Impact modified thermoplastic blends

Abstract: Tough transparent thermoplastics blends may be prepared by blending 10 to 99 weight percent of a block copolymer; 0.1 to 1 weight percent of particulate rubber having a particle size from 0.1 to 10 microns; and the balance a clear glassy polymer. These clear polymers are useful in a number of applications, particularly for those applications requiring quite high toughness and transparency such as packaging, containers or protective covering.

Description: This invention relates to impact modified thermoplastic blends. More particularly this invention relates to impact modified thermoplastic blends having a transparency of not less than 80 percent as measured on sheet material about 1 mm thick (.040 inches) thick. Such material is useful in a number of applications For example the blends may be used for lids for yogurt containers having a metal foil closure or for containers with snap top lids and in clear drinking glasses such as those used at sports stadiums or on airplanes and the like. General purpose polystyrene is used in a number of the above applications. While general purpose polystyrene has a high transparency, it is brittle and has a low falling dart resistance. Additionally, it fails a crush test in which a thermoformed cup is sealed over a vacuum source. There is a mandril inside the cup to prevent complete collapse. The cup is exposed to 71.13 cm (28 inches) of Mercury vacuum. The cup is observed to see if it collapses or cracks. The percent of the cups which fail or collapse and which pass is recorded. High impact polystyrene (HIPS) is known and used in some of these applications. Cups made of HIPS pass the crush test. Unfortunately, HIPS has a low transparency, as measured on a sheet 1 mm (.040 inches) thick, in the order of 40-50 percent. United States patent 4,145,376 issued March 20, 1979 to Labofina discloses a blend comprising polystyrene, a rubbery polymer such as polybutadiene and a sequenced polymer. The total amount of rubbery material in the blend is from 1 to 50 weight percent of the blend. The sequenced copolymer is used in an amount to provide from 3 to 90 weight percent of the total rubbery composition. The compositions of the present invention contain a sequenced polymer in an amount to provide over about 97 weight percent of the rubber material in the blend. The composition of the Labofina patent are opaque whereas the compositions made in accordance with the present invention have a transparency of at least 80 percent, preferably 90 percent most preferably over 95 percent. Blends of polystyrene and radial block copolymers are known. These blends are described, for example in U.S. patent 4,467,066 issued August 4, 1984 to Shell Oil Company. While these blends have a high clarity and toughness, cups made of about 50/50 blends of polystyrene and radial block copolymer do not pass the crush test. If the amount of radial block copolymer is increased the blend loses its stiffness. Chemical Abstract 97:7267d of European Patent Application 48388 filed March 12, 1982, in the name of BASE A.G., discloses a blend of 20-95 weight percent of an impact modified vinyl arene and a 1,3-diene; and 5-80 weight percent of a star-block copolymer comprising 55-80 parts of a vinyl arene and 20-45 parts of a 1,3-diene. The polymer blend has a good gloss and improved tensile strength. The exemplified blend, 90 percent impact modified styrene and 10 percent star-block copolymer would not have the high transparency required in the present invention. Furthermore, the blend of the reference contains a minimum of 20 percent of an impact copolymer of a vinyl arene and a diolefin. The impact modified copolymer, at the level at which it is used in the reference and the level of 1,3-diene in impact modified copolymer of about 6 percent would contribute more particulate impact modifier than is required in the present invention. Furthermore, the abstract is silent on particle size distribution of the impact modifier. Applicants have discovered novel thermoplastic blends which have a high resistance to impact, and good clarity. This is unexpected in view of the extremely low level of impact modifier present in the blend. A first aspect of the invention provides an impact modified thermoplastic blend, characterised by having a transparency of not less than 80 percent as measured using sheet material about 0.1cm (0.040 inches) thick comprising: a) from 10 to 99 weight percent of a transparent block copolymer which when blended with one or more clear glassy