POLYETHYLENE TEREPHTHALATE/POLYCARBONATE BLENDS HAVING A LOW LEVEL OF WARPAGE

Abstract: The present invention is directed to thermoplastic mold­ ing compositions comprising poly(ethylene terephthalate), aromatic polycarbonate, a certain graft modified rubber, and an amount of added talc sufficient to control the warpage of the composition and to maintain a high level of impact strength.

Description: POLYETHYLENE TEREPHTHALATE/POL?dARBONATE BLENDS HAVING A LOW LEVEL OF WARPAGE FIELD OF THE INVENTION The invention relates to thermoplastic compositions and, in particular, to blends containing poly (ethylene terephthalate), polycarbonate, an elastomeric graft and talc. SUMMARY OF THE INVENTION The present invention is directed to thermoplastic molding compositions comprising poly(ethylene terephthalate), aromatic polycarbonate, a certain graft modified rubber, and an amount of added talc sufficient to control the warpage of the comppsition and to maintain a high level of impact strength. BACKGROUND OF THE INVENTION Compositions consisting of aromatic polyester, polycarbonate and butadiene based core-shell polymers were disclosed in U.S. Patent 3,864,428. U.S. Patent 4,180,494 is noted to disclose similar systems which are said to offer improved solvent resistance. Compositions containing a graft copolymer of alkyl acrylate and/or alkyl methacrylate in combination with a saturated polyester resin and a polycarbonate resin have been disclosed in Japanese Kokai 53-129246. Talc, in combination with silica, has been disclosed in U.S. Patent 4,140,669 to bring about a reinforcement and warp resistance in polyalkylene terephthalate resins. U.S. 3,975,355 is noted to disclose sheets containing PET, polycarbonate and silica. The HDT of certain polyesters is disclosed to be improved upon the addition of talc in accordance with U.S. Patent 3,859,246. U.S. Patent 4,299,928 is noted to teach compositions comprising a polycarbonate resin and an acrylic rubber interpolymer composite. Importantly, the compositions disclosed in the above-mentioned U.S. Patent 3,864,428 were found to warp upon post-molding heat treatment, such as upon automotive off-line painting. The present invention concerns thermoplastic molding compositions comprising an aromatic polyester, an aromatic polycarbonate, a graft modified rubber and an additive amount of finely divided talc sufficient to control the warpage of articles molded therefrom, yet have substantially no effect on the level of their impact strength. DETAILED DESCRIPTION OF THE INVENTION AND ITS PREFERRED EMBODIMENTS In the present context, the term polyethylene terephthalate (PET) means both the homopolymer of ethyleneglycol and terephthalic acid as well as copolymers wherein some (i.e. up to 30%) of the ethylene glycol resins were replaced by ether diol residues having 3 to 8 carbon atoms or by C6-C15 cycloaliphatic diols, or by Cl-C2l aromatic diols. Examples of such additional diols ("codiols") include 3-methylpentanediol-(2,4), 2-methylpentanediol (1,4), 2,2,4-trimethylpentanediol-(1,3), 2-ethylhexanediol-(1,3), 2, 2-diethylpropanediol- (1,3), hexanediol (1,3), 1,4-di-(8-hydroxyethoxy)-benzene, 2,2-bis-(4hydroxycyclohexyl)-propane, 2,4-dihydroxy-1,1,3,3- tetramethyl-cyclobutane, 2,2-bis-(3-B-hydroxyethoxy- phenyl)-propane and 2,2-bis-(4-hydroxypropoxyphenyl)propane. Typical examples of the diol include poly methylene-a,-diols such as trimethylene glycol, tetramethylene glycol and hexamethylene glycol, neopentyl glycol, cyclohexane dimethylol, tricyclodecane dimethylol, 2,2-bis-(4-ss-hydroxyethoxypheny1)-propane, 4,4'-bis-(ss- hydroxyethoxy) -diphenylsulfone, and diethylene glycol. Further included within the scope are copolymers wherein some (up to about 15%) of the terephthalic acid residues are replaced by other dicarboxylic acid residues including isophthalic acid, naphthalenedicarboxylic acid, diphenylether dicarboxylic acid, diphenyldicarboxylic acid, diphenylsulfone dicarboxylic acid and diphenoxyethane dicarboxylic acid, as well as by aliphatic dicarboxylic acids