THERMOPLASTIC RESIN COMPOSITIONS HAVING IMPROVED MOLDABILITY

Abstract: A thermoplastic resin composition comprising by weight 100 parts of an amorphous resin (excluding poly­ phenylene ether) and from 0.01 to 25 parts of a diamide com­ pound of the formula R²-NH---R¹--NH-R³ wherein R¹, represents a linear or branched, saturated or unsaturated aliphatic hydrocarbon residue having 1 to 10 carbon atoms, an aromatic hydrocarbon residue having 6 to 10 carbon atoms, or a derivative thereof, and R² and R³ which may be the same or different each represent a linear or bran­ ched, saturated or unsaturated aliphatic hydrocarbon re­ sidue having 1 to 10 carbon atoms, a saturated or un­ saturated alicyclic hydrocarbon residue having 3 to 10 car­ bon atoms, or a derivative thereof. The moldability of the amorphous resin is improved without reducing its heat resis­ tance.

Description: The present invention relates to amorphous thermoplastic resin compositions having improved moldability. Amorphous thermoplastic resins are characterized by the fact that they can be molded by heating them to a temperature above the glass transition temperature, thereby reducing their viscosity. It is largely due to their good moldability that these amorphous thermoplastic resins have gained greater and wider usage as compared to thermosetting resins. In recent years, however, better moldability has been required of thermoplastic resins, and the improvement of their moldability has been an important problem in the art. In particular, ABS resins, polycarbonates, polyacrylates polysulfones and polyether sulfones have come into widespread use as materials for replacing metals because of their high strength and heat resistance; and, as engineering plastics, their use have been extended to include component parts for machines, automobiles and electrical and electronic equipment. These engineering plastics have high strength and heat resistance, but due to their high melting temperatures and melt viscosities, they frequently require to be molded at high molding temperatures and pressures. Hence, there has been a strong demand for the improvement of their moldability. General purpose plastics are also required to have good flowability because articles of large size, small thickness or a complex shape are required to be molded. When amorphous resins are heated above their glass transition temperature, there is no abrupt decrease of viscosity such as occurs in crystalline resins; and their molding is frequently difficult as compared with the crystalline resins. Methods for decreasing the intermolecular cohesive force of polymers have been generally used to improve the moldability of such amorphous thermoplastic resins. For example, the following techniques have been used: (1) To reduce the polarity of a polymer, it is modified by, for example, copolymerizing a monomer having low polarity; (2) The internal plasticization of a polymer is accelerated by employing a branched polymer; (3) The degree of polymerization of a polymer is reduced; (4) A highly flowable polymer, such as ethylene/vinylacetate copolymer (EVA) or low molecular weight polyethylene, is added; (5) A plasticizer is added. These techniques entail various problems which are still to be solved and which constitute great technical problems in the art. For example, according to techniques (1) and (2), a modification such as copolymerization frequently results in a deterioration in the inherent properties (such as heat resistance) of the resin to be modified. According to techniques (3) and (4), the mechanical strength of the polymer is reduced in many cases. In technique (5), the heat resistance of the polymer is sacrificed. The present inventors have extensively investigated additives which can improve the moldability of amorphous thermoplastic resins, while inhibiting a reduction in mechanical strength or heat resistance, and have come to believe that such additives desirably have the following properties: (1) They have good compatibility with the matrix component during molding in a flowable system, and produce the same flowability-improved effect as plasticizers; (2) During use, namely in a condition in which the flow of a system is suspended (at temperatures below the Tg or crystallization temperature of the matrix), they