polymers gives a transparent blend, wherein said block copolymer comprises: 60 to 85 weight percent of at least one block polymer of at least one C₈₋₁₂vinyl aromatic monomer which is unsubstituted or substituted by a C₁₋₄ alkyl radical and from 40 to 15 weight percent of at least one block polymer of at least one C₄₋₆ conjugated diolefin, or said block copolymer comprises from 70 to 80 weight percent of styrene and 30 to 20 weight percent of butadiene; and wherein said glassy polymer is selected from: (i) poly C₈₋₁₂ vinyl aromatic polymers; (ii) styrene acrylates; (iii) copolymers of a C₈₋₁₂ vinyl aromatic monomer and a C₃₋₈ alkenyl nitrile; (iv) polyphenylene ethers; (v) polyphenylene sulfides; (vi) polysulfones; and (viii) polycarbonates; (b) from 0.01 to 1 weight percent of rubber in a particulate form having a volume moment average particle diameter from 100 to 10000nm (0.1 to 10 microns), wherein said rubber is selected from: (i) homopolymer of C₄₋₆ conjugated diolefins; (ii) homogeneous homo and copolymers of C₄₋₈ alkyl esters of acrylic and methacrylic acids, which homo and copolymers having a Tg of less than 20°C; (iii) heterogeneous polymers comprising 40 to 60 weight percent of a first domain comprising 100 to 70 weight percent of one or more C₄₋₈ acrylate or methacrylate esters which form homopolymer having a Tg less than 0°C, and from 0 to 30 weight percent of one or more monomers selected from: methyl acrylate, ethyl acrylate, methyl methacrylate, and ethyl methacrylate; and from 60 to 40 weight percent of a subsequent domain comprising a homopolymer or a copolymer of one or more monomers selected from: methyl acrylate, ethyl acrylate, methyl methacrylate, and ethyl methacrylate; (iv) linear and radial block copolymers having a molecular weight of not less than 75,000 and a styrene content from 20 to 50 weight percent selected from: styrene-butadiene diblock copolymers, styrene-butadiene-styrene triblock copolymers, styrene-isoprene diblock copolymers, styrene-isoprene-styrene triblock copolymers, partially hydrogenated styrene-butadiene-styrene triblock copolymers, and partially hydrogenated styrene-isoprene-styrene triblock copolymers; and (v) copolymers comprising 100-60 weight percent of a C₄₋₆ conjugated diolefin and 0-40 weight percent of one or more monomers selected from C₂₋₆ alkenyl nitrile monomers, C₈₋₁₂ vinyl aromatic monomers; C₁₋₄ alkyl esters of acrylic acid; C₁₋₄ esters of methacrylic acid; and (c) the balance said one or more clear glassy polymers. A second aspect of the invention provides a sheet material, characterised by comprising at least one said blend of the first aspect of the invention. A third aspect of the invention provides an article comprising at least one blend of the first aspect of the invention. Said article may be characterised by being a container or a lid for a container. Preferred embodiments of the invention are described in the dependent claims. The present invention is illustrated by the following description. The wording of the appended claims should be regarded as being imported into this description; i.e., the importing of that wording is a convenient manner of including statements of invention in the description. The present invention also provides a thin walled article from the above composition said article having a wall thickness from 0.25 mm to 12.0 mm (0.10 to 0.50 inches) preferably from 0.25 to 0.5 mm (0.010 to 0.25 inches) thick. In the figures: Figures 1 is a plot of curve developed based on a regression analysis of data, showing the falling dart impact kg/cm/cm (ft. 1b./inch) and transparency as a function of weight percent particulate rubber. Figure 2 is an electron micrograph of a blend of the present invention comprising 50 percent of a radial block copolymer comprising 75 percent styrene; 0.2 percent of cis-polybutadiene and the balance polystyrene. The thermoplastic blends of the present invention may have a transparency of not less than 80, preferably not less than 95 percent when measured in sheet form, having a thickness of not greater than 1mm (0.040 inches). As used in this specification the term glassy polymer means a polymer which is hard at room temperature (e.g. has a Tg greater than 22°C). The clear glassy polymer may be a homopolymer or a copolymer or miscible blends of such co or homopolymers. The clear glassy polymer may be selected from: i) poly C₈ vinyl aromatic polymers; ii) copolymers comprising 70 to 90 weight percent of a C₈₋₁₂ vinyl aromatic monomer and 30 to 10 weight percent of a C3-6 alkenyl nitrile