POLYSULFONE-POLYPHOSPHONATE MOLDING COMPOSITIONS

Abstract: A thermoplastic composition comprising polysulfone and polyphosphonate is provided characterized by its ther­ mal stability and flame resistance. A preferred embodiment additionally comprising an acrylic rubber interpolymer com­ posite is characterized by its improved impact strength. The compositions are particularly suitable as thermoplastic molding compositions.

Description: POLYSULFONE-POLYPHOSPHONATE MOLDING COMPOSITIONS FIELD OF THE INVENTION The present invention relates to flame retardant polyblends and more particularly to blends comprising polysulfone and polyphosphonates. BACKGROUND OF THE INVENTION Among the key properties of polysulfones are their ability to withstand long periods of exposure to elevated temperatures in air and in water and their processability by conventional thermoplastic techniques. These and other mechanical and physical properties render these resins exceptionally well suited for applica- tions in hostile environments. One deficiency which tends to limit their use has been their relatively poor flame resistance. The addition of halogen containing flame retarding agents to polysulfones, although improving their flammability rating (UL94, V-O), presents a drawback in that the high temperatures required in the thermoplastic processing of polysulfones may cause a decomposition of the additives and consequential poor properties of the molded part. Polyphosphonates, characterized by their high level of flame retardance and mechanical properties, have been disclosed in U.S. Patents 2,682,522; 2,716,101; 2,891,915; 3,719,727; 3,919,363; 3,946,093; and 4,046,724; as well as in DAS 1,569,340 and in DOS 2,458,967 and 2,461,658. U.S. Patent 4,065,517 discloses polysulfone-polyarylphosphonate compositions having lesser flame retarding properties than the compositions of the present invention. It has now been found that a composition comprising polysulfone and certain polyphosphonate exhibits a profile of properties which render it attractive for a host of applications where the selection criteria entails flame resistance and thermal stability. BRIEF DESCRIPTION OF THE INVENTION A thermoplastic composition comprising polysulfone and polyphosphonate is provided characterized by its thermal stability and flame resistance. A preferred embodiment additionally comprising an acrylic rubber interpolymer composite is characterized by its improved impact strength. The compositions are particularly suitable as thermoplastic molding compositions. DETAILED DESCRIPTION OF THE INVENTION In the context of the present invention thermoplastic polysulfone resins are polymeric materials. having a basic structure composed of recurring units of the EMI2.1 <tb> formula <tb> <SEP> /\Ofl/\ <tb> <SEP> z <tb> where Y is the radical residuum of a dihydric polynuclear phenol having an aliphatic moiety in its backbone remaining after the removal of both OH groups and z is an integer denoting the degree of polymerization and has a value sufficiently large to afford a normally solid polymer preferably greater than 50 and most preferably from about 50 to about 80. Specific examples of dihydric polynuclear phenols which can be used to provide the Y component include: 2,2-bis(4hydroxyphenyl)propane; 2,4'-dihydroxydiphenylmethane; bis-(2-hydroxyphenyl)methane; bis-(4-hydroxyphenyl) methane; bis-(4-hydroxy-2,6-dimethyl-3-methoxyphenyl) methane; l,l-bis-(p-hydroxyphenyl)ethane; 1,2-bis-(4hydroxyphenyl)ethane; l,l-bis-(4-hydroxy-2-chlorophenyl) ethane; l,l-bis-(3-methyl-4-hydroxyphenyl)ethanei 1, 3-bis- (3-methyl-4-hydroxyphenyi) -propane; 2,2-bis-(3 isopropyl-4-hydroxyphenyl)¯propane; 2, 2-bis- (2-isopropyl- 4-hydroxyphenyl)propane; 2,2-bis-(4-hydroxynaphthyl) propane; 2,2-bis-(4-hydroxyphenyl)pentane; 3,3-bis-(4hydroxyphenyl)pentane; 2,2-bis-(4-hydroxyphenyl)heptane; bis- (4-hydroxyphenyl) phenylmethane; bis-(4-hydroxyphenyl) cyclobexylmethane; 