such as succinic acid, adipic acid and sebacic acid. The preferred polyethylene terephthalate resins are characterized in that their structure comprises units EMI3.1 <tb> of <SEP> the <SEP> general <SEP> formula <tb> <SEP> 0 <tb> <SEP> I1 <tb> -O-CH2CH2-O-C The polyesters may be branched by incorporating trihydric or tetrahydric alcohols or tribasic or tetrabasic acids' as described in German Offenlegungsschrift 1,900,270 and in U. S. Patent 3,692,744. Examples of suitable branching agents include trimesic acid, pyromellitic acid, trimethylolpropane and ethane, and pentaerythritol. It is advisable to use no more than 1 mol percent of branching agent, based on the quantity of acid component. The polyesters may also contain known monofunctional compounds such as phenol or benzoic acid as chain terminators. The intrinsic viscosity characterizing the suitable polyester resins in the practice according to the invention should preferably be in the range of 0.4 to 1.4 grams per deciliter and, more preferably, between 0.4 and 1.2 grams per deciliter, as measured usinq a solution of 0.1 gm of resin per 25 ml of a 1:1 mixture of trifluoroacetic acid and dichloroethane at 300C. Methods for the preparation of the polyester resin suitable in the present context are known and have been described in U. S. Patents 2,465,319 and 3,047,539. The composition of the invention may include crystallization rate promoters for the polyester (such as oligomeric polyesters) to allow lower mold temperatures and shorter injection cycles. Suitable promoters have been taught in U. S. Patent 4,223,113 which disclosure is incorporated herein by reference. Preferred oligomeric polyesters are those which are derived from the following acids and alcohols: di- and tricarboxylic acids, adipic acid, azelaic acid, citric acid C(OH) (COOH) (CH2COOH)2, fumaric, maleic acid HOOCHC=CHCOOH,glutaric acid, phthalic, isophthalic, terephthalic acid, trimellitic acid, trimesitinic acid, succinic acid, tartaric acid HOOC(CHOH)2COOH sebacic acid, monocarboxylic acids, cresotoic acid, salicyclic acid, acetic acid, isobutyric acid, caproic acid, caprylic acid, pelargonic acid, 2-ethylhexanoic acid, lauric acid, myristic acid, palmitic acid, stearic acid, oleic acid CH3(CH2)7CH=CH(CH2)7COOH, ricinolic acid CH3(CH2)3CH(OH)CH2CH=CH(CH7COOH), 2- ethylbutyric acid, behenic acid, benzoic acid, abictic acid, 2-phenylbutyric acid, tall oil, fatty acid, diand higher functional alcohols, ethylene glycol, propane diol 1,3/1,2, butanediol 1,3/1,4, pentanediol 1,5, hexanediol 1,6, dipropylene glycol 1,3/1,2, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycol Mn 400, neopentyl glycol HO-CH2-C(CH3)2-CH2OH, glycerol HOCH2-CHOH-CH2OH, trimethylolethane CH3C(CH2OH)3, trimethylolpropane C2H5C(CH2OH)3, pentaerythritol C(CH2OH)4, 2,2,4trimethyl-1,3-pentanediol, sucrose, monofunctional alcohols' 2-ethylhexanol, isonol, tertiary butanol, methanol, isopropanol EMI5.1 octylbenzyl alcohol, butyl alcohol, isobutyl alcohol, 2-ethylhexanol, isononyl alcohol, n-octyl alcohol, iso-octyl alcohol, n-decyl alcohol, isodecyl alcohol, butoxyethyl alcohol CH3(CH2)3-O(CH2)2OH, butoxyethyloxyethyl alcohol CH3(CH2)3-O(CH2)2O(CH2)2OH, cyclohexylalcohol, EMI5.2 n-hexyl alcohol, tetrahydrofurfuryl alcohol, 2-butoxyethyl alcohol CH3-CH-(OCH2CH2OH)-CH2CH3, ethyl alcohol, amyl alcohol, n-undecyl alcohol, tridecyl alcohol, butylbenzyl alcohol, methylcyclohexyl alcohol, methoxyethyl alcohol, benzyl alcohol, allyl alcohol CH2=CH-CH2OH, hydrobietyl alcohol. Especially preferred oligomer polyester promoters are those using adipic acid or sebacic acid as the dicarboxylic acid, 2-ethylhexane-1,3-diol, 2,2,4trimethylpentane-1,3-diol, butane-1,3-diol, hexane-1,6diol or butane-1,4-diol as the diol component and 2ethylhexanol, 3,5,5-trimethylhexanol or n-butanol as the monohydric alcohol component. Particularly suitable oligomers are poly (butane-1,3-diol adipate), poly- (hexane-l, 6-diol adipate) and poly- (butane-1, 4-diol adipate). The polycarbonate resins useful in the practice of the invention are