DEVICE FORMED FROM POLYCARBONATE, POLYARYLATE AND POLY(ALKYLENE TEREPHTHALATE)

Abstract: An electrical device formed from a blend of (a) an aromatic polycarbonate, (b) a polyarylate resin, (c) a poly(alkylene terephthalate) resin, (d) fiberglass, and (e) an additive effective to inhibit ester-arylate interchange. Also described herein is a composition comprising a polyester and an aromatic polycarbonate in particular proportions.

Description: DEVICE FORMED FROM POLYCARBONATE, POLYARYLATE AND POLY(ALKYLENE TEREPHTHALATE) REFERENCE TO RELATED APPLICATION This application is a Continuation-In-Part application of U.S. Patent Application Serial No. 924,063, filed October 28, 1986. FIELD OF THE INVENTION This invention is directed to an electrical device formed from a blend of (a) an aromatic polycarbonate resin, (b) a polyarylate resin, (c) a poly(alkylene terephthalate) resin, (d) fiberglass, and (e) an additive effective to inhibit ester-arylate interchange. The device has high stiffness, high strength, high heat deflection temperature, a V-0 flammability rating, and low warpage. This invention is also directed to a composition comprising (a) a polyester and (b) an aromatic polycarbonate, wherein said polyester comprises a weight ratio of from 1:2 to 2:1 poly(alkylene terephthalate) to polyarylate and said polycarbonate is present in a concentration of from 5 to 50 parts by weight per 100 parts by weight polyester. BACKGROUND OF THE INVENTION Polymer composites based on poly(butylene terephthalate) or poly(ethylene terephthalate), i.e., PBT and PET, respectively, with fiberglass and flame retardants have established a formidable market in electrical and electronic applications, such as connectors. However, the primary deficiency of these composites is their poor warp resistance. This is a particular problem in long connectors where it is extremely difficult to mold flat sections. Many approaches have been tried to solve this problem, including ,. _ the addition of various fillers (in addition to or replacing fiberglass) . Composites which include polysulfone offer a solution to this problem. However, such a polysulfone containing product is significantly more expensive than the fiberglass filled versions of PET or PBT, due to the significant portion of the formulation being polysulfone. Replacement of polysulfone by polyarylate or polycarbonate has been found to yield many of the desired features of the composition while allowing a significant lowering of the formulation raw material cost. Another deficiency (in addition to warp resistance) of the PBT or PET fiberglass filled composites is that these systems require a high level of flame retardant in order to achieve the desired UL-94 V-0 ratings at 1/32-inch and 1/16-inch thickness. The polycarbonate or polyarylate based material requires much lower flame retardant levels. The resultant melt stability (as lowered flame retardant concentration is possible) of the polycarbonate- or polyarylate-based composition is significantly better than the PBT- or PET-based systems. The economic advantage of the polyarylate and/or polycarbonate/PET system compared to PBT is based on much lower flame retardant required and the potential use of scrap grade PET (thus low cost). THE INVENTION This invention is directed to an electrical device formed by injection molding, extruding, or thermoforming a blend of (a) an aromatic polycarbonate resin, (b) a polyarylate resin, (c) a poly(alkylene terephthalate) , (d) a fiberglass and (e) an additive effective to inhibit ester-arylate interchange. The blend may. contain a flame retardant additive such as a brominated aromatic flame retardant. The resultant device has high stiffness, high strength, high heat deflection temperature, a V-O flammability rating, and low warpage. The warpage of such composition on an 8 inch x 8 inch x 65 mil plaque is less than 0.12 inches. This invention is also directed to a composition comprising (a) a polyester, and (b) an aromatic polycarbonate, wherein said