1,2-bis-(4-hydroxyphenyl)1,2-bis (phenyl)-propane; 2, 2-bis- (4-hydroxyphenyl) -1-phenyl- propane; 1,1-bis-(4-hydroxyphenyl)cyclohexane; 4,4dihydroxydiphenyl sulfone and the like. The preferred polysulfones from the standpoint of both usefulness and availability are those containing the repeating units: EMI3.1 The preparation of polysulfone resins suitable in the practice of the invention is described, inter alia, in U.S. 3,658,938, 4,008,203, 3,948,857, 4,127,713, 4,009,149, 3,708,454, 4,108,837 and 4,094,867 and in the article High Use Temperature Polyarylsulfones by G. T. Kwiatkowski et al in High Performance Plastics, National Technical Conference, SPE 1976, p. 59-61, all being incorporated herein by reference. Among the preferred polysulfones suitable in the practice of the invention are those available from Union Carbide Corporation under the registered trademark UdelO , for instance Udele P 1700 and Udels P 3500 having 5O respectively 8O repeating units oQ above formula, The thermoplastic polyphosphonates suitable in the context of the present invention are branched or unbranched aromatic polyphosphonates having a number average molecular weight of from 11,000 to about 220,004 preferably from 13,000 to 40,000 (the molecular weights being determined by membrane osmosis using membranes which are permeable to particles having a molecular weight of up to 3,000) and characterized by the recurring structures: EMI4.1 and in that the terminal members bound to the phosphorus in structures (1) and (2) are either of: EMI4.2 and in that the terminal members bound to the oxygen in structures (1) and (2) are any of: EMI4.3 The proportion of (2) based on the sum of (1) and (2) amounts to between 0.001 and 3 mole percent. In the above R1 represents at least one of the radicals: C1-C12 alkyl; C2-C12 alkenyl; C6 C30 cycloalkyl, C6-C30 cycloalkenyl, C7,-C30 arylalkyl or C-C30 arylalkenyl, the aryl group in each case being unsubstituted or substituted by 1 to 5 C1-C4 alkyl groups or by 1 to 5 halogen atoms (fluorine, chlorine or bromine) or by the above-mentioned alkyl groups and halogen atoms; X represents at least one of the following radicals: phenylene EMI5.1 biphenylene EMI5.2 C1-C4 alkylene bis-phenylene EMI5.3 alkylene EMI5.4 C5-C12 cycloalkylene bis-phenylene EMI5.5 cycloalkylene EMI5.6 thio-bis-phenylene EMI5.7 oxy-bis-phenylene EMI5.8 sulfonyl-bis-phenylene EMI5.9 carbonyl-bis-phenylene EMI5.10 and naphthylene EMI5.11 wherein each phenyl nucleus may be unsubstituted or substituted by 1 to 4 C1-C4 alkyl groups or by 1 to 4 halogen atoms (fluorine, chlorine or bromine) or by any of the above-mentioned alkyl groups and halogen atoms and wherein the naphthylene nucleus may be unsubstituted or substituted by 1 to 6 of at least one of the above-mentioned groups or atoms; Y represents a trifunctional or tetrafunctional residue of a trifunctional mononuclear or trifunctional or tetrafunctional polynuclear phenol from which the phenolic hydroxyl groups have been removed in the case of the polynuclear phenol, the aromatic nuclei carrying one or two phenolic hydroxy groups are connected by aliphatic C1-C7 hydrocarbon radicals or by at least one benzene radical; Y represents X where c = 0, a = 1, b = 1 and, at the same time, R2 = Y' --4O-X-O-)c " or R2 = X with Y1 = Y and c' = 1 or 2; a = P or 1, b = 0 or 1; c = 0 or 1 or 2, preferably 1 or 2; R2 = R1 where a and b are each 0, in which case Y must represent a trifunctional or tetrafunctional radical, as defined above; R2 represents EMI6.1 where a = I and b = 0, in which case Y must represent a trifunctional or tetrafunctional radical, as defined above; R2 represents X or Y' C-X-O)c where both a and b are 1; D represents the same or different groups and represents a C1-C alkyl group or halogen (F, CI or Br) and p = 0 or a number of from 1 to 5, preferably p = 0. The preferred