homopolycarbonates, copolycarbonates and terpolycarbonates or mixtures thereof. The polycarbonates generally have molecular weights of 10,000 - 200,000 (weight average molecular weight) preferably 20,000 - 80,000, and are additionally characterized by their melt flow of 1 - 24 gm/10 min. at 3000C per ASTM D-1238. These polycarbonates may be prepared, for example, by the known diphasic interface process from phosgene and dihydroxy compounds by polycondensation (see German OS 2,063,050; 2,053,052; 1,570,703; 2,211,956; 2,211,957 and 2,248,817 and French Patent 1,561,518 and the monograph, H. Schnell, Chemistry and Physics of Polycarbonates, Interscience Publishers, New York, 1964, all incorporated herein by reference). In the present context, dihydroxy compounds suitable for the preparation of the polycarbonates of the invention conform to the structural formulae (1) or (2) EMI6.1 wherein A denotes an alkylene group with 1 to 8 carbon atoms, an alkylidene group with 2 to 8 carbon atoms, a cycloalkylene group with 5 to 15 caron atoms, a cycloalkylidene group with 5 to 15 carbon atoms, a carbonyl group, an oxygen atom; S, -SO- or -SO2- radical; a radical of the general formula EMI7.1 g denotes the number 0 or 1; e denotes the number 0 or 1; Z denotes F, C1, Br or a C1-C2 alkyl and if several Z radicals are substituents in one aryl radi cal, they may be identical or different; d denotes 0 or an integer of from 1 to 4; and f denotes 0 or an integer of from 1 to 3. Among the useful dihydroxy compounds in the practice of the invention are hydroquinone, resorcinol, bis-(hydroxyphenyl)-alkanes, bis-(hydroxyphenyl)cycloalkanes, bis-(hydroxyphenyl)-ethers, bis-(hydroxyphenyl)-ketones, bis-(hydroxyphenyl)-sulfoxides, bis (hydroxyphenyl)-sulfones and a a-bis a,a-bis-(hydroxyphenyl)- diisopropyl-benzenes. These and further suitable aromatic dihydroxy compounds are described, for example, in U. S. Patents 3,028,365; 2,999,835; 3,148,172; 2,991,273; 3,271,367; and 2,999,846 (all incorporated herein by reference), in German Offenlegungsschriften (German Published Specifications) 1,570,703; 2,063,050; 2,063,052; 2,211,956 and in French Patent Specification 1,561,418 and in the monograph, H. Schnell, Chemistry and Physics of Polycarbonates, Interscience Publishers, New York, 1964. Further examples of suit able dihydroxy compounds are 2,2-bis-(4-hydroxyphenyl)propane (bishphenol A), 2,4-bis-(4-hydroxyphenyl)-2methylbutane, l,l-bis-(4-hydroxyphenyl)-cyclohexane, a,-bis-(4-hydroxyphenyl)-p-diisopropylbenzene, 2,2bis-(3-chloro-4-hydroxyphenyl)-propane, hydroxybenzophenone and 4,4'-sulfonyl diphenol. The most preferred dihydroxy compound is 2,2-bis-(4-hydroxyphenyl)-propane (bisphenol A). The polycarbonates of the invention may entail in their structure, units derived from one or more of the suitable dihydroxy compounds. The preparation of polycarbonate resins may be carried out in accordance with any of the processes known in the art, for example, by the interfacial polycondensation process, polycondensation in a homogeneous phase or by transesterification. The suitable processes and the associated reactants, catalysts, solvents and conditions are known in the art and have been described, inter alia, in the monograph by H. Schnell cited above. In the preparation of the polycarbonate resins of the invention, monofunctional reactants such as monophenols including 2,6-dimethylphenol, p-tert.butylphenol or 4-(1,1,3,3-tetramethylbutyl)-phenol, may be used in order to limit their respective molecular weights. Also, branching agents may be employed. Branching may be obtained by the incorporation of small amounts, preferably of between about 0.05 and 2.0 mol percent (relative to diphenols employed), of trifunctional or more than trifunctional compounds, especially compounds having three or more phenolic hydroxyl groups. Polycarbonates of this type are described, for example, in German Offenlegungsschriften (German Published Specifications) 1,570,533; 1,595,762; 2,116,974 and 2,113,347, British Specification 1,079,821 and U. S. Patent 