polyester comprises a weight ratio of from 1:2 to 2:1 poly(alkylene terephthalate) to polyarylate, and said polycarbonate is present in a concentration of from 5 to 50 parts by weight per 100 parts by weight of polyester. This invention is further directed to a composition comprising fiberglass, an additive effective to inhibit ester-arylate interchange, and a composition comprising a polyester, an aromatic polycarbonate, wherein said polyester comprises a weight ratio of form 1:2 to 2:1 poly(alkylene terephthalate) to polyarylate, and said polycarbonate is present in a concentration of from 5 to 50 parts by weight per 100 parts by weight of polyester. The Electrical Device The electrical device into which the blend of aromatic polycarbonate, polyarylate resin, poly(alkylene terephthalate) resin, fiberglass, and additive, can be formed include electrical connectors, terminations, contactors, and the like. More particularly, this invention relates to an electrical conductor assembly for use in switches, connectors, contactors, relays, and terminations, comprising a flame resistant composition shell, said composition shell comprising an aromatic polycarbonate resin, a poly arylate resin, a poly(alkylene terephthalate) resin, fiberglass, an additive effective to inhibit ester-arylate interchange, and optionally, a flame retardant additive. 4 Typically, the metal core comprises a metal conductor imbedded in said shell and said shell comprises a substantially rigid housing for abuttingly engaging and supporting said core, and in many cases, said core comprises a pin. The Aromatic Polycarbonate The thermoplastic aromatic polycarbonate resins that can be employed herein are homopolymers and copolymers and mixtures thereof, which have an intrinsic viscosity of from about 0.4 to about 1.0 dl/g as measured in methylene chloride at 25°C. The polycarbonates are prepared by reacting a dihydric phenol with a carbonate precursor. Typical of some of the dihydric phenols that may be employed are bisphenol-A, bis(4-hydroxyphenyl)methane, 2,2-bis{ -hydroxy-3-methylphenyl)propane, 4,4-bis(4-hydroxyphenyl)heptane, 2-2-(3,5,3', 5'tetrabromo-4,4'-dihydroxydiphenyl)propane, (3,3'dichloro-4,4'dihydroxydiphenyl)methane, and the like. Other dihydric phenols of the bisphenol type are described iii, for example, U.S. Patents, 2,999,835, 3,028,365 and 3,334,154. It is, of course, possible to employ two or more different dihydric phenols or a copolymer of a dihydric phenol with a glycol or with hydroxy or acid terminated polyesters. The carbonate precursor may be either a carbonyl halide, a carbonate ester, or a haloformate. The carbonyl halides which can be employed herein are carbonyl bromide, carbonyl chloride and mixtures thereof. Typical of the carbonate esters which may be employed herein are diphenyl carbonate, di-(halophenyl)carbonates, such as di-(chlorophenyl)carbonate or di-(bromophenyl)carbonate, etc. , di-(alkylphenyl)carbonates such as di(tolyl)carbonate, di(na hthyl)carbonate, di(chloronaphthyl)carbonate, etc. or mixtures thereof. The haloformates suitable for use herein include bis-halofor ate of dihydric phenols for example, bischloroformates of bisphenol-A, of hydroquinone, etc. or glycols for example, bishaloformates of ethylene glycol, neopentyl glycol, polyethylene glycol, etc. While other carbonate precursors will be apparent to those skilled in the art, carbonyl chloride, also known as phosgene, is preferred. The aromatic polycarbonate polymers may be prepared by methods well known in the art by using phosgene or a haloformate and by employing a molecular weight regulator, an acid acceptor and a catalyst. The molecular weight regulators which can be employed in carrying out the process include onohydric phenols, such as phenol, para-tertiary-butylphenol, para-bromophenol, primary and secondary amines, etc. Preferably, a phenol is employed as the molecular weight regulator. A suitable acid, acceptor may be either an organic or an inorganic acid acceptor. A suitable organic