Thermoplastic Resin Composition and Article Produced Therefrom

• US 20200131361A1
• Filed: 10/29/2019
• Published: 04/30/2020
• Est. Priority Date: 10/31/2018
• Status: Active Grant

• Current Assignee: Lotte Advanced Materials Co., Ltd. (Lotte Chemical Corporation)
• Original Assignee: Lotte Advanced Materials Co., Ltd. (Lotte Chemical Corporation)
• Inventors: CHOI, Ki Hong, KANG, Tae Gon, KIM, Sun Young, YANG, Sung Woo, LEE, Sang Hoon, CHANG, Seo Hee, HA, Dong In
• Granted Patent: US 11,492,487 B2
• Time in Patent Office: Days
• CPC Class Codes: C08J 2369/00 Characterised by the use of polycarbonates; Derivatives of polycarbonates
• CPC Class Codes: C08J 2409/06 Copolymers with styrene
• CPC Class Codes: C08J 2413/00 Characterised by the use of rubbers containing carboxyl groups
• CPC Class Codes: C08J 5/043 with glass fibres
• CPC Class Codes: C08K 2003/3045 Sulfates
• CPC Class Codes: C08K 3/30 Sulfur-, selenium- or tellurium-containing compounds
• CPC Class Codes: C08K 5/52 Phosphorus bound to oxygen only
• CPC Class Codes: C08K 5/5399 Phosphorus bound to nitrogen
• CPC Class Codes: C08K 7/14 Glass
• 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 2205/035 containing four or more polymers in a blend
• CPC Class Codes: C08L 51/04 grafted on to rubbers
• CPC Class Codes: C08L 51/06 grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
• CPC Class Codes: C08L 69/00 Compositions of polycarbonates; Compositions of derivatives of polycarbonates
• CPC Class Codes: H04R 2307/025 Diaphragms comprising polymeric materials
• CPC Class Codes: H04R 31/00 Apparatus or processes specially adapted for the manufacture of transducers or diaphragms therefor manufacture of microstructural arrangements of deformable or non-deformable structures in general B81C1/00182
• CPC Class Codes: H04R 31/003 for diaphragms or their outer suspension
• CPC Class Codes: H04R 7/02 characterised by the construction

Abstract

A thermoplastic resin composition and a molded article formed of the same. The thermoplastic resin composition includes: about 100 parts by weight of a polycarbonate resin; about 5 to about 20 parts by weight of a rubber modified aromatic vinyl copolymer resin; about 0.5 to about 3 parts by weight of a maleic anhydride-grafted rubber polymer; about 50 to about 100 parts by weight of glass fibers; about 10 to about 30 parts by weight of barium sulfate; and about 5 to about 20 parts by weight of a phosphorus flame retardant. The thermoplastic resin composition can have high specific gravity and good properties in terms of impact resistance, weather resistance, flame retardancy, fluidity, and the like.

Claims

1. A thermoplastic resin composition comprising:

about 100 parts by weight of a polycarbonate resin;

about 5 to about 20 parts by weight of a rubber modified aromatic vinyl copolymer resin;

about 0.5 to about 3 parts by weight of a maleic anhydride-grafted rubber polymer;

about 50 to about 100 parts by weight of glass fibers;

about 10 to about 30 parts by weight of barium sulfate; and

about 5 to about 20 parts by weight of a phosphorus flame retardant.

2. The thermoplastic resin composition according to claim 1, wherein the rubber modified aromatic vinyl copolymer resin comprises a rubber modified aromatic vinyl graft copolymer and an aromatic vinyl copolymer resin.

3. The thermoplastic resin composition according to claim 2, wherein the rubber modified aromatic vinyl graft copolymer is obtained by graft copolymerization of a monomer mixture comprising an aromatic vinyl monomer and a vinyl cyanide monomer to a rubber polymer.

4. The thermoplastic resin composition according to claim 1, wherein the maleic anhydride-grafted rubber polymer comprises maleic anhydride-grafted ethylene-octene rubber (EOR-g-MAH), maleic anhydride-grafted ethylene-butene rubber (EBR-g-MAH), maleic anhydride-grafted ethylene-propylene-diene monomer tripolymer (EPDM-g-MAH), maleic anhydride-grafted styrene-ethylene-butylene-styrene copolymer (SEBS-g-MAH), maleic anhydride-grafted polypropylene (PP-g-MAH), and/or maleic anhydride-grafted polyethylene (PE-g-MAH).

5. The thermoplastic resin composition according to claim 1, wherein the phosphorus flame retardant comprises a phosphate compound, a phosphonate compound, a phosphinate compound, a phosphine oxide compound, and/or a phosphazene compound.

6. The thermoplastic resin composition according to claim 1, wherein the maleic anhydride-grafted rubber polymer and the barium sulfate are present in a weight ratio of about 0.03:

1 to about 0.1;

1.

7. The thermoplastic resin composition according to claim 1, wherein the glass fibers and the barium sulfate are present in a weight ratio of about 3:

1 to about 5;

1.

8. The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has a notched Izod impact strength of about 10 kgf·

cm/cm to about 20 kgf·

cm/cm, as measured on a ⅛

″

thick specimen in accordance with ASTM D256.

9. The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has a yellow index difference (Δ

YI) of about 1 to about 5, as measured on an injection molded specimen having a size of 50 mm×

90 mm×

3 mm in accordance with Equation 1;

Δ

YI=YI₁−

YI₀ 

 

[Equation 1]

where YI₀ is an initial yellow index of the specimen of the thermoplastic resin composition and YI₁ is a yellow index of the specimen measured after exposure under conditions of 85°

C. and 85% RH for 500 hours.

10. The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has a flame retardancy of V-1 or higher, as measured on a 3 mm thick specimen in accordance with UL-94.

11. The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has a melt-flow index (MI) of about 30 g/10 min to about 45 g/10 min, as measured under conditions of 250°

C. and 10 kgf in accordance with ASTM D1238.

12. The thermoplastic resin composition according to claim 1 , wherein the thermoplastic resin composition has a specific gravity of about 1.55 to about 1.65, as measured at 23°

C. in accordance with ASTM D792 A.

13. The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has:

a notched Izod impact strength of about 10 kgf·

cm/cm to about 20 kgf·

cm/cm, as measured on a ⅛

″

thick specimen in accordance with ASTM D256;

a yellow index difference (Δ

YI) of about 1 to about 5, as measured on an injection molded specimen having a size of 50 mm×

90 mm×

3 mm in accordance with Equation 1;

Δ

YI=YI₁−

YI₀ 

 

[Equation 1]

where YI₀ is an initial yellow index of the specimen of the thermoplastic resin composition and YI₁ is a yellow index of the specimen measured after exposure under conditions of 85°

C. and 85% RH for 500 hours;

a flame retardancy of V-1 or higher, as measured on a 3 mm thick specimen in accordance with UL-94;

a melt-flow index (MI) of about 30 g/10 min to about 45 g/10 min, as measured under conditions of 250°

C. and 10 kgf in accordance with ASTM D1238; and

a specific gravity of about 1.55 to about 1.65, as measured at 23°

C. in accordance with ASTM D792 A.

14. A molded article formed of the thermoplastic resin composition according to claim 1.

15. A molded article according to claim 14, wherein the molded article is a speaker.