separate from a phase of the matrix component to prevent reduction of the heat resistance of the matrix. Such additives are required to cause phase separation from the matrix, but on the other hand, in order to prevent the reduction of mechanical strength, such additives must have an interfacial adhesion strength between the additives and the matrix which has been phase separated. Therefore, the additives also need to be a compound having an affinity for the matrix. The present inventors have continued their investigations in order to define more specifically compounds satisfying the desiderata (1) and (2), and judged that compounds meeting the following requirements (a), (b) and (c) are suitable: (a) Low molecular weight compounds which have a unit compatible with a matrix component so as to act as a plasticizer during molding in a flowing system; (b) Compounds which separate from the matrix phase by crystallisation at temperatures below the molding temperature (temperatures below the Tg or crystallizing temperature of the matrix); (c) Compounds which have relatively strong polarity so that they crystallize reliably at temperatures below the molding temperature, and which contain a unit having an affinity for the matrix component so as to retain an interfacial adhesion strength with respect to the matrix, even when they have separated from the matrix phase upon crystallization. Extensive investigations based on this analysis led to the discovery that specific diamide compounds act effectively on polyphenylene ether resins. An invention based on this discovery was the subject of JP-A-233289/82 and EP-A-115218. An object of the present invention is to improve the moldability of other thermoplastic resins. To this end the present inventors have continued their investigations and have found that the addition of the above-described diamide compounds to various thermoplastic resins produces results similar to those obtained previously with regard to the polyphenylene ether resin. This discovery has led to the present invention. According to the present invention there is provided a thermoplastic resin composition comprising a diamide compound as a moldability improver, characterised in that the composition comprises 100 parts by weight of amorphous thermoplastic resin, other than a resin containing polyphenylene ether, and selected from styrene resins, vinyl chloride resins, polycarbonate resins, polyarylate resins, polysulfone resins, polyether sulfones and blends thereof and 0.01 to 25 parts by weight of a diamide compound of the following formula (I): wherein R¹ represents a linear or branched, saturated or unsaturated aliphatic hydrocarbon residue having 1 to 10 carbon atoms or an aromatic hydrocarbon residue having 6 to 10 carbon atoms and R² and R³ which may be the same or different each represents a linear or branched, saturated or unsaturated aliphatic hydrocarbon residue having 1 to 10 carbon atoms, a saturated or unsaturated alicyclic hydrocarbon residue having 3 to 10 carbon atoms or an aromatic hydrocarbon residue having 6 to 10 carbon atoms. The amorphous thermoplastic resin is selected, for example, from styrene resins (such as polystyrene, high-impact polystyrene, AS resin and ABS resin), vinyl chloride resins, acrylic resins, polycarbonate resins, polynorbornene resins, polyarylate resins, polysulfone resins and polyether sulfone resins. Accordingly various amorphous thermoplastic resins may be used in the present invention. In the present specification the term "amorphous thermoplastic resins" denotes those amorphous thermoplastic polymers which have a crystallinity, determined by X-ray difffraction under normal use conditions, of 20% or less. The preferred amorphous thermoplastic resins used in the present invention have a glass transition point of at least 100°C, especially of at least 120°C. Examples of the amorphous thermoplastic resins which are preferably used in the present invention include polystyrene, high impact polystyrene, styrene copolymers (such as ABS resin), polyvinyl chloride, polymethacrylic acid esters, polyacrylic acid derivatives, polycarbonates, polynorbornene resins, polyarylates, polysulfones and polyether sulfones, and modification products of these thermoplastic resins, such as styrene-grafted polycarbonate. In