acid acceptor is a tertiary amine and includes materials, such as pyridine, triethylamine, dimeth laniline, tributylamine, etc. The inorganic acid acceptor may be•one which can be either a hydroxide, a carbonate, a bicarbonate, or a phosphate of an alkali or alkaline earth metal. The catalysts which are employed herein can be any of the suitable catalysts that aid the polymerization of, for example, bisphenol-A with phosgene. Suitable catalysts include tertiary amines, such as triethylamine, tripropylamine, N,N-dimethylaniline, quaternary ammonium compounds, such as tetraethylammonium bromide, cetyl triethyl ammonium bromide, tetra-n-heptylammonium iodide, and quaternary phosphonium compounds, such as n-butyltriphenyl-phosphonium bromide and methyl-triphenyl phosphonium bromide. The polycarbonates can be prepared in a one-phase (homogeneous solution) or a two-phase (interfacial) systems when phosgene, or a haloformate are used. Bulk reactions are possible when the diar lcarbonate precursors are used. Also, aromatic polyester carbonates may be used. These are described in, for example, U.S. Patent 3,169,121. The preferred polyester carbonate results from the condensation of phosgene, terephthaloyl-chloride, isophthaloyl chloride with bisphenol-A and a small amount of p-tertbutylphenol. The Polyarylate Resins The polyarylate resins which are suitable for use in this invention are derived from a .dihydric phenol and at least one aromatic dicarboxylic acid and have a reduced viscosity of from about 0.4 to greater than about 1.0, preferably from about 0.6 to about 0.8 dl/gm, as measured in chloroform (0.5 g/lOOml chloroform) or other suitable solvent at 25°C. A particularly desirable dihydric phenol is of the following formula: wherein Y is independently selected from, hydrogen, alkyl groups of 1 to 4 carbon atoms, chlorine or bromine, each a, independently, has a value of from 0 to 4, inclusive, and R- is a divalent saturated or unsaturated aliphatic hydrocarbon radical, particularly an alkylene or alkylidene radical having from 1 to 6 carbon atoms, or a cycloalkylidene or cyσloalkylene radicals having up to and including 9 carbon atoms, 0, CO, SO-, or S. The dihydric phenols may be used individually or in combination. The dihydric phenols that may be used in this invention include the following: 2,2-bis-4(4-hydroxyphenyl)propane; bis-(2-hydroxyphenyl)methane, bis-(4-hydroxyphenyl)methane, bis-(4-hydroxy-2,6-dimethyl-3-methoxyphenyl) methane, 1,1-bis-(4-hydroxyphenyl)ethane, 1,2-bis-(4-hydroxyphenyl)ethane, 1,1-bis-(4-hydroxy-2-chlorophenyl)ethane, 1,3-bis-(3-methyl-4-hydroxyphenyl)ethane, 1,3-bis-(3-methy1-4-hydroxyphenyl)propane, 2,2-bis-(3-phenyl-4-hydroxyphenyl)propane, 2,2-bis-(3-isopropyl-4-hydroxyphenyl) propane, 2,2-bis-(2-isopropyl-4-hydroxyphenyl) propane, 2,2-bis-(4-hydroxyphenyl)pentane, 3,3-bis-(4-hydroxyphenyl)pentane, 2,2-bis-(4-hydroxyphenyl)heptane, 1,2-bis-(4-hydroxyphenyl)1,2-bis-(phenyl)- propane, 4,4*-(dihydroxyphenyl)ether, 4,4'-(dihydroxyphenyl)sulfide, 4,4'-(dihydroxyphenyl)sulfone, 4,4'-(dihydroxyphenyl)sulfoxide, 4,4'-(dihydroxybenzophenone) , and naphthalene diols The aromatic dicarboxylic acids that may be used in this invention include terephthalic acid, isophthalic acid, any of the naphthalene dicarboxylic acids and mixtures thereof, as well as alkyl substituted homologs of these carboxylic acids, wherein the alkyl group contains from 1 to about 4 carbon atoms, and acids containing other inert substituents, such as halides, alkyl or aryl ethers, and the like. Acetoxybenzoic acid can also be used. Preferably, mixtures of isophthalic and terephthalic acids are used. The isophthalic acid to terephthalic acid ratio in the mixture is about 0:100 to about 100:0, while the most preferred acid ratio is -about 75:25 to about 50:50. Also, from about 0.5 to about 20 percent of aliphatic diacids containing from 2 to about 10 carbon atoms, such as adipiσ acid, sebacic acid, and the like may be additionally used in the polymerization reaction. The