monomer; iii) styrene acrylates; iv) polyphenylene ethers; v) polyphenylene sulfides; vi) polysulfones; and (vii) polycarbonates. Clear glassy polymers may be polystyrene, styrene-alkenyl nitriles (e.g. SAN), polycarbonates. The glassy polymer may comprise one or more polymers selected from i) homopolymers of C₈₋₁₂ vinyl aromatic monomers which are unsubstituted or subsitituted by a C₁₋₄ alkyl radical ii) copolymers comprising 50 to 90 weight percent of one or more C₈₋₁₂ vinyl aromatic monomers which are unsubstituted or substituted by a C₁₋₄ alkyl radical and 10 to 50 weight percent of one or more C₁₋₄ alkyl esters of acrylic or methacrylic acid; iii) copolymers comprising 70 to 90 weight percent of one or more C₈₋₁₂ vinyl aromatic monomers which are unsubstituted or substituted by a C₁₋₄ alkyl radical and 30 to 10 weight percent of a C₃₋₆ alkenyl nitrile monomer; iv) polymers having a backbone of the formula wherein R₁ and R₂ are independantly selected from : a hydrogen atom, a chlorine atom, C₁₋₄ alkyl radicals and a C₆₋₁₀ aromatic radical which is unsubstituted or substituted by a C₁₋₄ alkyl radical; and n is an integer from 300 to 700; v) polymers having a backbone of formula wherein n is an integer of at least 250; vi) polymers having a molecular weight from about 30,000 to 100,000, preferably from about 40,000 to 60,000 having as the backbone one or more recurring units selected from: vii) one or more homo-and co-polycarbonates which are based on one or more poly phenols selected from : hydroquinone, resorcinol, and polyphenols of the formula. wherein R₁ R₂, R₃ and R₄; are independently selected from : a hydrogen atom, a chlorine atom, a bromine atom, and a C₁₋₄ alkyl radical; and X is a bond or divalent radical selected from: C₁₋₁₀ alkylene radicals; C₂₋₈ alkenylene radicals, and C₆₋₈ cycloalkylene radicals. If the clear glassy polymer is added as a separate component, the glassy polymer may be used in the blend in an amount from about 10 to 90, preferably 20 to 70, most preferably from 40 to 60 weight percent. Some C₈₋₁₂ vinyl aromatic monomers are styrene, alpha methyl styrene, para methylstyrene and para tertiary butyl styrene. Polystyrene is a particularly useful polymer. C₁₋₄ alkyl esters of acrylic and methacrylic acid may be methyl methacrylate, ethyl methacrylate, methyl acrylate, ethyl acrylate and butyl acrylate. Preferably the acrylate polymers are homopolymers of methyl methacrylate, ethyl acrylate and copolymers of methyl methacrylate and ethyl acrylate. C₃₋₆ alkenyl nitriles may be acrylonitrile and methacrylonitrile. The block copolymer in the thermoplastic blend is a block copolymer which when blended with a clear glassy polymer gives a transparent blend. The block copolymer may be a block copolymer of a vinyl aromatic block polymer and a conjugated diolefin block polymer; an acrylic block polymer and a conjugated diolefin block polymer; a vinyl aromatic block polymer and an acrylic block polymer; and a block of a vinyl aromatic acrylate polymer ) (e.g. styrene-methyl(meth)acrylate-butyl acrylate) and a rubbery acrylate block (e.g. butyl acrylate homopolymer). The block copolymer may comprise at least one block polymer of one or more C₄₋₆ conjugated diolefins and at least one block of one or more C₈₋₁₂ vinyl aromatic monomers which are unsubstituted or substituted by a C₁₋₄ alkyl radical. Preferably the block copolymer comprises from 60 to 85, most preferably from 70 to 80 weight percent of a poly vinyl aromatic monomer and from 40 to 15 most preferably from 30 to 20 weight percent of a poly C₄₋₆ conjugated diolefin which is unsubstituted or substituted by a chlorine atom. The block copolymer may be a radial block copolymer. Some vinyl aromatic monomers are styrene, alpha methyl styrene, para methylstyrene and para tertiary butyl styrene. A particular vinyl aromatic is styrene. The conjugated diolefin may be unsubstituted or substituted by a chlorine atom. Some conjugated diolefins are butadiene and isoprene. Radial block copolymers are commercially available; for example those sold by Phillips under the tradename "KR". The methods for preparing such resins are disclosed in the literature. The resins are produced by a sequential anionic polymerization using for example a lithium based catalyst. The blends according to the present invention must contain rubber in a particulate form having a volume moment average particle diameter from 100 to 10000 nm (0.1 to 10 microns) as defined by statistical equation Σ i n i d 4 i Σ i n i d 3 i wherein ni is the number of particles in the diameter