3,544,514 (incorporated herein by reference). Some examples of compounds with three or more than three phenolic hydroxyl groups which can be used are phloroglucinol, 4,6-dimethyl-2,4,6-tri-(4-hydroxy- phenyl)-heptane, 2,4,6-trimethyl-2,4,6-tri-(4-hydroxy- phenyl)-heptane, 1,4,5-tri-(4-hydroxyphenyl)-benzene, l,l,l-tri-(4-hydroxyphenyl)-ethane, tri-(4-hydroxyphenyl)-phenylmethane, 2,2-bis[4,4-bis-(4-hydroxyphenyl)- cyclohexyl]-propane, 2,4-bis-(4-hydroxyphenylisopropyl)phenol, 2,6-bis- (2-hydroxy-5' -methylbenzyl) -4-methyl- phenol, 2-(4-hydroxyphenyl)-2-(2,4-dihydroxyphenyl)- propane, hexa (4- (4-hydroxyphenylisopropyl) -phenyl) - ortho-terephthalic acid ester, tetra-(4-hydroxyphenyl)methane, tetra- (4- (4-hydroxyphenylisopropyl) -phenoxy) - methane and 1,4-bis ((4' , 4"-dihydroxy-triphenyl) -methyl) - benzene. Some of the other trifunctional compounds are 2,4-dihydroxybenzoic acid, trimesic acid, cyanuric chloride and 3,3-bis-(4-hydroxyphenyl)-2-oxo-2,3dihydroindole. Among the resins suitable in the practice of the invention are included phenolphthalein based polycarbonate, copolycarbonates and terpolycarbonates such as are described in U. S. Patents 3,036,036 and 4,210,741, both incorporated by reference herein. Graft Modified Rubber In the context of the invention, the graft modified rubber is characterized in that its glass transition temperature is below 100C, preferably below OOC and further, in that its rubber elastic core comprises at least substantially of polybutadiene or a copolymer thereof. In these grafts, a monomer mixture phase of styrene or methylmethacrylate or mixtures thereof or mixtures of either of the above with acrylonitrile is graft polymerized onto a rubber. In principle, any rubber may be used as the graft backbone so long as its properties meet the glass transition criteria set out above. Crosslinking of the core is an optional feature of the graft modified rubber. Particularly suitable rubbers are polybutadiene, butadiene/styrene copolymers having up to 30% by weight of copolymerized styrene, copolymers of butadiene and acrylonitrile with up to 20% by weight of acrylonitrile, copolymers of butadiene with up to 20% by weight of a lower alkyl ester of an acrylic or a methacrylic acid (for example, methylacrylate, ethylacrylate, methylmethacrylate and ethylmethacrylate) The weight ratio of rubber to graft polymerized monomer is generally within the range of from 85:15 to 40:60. The impact modifying graft is present in the molding composition in the form of particles having an average size of from about 0.1 to about 5 microns. In regard to the grafts based on butadiene and its copolymers, these have been described in U. S. Patents 3,238,275 and in 3,919,353, both incorporated by reference herein. Essentially, the molecules of acrylonitrilebutadiene-styrene (ABS) graft polymers which are among the preferred embodiments of the invention, consist of two or more polymeric parts of different compositions chemically united. The graft polymers may be prepared by polymerizing at least one conjugated diene, such as butadiene, or a conjugated diene with a monomer polymerizable therewith, such as mentioned above to provide a backbone, with subsequent polymerization of at least one and preferably two, grafting monomers, in the presence of the prepolymerized backbone to complete the graft polymer. The backbone, as mentioned, is preferably a conjugated diene polymer or copolymer such as poly butadiene butadiene-styrene, butadiene-acrylonitrile or the like. A specific conjugated diene monomer which may be utilized in preparing the backbone of the graft polymer is generically described by the formula: EMI11.1 wherein X may be selected from the group consisting of hydrogen, alkyl groups containing from 1 to 5 carbon atoms, chloro and bromo. Examples of dienes that may be used are butadiene; isoprene; 1,2-hepta- diene; methyl-1,3-pentadiene; 2,3-dimethyl-1,3-butadiene; 1,3-pentadiene; 2-methyl-3-ethyl-1,3-butadiene; 2-ethyl-1,3-pentadiene; 1,3- and 2,4-hexadiene, chloro- and bromo-substituted