polyarylates can be prepared by any of the well known prior art polyester forming reactions, such as the reaction of the acid chlorides of the aromatic dicarboxylic acids with the dihydric phenols; the reaction of the diaryl esters of the aromatic dicarboxylic acids with the dihydric phenols; or the reaction of the aromatic diacids with diester derivatives pf the dihydric phenol. These processes are described in, for example, U.S. Patents 3,317,464; 3,948,856; 3,780,148; 3,824,213; and 3,133,898. The polyarylates are preferably prepared by the process as set forth in U.S. Patent 4,321,355. This' process comprises the following steps: (a) reacting an acid anhydride derived from an acid containing from 2 to 8 carbon atoms with at least one dihydric phenol to form the corresponding diester; and (b) reacting said diester with, at least one aromatic dicarboxylic acid at a temperature sufficient to form the polyarylate, wherein the improvement comprises removing residual acid anhydride after formation of the dihydric phenol diester so that its concentration is less than about 1500 parts per million. " The acid anhydride suitable is derived from an acid containing from 2 to 8 carbon atoms. The preferred acid anhydride is acetic anhydride. The dihydric phenol is described above. Generally, the dihydric phenol reacts with the acid anhydride under conventional esterification conditions to form the dihydric phenol diester. The reaction may take place in the presence or absence of a solvent. Additionally, the reaction may be conducted in the presence of a conventional esterification catalyst or in the absence thereof. The Poly(alkylene terephthalate) The poly(alkylene terephthalates) include poly(ethylene terephthalate), poly(butylene terephthate) , or mixtures thereof. The Additive to Inhibit Ester-Arylate Interchange It is desirable to inhibit the transesterification reaction which occurs between the poly arylate and the poly(arkylene terephthalate). The transesterification reaction has been observed in poly arylate/polyester blends. The ester exchange rate is not desirable since the ester exchange rate at typical processing temperatures leads to undesirable property shifts (e.g., transparency, crystallization rate changes or disappearance of crystallinity and thus considerably lower solvent resistance). Thus, it is desirable to be able to control or eliminate transerterification between the polyarylate and poly(alkylene terephthalate). These additives include phosphites, phosphonites, a hydroxy-or amino-substituted carboxylic acid derivative and arsenic oxides, such as As-O^. The aromatic phosphites and phosphonites are of the following formula: f wherein R , R- and R 3 can be the same or different and are independently straight chain or branched chain alkyl radicals containing from 1 to about 25 carbon atoms, or substituted or unsubstituted aryl radicals containing from 6 to about 30 carbon atoms? b is 1 or zero, with the proviso that both b's are 1 when A is a chemical bond and only one b can be zero when A is- oxygen; A is a chemical bond or an oxygen atom; at least one of R , R. and R 3 must be an aromatic group. The perferred alkyl radicals are those containing from 5 to about 20 carbon atoms; most preferred alkyl groups containing from 8 to about 18 carbon atoms. The aryl radicals are preferably selected from those having the following formulae: -// and/or wherein A, is a direct bond, S, S0 2 , 0, CO, alkylene or alkylidene containing from 1 to about 8 carbon atoms, and R. is independently an alkyl group of 1 to about 6 carbon atoms or a halogen atom. The following alkyl and aryl radicals are most preferred: octyl; nonyl; decyl; dodecyl. and -O - Q wherein R 5 is a direct bond 0, CO, S, S0 2 or CfCH o . The preferred phosphites include octyl diphenyl phosphite and tris(2,4-di-tert-butyl phenyl phosphite) having the following formula: The disphosphites and/or diphosphonites are of the following formula: / \ O \ / R, wherein A_ Δ is 0 or a chemical bond; RO_ is an