the present invention there may also be used blends (polymer alloys) of these thermoplastic resins with each other, for example, an alloy of polycarbonate and polystyrene, an alloy of ABS resin and vinyl chloride polymer or an alloy of polycarbonate and a vinyl chloride polymer. Homo- or co-polymers of styrene, α-methylstyrene or halogenated styrene, or copolymers of such a styrene monomer and a vinyl monomer copolymerizable therewith may be used as the polystyrene-type resins. Modified polystyrene resins obtained by grafting such a styrene monomer onto a polymer such as polybutadiene may also be used. Preferred polycarbonate resins are resins represented by the following general formula (II): wherein R¹¹ and R¹² each represent hydrogen or an alkyl group having 1 to 8 carbon atoms, R¹³ and R¹⁴ each represent hydrogen, halogen or an alkyl group having 1 to 6 carbon atoms, and n is at least 20, preferably at least 50. Prefered polynorbornene resins are resins represented by the following general formula (III): wherein R¹⁵ and R¹⁶ each represent hydrogen or a hydrocarbon residue having 1 to 20 carbon atoms, and X² represents a polar substituent, preferably (CH₂) m COOR¹⁷, (CH₂) m OCOR¹⁸, (CH₂) m COOM, (CH₂) m CN, (CH₂) m CONR¹⁹R²⁰ or (CH₂) m X in which m represents an integer of 0 to 17, R¹⁷ to R²⁰ each represent a hydrocarbon residue having 1 to 20 carbon atoms, M represents hydrogen or an alkali metal or an alkaline earth metal, and X represents halogen. Preferred polysulfone resins are resins represented by the following general formula (IV): wherein R²¹, R²², R²³ and R²⁴ each represent hydrogen or a hydrocarbon residue having 1 to 8 carbon atoms, R²⁵ and R²⁶ each represent hydrogen, halogen or a hydrocarbon residue having 1 to 6 carbon atoms, and n is at least 30, preferably at least 60. Preferred polyarylate resins are resins represented by the following general formula (V): wherein R²⁷, R²⁸ and R²⁹ each represent hydrogen or a hydrocarbon residue having 1 to 8 carbon atoms, R³⁰ and R³¹ each represent hydrogen, halogen or a hydrocarbon residue having 1 to 6 carbon atoms, and n is at least 30, preferably at least 60. As stated, the diamine compounds which are used in the present invention are compounds of the general formula (I), as previously set forth and defined. Examples of R¹ include methylene, ethylene, trimethylene, propylene, tetramethylene, isobutylene, pentamethylene, cyclohexylene, octamethylene, decamethylene and phenylene groups. Examples of R² and R³ include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, t-butyl, pentyl, isopentyl, cyclopentyl, hexyl, isohexyl, cyclohexyl, heptyl, octyl, decyl, phenyl, tolyl and xylyl. The diamide compounds which are used in the present invention dissolve in the matrix component under flow conditions during molding, and separate from a phase of the matrix component as a result of crystallization during use. Therefore, it is preferred for the diamide compounds to have a melting point slightly lower than the molding temperature. The molding temperature is generally prescribed between the temperature at which the system begins to flow (the Tg of the matrix) as a lower limit and the temperature at which the system begins to decompose as an upper limit, and is adjusted to a suitable point depending upon the system to be molded. Accordingly, the desirable melting point of the diamide compound in accordance with the present invention (which is set at a temperature slightly lower than the molding temperature) is selected according to the molding temperature for the intended thermoplastic resins. Generally, it is between 100 and 400°C. The amount of the diamide compound added is 0.01 to 25 parts by weight, preferably 0.1 to 20 parts by weight, more preferably 0.5 to 10 parts by weight, per 100 parts by weight of the thermoplastic resin. Various additives may be used with the amorphous thermoplastic resins according to their intended use. For example, reinforcing agents (e.g., glass fibers and inorganic fillers) stabilizers, plasticizers, fire retardants, mold releasing agents and coloring agents may be used. The effect of improving moldability by the addition of the diamide compound in accordance with this invention is produced not only with the thermoplastic resin alone, but also with a mixture of