embodiment is halogen free wherein R1 represents at least one of the radicals methyl or ethyl, particularly methyl; X represents at least one of the radicals phenylene, biphenylene, C1-C4 alkylene bis-phenylene, in which case each phenyl nucleus may be substituted by 1 to 4 methyl groups, cyclohexylene-bisphenylene, oxy-bis-phenylene, thio-bis-phenylene, sulfonyl-bis-phenylene, particularly C1-C4 alkylenebis-phenylene, in which case each phenyl nucleus may be substituted by one or two methyl groups; Y represents a trifunctional or tetrafunctional residue of a trifunctional mononuclear or trifunctional or tetrafunctional polynuclear phenol from which the phenolic hydroxyl groups have been removed; in the case of the polynuclear phenol, the aromatic nuclei carrying one or two phenolic hydroxy groups may be connected by aliphatic C1-C7 hydrocarbon radicals- or by at least one benzene radical; a = O or the number 1; b = O or the number 1; c = one of the numbers 1 or 2; R2 = R1 where a and b are each 0; R2 represents EMI7.1 where a = 1 and b = 0; R2 represents X or Y'-(O-X-O-)c, where a and b are each the number 1; D represents the same or different groups selected among a C1-C4 alkyl group and p = 0 or a number of from 1 to 5, more particularly p = 0. In the Examples that follow, percentages are by weight, relative to the weight of the compositions. EXAMPLES Examples 1-5 In the practice of the invention, a composition comprising at least 3 percent, preferably 5 to 50 percent, of polyphosphonate and at least 50 percent, preferably 50 to 95 percent, most preferably from 65 to about 95 percent of polysulfone is prepared by blending upon melting, such as by coextrusion. Table 1 summarizes the properties of a series of compositions prepared by coextrusion at 3000C, wherein the polysulfone used was Udele P-1700 and the polyphosphongte was poly-(4,4'-dioxydiphenyl)-methylphosphonate, having a relative viscosity of 1.404 as measured in a 0.5% solution of CH2C12 at 250C. Table 1 1 2 3 4 5 polysulfone, % wt. 100.0 95.0 94.0 93.0 80.0 Polyphosphonate, % wt. 0.0 5.0 6.0 7.0 20.0 HDr( C), 1.82 MPa 172 164 163 162 156 UL-94, 1/8", 3,18 mm failed V-0 V-0 V-0 V-0 UL-94, 1/16", 1,59 mm failed V-1 V-0 V-0 V-0 UL-94, SV, 1/8", 3,18 mm failed failed passed passed passed Impact strength, Izod Unnotched, Jlm 1/8", 3, 18mm 1518 1542 1530 1572 1432 Unnotched, J/m 1/4" 6,35mm 831 861 835 816 836 Tensile yield strength, MPa 72.8 74.7 74.0 73.0 75.4 Flexural strength, MPa 60.5 108 109 110.8 67.0 Flexural Modulus, GPa 2.40 2.60 2.62 2.65 2.80 Examples 6-10 Table 2 summarizes the results obtained upon evaluating compositions prepared in accordance with the invention where the polysulfone was Udel@ P-3500. Coextrusion was carried out at 3100C and the polyphospho @nate was poly-(4,4'-dioxydiphenyl)-methylphosphonate, having a relative viscosity of 1.404 as measured in a 0.5% solution of CH2C12 at 250C. Table 2 6 7 8 9 10 Polysulfone, % wt. 100 95.0 94.0 92.0 90.0 Polyphosphonate, % wt. 0 5.0 6.0 8.0 10.0 HDr(0C), 1.82 MPa 172 171 169 165 162 UL-94, 1/8", 3,18 mm V > 2 VL0 V-0 V-0 V-0 Ul-94, V16, 1,59 mm failed WO v-0 V-0 V-0 UL-94, 5V, l/8 3,18 mm failed passed passed passed passed Imact Strength, Izod Unnotched, JAn 1/8, 3,18 mm 1567 1550 1543 1547 1588 Unnotched, J/m 1/4" ,6,35 mm 819 813 808 818 839 Tensile yield stren@th, MPa 72.1 74.0 73.2 73.6 74.0 Flexural stnffluth, MPa 103.7 107.5 108.0 109.0 115.0 Flexural Modulus, GPa 2.48 2.50 2.49 2.68 2.75 In a preferred embodiment of the invention, an acrylic rubber interpolymer composite is introduced in the composition as described above. Acrylic rubber interpolymer composites are described in U.S. Patents 3,808,180 and 4,096,202, both incorporated by reference herein. Briefly, the technology described therein is that of the preparation of a specific class of multiphase compounds termed impact modifiers. The impact modifier is a