class di of the sample. (Allen T., Particle Size Measurement, Chapman and Hall 1974) The rubber in particulate from may have a particle size from 100 to 10000 nm (0.1 to 10), preferably from 200 to 3000 nm (0.2 to 3), most preferably from 300 to 1500 nm (0.3 to 1.5 microns). The rubber particles may be introduced into the blends of the present invention in the following ways. It may be a powder derived from a latex of a rubber polymer onto which has been grafted a polymer which is compatible with a glassy polymer. It may be in the form of a particulate toughened thermoplastic in which the particles are in the form of grafted and/or occluded rubber particles such as high impact polystyrene (HIPS); ABS (both emulsion and bulk) or analogous toughened acrylates such as ZYLAR resin sold by Polysar. The thermoplastic may be a clear glassy polymer, as defined above, or it may be present merely as a carrier for the particulate material provided it does not reduce the transparency of the blend to below 80 percent, more preferably to not below 90 percent, most preferably to not below 95 percent. The rubber polymer within these particles may be selected from : (i) homopolymers of C₄₋₆ conjugated diolefins which are unsubstituted or substituted by a chlorine atom; (ii) homogeneous homo- and copolymers of C₄₋₈ alkyl esters of acrylic and methacrylic acid which homo- and copolymers have a Tg less than 20°C; (iii) heterogeneous polymers comprising 40 to 60 weight percent of a first domain comprising 100 to 70 weight percent of one or more C₄₋₈ acrylate or methacrylate esters which form homopolymers having a Tg less than 0°C, and from 0 to 30 weight percent of one or more monomers selected from : methyl acrylate, ethyl acrylate, methyl methacrylate and ethyl methacrylate; and from 60 to 40 weight percent of a subsequent domain comprising a homopolymer or a copolymer of one or more monomers selected from : methyl acrylate, ethyl acrylate, methyl methacrylate, and ethyl methacrylate; (iv) linear and radial block copolymers having a molecular weight of at least 75,000 and a styrene content from 20 to 50 weight percent selected from: styrene-butadiene diblock copolymers, styrene-butadiene-styrene triblock copolymers, styrene-isoprene diblock copolymers, styrene-isoprene-styrene triblock copolymers, partially hydrogenated styrene-butadiene-styrene triblock copolymers, and partially hydrogenated styrene-isoprene-styrene triblock copolymers; (v) copolymers comprising 100-60 weight percent of a C₄₋₆ conjugated diolefin and 0-40 weight percent of one or more monomers selected from : C₂₋₆ alkenyl nitrile monomers, C₈₋₁₂ vinyl aromatic monomers; C₁₋₄ alkyl esters of acrylic acid; C₁₋₄ esters of methacrylic acid. If the rubber is a poly C₄₋₆ conjugated diolefin it is preferably in the cis- configuration. The polymer may contain it least about 55 more preferably at least 95, most preferably at least 98 weight percent of the polymer in the cis- configuration. The rubber particles may be incorporated in the blend in the form of high impact polystyrene, an impact modified acrylate or a graft copolymer. The high impact polystyrene may comprise from 90 to 95 weight percent of one or more C₈₋₁₂ vinyl aromatic monomers, preferably polystyrene and from 5 to 10 moot preferably about 6 weight percent of a cis- poly C₄₋₆ conjugated diolefin which is unsubstituted or substituted by a chlorine atom. Some cis- conjugated diolefins contain at least about 55 percent, preferably greater than 95, most preferably about 98 percent of the monomer units in a cis- configuration. The remaining monomer units in the conjugated diolefin are in the trans configuration or are in a vinyl configuration. These polymers are well known in the industry. The impact polystyrene is prepared by dissolving the cis-C₄₋₆ polybutadiene in styrene monomer. The styrene is then polymerized. The rubber particles may be incorporated in the blend in the form of an impact modified styrene acrylate comprising from 0.1 to 10 weight percent of a cis- polymer of one or more C₁₋₄ conjugated diolefins which are unsubstituted or substituted by a chlorine atom onto which is grafted a copolymer comprising: from 10 to 50 weight percent of one or more acrylate or methacrylate esters which form hompolymers having a Tg greater than 35°C; from 50 to 90 preferably from 70 to 90 weight percent of one or more C₈₋₁₂ vinyl aromatic monomers which are unsubstituted or substituted by a C₁₋₄ alkyl radical; end from 0 to 9.9 weight percent of one or more acrylate or methacrylate esters which form