REINFORCED IMPACT MODIFIED POLYCARBONATES

Abstract: Novel thermoplastic molding compositions are disclosed which comprise (a) a bisphenol-A polycarbonate; (b) at least one reinforcing agent selected from the group consisting essentially of glass fibers, glass beads, and mixtures of glass fibers and glass beads in admixture with; (c) a minor amount of at least one component selected from the group comprising polyolefins, olefin based copolymers and olefin based ter- Polymers, such as, ethylene-propylene copolymers, ethylene-butadiene copolymers, propylene-butadiene copolymers, ethylene-propylene-butadiene terpolymers, ethylene-acrylic acid copolymers, propylene-acrylic acid copolymers, ethylene-ethyl acrylate copolymers, ethylene-vinyl acetate copolymers and ethylene-propylene-acrylic acid terpolymers.

Description: Description Reinforced Impact Modified Polycarbonates This invention relates to thermoplastic molding composi¬ tions having improved notched Izod impact strength comprising (a) a bisphenol-A polycarbonate; (b) at least one reinforcing agent selected from the group consisting essentially of glass fibers, glass beads, and mix¬ tures of glass fibers and glass beads, in admixture with; (c) a minor amount of at least one component selected from the group comprising polyolefins, olefin based copolymers and olefin based terpolymers, such as ethylene-propylene copolymers, ethylene-butadiene copolymers, propylene-butadiene copolymers, ethylene-propylene-butadiene terpolymers, ethylene-acrylic acid copolymers, propylene-acrylic acid copolymers, ethylene-ethyl acrylate copolymers, ethylene-vinyl acetate copolymers and ethylene-propylene-acrylic acid terpolymers. Background of the Invention The use of bisphenol-A polycarbonates as molding composi¬ tions, both with and without reinforcing agents is well known and these materials have been widely employed in the manufacture of various thermoplastic molded articles. In the preparation of such bisphenol-A polycarbonates for use as molding compositions, one may employ a variety of rein¬ forcing agents in various amounts which improve the flexural properties of the molded article in proportion to the amount of such material employed. It has now been found that the incorporation of a relative¬ ly minor amount of at least one component selected from the group comprising polyolefins, ethylene-propylene copolymers, ethylene-butadiene copolymers, propylene-butadiene copolymers, 5 ethylene-propylene-butadiene terpolymers, ethylene-acrylic acid copolymers, propylene-acry1ic acid copolymers, ethylene-ethyl aerylate copolymers, ethylene-vinyl acetate copolymers, ethylene- propy1ene-acry1ic acid terpolymers and olefin based copolymers and terpolymer elastomers, in admixture with a quantity of at 0 least one reinforcing agent selected from the group consisting essentially of glass fibers, glass beads, and mixtures of glass fibers and glass beads into a bisphenol-A polycarbonate will significantly improve the notched Izod impact strength charac¬ teristics of the resultant polycarbonate molding composition 5 over those which could be realized via the use of glass fiber or glass bead reinforcing agents alone. Description of the Invention The present invention provides for a novel thermoplastic molding composition which comprises Q (a) a bisphenol-A polycarbonate; (b) at least one reinforcing agent selected from the group consisting essentially of glass fibers, glass beads, and mix¬ tures of glass fibers and glass beads, in admixture with; - (c) a minor amount of at least one component selected from the 5 group comprising polyolefins, olefin based copolymers and olefin based terpolymers, such as, ethylene-propylene copolymers, ethylene-butadiene copolymers, propylene-butadiene copolymers, ethylene-propylene-butadiene terpolymers, ethylene-acrylic acid copolymers, propylene-acrylic acid copolymers, ^ ethylene- ethyl acrylate copolymers, ethylene-vinyl acetate copolymers and ethylene-propylene-acrylic acid terpolymers. The polycarbonate resin has recurring units of the formula wherein each -R- is selected from the group consisting of phenylene, halo-substituted phenylene and alky! substituted phenylene, and X and Y are each selected from the group consist¬ ing of hydrogen, hydrocarbon radicals free from aliphatic unsaturation and of radicals which together with the adjoining atom form a cycloalkane radical, the total number of carbon.atoms in X and Y being up to 12. The preferred polycarbonate resins may be derived from the reaction of bisphenol-A and phosgene. These polycarbonates have from 10-400 recurring units of the formula: - The polycarbonates are described in U.S. Patents Nos. 3,028,365; 3,334,154 and 3,915, 926 all of which are incorporated by reference. The polycarbonate should have an intrinsic vis¬ cosity between 0.2 and 1.0, preferably from 0.30 to 0.65 as measured at 20°C in methylene chloride. Although it is only necessary