Thermoplastic resin composition

• US 5,449,722 A
• Filed: 03/18/1994
• Issued: 09/12/1995
• Est. Priority Date: 03/19/1993
• Status: Expired due to Term

• Current Assignee: Mitsubishi Chemical Corporation (Mitsubishi Chemical Group Corp.)
• Original Assignee: Mitsubishi Petrochemical Co., Ltd. (Mitsubishi Chemical Group Corp.)
• Inventors: Nishida, Koji, Takagi, Kiyoji, Seki, Motohiro, Sano, Hironari
• Primary Examiner(s): Seidleck, James J.
• Assistant Examiner(s): ZEMEL, IRINA SOPJIA
• Application Number:
  US08/210,365
• Time in Patent Office: 543 Days
• Field of Search: 525/98, 525/179, 525/92, 525/93, 525/96, 525/130, 525/177, 525/166, 525/66, 525/132, 525/240, 525/397, 524/448, 524/449, 524/451
• US Class Current: 525/98
• CPC Class Codes: C08L 101/00 Compositions of unspecified macromolecular compounds
• CPC Class Codes: C08L 23/02 not modified by chemical after-treatment
• CPC Class Codes: C08L 25/00 Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
• 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 53/02 of vinyl-aromatic monomers and conjugated dienes
• 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 71/00 Compositions of polyethers obtained by reactions forming an ether link in the main chain of polyacetals C08L59/00; of epoxy resins C08L63/00; of polythioether-ethers C08L81/02; of polyether-sulfones C08L81/06; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 77/00 Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain of polyhydrazides C08L79/06; of polyamideimides or polyamide acids C08L79/08; Compositions of derivatives of such polymers

Abstract

Disclosed is a thermoplastic resin composition comprising:

30 to 97% by weight of at least one of (a) a crystalline thermoplastic resin component and (b) a non-crystalline thermoplastic resin component, 3 to 70% by weight of (c) a rubbery polymer component which is ununiformly mixed with at least one of Component (a) and Component (b) and 0 to 40% by weight of (d) an inorganic filler,

wherein Component (c) forms a network and at least one of the ratio of flexural modulus of Component (a) to Component (c) and that of Component (b) to Component (c) is 5 or more.

Claims

1. thermoplastic resin composition which comprises:

30 to 97% by weight of

(a) a crystalline thermoplastic resin component; and

(b) a non-crystalline thermoplastic resin component; and

3 to 70% by weight of (c) a rubbery polymer component which is ununiformly mixed with Component (a) and Component (b) and

0 to 40% by weight of (d) an inorganic filler,

wherein Component (c) forms a network and substantially exists at the interface of Component (a) and Component (b), and at least one of the ratio of flexural modulus of Component (a) to Component (c) and that of Component (b) to Component (c) is 5 or more.

2. The thermoplastic resin composition according to claim 1, wherein the composition satisfies at least one of the following conditions (i) and (ii) and also satisfies the conditions (iii):

(i) when a melt shear viscosity ratio of Component (c)/Component (a) is 0.1 to less than 1.0, the content of Component (c) based on the total weight of (a)+(b)+(c) is 25 to 70% by weight;

when the ratio of the same is 0.01 to less than 0.1, the content of Component (c) is 15 to 65% by weight; and

when the ratio of the same is less than 0.01, the content of Component (c) is 5 to 50% by weight,

(ii) when a melt shear viscosity ratio of Component (c)/Component (b) is 0.1 to less than 1.0, the content of Component (c) based on the total weight of (a)+(b)+(c) is 25 to 70% by weight;

when the ratio of the same is 0.01 to less than 0.1, the content of Component (c) is 15 to 65% by weight; and

when the ratio of the same is less than 0.01, the content of Component (c) is 5 to 50% by weight, and

(iii) the melt shear viscosity ratio of Component (b)/Component (a) is 30/1 to 1/30.

4. The composition according to claim 1, wherein said composition has a structure that the number m of regions of Component (a) and/or Component (b) which are enclosed with the network of Component (c) existing in a square having a side length of 1 μ

m is a number which makes the average value of the index R of the following formula (I) 0.9 or less, ##EQU3##

5. The composition according to claim 1, wherein Component (a) comprises at least one crystalline thermoplastic resin selected from the group consisting of a saturated polyester, a polyamide, a polyolefin, a polyphenylene sulfide and a polyacetal.

6. The composition according to claim 1, wherein Component (b) comprises at least one non-crystalline thermoplastic resin selected from the group consisting of a polyphenylene ether, a polycarbonate and a polystyrene resin.

