POLYCARBONATE COMPOSITIONS

Abstract: Ternary compositions which comprise a mixture of a high molecular weight thermoplastic, aromatic polycarbonate, an acrylate copolymer, and an organic, ester-type plasticizer.

Description: Description Polycarbonate Compositions The present invention is directed to high molecular weight, aromatic polycarbonate compositions having improved aged impact strength and improved low temperature impact strength. Background of the Invention It is well known that high molecular weight, aromatic polycarbonate resins have high impact strength below a critical thickness of between about ;/2 and 1/4 inches. Above this average thickness, the impact strength of such polycarbonate resins is low. It is also known that the i pact strength of these polycarbonate resins decreases rapidly as temperatures decrease below about -5°C as well as after aging at elevated temperatures above about 100°C. These characteristics limit the fields of applications of these resins. Thus, unmodified poly¬ carbonates are not practical for use at low or high temperatures, particularly when good impact strength is required. Therefore, it is desirable to improve the impact strength of polycarbonate resins at bogh low and high temperatures as well as improve their aged impact strength and thereby expand the fields of application of such resins. Polycarbonate compositions having improved impact strength at both high and low temperatures as well as improved aged impact strength are disclosed in co-pending applications Serial Nos. 69,822; 69,823; 69,824; and 69,825 all of which were filed August 27, 1979 as well as in co-pending applications Serial Nos. filed of even date with this application. DESCRIPTION OF THE INVENTION ' . • It lias now been found that additional ternary compositions comprising a high molecular weight, thermoplastic, aromatic poly¬ carbonate, an acrylate copolymer, and an organic, ester-type plas- ticizer also exhibit improved aged impact strength and that cer¬ tain formulations thereof exhibit improved impact strength at both low and high temperatures as compared to unmodified polycarbonate resins. OMPI The high molecular weight, thermoplastic, aromatic polycar¬ bonates which can be employed in the present invention are those ho opolycarbonates and copolycarbonates and mixtures thereof which have average molecular weights of about 8,000 to more than 200,000, preferably about 20,000 to 80,000, and an intrinsic viscosity (I.V.) of about 0.40 to 1.0 deciliters/grams (dl/g) as measured in methylene chloride at 25°C. These polycarbonates are typically derived from dihydric phenols such as, for example, 2,2-bis(4-hydroxyphenyl) ropane (also referred to as bisphenol-A; i.e., BPA), bis (4-hydroxyρhenyl)methane, 2,2-bis (4-hydroxy-3-meth- ylphenyl) ropane, 4,4-bis( -hydroxyphenyl)heptane, 2,2-(3,5,3' ,5'- tetrachloro-4,4'-dihydroxyphenyl)propane, 2,2- (3,5,3*,5'-tetra- bromo- , '-dihydroxydiphenyl) ropane, and (3,3'-dichloro-4,4*- dihydroxydiphenyl)methane. Other dihydric phenols which are suit- able for use in preparing these polycarbonates are disclosed in U.S. Pat. Nos. 2,999,835; 3,028,365; 3,334,154; and 4,131,575. The aromatic polycarbonates of the invention can be manufac¬ tured by known processes such as, for example, the interfacial polymerization technique wherein a dihydric • phenol is reacted with a carbonate precursor, such as phosgene, in the presence of a suitable organic medium, such as methylene chloride. These pro¬ cesses are disclosed in the above identified U.S. Pats as well as in U.S. Pat. Nos. 4,018,750 and 4,123,436. Transesterification processes can also be employed to prepare these resins such as are disclosed in U.S. Pat. No. 3,153,008, as well as other pro¬ cesses known to those skilled in the art. . * The aromatic polycarbonates of the invention can also in¬ clude the polymeric derivates of a dihydric phenol, a dicarboxy- lic acid, and carbonic acid, such as are disclosed in U.S. Pat. No. 3,169,131. It is also ossible to employ two or more different dihydric phenols or a copolymer of a dihydric phenol with a glycol or with hydroxy or acid terminated polyester, or with a dibasic acid in the event a carbonate copolymer or interpolymer rather than a homopolymer is desired for use in preparing the aromatic polycar¬ bonate to be employed in the invention. In addition, blends of any of the above materials can be used to provide the aromatic polycarbonate. Further, branched polycarbonates, such as are disclosed in U.S. Pat. No. 4,001,184 can also be employed as,can blends of a linear polycarbonate and ' a branched polycarbonate to provide the aromatic polycarbonate of the invention. The "acrylate" copolymer employed in the invention is a copolymer of a C-^-C j methacrylate and a C^-Cg acrylate, wherein the "C^-Cg" represents both saturated and unsaturated, straight or branched chained aliphatic hydrocarbon radicals having from 1 to 5 carbon- atoms and which can be employed in amounts of about 2-4 parts by weight per hundred parts of aromatic polycarbonate. Preferred acrylates for use in the acrylate copolymer are methyl acrylate, ethyl acrylate, isobutyl acrylate, 1,4-butanediol diacryl