homopolymers having a Tg greater than 20°C. Such impact modified acrylates may be prepared by conventional bulk polymerization in which the rubber is dissolved in the monomers and the monomers are subsequently polymerized. Alternately the polymer may be prepared by a suspension process in which a latex of the rubber is added to an aqueous suspension of the monomers prior to or during polymerization. Some vinyl aromatic monomers have been discussed above. Acrylate and methacrylate esters which form homopolymers having a Tg greater than 35°C may be methyl methacrylate, ethyl methacrylate, and t-butyl acrylate. Acrylate and methacrylate esters which form homopolymers having a Tg less than 20°C may be ethyl acrylate, propyl acrylate, butyl acrylate and ethyl hexyl acrylate. Some rubbery substrates for the impact modified acrylates and methacrylate copolymers may comprise cis-polymers of C₄₋₆ conjugated diolefins. A particular rubber may include cis- polybutadiene. This polymer has been discussed above. The particulate rubber may be incorporated in an acrylate homopolymer comprising 60 to 99.5 weight percent of a matrix of a polymer formed from one or more monomers selected from : a C₁₋₂ alkyl esters of acrylic or methacrylic acid, having dispersed therein from 0.5 to 40 weight percent of a soft acrylic such as butyl acrylate. Such a polymer is disclosed in Canadian Patent 901,397 issued May 30, 1972 to Rohm & Haas Company (Dunkelberger). The impact modified acrylic polymer may comprise a glassy matrix as described above having dispersed through the matrix a core/shell acrylate polymer comprising 40 to 60 weight percent of a first domain, such as a core which is an acrylate polymer having a Tg less than -20°C, such as a butyl acrylate homopolymer or a butyl acrylate copolymer which may contain up to 30, preferably less than 15 weight percent of one or more monomers selected from : methyl acrylate, ethyl acrylate, methyl methacrylate and ethyl methacrylate and 60 to 40 weight percent of a subsequent domain, such as a shell which is an acrylate polymer having a Tg greater than 20°C. preferably from about 35°C. to 60°C. Such heterogeneous polymers may have a subsequent or second domain of one or more monomers selected from : methyl methacrylate, ethyl methacrylate, methyl acrylate and ethyl acrylate. The particulate rubber may be incorporated in the blend in the form of a styrene-acrylate graft copolymer. Such a graft copolymer may comprise: from 2 to 20, preferably 4 to 12 parts by weight of linear and radial di and tri block copolymers having a molecular weight of not less than 75,000, preferably from 175,000 to 275,000 and a styrene content of from 20 to 50 weight percent selected from : styrene-butadiene-diblock copolymers, styrene-butadiene-styrene triblock copolymers, partially hydrogenated styrene-butadiene-styrene triblock copolymers, and partially hydrogenated styrene-isoprene-styrene triblock copolymers onto which has been grafted a polymer comprising: i) from 50 to 75, preferably 50 to 65 parts by weight of a C₈₋₁₂ vinyl aromatic monomer which is unsubstituted or substituted at the vinyl radical by a C₁₋₂ alkyl radical and which is unsubstituted or substituted in the aromatic ring by up to two substitutents selected from: C₁₋₄ alkyl radicals; ii) from 7 to 30, preferably from 8 to 20 parts by weight of a C₁₋₈ alkyl or hydroxy alkyl ester of a C₃₋₆ ethylenically unsaturated carboxylic acid which forms a homopolymer having a Tg less than 20°C; iii) from 10 to 50, preferably 15 to 40 parts by weight of methyl methacrylate. The impact modifier may be introduced into the blend in the form of an impact modified polymer comprising: from 10 to 5 weight percent of a copolymer comprising 100-60 weight percent of a C₄₋₆ conjugated diolefin and 0-40 weight percent of at least one monomer selected from : C₃₋₆ alkenyl nitrile monomers; C₈₋₁₂ vinyl aromatic monomers C₁₋₄ alkyl esters of acrylic acid and C₁₋₄ alkyl esters of methacrylic acid onto which has been grafted 90 to 95 weight percent of a copolymer comprising 70 to 90 weight percent of a C₈₋₁₂ vinyl aromatic monomer which is unsubstituted or substituted by a C₁₋₄ alkyl radical 30 to 10 weight percent of a C₃₋₆ alkenyl nitrile. These polymers are typically referred to as ABS resins. When using ABS care should be taken in selecting the clear glassy polymer if present. Preferably the ABS is used with a styrene-acrylonitrile (SAN) polymer. However, simple testing may be carried out to determine the transparency of the blend. The thermoplastic blends of the