to use a reinforcing amount of the reinforcing agent in the compositions of the present invention, from 1-60 parts by weight of the total weight of the resultant molding composition may comprise the reinforcing 5 agent. A preferred range is from 5-40 parts by weight. The preferred reinforcing agents for use in the present invention are of glass, and it is preferred to use fibrous glass filaments, glass beads, or mixtures of these. The pre¬ ferred glass filaments for plastics reinforcements are made ° by mechanical pulling, and have filament diameters in the range of from about (0.000112) 0.000284cm to about (0.00075 inch 0.0019cm. However, this is not critical to the present inven¬ tion. The glass beads which may be advantageously employed either 5 alone or together with the treated glass fibers described above will have diameters on the order of 0.0003cm (0.0001) to about . 0.025cm (O.OlOinches) and are generally prepared via spraying of the molten glass as fine droplets into liquid baths. The glass fibers may be employed in amounts up to about 0 40 parts by weight of the total composition and the glass beads may be employed in amounts up to about 60 parts by weight of the total composition. The glass fibers and glass beads may be advantageously employed in varying proportions such that the combined quantity of glass fibers and glass beads make up from 5 about 1 to about 60 parts by weight of the total composition. The preferred range of the combined glass fibers and glass beads is from about 5 to about 40 parts by weight of the total mold¬ ing composition. The polyolefin copolymers , such as ethyl ene-propylene ' copolymers , and olefin terpolymers , such as ethylene-propylene- butadiene terpolymers, which may be suitably employed in practicing the present invention are all commercially available products whose preparation is well known. The olef in-acrylic acid copolymers , such as ethylene- acryl ic acid copolymers , and di olef in-acrylic acid terpolymers , such as ethyl ene-propylene-acryl ic acid terpolymers and other olefin based thermoplastic elastomers , which may be suitably employed in practicing the present invention are also commercial¬ ly available products whose preparation is well known, as will be readily apparent to those skilled in the art. Exemplary of various commercially available products which may be advantageously employed as impact modifying agents in propylene block copolymers ; al l of which are manufactured and sold by Hercules , Inc. :, US ^LB 342 and USp-R.B 703, both ethylene homopolymers, manu¬ mers manufactured and sold by the Dow Chemical Company; Vynathene-'EY 903, an ethyl ene-vinyl acetate copolymer manu¬ factured and sold by USI Chemicals ; Dexorr ι004, a propyl ene-acr 1 i c acid copolymer, manufactured and sold by Exxon Chemicals ; Some ^oiT, Some " f®402T and Some " f®.3αi&, .all olefin based - thermoplastic elastomers , manufactured and sold by the Du Pont Company: and EpoleneS'C-17, an olefin ol igomer, manufactured and sold by Eastman Chemical Products . The compositions of the present invention may contain from about 0.5 to about 10 percent by weight of combined impact modifying component(s) described above, without taking into account the amount of reinforcing agents to be employed, and will preferentially contain from about 2 to about 6 percent by weight of the combined impact modifying component(s). The compositions of the present invention may be prepared by any standard procedure and the particular method employed is not critical. The compositions of the present invention may also include flame retardants such as those described in U.S. Patent No. 3,915,926 which is incorporated herin by reference. Description of the ; 'Preferred Embodiments The following examples are set forth to further illustrate the present invention and are not to be construed as limiting the invention thereto. • Example I - Control A blend of 91 parts by weight of bisphenol-A polycarbonate and 9 parts by weight of chopped glass fibers was prepared, extruded in a twin screw extruder and molded into sample parts of approximately 0.3cm (1/8 inch) thickness. The results of impact and flexural tests on the resultant molded parts are set forth in Table I. Examples II - XXIII A blend of 91 parts by weight of bisphenol-A polycarbonate and 9 parts by weight of chopped glass fibers was blended with 4 parts per 100 by weight of various commercially available compositions as impact modifying agents as set forth in Table I. The various resultant blends were extruded and molded -in the • same manner as in Example I. The results of impact and flexur¬ al tests on the resultant molded parts are also set forth in Table I. "B - Table I - Examples I - XXIII Base: 91 Parts By Height Poly(BPA Carbonate) and 9 Parts B Weight Chopped Glass Fibers Example Additive Flexural (xlO ) (PSI)kg/cm Izod Impact ( Ft. -lb./in.)kg-cm/ cm No. (4 phr) Modulus Yield Str. Notched