aromatic radical and the R 's are independently alkyl or aromatic radicals. Preferably, the diphosphites and/or diphosphonites are the following formula: wherein A_ is as defined above, A- is a direct chemical bond, S, SO_, 0, CO, alkylene or alkylidene containing from 1 to about 8 carbon atoms and the R 's are independently aliphatic radicals containing from 1 to about 25 carbon atoms, or substituted or unsubstituted aromatic radicals of from 6 to about 30 carbon atoms. R_ is preferably selected from the following: methyl, ethyl, isopropyl, butyl, isobutyl, phenyl, alkyl or aryl substituted phenyl (wherein the alkyl group may contain up to about 25 carbon atoms and may be linear or branched) , halogen substituted phenyl, hydroxy substituted aryl, naphthyl, alkyl, or aryl substituted naphthyl, halogen substituted naphthyl, and the like. The preferred R 7 groups can be represented as: < R .V wherein R g is independently an alkyl group of 1 to about 6 carbon atoms and the R~'s are independently alkyl groups of 1 to about 6 carbon atoms. A preferred disphosphonite is tetrakis [2,4-di-tert- butyl-phenyl]-4,4'-biphenylene disphosphonite and has the following formula: Such material is commercially available under the designation Sandostab P-EPQ (Sandoz Corporation). Preferred diphosphites have the following formula: X° >-° . -< κ ' w h erein R 10 is selected from a direct bond, o, CO, S, S0 2 , C(CH_) 9 , and R.. is selected from the following: The phosphites and/or phosphonites are used in amounts which effectively reduce the. transestherification between the polyarylate and polyester after blending in an extruder. This amount is from about 0.02 to about 2.5, preferably from about 0.05 to about 0.50 percent by weight. The hydroxy-or a ino-substituted carboxylic acid derivations.are of the formula: 0 II R 12-„- C - χ: X 1 H wherein: X 1 is O or NH; X 2 or O χ3 when X 1 is NH and is OR 13 or NHR 13 when X 1 is 0; Z is CH or a single-ring aromatic carbocyclic radical in which the X X H and 0 II -C-X 2 moieties occupy ortho positions; R. is hydrogen, a lower alkyl radical or a lower aryl radical which optionally contains hydroxy or COOR... substituents; and R 13 i.s hydrogen, lower alkyl or lower aryl. Illustrative compounds of this type are methyl salicylate, ethyl salicylate, phenyl salicylate, salicylamide, glycine, malic acid, mandelic acid and dibutyl tartrate. In the composition containing polyester and aromatic polycarbonate, the polyester comprises a weight ratio of from 1:2 to 2:1 polγ(alkylene terephthalate) to polyarylate, the polycarbonate being present in a concentration of from 5 to 50 parts by weight per 100 parts by weight of polyester. Specifically, the blends contain from about 5 to about 20, preferably from about 5 to about 15, by weight percent of the aromatic polycarbonate, from about 15 to about 40, preferably from about 20 to about 30 by weight percent of the polyarylate, from about 20 to about 40, preferably from about 25 to about 30 weight percent of the poly(alkylene terephthalate) resin, from about 15 to about 40, preferably from about 25 to about 30 weight percent of the fiberglass and from about 0.02 to about 2.5, preferably from about 0.05 to about 0.50 weight percent of the additive effective to inhibit ester-arylate interchange. If used, the flame retardant is present in amounts of from about 4 to about 12 weight percent. Other Additives Other additives which may be used in combination with the blends include mineral fillers such as carbonates including chalk, calcite and dolomite; silicates including mica, talc, wollastonite; silicon dioxide; glass spheres; glass powders; aluminum; clay; quartz; and the like. Additional additives include pigments, such as titanium dioxide; thermal stabilizers such as zinc oxide; ultraviolet light stabilizers, plasticizers, flame retardants such s decabromodiphenyloxide, or brominated polystyrene, lubricants, and the like. Additionally, the blends may include an aromatic phosphite and/or phosphonite. Fabrication