present invention may be prepared by tumble blending, the block copolymer, the rubber particles and the clear glassy polymer in the required proportions. The resulting blend may then be extruded in sheet form. The resulting sheet may then be thermoformed or blow molded. Alternately, the blend may be extruded as strands and chopped to length. The resulting pellets may then be injection molded or injection blow molded to form the required article. The temperatures during processing are easily determined by non inventive testing known to those skilled in the art. The thermoplastic blends of the present invention may be used to make a variety of articles including thermoformed articles; thermoformed, blow molded or injection molded articles which may be thin walled. As used in this specification the word thin walled article is used for simplicity. It is intended that this word includes sheet material, drinking glasses, bowls, lids, trays and other articles The blend may be extruded, as a sheet,in the case of disposable articles. The extruded sheet may then be heated and thermoformed or pressure formed. The heated sheet is placed over a female die which is connected to a vacuum. The sheet may be urged into place with a male die then optionally a vacuum is applied. The sheet material is drawn into the die and conforms with the interior die surface or pressure may be applied by the male mold to force the thermoplastic to conform with the interior of the mold. The wall thickness is usually less than that of the sheet due to the elongation of the plastic as it conforms to the interior die surface. The molded part may have a wall thickness less than 13 mm (0.5 inches) preferably from about 13 mm (0.50 inches) to about 0.25 mm (0.10 inches), most preferably in the range from 0,5 mm (0.25 inches) to 0,25 mm (0.10 inches). Alternately the blends of the present invention may be injection molded or blow molded. The formed product then leaves the mold and excess material is trimmed from the product. The thermoplastics of the present invention may be used to manufacture a number of articles, such as clear lids on tamper proof food containers, such as yogurt cups; clear lids for prepackaged foods served on airplanes, trains and the like, and drinking cups. In sheet form the blends of the present invention may be used over windows or lights as signs, etc. The sheet material may be injection blow molded to form bottles, or thermoformed or press molded to form cups. The following examples are intended to illustrate the invention. In the examples, unless otherwise indicated parts are parts by weight (e.g. grams). Example I As a comparative example a blend of material, in accordance with U.S. 4,145,376 was prepared. The blend comprised: The blend was compounded using a Haake mixer at 210°C/70 rpm for 5 min. The resulting product was compression molded as a sheet 0.686 cm (0.027 inches) thick. The transparency of the sheet measured using a Datacolour Elrephro 200 was 47 percent (transparency obtained by measuring percent opacity and subtracting from 100). This demonstrates that the blends of U.S. 4,145,376 do not have the high transparency of the blends of the present invention. Example II In the examples the following polymers were used: i) polystyrene sold under the Trademark POLYSAR. The grade number is 210. This is a medium flow injection molding and extrusion grade of polystyrene having a typical tensile yield as determined by ASTM D638 of 421,8 kg/cm² (6000 psi); ii) radial block styrene-butadiene copolymers having a styrene content of about 75 weight percent sold by Phillips under the tradename KR; iii) particulate rubber incorporated as impact modified polystyrene containing 6 weight percent cis-polybutadiene having a volume moment average diameter from 300 to 1500 nm (0.3 to 1.5 microns) produced by Polysar Limited under the experimental grade number 2172. Blends were prepared by tumble blending or extrusion compounding to give pellets. The dry or extruded blend was then extruded as a sheet 1 mm (0.040 inches) thick. The sheet was then thermoformed into a cup. The excess sheet material was trimmed from the cup. The cup was then subjected to a vacuum crush test. The cup is placed over a vacuum source with a mandrel inside to prevent complete collapse of the cup. The cup is clamped into place on a seal to prevent air leaks. The vacuum is applied to 71.13 cm (28 inches) of Mercury. The cups pass if they do not crack or collapse. The cups fail if they crack, collapse, or implode. The percent of cups which pass or fail was