multiphase composite interpolymer comprising about 25 to 95 weight percent of a first elastomeric phase and about 75 to 5 weight percent of a final rigid thermoplastic phase. One or more intermediate phases are optional, for example, a middle stage polymerized from about 75 to 100 percent by weight styrene. The first stage is polymerized from about 75 to 99.8 weight percent C1 to C6 acrylate resulting in an acrylic rubber core having a Tg below about 100C and cross-linked with 0.1 to 5 weight percent cross-linking monomer and, further, containing 0.1 to 5 percent by weight graft-linking monomer. The preferred alkyl acrylate is butyl acrylate. The crosslinking monomer is a polyethylenically unsaturated monomer having a plurality of addition polymerizable reactive groups all of which polymerize at substantially the same rate of reaction. Suitable cross-linking monomers include polyacrylic and polymethacrylic esters of polyols such as butylene diacrylate and dimethacrylate, trimethylol propane trimethacrylate, and the like; diand trivinyl benzene, vinyl acrylate and methacrylate, and the like. The preferred cross-linking monomer is butylene diacrylate. The graft-linking monomer is a polyethylenically unsaturated monomer having a plurality of addition polymerizable reactive groups, at least one of which polymerizing at a substantially different rate of polymerization from at least one other of said reactive groups. The function of the graft-linking monomer is to provide a residual level of unsaturation in the elastomeric phase, particularly in the latter stages of polymerization and, consequently, at or near the surface of the elastomer particles. When the rigid thermoplastic phase is subsequently polymerized at the surface of the elastomer, the residual unsaturated addition polymerizable reactive group contributed by the graft-linking monomer participates in the subsequent reaction so that at least a portion of the rigid phase is chemically attached to the surface of the elastomer. Among the effective graft-linking monomers are allyl group-containing monomers of allyl esters of ethylenically unsaturated acids such as allyl acrylate, allyl methacrylate, diallyl maleate, diallyl fumarate, diallyl itaconate, allyl acid maleate, allyl acid fumarate, and allyl acid itaconate. The preferred graft-linking monomers are allyl methacrylate and diallyl maleate. A most preferred interpolymer has only two stages, the first stage comprising about 60 to 95 percent by weight of the interpolymer and being polymerized from a monomer system comprising 95 to 99.8 percent by weight butyl acrylate, 0.1 to 2.5 percent by weight butylene diacrylate as cross-linking agent, 0.1 to 2.5 percent by weight allyl methacrylate or diallyl maleate as a graft-linking agent with a final stage polymerized from about 60 to 100 percent by weight methyl methacrylate. The final stage monomer system can be comprised of C1 to C16 methacrylate, styrene, acrylonitrile, alkyl acrylates, allyl methacrylate, diallyl methacrylate, and the like, as long as the over Tg is at least 200C. Preferably, the final stage monomer system is at least 50 weight percent C1 to C4 alkyl methacrylate. It is further preferred that the final stage polymer be free of acid, hydroxyl amino and amide groups. A certain such acrylic rubber interpolymer composite characterized in that acrylic rubber core is comprised of n-butyl acrylate and in that its crosslinking agent is 1,3-butylene diacrylateand in which the fraft-linking agent is diallyl maleate and the second phase monomeric system of which is methyl methacrylate was discovered to have an unexpected and profound effect on the impact performance of the presently disclosed blends of polysulfone and polyphosphonates. The acrylic rubber interpolymer composite used in the course of the experiments described below is available under the trademark Acryloido KM-330 from the Rohm