the resin with the above-described various additives. The amorphous thermoplstic resin, the diamide compound and the additives may be melt-kneaded by a conventional method, for example, by using a Banbury mixer, a kneader or an extruder. The present invention will now be explained in greater detail by reference to the following non-limiting Examples and Comparative Examples. Example 1 and Comparative Example 1 The melt index shown in Tables 1 to 5 was measured according to ASTM D1238 (250°C, 5kg); the melt index shown in Tables 6 to 8 was according to ASTM D1238 (290°C, 20 kg); the tensile modulus and the strength at break were measured according to ASTM D638, and the heat distortion temperature was measured according to ASTM D648. 100 Parts by weight of a high impact polystyrene ("HT-76", a trade name for a product of Mitsubishi Monsanto Co. Ltd.) and 5 parts by weight of N,N'-diphenyladipic diamide (melting point: 135°C) of the following structural formula were melt-kneaded at 250°C for 5 minutes using a Brabender plastomill. After kneading, the melt index (250°C, 5 kg load) of the mixture, as a measure of moldability (flowability), was measured. Furthermore, test pieces were formed from the mixture by a press, and their tensile modulus, strength at break and heat distortion temperature were measured. The above procedure was repeated by imparting the same heat history without using N,N'-diphenyladipic diamide (Comparative Example 1). The results obtained are shown in Table 1 below. The results of Table 1 demonstrate that the addition of N,N'-diphenyladipic diamide markedly increased the flowability (moldability) of the resin while inhibiting a reduction in mechanical strength and heat resistance. Example 2 Example 1 was repeated except that 5 parts by weight of N,N'-dihexyladipic diamide was used instead of N,N'-diphenyladipic diamide. The results obtained are shown in Table 2 below. Example 3 Example 1 was repeated except that 5 parts by weight of N,N'-dihexylterephthalic diamide was used instead of N,N'-diphenyladipic diamide. The results obtained are shown in Table 2 below. Example 4 Example 1 was repeated except that 5 parts by weight of N,N'-diphenylsuccinic diamide was used instead of N,N'-diphenyladipic diamide, The results obtained are shown in Table 2 below. Example 5 Example 1 was repeated except that 5 parts by weight of N,N'-dihexylsebacic diamide was used instead of N,N'-diphenyladipic diamide. The results obtained are shown in Table 2 below. Example 6 and Comparative Example 2 100 Parts by weight of ABS resin ("Cycolac LM1101", a trade name for a product of Ube Industries, Ltd.) and 5 parts by weight by N,N'-diphenyladipic diamide were melt-kneaded at 260°C for 7.5 minutes by a Brabender plastomill. After kneading, the same procedure as in Example 1 was repeated. The results obtained are shown in Table 3 below. The above procedure was repeated except that the diamide compounds was not used (Comparative Example 2). The results obtained are shown in Table 3 below. Example 7 Example 6 was repeated except that N,N'-dihexyladipic diamide was used instead of N,N'-diphenyladipic diamide. The results obtained are shown in Table 3 below. Examples 8 and 9 and Comparative Example 3 100 Parts by weight of polycarbonate resin ("lupilon S-3000", a trade name for a product of Mitsubishi Gas Chemical Co. Ltd.) and a predetermined amount of N,N'-diphenyladipic diamide were melt-kneaded at 260°C for 5 minutes using a Brabender plastomill. After kneading, the same procedure as in Example 1 was repeated. The results obtained are shown in Table 4 below. The above procedure was repeated except that the diamide compound was not used (Comparative Example 3). The results obtained are shown in Table 4 below. Example 10 Example 8 was repeated except that N,N'-diphenylsuccinic diamide was used instead of N,N'-diphenyladipic diamide. The results are also shown in Table 4. Example 11 and Comparative Example 4 100 Parts by weight of a polymer alloy ("ARLOY 1100", a trade name for a product of ARCO Chemical Company) of polycarbonate and modified polystyrene and 5 parts by weight of N,N'-diphenyladipic diamide were melt-kneaded at 260°C for 5 minutes using a Brabender plastomill. After kneading, the same procedure as in Example 1 was repeated. The above procedure