Unnotched I II III IV V VI VII VIII IX X XI XII XIII XIV Base: 91 Parts By Weight Poly(BPA Carbonate) 3 and 9 Parts by Weight Chopped Glass Fibers Example No. XV XVI XVII XVIII XIX XX XXI XXII XXIII a. IV = 0.48 V indicates that at least one sample did not fall when subjected to the machine l imit of 40 ft. -lb. /in. Exa ple XXIV - Control A blend of 60 parts by weight of bisphenol-A polycarbonate, 20 parts by weight of chopped glass fibers and 20 parts by weight of glass beads was prepared, extruded and molded into sample parts in the same manner as in Example I. The results of impact and flexural tests performed on the resultant molded parts are set forth in Table II. Examples XXV - XXX Blends of 60 parts by weight of bisphenol-A polycarbonate, 20 parts by weight of chopped glass fibers and 20 parts by weight of glass beads in admixture with 4 parts per 100 by weight of various compositions as impact modifying agents were prepared, extruded and molded in the same manner as in Example XXIV. The results of impact and flexural tests performed on the resultant molded parts are set forth in Table II. Table II - Examples XXIV - XXX Base: 60 Parts by Weight Po1y(BPA Carbonate) 8 , 20 Parts by Weight Chopped Glass Fibers and 20 Parts by Weight Glass Beads - Example No. XXIV XXV XXVI XXVII XXVIII XXIX XXX a. IV = 0.48 -π- Example XXXI - Control A blend of 70 parts by weight of bisphenol-A polycarbonate and 30 parts by weight of glass beads was prepared, extruded and molded into sample parts in the same manner as in Example I. The results of impact and flexural tests performed on the re- sultant molded parts are set forth in Table III. Examples XXXII - XXXVI Blends of 70 parts by weight of bisphenol-A polycarbonate and 30 parts by weight of glass beads in admixture with 4 parts per 100 by weight of various compositions as impact modifying agents as set forth in Table III were prepared, extruded and molded into sample parts in the same manner as in Example XXXI. The results of impact and flexural tests performed on the resultant molded parts are also set forth in Table III. Table III - Examples XXXI - XXXVI Base: 70 Parts By We1< nht Poly(BPA Carbonate) 9 and 30 Parts By Weight Glass Beads Example Additive Flexural (xlO " ■3 ) (PSI)kg/cm 2 Izod Impact(Ft.lb./1n.)kg-cm/cm No. (4 phr) Modulus Yield Str. Notched Unnotched XXXI XXXII XXXIII XXXIV XXXV XXXVI • a. IV = 0.48 Although the above examples show various modifications of the present invention, it will be appreciated by one skilled in the art that other variations are possible in light of the above teachings. It is, therefore, to be understood that changes may be made in the particular embodiments of the invention described which are within the full intended scope of the invention, as defined by the appended claims.

Claims: Claims 1. A thermoplastic molding composition which comprises (a) a bisphenol-A polycarbonate; (b) at least one reinforcing agent selected from the group consisting essentially of glass fibers, glass beads, and mixtures of glass fibers and glass beads, in admixture with; (c) a minor amount of at least one component selected from the group comprising polyolefins, olefin based copolymers and olefin based terpolymers. 2. A thermoplastic molding composition according to claim 1 which comprises (a) a bisphenol-A polycarbonate 1 , (b) at least one reinforcing agent selected from the group consisting essentially of glass fibers, glass beads, and mixtures of glass fibers and glass beads, in admixture with; (c) a minor amount of at least one component selected from the group comprising polyolefins, ethylene-propylene copolymers, ethylene-butadiene copolymers, propylene- butadiene copolymers, ethylene-propylene-buyadiene terpolymers, ethylene-acrylic acid copolymers,propylene- acrylic acid copolymers, ethylene-ethyl acrylate copolymers, ethylene-vinyl acetate copolymers and ethylene-propylene- acrylic acid terpolymers. 3. A thermoplastic molding composition according to claim 2 which comprises (a) a bisphenol-A polycarbonate; (b) at least one reinforcing agent selected from the group consisting essentially of glass fibers, glass beads, and mixtures of glass fibers and glass beads in admixture with; (c) a minor amount of at least one component selected from the group comprising polyethylene, polypropylene, ethylene-propylene copolymers, ethylene-butadiene copoly¬ mers, propylene-butadiene copolymers and ethylene-propylene- butadiene terpolymers. 4. A thermoplastic molding composition according to claim 2 which comprises (a) a bisphenol-A polycarbonate; (b) at least one reinforcing agent selected from the group consisting essentially of glass fibers, glass beads, and mixtures of glass fibers and glass beads in admixture with; (c) a minor amount of at least one component selected from the group consisting essentially of ethylene-acrylic acid copolymers, propylene-acrylic acid copolymers, ethylene-ethyl acrylate copolymers, ethylene-vinyl acetate copolymers and ethylene-propylene acrylic acid terpolymers. 