and Haas Company of Philadelphia, Pennsylvania and may be characterized by the weight ratios of its constituents as follows: n-butyl acrylate/1.3 butylene diacrylate/ diallyl maleate/methyl methacrylate = 79.2/0.4/0.4/20.0. In the preferred practice of the invention a blend of polysulfone, polyphosphonate and acrylic rubber interpolymer composite was found to exhibit a surprising and unexpected high level of flame retardance coupled with an improved impact performance. The blend may contain from about 2 to about 20 percent, preferably 6 to 15 percent of the acrylic rubber interpolymer composite, about 50 to 97 percent of polysulfone and about 1 to 30 percent polyphosphonate. The percentages noted above are relative to the weight of the blend. The Examples set out below will serve to demonstrate the preparation of the blends of the preferred embodiment of the invention and the properties of articles molded thereof. Examples 11-15 Blends of polysulfone, polyphosphonate and acrylic rubber interpolymer composite were prepared by coextrusion at 2700C. The properties thereof are tabulated below and are compared to those of polysulfone resin, Udele P 1700 and to those of a blend of polysulfone and polyphosphonate. Table 3 11 12 13 14 15 Composition, wt. % polysulfonate(1) 100 94.0 84.0 80.0 78.0 polyphosphonate (2) - 6.0 10.0 10.0 10.0 interpolymer composite(3) - - 6.0 10.0 12.0 Properties Heat distortion temperature(4) OC (1.82 MPa) 172 163 156 156 155 Flammability rating, UL 94 1/8", 3,18 mm failed V-0 V-0 V-0 V-0 1/16", 1,59 mm failed V-0 V-0 V-0 V-0 5V, 1/8", 3,18 mm failed passed passed passed passed Impact strength, Izod(5) (J/m) notched 1/8", 3,18 mm 63 59 71 171 232 notched 1/4", 6,35 mm 60 60 62 132 134 unnotched 1/8", 3,18 mm 1518 1530 1545 1556 1525 unnotched 1/4", 6,35 mm 821 835 817 812 819 Tensile strength, MPa 72.8 74.0 57.0 51.0 46.0 Flexural strength, MPa 60.5 109.0 102.0 86.0 87.3 Flexural modulus, GPa 2.40 2.62 2.56 2.46 2.32 (1)Udel# P P 1700, a product by Union Carbide Corporation (2)Poly-(4,4'-dioxydiphenyl)-methylphosphonate, having a relative viscosity of 1,404 as measured in a 0.58 solution in CH2Cl2 at 25 C (3)Acryloid# KM-330, a product of Rohm and Haas Company (4)Per ASTM D-648 (5)Per ASTM D-256 Examples 16-21 Blends comprising Udel P 3500 polysulfone and an acrylic rubber interpolymer composite, Acryloid# KM 330 were prepared by coextrusion at 2900C and compared to (Example 21) a ternary blend where ABS (ABSON 822 from Mobay Chemical Corporation) was substituted for Acryloid# KM 330. The properties of these, set in comparison to those of polysulfone (Example16) and of a binary blend of polysulfone and polyphosphonate are tabulated below. Table 4 16 17 18 19 20 21 Composition, wt.% polysulfone (1) 100 95.0 80.0 z0 79.0 77.0 z0 78.0 polyphosphonate(2) - 5.0 9.0 9.0 10.0 10.0 interpolymer composite(2) - 0 11.0 12.0 13.0 ABS(4) - - - - - 12.0 Properties Heat distortion temperature C, at 1.82 MPa (5) 172 171 161 159 158 159 Flammability ratinq, UL-94 1/8". 3,18 mm V-2 V-0 V-0 V-0 V-0 V-0 1/16", 1,59 mm failed V-0 V-0 V-0 V-0 V-1 UL-94, 5V, 1/8", 3, 18failed passed passed passed passed failed Impact strength, mm (J/m) (6) notched 1/8", 3,18mm 68 64 193 235 248 49 notched 1/4", 6,35mm 65 53 179 200 212 44 unnotched 1/8",3,18mm1567 1550 1460 1416 1481 681 unnotched 1/4", 6,35mm819 813 805 800 801 550 Tensile strength, MPa 72.1 74.0 36.8 33.4 48.8 57.9 Flexural strength, MPa 103.7 107.5 93.1 87.2 86.5 101.7 Flexural modulus, GPa 2.48 2.50 2.29 2.17 2.10 2.52 (1)Udel# P 3500 (2)Poly-(4,4'-dioxydiphenyl)-methylphosphonate, having a relative viscosity of 1.404 measured in a 0.58 solution in CH2Cl2 at 250C (3)Acryloid# KM 330 (4)ABSON 822 from Mobay Chemical Corporaton; suspension ABS comprising 6-7% polybutadiene, 14-16% acryloni trile and 76-78% styrene. Per ASTM D-648 (6)per ASTM D-256 Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.