te, n-butyl acrylate, and 1,3-butylene diacrylate. Pre¬ ferred methacrylates for use in this copolymer include methyl methacrylate, isobutyl methacrylate, 1,3-butylene dimethacrylate, butyl methacrylate and ethyl methacrylate. Based on the total weight of the copolymer, the acrylate por¬ tion thereof can range from about 50-85 weight percent and the methacrylate portion thereof can range from about 15-50 weight percent. The preferred acrylate copolymer for use in this invention is a copolymer of n-butyl acrylate and methyl methacrylate wherein the weight ratio of n-butyl acrylate: methyl methacrylate is about 3:2. Suitable acrylate copolymers can be prepared by methods well known to those skilled in the art or can be obtained commercially. For example, Rohm and Haas' Acryloid® KM 330 copolymer, which is a copolymer of n-butyl acrylate and methyl methacrylate, is suit- able for use in the present invention. The organic, ester-type plasticizers which can be employed in the invention are azelate esters, adipate esters and phthalate esters, all of which are commercially available. The azelate esters include such compounds as di—n-hexyl azelate and di-(2- ethylhexyl)azelate. Di-cyclohexyl phthalate and di(2-ethyl hexyl) adipate illustrate the type of phthalate ester and adipate ester compounds which can be used. For low temperature applications, di-n-hexyl azelate is preferred. The amount of organic, ester-type plasticizer which can be employed in the ternary compositions of the invention can range from about 0.4 - 2.0 parts by weight, preferably 0.5 - 1.5 parts by weight, per hundred parts of the aromatic polycarbonate. It is also regarded to be among the .features of this inven¬ tion to include in the ternary polycarbonate composition conven- tional additives for purposes such as reinforcing, coloring or stabilizing the composition in conventional amounts. The compositions of the invention are prepared by mechanical¬ ly blending the high molecular weight aromatic polycarbonate with the organic, ester- ype plasticizer and the acrylate copolymer by conventional methods. EXAMPLES The following examples set forth the best mode currently known to illustrate the invention and should not be construed as limiting the scope of the invention. In the examples, all parts and percentages are by weight unless otherwise specified. EXAMPLE 1 Ninety-five and one-half (95.5) parts of an aromatic poly¬ carbonate, derived from 2,2-bis (4-hydroxyphenyl) propane and having an intrinsic viscosity (I.V.) in the range of from about 0.46 to about 0.49 dl/g as determined in methylene chloride solu¬ tion at 25°C, was mixed with four (4) parts of an acrylate copoly¬ mer of n-butyl acrylate and methyl methacrylate having a weight ratio of n-butyl-acrylate: methyl methacrylate of about 3:2, and one half (0.5) part of di-n-hexyl azelate as the organic, ester- type plasticizer. The ingredients were then blended together by mechanically mixing them in a laboratory tumbler and the result¬ ing mixture was fed to an extruder which waφ operated at about 265°C. The resulting extrudate was comminuted into pellets and the pellets were injection molded at about 290°C - 310°C into test specimens of about 5" by 1/2" by 1/4" and 5" by 1/2" by 1/8 the latter dimensions being the specimen thicknesses. Izod impact strengths of these specimens were measured according to the notched Izod test, ASTM D256, and are set forth in Table I. The ductile-brittle (D/B) transition temperatures, (the highest temperature at which a sample begins to exhibit a brittle mode of failure rather than a ductile mode of failure) were obtained according to the procedures of ASTM D256 and are also listed in Table I. The sample labeled CONTROL was obtained from a polycar¬ bonate resin having an I.V. of about 0.46 - 0.49 dl/g and was pre- pared without either the acrylate copolymer or the o.rganic ester-type plasticizer. • EXAMPLE 2 The procedure of Example 1 was repeated exactly, except that the weight parts of polycarbonate, acrylate copolymer and the di- n-hexyl azelate (DNHA) in the test specimen were, respectively, 95, 4 and 1. The test results obtained are listed in Table I. EXAMPLE 3 The procedure of Example 1 was repeated exactly, except that the weight parts of polycarbonate, acrylate copolymer and DNHA in the test specimens were, respectively, 94.5, 4 and 1.5. The test results obtained are listed in Table I. EXAMPLE 4 The procedure of Example 1 was repeated exactly, except that the weight parts of polycarbonate,acrylate copolymer and DNHA in the test specimens were, respectively, 96, 3 and 1. The test results obtained are listed in Table I. TABLE I Impact Strength, ft. lb./in. 1/4" Thick 1/8" Thick 1/8", Heat Aged at 125°C D/B C ** Composition of: Not Aged Not Aged 24 hrs. 48 hrs. 1/8", Not Aged Example 1 12.B 1 * 12.0 1 12.6 1 -12/-18 Example 2 11.6 1 15.3 1 11.9 1 11.0 1 -12/-18 Example 3 10.7 1 15.3 1 12.6 1 12.3 1 -12/-18 Example 4 3.7 2 15.3 1 2.6 2 2.5 2 * CONTROL 1.6 2 14.8 1 1.3 2 * >-5 I 00 I 1 Samples failed with 100% ductility. 2 Samples failed with 0% ductility. * Test not made. ** Change from ductile mode of failure to brittle mode of failure noted over indicated range.