The blends, and one or more optional additives are generally compounded in an extruder. The compounding is carried out at temperatures of from about 200'C to about 400°C. The compounded material may be pelletized by conventional techniques. The compounded material may be shaped into the desired article by conventional molding techniques such as by injection molding, compression molding or thermoforming. The electrical device of this invention can be fabricated by the steps of: (1) forming a support member comprising an aromatic polycarbonate resin, a polyarylate resin, a poly(alkylene terephthalate) resin, fiberglass, an additive effective to inhibit ester-arylate interchange, and any optional additives; and (2) positioning an electrical conductor to proximity to said support member. EXAMPLES The following examples serve to give specific illustrations of the practice of this invention but they are not intended in any way to limit the scope of this invention. The following designations used in the Examples have the following meaning: Polycarbonate: an aromatic bisphenol-A polycarbonate (Lexan 101 sold by General Electric Co.) having a reduced viscosity of 0.64 dl/g as measured in chloroform at 25 β C. Polyarylate: (Ardel D-100 sold by Union Carbide Corp.) prepared from bisphenol-A and a mixture of 50 mole percent each of isophthalic and terephthalic acid chlorides and having a reduced viscosity of 0.66 dl/g as measured in p-chlorophenol at 49 β C (0.2g/100ml) . PET: poly(ethylene terephthalate) with a reduced viscosity of 0.76 dl/g as measured in 60/40 phenol/tetrachloroethane, 0.2 g/100 ml at 25 β C (Cleartuf 7202A obtained from Goodyear Tire & Rubber Co.). DBDPO: Decabromodiphenyloxide _• Mark 2112 - tris (2,4-di-tert-butyl phenyl phosphite) having the formula: Sandostab - P-EO - (tetrakis [2,4-di-t-butyl phenyl] iphenylene diphosphonite) having the formula: EXAMPLES 1 TO 3 The materials listed in Table 1 were blended in a 1 inch Killion extruder at 270 β C. The samples were then injection molded (using a 1-1/4 oz. Newbury reciprocating screw injection molding machine) into test specimens at 260-270 β C. The test specimens were tested for the following: Tensile Modulus, Tensile Strength, % Elongation ASTM D-638 Tensile impact strength ASTM D-1822 Notched izod impact strength ASTM D-256 Heat Distortion Temperature ASTM D-648 Flammability UL-94 The test results are listed in Table 1 (as molded) and Table 2 (annealed) . The balance of properties for these formulations indicate that the molded article has high stiffness, high strength, high heat deflection temperature, and V-O flammability rating. Note that for polyarylate blends phosphite stabilizers are added as two-phase behavior is required for the property . balance. If esterexchange between polyarylate and PET occurs, single phase behavior results with modulus-temperature characteristics not desired for electrical/ electronic applications. Also two-phase behavior is desired for optimizing the environmental stress rupture resistance. With polycarbonate/PET systems, the addition of stabilizers to prevent ester-exchange is also desired. The rate of ester-exchange (or at least the propensity of polycarbonate/PET blends to yield single-phase behavior) superficially appears lower for polycarbonate/PET as compared to polyarylate/PET blends. TABLE 1 FORMULATIONS AND PROPERTIES OF POLYARYLATE AND POLYCARBONATE COMPOSITIONS (AS MOLDED) Example C Coonnttrrooll _1 _2 3 Polyarylate 40 30 25 20 PET 27 27 30 30 Polycarbonate - 10 10 15 Fiberglass 26 26 28 28 DBDPO 6.3 6.3 6.3 6.3 Mark 2112 0.7 0.7 0.7 0.7 Tensile Modulus (psi) 1,140,000 1,080,000 1,160, r ooo" 1,100,000 Tensile Strength (psi) 16,800 16,100 16, ,800 16,200 % Elongation , 2.0 2.0 2.0 2.2 Notched Izod Impact Strength (ft-lbs/in. of notch) 1.1 1.1 1.2 1.1 Tensile Impact Strength ft-lbs/in 19 30 25 28 Heat Distortion Temperature 264 psi, 1/8", • C 119°C 113 °C 115°C 102 'C Heat Distortion Temperature 66 psi, 1/8" 1 14499''CC 1 14488 »» CC 1 15511--CC 1 14400°°CC