7. The composition according to claim 1, wherein Component (c) is a rubbery polymer having a flexural modulus of 10,000 kg/cm² or less.

8. The composition according to claim 1, wherein Component (c) comprises at least one rubbery polymer of a hydrogenated product of a block copolymer comprising an aromatic vinyl compound polymer block and a conjugated diene compound polymer block, a polyolefin rubbery copolymer or a graft-modified product thereof.

9. The composition according to claim 1, wherein Component (d) comprises at least one inorganic filler selected from the group consisting of talc, mica, kaolin, clay, diatomaceous earth and a glass fiber.

10. The composition according to claim 1, wherein said composition has at least one melt shear viscosity ratio of Component (c) to Component (a) and Component (c) to Component (b) of 1.0 or less.

11. A thermoplastic resin composition which comprises:

(a) 5 to 85% by weight of a crystalline thermoplastic resin component,

(b) 5 to 85% by weight of a non-crystalline thermoplastic resin component which is ununiformly mixed with Component (a),

(c) 10 to 60% by weight of a rubbery polymer component which is ununiformly mixed with Component (a) and Component (b) and

(d) 0 to 40% by weight of an inorganic filler, wherein Component (c) forms a network and exists substantially at the interface of Component (a) and Component (b).

3. The thermoplastic resin composition according to claim 11, wherein the composition satisfies at least one of the following conditions (i) and (ii) and also satisfies the condition (iii):

(i) when a melt shear viscosity ratio of Component (c)/Component (a) is 0.1 to less than 1.0, the content of Component (c) based on the total weight of (a)+(b)+(c) is 25 to 60% by weight;

when the ratio of the same is 0.01 to less than 0.1, the content of Component (c) is 15 to 60% by weight; and

when the ratio of the same is less than 0.01, the content of Component (c) is 10 to 50% by weight,

(ii) when a melt shear viscosity ratio of component (c)/component (b) is 0.1 to less than 1.0, the content of Component (c) based on the total weight of (a)+(b)+(c) is 25 to 60% by weight;

when the ratio of the same is 0.01 to less than 0.1, the content of Component (c) is 15 to 60% by weight; and

when the ratio of the same is less than 0.01, the content of Component (c) is 10 to 50% by weight, and

(iii) the melt shear viscosity ratio of Component (b)/Component (a) is 15/1 to 1/15.

12. The composition according to claim 11, wherein said composition comprises:

(a) 7 to 75% by weight of the crystalline thermoplastic resin component,

(b) 10 to 70% by weight of the non-crystalline thermoplastic resin component,

(c) 10 to 55% by weight of the rubbery polymer component and

(d) 0 to 35% by weight of the inorganic filler.

13. The composition according to claim 11, wherein said composition comprises:

(a) 10 to 65% by weight of the crystalline thermoplastic resin component,

(b) 15 to 50% by weight of the a non-crystalline thermoplastic resin component,

(c) 12 to 40% by weight of the rubbery polymer and

(d) 0 to 25% by weight of the inorganic filler.

14. The composition according to claim 11, wherein said composition has a structure that the number m of regions of Component (a) and/or Component (b) which are enclosed with the network of Component (c) existing in a square having a side length of 1 μ

m is a number which makes the average value of the index R of the following formula (I) 0.9 or less, ##EQU4##

15. The composition according to claim 11, wherein Component (d) substantially exists in Component (a).

16. The composition according to claim 11, wherein Component (a) comprises at least one crystalline thermoplastic resin selected from the group consisting of a saturated polyester, a polyamide, a polyolefin, a polyphenylene sulfide and a polyacetal.

17. The composition according to claim 11, wherein Component (b) comprises at least one non-crystalline thermoplastic resin selected from the group consisting of a polyphenylene ether, a polycarbonate and a polystyrene resin.

18. The composition according to claim 11, wherein Component (c) is a rubbery polymer having a flexural modulus of 10,000 kg/cm² or less.

19. The composition according to claim 11, wherein Component (c) comprises at least one rubbery polymer of a hydrogenated product of a block copolymer comprising an aromatic vinyl compound polymer block and a conjugated diene compound polymer block, a polyolefin rubbery copolymer or a graft-modified product thereof.

20. The composition according to claim 11, wherein Component (d) comprises at least one inorganic filler selected from the group consisting of talc, mica, kaolin, clay, diatomaceous earth and a glass fiber.

21. The composition according to claim 11, wherein said composition has melt shear viscosity ratios of Component (c) to Component (a) and Component (c) to Component (b) of 1.0 or less.