butadienes such as dichlorobutadiene, bromobutadiene, chloroprene, dibromobutadiene, mixtures thereof and the like. The preferred conjugated diene utilized herein is butadiene. The first monomer or group of monomers polymerized in the presence of the prepolymerized backbone are preferably monovinyl aromatic hydrocarbons. Among the monovinyl aromatic monomers are those generically described by the formula: EMI11.2 wherein Y1-Y7 independently may be selected from the group consisting of hydrogen, alkyl groups containing from 1 to 5 carbon atoms, chloro and bromo. Examples of the preferred monovinyl aromatic compounds and substituted monovinyl aromatic compounds that may be used are styrene and other vinyl-substituted aromatic compounds including alkyl-, cycloalkyl-, aryl-, alkaryl-, aralkyl-, alkoxy-, arloxy- and other substituted vinyl aromatic compounds. Other suitable monomers include 4-methylstyrene; 3,5-diethylstyrene and 4-npropylstyrene, a-methylstyrene, ct-methylvinyltoluene, a-chlorostyrene, vinyltoluene, a-bromostyrene, chlorophenylethylenes, dibromophenylethylenes, tetrachlorophenylethylenes, l-vinylnaphthalene, 2-vinylnaphthalene, mixtures thereof and the like. The preferred monovinyl aromatic hydrocarbon used herein is styrene and/or a-methylstyrene. The second group of monomers that are polymerized in the presence of the prepolymerized backbone are acrylonitrile, substituted acrylonitrile and/or acrylic acid esters exemplified by acrylonitrile and alkyl acrylates such as methylmethacrylate. The acrylonitrile, substituted acrylonitrile or acrylic acid esters are described generically by the formula: EMI12.1 wherein Yg-Ylo independently may be selected from the group consisting of hydrogen, alkyl groups containing from 1 to 5 carbon atoms, chloro and bromo and Z is selected from the group consisting of cyano and carbalkoxy wherein the alkyl group of the carbalkoxy group contains Mo-2459 from 1 to about 12 carbon atoms. Examples of monomers of this description, i.e., acrylonitrile, substituted acrylonitrile or acrylic acid esters of the above formula are acrylonitrile, a-chloroacrylonitrile, 6-chloroacrylonitrile, a-bromoacrylonitrile and S-bromoacrylonitrile methylacrylate, methylmeth- acrylate, ethylacrylate, butylacrylate, propylacrylate, isopropylacrylate, isobutylacrylate, mixtures thereof and the like. The preferred acrylic monomer used herein is acrylonitrile and the preferred acrylic acid esters are ethyl acrylate and methyl methacrylate. In preparing the graft polymer of this invention, a certain percentage of the polymerizing monomers that are grafted on the backbone will occur as free copolymer. If styrene is utilized as one of the grafting monomers and acrylonitrile as the second grafting monomer, a certain portion of the composition will occur as styrene acrylonitrile copolymer. In certain instances, one of the first group, i.e., monovinyl aromatic monomers such as a-methylstyrene (or other monomer) is copolymerized with one of the second group, i.e., acrylonitrile, substituted acrylonitrile, etc., and a certain percentage of the composition is comprised of, for example, an a-methylstyrene acrylonitrile copolymer (or other copolymer). It is contemplated in this invention that the composition referred to as graft polymer contain up to 90% copolymer existing either as free copolymer from the preparation of the graft or as an added copolymer component. These added copolymers are preferably materials having high heat distortion temperatures such as is the case when a-methylstyrene acrylonitrile copolymers are added. Graft polymers suitable in the present context may be prepared by bulk-, bulk suspension-, emulsionor emulsion suspension-polymerization, descriptions of which processes are provided in U. S. Patents 3,751,526, 3,758,640, 3,981,944, 3,950,455 and 3,852,393, all incorporated herein by reference. Graft polymers suitable in the present context are known in the art as, for instance, ABS and MBS. ABS resins are available in commerce from, among others, Bayer AG of