence

Abstract

A thermoplastic resin composition includes (A) a first rubber-modified acrylic-based graft copolymer having an average rubber particle diameter of greater than or equal to about 100 nm and less than about 200 nm, (B) a second rubber-modified acrylic-based graft copolymer having an average rubber particle diameter of greater than or equal to about 200 nm and less than or equal to about 400 nm, (C) a first vinyl-based copolymer of an aromatic vinyl monomer and a unsaturated nitrile monomer, and (D) a second vinyl-based copolymer of an alkyl (meth)acrylate monomer, an aromatic vinyl monomer, and a unsaturated nitrile monomer. A molded article can be made using the same.

Claims

1. A thermoplastic resin composition, comprising:

(A) a first rubber-modified acrylic-based graft copolymer having an average rubber particle diameter of greater than or equal to about 100 nm and less than about 200 nm,

(B) a second rubber-modified acrylic-based graft copolymer having an average rubber particle diameter of greater than or equal to about 200 nm and less than or equal to about 400 nm,

(C) a first vinyl-based copolymer of an aromatic vinyl monomer and a unsaturated nitrile monomer, and

(D) a second vinyl-based copolymer of an alkyl (meth)acrylate monomer, an aromatic vinyl monomer, and an unsaturated nitrile monomer.

2. The thermoplastic resin composition of claim 1, wherein the first rubber-modified acrylic-based graft copolymer (A) comprises:

(a1) about 40 to about 70 wt % of an acrylic-based rubbery polymer core, and

(a2) about 30 to about 60 wt % of a shell layer formed by grafting a copolymer of an aromatic vinyl monomer and unsaturated nitrile monomer on the acrylic-based rubbery polymer core.

3. The thermoplastic resin composition of claim 1, wherein the first rubber-modified acrylic-based graft copolymer (A) comprises:

(a1)) an acrylic-based rubbery polymer core comprising (a1-1) an internal core layer consisting of a copolymer of an alkyl (meth)acrylate monomer and an aromatic vinyl monomer and (a1-2) an external core layer consisting of an alkyl (meth)acrylate-based polymer; and

(a2) a shell layer formed by grafting a copolymer of an aromatic vinyl monomer and unsaturated nitrile monomer on the acrylic-based rubbery polymer core.

4. The thermoplastic resin composition of claim 1, wherein the first rubber-modified acrylic-based graft copolymer (A) has a grafting ratio of about 40 to about 80%.

5. The thermoplastic resin composition of claim 1, wherein the second rubber-modified acrylic-based graft copolymer (B) comprises:

(b1) about 30 to about 80 wt % of an acrylic-based rubbery polymer core and

(b2) about 20 to about 70 wt % of a shell layer formed by grafting a copolymer of an aromatic vinyl monomer and unsaturated nitrile monomer on the acrylic-based rubbery polymer core.

6. The thermoplastic resin composition of claim 1, wherein the second rubber-modified acrylic-based graft copolymer (B) comprises:

(b1) an acrylic-based rubbery polymer core comprising;

(b1-1) a first core layer consisting of an alkyl (meth)acrylate-based polymer,

(b1-2) a second core layer consisting of a copolymer of an alkyl (meth)acrylate monomer and an aromatic vinyl monomer formed outside the first core layer, and

(b1-3) a third core layer consisting of a copolymer of an alkyl (meth)acrylate monomer and an aromatic vinyl monomer formed outside the second core layer, and

(b2) a shell layer formed by grafting an aromatic vinyl monomer and a unsaturated nitrile monomer on the third core layer.

7. The thermoplastic resin composition of claim 1, wherein the first vinyl-based copolymer (C) comprises:

about 60 to about 70 wt % the aromatic vinyl monomer, and

about 30 to about 40 wt % of the unsaturated nitrile monomer.

8. The thermoplastic resin composition of claim 1, wherein the first vinyl-based copolymer (C) has a weight average molecular weight of about 80,000 to about 200,000 g/mol.

9. The thermoplastic resin composition of claim 1, wherein the second vinyl-based copolymer (D) comprises:

about 5 to about 30 wt % of the alkyl (meth)acrylate monomer,

about 50 to about 80 wt % of the aromatic vinyl monomer, and

about 10 to about 35 wt % of the unsaturated nitrile monomer.

10. The thermoplastic resin composition of claim 1, wherein the second vinyl-based copolymer (D) has a weight average molecular weight of about 90,000 to about 200,000 g/mol.

11. The thermoplastic resin composition of claim 1, wherein the thermoplastic resin composition comprises:

about 30 to about 50 wt % of the first rubber-modified acrylic-based graft copolymer (A) and the second rubber-modified acrylic-based graft copolymer (B), and

about 50 to about 70 wt % of the first vinyl-based copolymer(C) and the second vinyl-based copolymer (D).

12. The thermoplastic resin composition of claim 1, wherein the thermoplastic resin composition comprises:

about 20 to about 40 wt % of the first rubber-modified acrylic-based graft copolymer (A),

about 10 to about 30 wt % of the second rubber-modified acrylic-based graft copolymer (B),

about 40 to about 65 wt % of the first vinyl-based copolymer (C), and

about 5 to about 30 wt % of the second vinyl-based copolymer (D).

13. The thermoplastic resin composition of claim 1, wherein the thermoplastic resin composition further comprises a colorant (E).

14. The thermoplastic resin composition of claim 13, wherein the colorant (E) comprises carbon black, carbon black master batch, or a combination thereof.

15. A molded article using the thermoplastic resin composition of claim 1.

16. The molded article of claim 15, wherein the molded article is black, and

an L value of the molded article in a color coordinate of International Commission on Illumination (CIE) may be about 25 to about 29.