UL-94 1/16" V V -- 00 V V -- 00 V V - - 00 V V -- 0O TABLE 2 FORMULATIONS AND PROPERTIES OF POLYARYLATE AND POLYCARBONATE COMPOSITIONS (ANNEALED) Example Control _1 2 3 Polyarylate 40 30 25 20 PET 27 27 30 30 Polycarbonate 10 10 15 Fiberglass 26 26 28 28 DBDPO 6.3 6.3 6.3 6.3 Mark 2112 0.7 0.7 0.7 0.7 Tensile Modulus (psi) ,180 ,000 1,080,000 1,230,000 1,200,000 Tensile Strength (psi) 15 ,500 16,200 16,900 16,800 % Elongation 1.5 1.6 1.6 1.7 Notched Izod Impact Strength (ft-lbs/in. of notch) 1.0 0.9 1.0 1. Tensile Impact Strength ft-lbs/in 9 17 21 2 Heat Distortion Temperature 264 psi, 1/8", β C 142*C 141' C 141* C 139* Heat Distortion Temperature 66 psi, 1/8" 159'C 154" C 175° C 150° EXAMPLES 4 AND 5 The second series of formulations tested are listed in Table 3 (as molded) and Table 4 (annealed) for polyarylate/PET and polycarbonate/ PET-based composites. The results demonstrate a property profile desired for electrical/electronic applications. TABLE 3 (AS MOLDED) Example _4 Polyarylate 30 30 Polycarbonate 8.3 8.3 PET 25 25 Fiberglass 30 30 DBDPO 6.0 Brominated Polystyrene - 6.0 Sandostab P-EPQ 0.7 0.7 Tensile Modulus (psi) 1,250,000 1,190,000 Tensile Strength (psi) 15,900 15,600 % Elongation 1.6 1.6 Notched Izod Impact Strength (ft-lbs/in. of notch) 1.1 1.1 Tensile Impact Strength ft-lbs/in 34 23 Heat Distortion Temperature 264 psi, 1/8", "C 125°C 131"C Heat Distortion Temperature 66 psi, 1/8" 144°C 158 β C TABLE 4 ANNEALED Example Polyarylate 30 30 Polycarbonate 8.3 8.3 PET 25 25 Fiberglass 30 30 DBDPO 6.0 Brominated Polystyrene 6.0 Sandostab P-EPQ 0.7 0.7 Tensile Modulus (psi) 1,330,000 1,240,000 Tensile Strength (psi) 15,900 15,000 % Elongation 1.2 1.3 Notched Izod Impact Strength (ft-lbs/in. of notch) 0.9 1.0 Tensile Impact Strength ft-lbs/in 5 15 29 Heat Distortion Temperature 264 psi, 1/8", β C 136 β C 143°C Heat Distortion Temperature 66 psi, 1/8" 171°C 158°C Example 6 The formulation listed in Table 5 along with the processing variables were run in an 8 1/4 inch prototype connector mold and thus injection molded prototype connectors were obtained. TABLE 5 Example 7 Formulation 30% Polyarylate 8.3% Polycarbonate 25% PET 30% Fiberglass OCF-497 6% Decabromodiphenyloxide 0.7% Sandostab P-EPQ Temperature, Barrel, Rear 221* 'C Middle 256' 'C Front 265 β C Nozzle 265 C Stock 265" C Mold 93 . C Pressure: Boost 9000 > psi Hold 5000ι psi Screw RPM Machine: 2.2 oz. Arburg Mold: 8-1/4 inch prototype connector Example 6 and Control Samples of the various composites being evaluated for electrical/electronic applications were molded in an 8 inch x 8 inch x 65 mil cavity mold at 509 β F (for UL-9 ' 4 flammability testing) . The compression molded plague was then placed on a flat surface to determine the warpage. The maximum height from the flat surface to the bottom of the plague (around the edge) was determined. The results are given in Table 6. The sample based on a matrix of PBT was clearly warped and exhibited a typical "saddle" warp. The polycarbonate or polyarylate/polyester composites all exhibited much lower warpage during compression molding than the PBT sample. TABLE 6 Example 1 Control Polyarylate 30 - Polycarbonate 8.3 - PET 25 - PBT - 59.7 Fiberglass OCF-497 x 12 30 30 DBDPO 6 _ Brominated Polystyrene (Pyrocheck 68PB) 10 r Sandostab P-EPQ 0.7 Mark 2112 0.3 Warpage (8" x 8" x 65 mil plaque) 0.05 0.36 (inches)

Claims: WHAT IS CLAIMED IS: 1. An electrical device formed from a blend comprising (a) an aromatic polycarbonate, (b) a polyarylate resin, (c) a poly(alkylene terephthalate) resin, (d) fiberglass, and (e) an additive effective to inhibit ester-arylate interchange. 2. A device as defined in claim 1 wherein the aromatic polycarbonate resin is prepared from a dihydric phenol and a carbonate precursor. 3. A device as defined in claim 1 wherein the aromatic polycarbonate is the reaction product of bisphenol-A and phosgene. 4. A device as defined in claim 1 wherein the aromatic polycarbonate is the reaction product of bis(3,5-dimethyl-4-hydroxyphenyl)sulfone and a carbonate precursor. 