Leverkusen, West Germany and from Dow Chemical Corporation. MBS is available, for instance, under the trade name Acryloid KM-653 from Rohm and Haas Company. Talc, a magnesium silicate, is a mineral well known in the art. Exemplifying the many talc products that are suitable in the present context is MP-12-50, a product of Pfizer Corporation. The chemical composition and physical properties of that suitable talc are listed below. CHEMICAL COMPOSITION SiO2 61.3% MgO 31.1% CaO 0.2% A12O3 1.5% Fe 3 0.98 CaO-max 0.5% L.O.I. 6.0% PHYSICAL PROPERTIES (typical) Specific gravity 2.70 Weight per solid gal-lb 22.49 One pound bulks - gal 0.04446 Loose density-lb/ft.3 6.7 g/cc .11 3 Tapped density-lb/ft. 22.6 g/cc .36 Retention-325 mesh nil Dry brightness 92 Oil Absorption 50 pH value 8.8 Hegman fineness 6.0+ In the context of the present invention, thermoplastic molding compositions are prepared comprising a blend of (i) an aromatic polycarbonate resin, (ii) polyethylene terephthalate, (iii) a graft modified rubber and (iv) an additive amount of finely divided talc sufficient to control the warpage of articles molded therefrom yet have no substantial effect on the level of their impact strength. Preferably, compositions in the context of the invention comprise blends containing 30 to 89.5% poly (ethylene terephthalate), 5 to 61.5% of the polycarbonate resin, 5 to 50% of the graft modified rubber and 0.1 to about 4.5% of talc. In a more preferred embodiment, the respective ranges are 35 to 80% polyethylene terephthalate, 9 to 40% polycarbonate, 8 to 40% graft modified rubber and 0.5 to 3.5% talc, in all cases the percents are in relation to the weight of the blend. In the preparation of the composition it is very important to make certain that the ingredients are substantially free of moisture, the adverse effects of water vapor upon the processing of thermoplastic poly (ethylene terephthalate) generally and polycarbonate resins in particular being well recognized in the art. Although it is not essential, best results are obtained upon precompounding of the ingredients, followed by pelletizing and then molding, all of which procedures are well known in the art. The examples below are intended as an illustration of the invention and are not to be construed as a limitation thereof. EXAMPLES Compositions in accordance with the invention were prepared and their properties determined as summarized below. The compositions were all based on batches, the common components of which were: PET, available as Vituf VFR 5041 from Goodyear Chemical - a poly(ethylene terephthalate) charac terized by its intrinsic viscosity of 1.04 dl/gm determined using a solution of 0.1 gm of resin in 25 ml of a 1:1 mixture of trifluoroacetic acid and dichloromethane at 30 C. Polycarbonate, available as Merlon M-50 from Mobay Chemical Corporation, is a homopolycarbonate derived from bisphenol A, phenol and phosgene, characterized in that its relative viscosity is 1.322 as measured on a 0.5% solution in dichloromethane at 250C. Graft Copolymer I (used in Compositions 1-5), an ABS copolymer characterized in that its polybuta diene content is 80% by weight and in that its S/AN ratio is about 72/28 and in that its glass transition temperature is below about -650C avail able from Bayer AG. Graft Copolymer II (used in Compositions 6-7), an MBS copolymer characterized in thät its polybutadiene content is about 70% by weight and in that its glass transition temperature is well below OOC available as Acryloid KM-653 from Rohm & Haas Company, Philadelphia, Pennsylvania. The actual quantities of the individual components were 3 pounds of PET, 2.5 pounds of polycarbonate and 1.5 pounds of the graft copolymer (either I or II). To these basic components were added in each case 17 gms of an antioxidant octadecyl-3-(3',5'-di-tertbutyl-4'-hydroxyphenyl)-propionate, and 17 gms of a stabilizer: tris- [(3-ethloxetanyl-3)methyl]phosphite. The talc used in the preparation of the compositions was MP12-50 available from Pfizer Corporation. The components were all