5. A thermoplastic molding composition as defined in claim 1 wherein the polycarbonate consists essentially of recurring units of the formula: - R - C - R - O - C - 0 wherein each -R- is selected from the group consisting of phenylene, halo-substitued phenylene and alky! substituted phenylene and X and Y are each selected from the group consisting of hydrogen, hydrocarbon radicals free from aliphatic unsaturation and of radicals which together with the adjoining. I atom form a cycloalkane radical, the total number of carbon atoms in X and Y being up to 12. 6. A thermoplastic molding composition as defined in claim 5 — 7. A thermoplastic molding composition as defined in claim 6 wherein the polycarbonate resin consists of from 10 to 400 repeating units. 8. A thermoplastic molding composition according to claim 1 wherein the impact modifying agent is present in an amount from about 0.5 to about 10 percent by weight. 9. A thermpolastic molding composition according to claim 1 wherein the impact modifying agent is present in an amount from about 2 to about 6 percent by weight. 10. A thermoplastic molding composition as defined in claim 1 which includes a flame retardant amount of a flame retardant agent. 11. A method of preparing a reinforced bisphenol-A polycarbonate having improved notched Izod impact strength properties which comprises adding to the polycarbonate molding powder at least one reinforcing agent selected from the group consisting essentially of glass fibers, glass beads, and mixtures of glass fibers and glass beads; in ad- • mixture with a minor quantity of; at least one component selected from the group com¬ prising polyolefins, olefin based copolymers and olefin based terpolymers. 12. A method of preparing a reinforced bisphenol-A polycarbonate having improved notched Izod impact strength properties according to claim 11 which comprises adding to the poly¬ carbonate molding powder at least one reinforcing agent selected from the group consisting essentially of glass fibers, glass beads, and mixtures of glass fibers and glass beads; in admixture with a minor quantity of; at least one component selected from the group compris¬ ing polyolefins ethylene-propylene copolymers, ethylene-butadiene copolymers, propylene-butadiene copolymers, ethylene-propylene-butadiene terpolymers, ethylene-acrylic acid copolymers* propyϊene-acrylic- ~ ~ acid copolymers, ethylene-ethyl acrylate copolymers, ethylene-vinyl acetate copolymers and ethylene- propylene-acrylic acid terpolymers. " BU £4 OMPI WIP 13. A method of preparing a reinforced bisphenol-A poly¬ carbonate molding composition having improved notched Izod impact properties according to claim 12 which comprises adding to the polycarbonate molding powder at least one reinforcing agent selected from the group consisting essentially of glass fibers, glass beads, and mixtures of glass fibers and glass beads, in admixture with a minor quantity of; at least one component selected from the group comprising polyethylene, polypropylene, ethylene- propylene copolymers, ethylene-butadiene copolymers, propylene-butadiene copolymers and ethylene-propylene- butadiene terpolymers. 14. A method of preparing a bisphenol-A polycarbonate molding composition having improved notched Izod impact properties according to claim 12 which comprises adding to the polycarbonate molding powder at least one reinforcing agent selected from the group consisting essentially of glass fibers, glass beads, and mixtures of glass fibers and glass beads, in admixture with a minor quantity of; at least one component selected from the group consisting essentially of ethylene-acrylic acid copolymers, propylene-acrylic acid copolymers, ethylene-ethyl acrylate copolymers, and ethylene- propylene-acrylic acid terpolymers. 15. A method of preparing a thermoplastic molding composition as defined in claim 11 wherein the polycarbonate consists essentially of recurring units of the formula: - R - C R - 0 - 0 - i Y wherein each -R- is selected from the group consisting of phenylene, halo-substituted phenylene and alkyl sub¬ stituted phenylene and X and Y are each selected from the group consisting of hydrogen, hydrocarbon radicals free from aliphatic unsaturation and of radicals which together with the adjoining -!- \ atom form a cycloalkane radical, the total number of carbon atoms in X and Y being up to 12. 16. A method of preparing a thermoplastic molding composition as defined in claim 15 wherein the polycarbonate has the recurring unit 17. A method of preparing a thermoplastic molding composition as defined in claim 16 wherein the polycarbonate resin consists of from 10 to 400 repeating units. fV i p o

Inventors: HOLUB F, WILSON P
Applicants: GEN ELECTRIC, GENERAL ELECTRIC CO
Application year: 1979
Main classification: C08K7
IPC codes: C08K7, C08L23, C08L69