Claims: Clai s 1. A ternary polycarbonate composition comprising in admix¬ ture, a high molecular weight aromatic polycarbonate, a minor amount of an acrylate copolymer which is a copolymer of a C-^-Cg acrylate and a C- -C5 methacrylate, and a minor amount of an organ¬ ic, ester- ype plasticizer. 2. The composition of claim 1 wherein said acrylate copoly¬ mer is present in an amount of about 2 - 4 parts by weight per hundred parts of aromatic polycarbonate. 3. The composition of claim 1 wherein said-organic, ester- type plasticizer is present in an amount of about 0.4 - 2.0 parts by weight per hundred parts of aromatic polycarbonate. 4. The composition of claim 3 wherein said organic, ester- type plasticizer is present in an amount of about 0.5 - 1.5 parts by weight per hundred parts of aromatic polycarbonate. 5. The composition of claim 1 wherein the acrylate portion of said acrylate copolymer is selected from the group consisting of ethyl acrylate, n-butyl acrylate, l f S^-butylene diacrylate, iso¬ butyl acrylate, 1,4-butanediol diacrylate and methyl acrylate and the methacrylate portion of said acrylate copolymer is selected from the group consisting of methyl methacrylate, 1,3 butylene dimethacrylate, isobutyl methacrylate, butyl methacrylate and ethyl methacrylate. 6. The composition of claim 5 wherein the aromatic polycar¬ bonate is derived from 2,2-bis (4-hydroxyphenyl)propane. 7. The composition of claim 5 wherein the weight ratio of acrylate: methacrylate in said acrylate copolymer ranges from about 15-50: 50-85. 8. The composition of claim 1 wherein said organic, ester- type plasticizer is a member selected from the group consisting of azelate esters, adipate esters, and phthalate esters. TITUTE SHEET OMPI 9. A ternary polycarbonate composition comprising an admix¬ ture of a high molecular weight aromatic polycarbonate; an acry¬ late copolymer in an amount of about 2-4 parts by weight per hun¬ dred parts of said aromatic polycarbonate, said acrylate copoly- mer being a copolymer of a acrylate and a C1-C5 methacrylate, said acrylate being a member selected from the group consisting of methyl acrylate, ethyl acrylate, n-butyl acrylate, 1,3-butylene diacrylate, isobutyl acrylate, and 1, -butanediol diacrylate, and said methacrylate being a member selected from the group consist- ing of methyl methacr late, ethyl methacrylate, butyl methacrylate, isobutyl methacrylate, and 1,3-butylene dimethacrylate; and, an organic, ester-type plasticizer in an amount, of about 0.4 - 2.0 parts by weight per hundred parts of said aromatic polycarbonate and selected from the group consisting of azelate esters, adipate esters, and phthalate esters. 10. The composition of claim 9 wherein said aromatic polycar¬ bonate is derived from 2,2-bis(4-hydroxy phenyl)propane. 11. The composition of claim 9 wherein said organic, ester- type plasticizer"is present in an amount of about 0.5 - 1.5 parts by weight per hundred parts of said aromatic polycarbonate. 12. The composition of claim 9 wherein the weight ratio of acrylate: methacrylate in said acrylate copolymer ranges from about 15-50: 50-85. SUBSTITUTE SHEET O-vTPI

Inventors: LIU PING YUAN, LIU, PING, YUAN
Applicants: GEN ELECTRIC, GENERAL ELECTRIC COMPANY
Application year: 1981
Main classification: C08L69
IPC codes: C08K5, C08L69