5.- A device as defined in claim .1 wherein the aromatic polycarbonate is the reaction product of bis(3,5-dimethyl-4-hydroxyphenyl)- sulfone, a dihydric phenol and a carbonate precursor.- 6. A device as defined in claim 1 wherein the polycarbonate is a poly(ester carbonate) . 7. A device as defined in claim 1 wherein the polyarylate resin is derived from a dihydric phenol and at least one aromatic dicarboxylic acid. 8. A device as defined in claim 8 wherein the dihydric phenol is of the following formula: wherein Y is independently selected from, hydrogen, alkyl groups of 1 to 4 carbon atoms, chlorine or bromine, each a, independently, has a value of from 0 to 4, inclusive, and R. is a divalent saturated or unsaturated aliphatic hydrocarbon radical selected from an alkylene or alkylidene radical having from 1 to 6 carbon atoms, or a cycloalkylidene or cycloalkylene radical having up to and including 9 carbon atoms, 0, CO, SO , or S. 9. A device as defined in claim 1 wherein the polyarylate is derived from bisphenol A and a mixture of isophthalic and terephthalic acids. 10. A device as defined in claim 1 wherein the poly(alkylene terephthalate) is poly(ethylene terephthalate) . 11. A device as defined in claim 1 wherein the poly(alkylene terephthale) is poly(butylene terephthalate) . 12. A device as defined in claim 1 wherein the additive effective to inhibit ester-arylate interchange is selected from phosphites, phosphonites, a hydroxy-or a ino-substituted carboxylic acid derivative, and arsenic oxides. 13. A device as defined in claim 1 which contains a falme retardant additive. 14. An electrical conductor assembly for use in switches, connectors, contactors, relays, terminations, and the like comprising (a) an aromatic polycarbonate resin, (b) a polyarylate resin, (c) a poly(alkylene terephthalate) resin, (d) fiberglass, and (e) an additive effective to ' inhibit ester-arylate interchange, and an electrical conductive metal core extending at least partially through said shell. 15. The article of claim 14 wherein said metal core comprises a metal conductor embedded in said shell. 16. The article of claim 14 wherein said shell comprises a substantially regid housing for abuttingly engaging and supporting said core. 17. The process for fabricating an electrical conductor assembly comprising the steps of forming a support member comprising an aromatic polycarbonate, a polyarylate resin, a poly(alkylene terephthalate) resin, fiberglass, and additive effective to inhibit ester-arylate interchange; and positioning an electrical conductor in proximity to said support member. 18. The process of claim 17 wherein said forming comprises mixing said polycarbonate, polyarylate, poly(alkylene terephthalate) , fiberglass and additive and molding said mixture. 19. A composition comprising (a) a polyester and (b) an aromatic polycarbonate, wherein said polyester comprises a weight ratio of from 1:2 to 2:1 poly(alkylene terephthalate) to polyarylate, and said polycarbonate is present in a concentration of from 5 to 50 parts by weight per 100 parts by weight of polyester. 20. A composition comprising a fiberglass, an additive effective to inhibit ester-arylate interchange, a polyester, and an aromatic polycarbonate, wherein said polyester comprises a weight ratio of from 1:2 to 2:1 poly(alkylene terephthalate) to polyarylate, and said polycarbonate is present in a concentration of from 5 to 50 parts by weight per 100 parts by weight of polyester. 21. A composition as defined in claim 20 wherein the fiberglass is present in amounts of from about 20 to about 40 weight percent. 22. A composition as defined in claim 20 wherein the additive is present in amounts of from about 0.02 to about 25 weight percent.

Inventors: MCKENNA LAWRENCE ANTHONY, ROBESON LLOYD MAHLON, MCKENNA, LAWRENCE, ANTHONY, ROBESON, LLOYD, MAHLON
Applicants: AMOCO CORP, AMOCO CORPORATION
Application year: 1987
Main classification: C08L67
IPC codes: C08K5, C08K7, C08L67, C08L69, H01B3