Claims: WHAT IS CLAIMED IS: 1. A molding composition comprising (a) thermoplastic polyphosphonate characterized by the recurring structural units EMI17.1 wherein R1 denotes a member selected from the group consisting of C1-C12 alkyl, C2-C12 alkenyl, C6-C30 cycloalkyl, C6-C30 cycloalkenyl, C-C30 arylalkyl and CC30 arylalkenyl wherein all aryl groups are unsubstituted or substituted by 1 to 5 C1-C4 alkyl groups or halogens or both and X is selected from the group consisting of phenylene, biphenylene, C1-C4 alkylene bis-phenylene, C5-C12 cycloalkylene bis-phenylene, thio-bis-phenylene, oxy-bis-phenylene, sulfonyl-bis-phenylene, carbonyl-bisphenylene and naphthylene wherein any phenyl nucleus and naphthylene nucleus is either unsubstituted or substituted by a C1- C4 alkyl or halogen atom or by both alkyl and halogen atoms and (b) a thermoplastic polyarylsulfone. 2. The composition of Claim 1 wherein said R1 is methyl. 3. The composition of Claim 1 or 2 wherein said X is diphenyl. 4. The molding composition of Claim 1 wherein said polyarylsulfone is present in an amount of about 50 to 95 percent and said polyphosphonate is present in an amount of about 5 to 50 percent, said percents being relative to the weight of said composition. 5. A molding composition comprising a) a thermoplastic polysulfone characterized by the recurring structural units: EMI18.1 wherein Y is a radical residuum of a dihydric polynuclear phenol having an aliphatic moiety in its backbone and b) a polyphosphonate characterized by the recurring structural units: : EMI18.2 wherein R1 denotes a member selected from the group consisting of C1-C12 alkyl, C2-C12 alkenyl, C6-C cycloalkyl, C6-C30 cycloalkenyl, 9 -C30 arFlalkyl and Ca-C30 arylalkenyl wherein all aryl groups are unsubstituted or substituted by 1 to 5 C1-C4 alkyl groups or halogens or both and X is selected from the group consisting of phenylene, biphenylene, C1-C4 alkylene bis-phenylene, C5-C12 cycloalkylene bis-phenylene, thio-bis-phenylene, oxy-bis-phenylene, sulfonyl-bis pheny lene, carbonyl-bis-phenylene and naphthylene wherein any phenyl nucleus and naphthylene nucleus is either unsubstituted or substituted by a C1-C4 alkyl or halogen atom or by both alkyl and halogen atoms and c) an acrylic rubber interpolymer composite comprising i) about 25 to 95 percent by weight of a first elastomeric phase polymerized from a monomer system comprising about 75 to 99.8 percent by weight n-butyl acrylate, 0.1 to 5 percent by weight cross linking member, 0.1 to 5 percent by weight graft-linking monomer, and ii) about 75 to 5 percent of a second rigid thermoplastic phase polymerized in the presence of said elastomeric phase. 6. The molding composition of Claim 5 wherein said polysulfone is present in an amount of about 50 to 97 percent, said polyphosphonate is present in an amount of about 1 to 30 percent and said acrylic rubber interpolymer composite is present in an amount of about 2 to 20 percent, said percents being relative to the weight of said ternary composition. 7. The molding composition of Claim 5 or 6 wherein said cross-linking member is 1,3-butylene memDer diacrylate, said graft-linking/is diallyl maleate and said second, rigid thermoplastic phase is methyl methacrylate. 8. The molding composition of Claim 7 wherein said butyl acrylate, 1,3-butylene diacrylate, diallyl maleate and methyl methacrylate relate to each other, by weight, as 79.2 to 0.4 to 0.4 to 20.0.

Inventors: SCHMIDT, MANFRED, DR.
Applicants: MOBAY CORPORATION
Application year: 1982
Main classification: C08L81
IPC codes: C08L81, C08L85, C08L51, C08L33