dried and then tumble blended prior to compounding. Extrusion was carried out on a 1-1/2" Hartig extruder with the compression ratio of 2.75/1, at the following conditions: Zone set temperature (OC): Rear 2700C Middle 2650C Front 2700C Die 2340C Screw speed 80 rpm Screw set 57 Screen Pack 20-40-60 Extruded pellets, after drying at about 1100C for about 16 hours in a hot air circulating oven, were injection molded using 4-oz. Newbury molding machine to prepare test bars. The injection molding conditions were as follows: Zone set temperature (OC): Rear 2600C Front 2600C Nozzle 2540C Mold Surface 700C Melt temperature (OC): 260 Cycle time (seconds): Injection 12 Cooling 25 Total Cycle 37 Injection pressure (psi): Primary 850 Secondary 800 TABLE 1 1 2 3 4 5(4) 6(5) 7(5) Talc (phr)(l) - 2.14 3.21 4.28 6.42 2.14 3.21 Impact strength (JM) at 230C (2) as molded 731.6/ 646.1/ 704.9/ 309.7/ 170.9/ 731.6/ 752.9/ 747.6 710.2 843.7 480.6 256.3 683.5 672.8 after heat ing 672.8/ 507.3/ 518.0/ 165.5/ 106.8/ 683.5/ 646.V 688.9 598.1 576.7 208.2 133.5 667.5 624.8 (3) FBrpage mm mm 1.7 1.2 0.7 0.6 1.2 1.6 0.4 <RTI ID=18.8> (l)Relative to the total weight of PET, polycarbonate and graft copolymer. (2)Notched Izod, specimens 1/8 x 1/2 x 5 in.; the values are given as gate/end sides; heating was carried out at 1300C for 30 minutes. (3)Specimens 1/8 x 1/2 x 5", after heating for 30 minutes at 1300C. (4)CompositionNo.5 is indicated to be inferior insofar as its impact performance is considerably lower than any of the other compositions. (5) Compositions entailing Acryloid KM-653, an MBS co polymer. In considering the advance represented by the findings summarized above, it is worth while to note that in similar compositions wherein graft copolymer was based on an acrylate rubber (Acryloid KM 330 from Rohm & Haas), the addition of talc had an adverse effect on the degree of warpage. Compo s ition 8 9 10 Talc (phr) (1) 0.53 2.14 3.21 Impact strength J/m at 230C(2) as molded 817/687 833/705 908/769 After heating 854/673 780/673 785/694 Warpage (mm) (3) 0.1 0.5 0.6 (1)Relative to the total weight of PET, polycarbonate and graft copolymer. (2)Notched Izod, specimens 1/8 x 1/2 x 5 in.; the values are given as gate/end sides; heating was carried out at 1300C for 30 minutes. (3)Specimens 1/8 x 1/2 x 5", after heating for 30 minutes at 13oOC. Although the invention has been described in detail 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 without departing from the spirit and scope of the invention except as it may be limited by the claims.

Claims: WAR INS CLAIMED IS: 1. A thermoplastic molding composition comprising a blend of (i) a high molecular weight thermoplas tic poly- (ethylene terephthalate) (ii) a high molecular weight thermoplas tic aromatic polycarbonate resin, (iii) a graft modified butadiene based rubber, characterized in that its glass transition temperature is below about 100C, and (iv) a warpage reducing amount of talc. 2. The composition of Claim 1 wherein said (i) is present at an amount of about 30 to 89.5%, said (ii) is present at an amount of about 5 to 61.5%, said (iii) is present at an amount of about 5 to 50 & and said (iv) is present at an amount of about 0.1 to about 4%, said percents being in relation to the weight of said blend. 3. The composition of Claim 1 wherein said rubber is a butadiene copolymer. 4. A thermoplastic molding composition comprising a blend of about 30 to 89.5percent of polyethylene terephthalate resin, about 5 to61.5percent of a bisphenol A based polycarbonate, about 5 to about 50 percent of a graft modified rubber having a polybutadiene core and a styrene-acrylonitrile graft and about 0.1 to 4.0 percent of talc, said percents being in relation to the weight of said blend. 5. The composition of Claim 4 wherein said graft modified rubber is a terpolymer of methyl methacrylate butadiene styrene.

Inventors: CHUNG, JAMES Y.J., WITMAN, MARK W.
Applicants: MOBAY CORPORATION
Application year: 1984
Main classification: C08L67
IPC codes: C08L51, C08K3, C08L21, C08L69, C08L67, C08L7