was repeated except that the diamide compound was not added (Comparative Example 4). The results obtained are shown in Table 5 below. Example 12 Example 11 was repeated except that N,N'-dihexylterephthalic diamide was used instead of N,N'-diphenyladipic diamide. The results obtained are shown in Table 5 below. Examples 13 to 15 and Comparative Example 5 100 Parts by weight of polyarylate resin ("U Polymer U-100", a trade name for a product of Unitika Ltd.) and a predetermined amount of N,N'-diphenyladipic diamide were melt-kneaded at 320°C for 5 minutes using a Brabender plastomill. After kneading, the same procedure as in Example 1 was repeated. The above procedure was repeated except that N,N'-diphenylsuccinic diamide was used instead of N,N'-diphenyladipic diamide (Example 15). The above procedure was repeated except that the diamide compound was not added (Comparative Example 5). The results obtained are shown in Table 6 below. Examples 16 and 17 and Comparative Example 6 100 Parts by weight of polyether sulfone resin ("200 P", a trade name of a product of ICI) and a predetermined amount of N,N'-diphenyladipic diamide were melt-kneaded at 320°C for 5 minutes using a Brabender plastomill. After kneading, the same procedure as in Example 1 was repeated. The above procedure was repeated except that the diamide compound was not added (Comparative Example 6). The results obtained are shown in Table 7 below. Example 18 Example 16 was repeated except that 3 parts by weight of N,N'-diphenylsuccinic diamide were used instead of N,N'-diphenyladipic diamide. The results obtained are shown in Table 7 below. Example 19 and Comparative Example 7 100 Parts by weight of polysulfone resin ("NDEL P1700", a trade name for a product of Nissan Chemical Co., Ltd.) and 5 parts by weight of N,N'-diphenyladipic diamide were melt-kneaded at 320°C for 5 minutes using a Brabender plastomill. After kneading, the same procedure as in Example 1 was repeated. The above procedure was repeated except that the diamide compound was not used (Comparative Example 7). The results obtained are shown in Table 8 below.

Claims: A thermoplastic resin composition comprising a diamide compound as a moldability improver, characterised in that the composition comprises 100 parts by weight of amorphous thermoplastic resin, other than a resin containing polyphenylene ether,and selected from styrene resins, vinyl chloride resins, polycarbonate resins, polyarylate resins, polysulfone resins, polyether sulfones and blends thereof and 0.01 to 25 parts by weight of a diamide compound of the following formula (I): wherein R¹ represents a linear or branched, saturated or unsaturated aliphatic hydrocarbon residue having 1 to 10 carbon atoms or an aromatic hydrocarbon residue having 6 to 10 carbon atoms and R² and R³ which may be the same or different each represents a linear or branched, saturated or unsaturated aliphatic hydrocarbon residue having 1 to 10 carbon atoms, a saturated or unsaturated alicyclic hydrocarbon residue having 3 to 10 carbon atoms or an aromatic hydrocarbon residue having 6 to 10 carbon atoms. A composition as claimed in Claim 1, wherein the amount of the diamide compound is from 0.1 to 20 parts by weight. A composition as claimed in Claim 1 or 2, wherein the diamide compound has a melting point of from 100 to 400°C. A composition as claimed in Claim 1, 2 or 3, wherein the diamide compound is one having the general formula (I) in which R² and R³ each represent an aromatic hydrocarbon residue and which has a melting point of from 100 to 400°C. A composition as claimed in any preceding claim, wherein the amorphous thermoplastic resin has a glass transition temperature of at least 100°C. A composition as claimed in Claim 5, wherein the amorphous thermoplastic resin has a glass transition temperature of at least 120°C. A composition as claimed in any of Claims 1 to 5, wherein the amorphous thermoplastic resin is an acrylonitrilebutadiene-styrene resin.

Inventors: ABE, KATSUHIRO MITSUBISHI PETROCHEM. CO. LTD., BABA, MITSUSHIGE MITSUBISHI PETROCHEM. CO. LTD., KOBAYASHI, YOSHINOBU MITSUBISHI PETROCHEM. CO. LTD
Applicants: MITSUBISHI PETROCHEMICAL CO., LTD.
Application year: 1985
Main classification: C08K5
IPC codes: C08L67, C08L7, C08L51, C08L101, C08L69, C08K5, C08L23, C08L81, C08L21