Resin blends exhibiting improved impact properties

• US 4,902,737 A
• Filed: 06/22/1988
• Issued: 02/20/1990
• Est. Priority Date: 12/23/1986
• Status: Expired due to Term

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Peascoe, Warren J., McHale, Angelika H.
• Primary Examiner(s): SHORT, PATRICIA A
• Application Number:
  US07/209,884
• Time in Patent Office: 608 Days
• Field of Search: 525/67, 525/903, 524/148, 524/537, 524/409
• US Class Current: 524/409
• 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 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
• CPC Class Codes: Y10S 525/903 Interpenetrating network

Abstract

A resin composition comprising:

(i) at least one aromatic carbonate resin;

(ii) at least one polyester resin; and

(iii) an impact improving effective amount of at least one two-phase interpolymer comprised of at least one cross-linked polyacrylate and at least one cross-linked styrene-acrylontrile resin.

Claims

1. A resin composition comprising:

(i) at least one aromatic carbonate resin;

(ii) at least one polyester resin; and

(iii) an impact improving effective amount of at least one two-phase interpolymer comprised of a cross-linked acrylate and a cross-linked styrene-acrylonitrile, said interpolymer being free of linear or non-cross-linked styrene-acrylonitrile and free of any grafting or graft-linking.

2. The composition of claim 1 wherein said cross-linked acrylate is comprised of the polymerized and cross-linked reaction products of at least one alkyl acrylate monomer, at least one alkyl methacrylate monomer, or mixtures thereof.

3. The composition of claim 2 wherein said alkyl acrylate monomer is selected from C₂ -C₁₀ alkyl acrylate monomers.

4. The composition of claim 3 wherein said alkyl acrylate monomer is selected from C₄ -C₈ alkyl acrylate monomers.

5. The composition of claim 4 wherein said alkyl acrylate monomer is butyl acrylate.

6. The composition of claim 2 wherein said alkyl methacrylate monomer is selected from C₈ -C₂₂ alkyl methacrylate monomers.

7. The composition of claim 2 wherein said interpolymer is comprised of from about 40 to about 90 weight percent of said cross-linked acrylate and from about 10 to about 60 weight percent of said cross-linked styrene-acrylonitrile.

8. The composition of claim 7 wherein said interpolymer is comprised of from about 50 to about 80 weight percent of said cross-linked acrylate and from about 20 to about 50 weight percent of said cross-linked styrene acrylonitrile.

9. The composition of claim 8 wherein said cross-linked acrylate is comprised of the polymerized and cross-linked reaction products of at least one C₄ -C₈ alkyl acrylate monomer.

10. The composition of claim 9 wherein said alkyl acrylate monomer is butyl acrylate.

11. The composition of claim 1 wherein said aromatic carbonate resin is a polycarbonate resin.

12. The composition of claim 11 wherein said polyester resin is a polyalkylene terephthalate resin.

13. The composition of claim 12 wherein said polyalkylene terephthalate resin is polyethylene terephthalate.

14. The composition of claim 12 wherein said polyalkylene terephthalate resin is poly(butylene terephthalate) resin.

15. The composition of claim 11 wherein said polyester resin is comprised of the reaction products of a glycol portion comprised of 1,4-cyclohexanedimethanol, ethylene glycol, or mixtures thereof, and an acid portion comprised of isophthalic acid, terephthalic acid, or mixtures thereof.

16. The composition of claim 1 wherein said aromatic carbonate resin is a copolyester-carbonate resin.

17. The composition of claim 16 wherein said polyester resin is a polyalkylene terephthalate resin.

18. The composition of claim 17 wherein said polyalkylene terephthalate resin is polyethylene terephthalate resin.

19. The composition of claim 17 wherein said polyalkylene terephthalate resin is poly(butylene terephthalate) resin.

20. The composition of claim 16 wherein said polyester resin is comprised of the reaction products of a glycol portion comprised of 1,4-cyclohexane dimethanol, ethylene glycol, or mixtures thereof, and an acid portion comprised of isophthalic acid, terephthalic acid, or mixtures thereof.

21. The composition of claim 1 which contains from about 1 to about 30 weight percent of said interpolymer (iii), based on the total amounts of (i)-(iii) present.

22. The composition of claim 21 which contains from about 3 to about 25 weight percent of said interpolymer (iii).

23. The composition of claim 22 which contains from about 4 to about 20 weight percent of said interpolymer (iii).

25. The composition of claim 1 wherein said two-phase interpolymer (iii) is formed by a two stage polymerization process comprising first emulsion polymerizing at least one alkyl acrylate, alkyl methacrylate, or mixtures thereof in the presence of a cross-linking agent and then emulsion polymerizing, in the presence of said cross-linked acrylate and a cross-linking agent, a styrene monomer and an acrylonitrile monomer.

26. The composition of claim 1 which additionally contains a flame retarding amount of at least one flame retardant compound.

27. The composition of claim 26 wherein said flame retardant compound is a halogenated aromatic polycarbonate.

28. The composition of claim 27 wherein said halogenated polycarbonate is a brominated polycarbonate.

29. The composition of claim 28 which additionally contains antimony oxide.

30. The composition of claim 1 which contains glass filler.

31. The composition of claim 30 wherein said glass filler is fibrous glass.

32. The composition of claim 31 which contains up to about 50 weight percent of said fibrous glass.

33. The composition of claim 32 which contains up to about 30 weight percent of said fibrous glass.

24. A resin composition comprising:

(i) at least one aromatic carbonate resin;

(ii) at least one polyester resin; and

(iii) an impact improving effective amount of at least one two-phase interpolymer comprised of a cross-linked acrylate and a cross-linked styrene-acrylonitrile, said interpolymer being free of linear or non-cross-linked styrene-acrylonitrile and free of any grafting or graft-linking, wherein the first crosslinked acrylate phase is joined to said second cross-linked stryene-acrylonitrile phase by an interpenetrating network of said cross-linked acrylate and said cross-linked styrene-acrylonitrile.