measured. In addition to the above tests the sheet material was subjected to a falling dart test (ASTM No. D-3029G) and the transparency of the sheet was measured using a Datacolour Elrephro 200. The compositions and the results are set out in table 1. Composition Cup Crush Test Falling Dart Impact Kg/cm/cm (Ft.lb./in.) Transparency % Elongation % (Transverse direction) polystyrene 100% fail -- 99 Polystyrene Radial Block copolymer 50:50 100% fail 9.2 (1.7) 95 47.3 Polystyrene: Radial Block copolymer: rubber particles 54.8:44.5:0.7 100% pass 148.5 (27.5) 87 103 Polystyrene: Radial block copolymer: rubber particles 50.04:49.45:0.06 100% pass 8/00 (15.0) 95 63.6 Impact Polystyrene 100% pass 256.5 (47.5) 48 27 These results show that the blends of the present invention have unique properties in their ability to provide a high degree of toughness while maintaining essentially the same transparency. Example III The same polymers that were used in Example II were blended in a series of ratios. The blends comprised: i) 50 percent of a radial block copolymer having a styrene content of about 75 weight percent sold by Philips under the tradenames KR-05 to KR-04 (which are similar to KR-03, KR-02 and KR-01). ii) 0.3; 0.6; 0.9; 1.0 parts of an high cis rubber having a volume moment average diameter from 300 to 1500 nm (0.3 to 1.5 microns present in an amount of 6 percent of weight of a high impact polystyrene produced by Polysar Limited under the experimental designation 2172. (This corresponds to high impact polystyrene content of 5, 10, 15 and 18 weight percent.) iii) the balance to bring the composition to 100 weight percent of polystyrene sold under the trademark POLYSAR grade 210. The blends were extruded to give pellets and then extruded as sheet material 7 nm (0.040 inchs) thick. The falling dart impact of the samples, was determined using ASTM D-30296. The transparency of the sheet was determined use a Datacolour Elrephro 200. The results were then fitted to a curve using a regression analysis and the resulting curve is plotted in figure 1. Example IV A blend of the materials referred to in Example II was prepared. The blend comprised: 50 percent of a radial block copolymer having a styrene content of about 75 weight percent sold by Phillips under the tradename KR-05; 0.2 weight percent of particulate cis-polybutadiene having a volume moment average diameter from 300 to 1500 nm (0.3 to 1.5 microns) present in an amount of 6 percent by weight of a high impact polystyrene produced by Polysar Limited under the experimental designation 2172; (corresponding to a HIPS content of 3.3 weight percent); and The balance to bring the composition to 100 weight percent polystyrene sold under the trademark POLYSAR grade 210. The resulting sample has a transparency of 93.2 percent; an elongation in the transverse direction of 57.6 percent and a falling dart impact of 68.6 kg/cm/cm (12.7/ft. 1b.inch). An electron micrograph (Mag 65,547 X; OsO₄ stain) was taken of a portion of the blend. Figure 2 is a copy of the electron micrograph. Without wishing to be bound by theory in the figure the wavy lines portion of the matrix is attributed to the radial block copolymer-polystyrene blend. The circular domains are attributed to the polybutadiene particles. It is believed that the clear area around the particles is a polystyrene domain. It is also believed that the normal polybutadiene domains having occluded polystyrene, in HIPS, have been partially dispersed in the blend giving rise to the single or small groups of rubber particles shown in figure 2. Example V A further series of blends were prepared. In the blends the following materials were used. SAN - Dow Styrene acrylonitrile copolymer sold under the tradename TYRIL 860. ABS - Dow acrylonitrile butadiene Styrene polymer containing about 6 percent of occluded polybutadiene having a particle size of about 1000 nm (1 micron). 77-5 - Styrene acrylate comprising about 20 percent methyl methacrylate and about 80 percent styrene which is supension polymerized in the presence of a sufficient amount of a polybutadiene latex to provide a rubber content of 0.5 percent. 77-3 - a styrene acrylate comprising about 20 percent methyl methacrylate and about 80 percent styrene which is polymerized in the presence of a sufficient amount of a polybutadiene latex to provide a rubber content of 0.1 percent. ZYLAR 92 Resin a polymer comprising about 50 percent Styrene about 30 percent methyl methacrylate about 6 percent butyl acrylate grafted on to an styrene-butadiene block copolymer. Polystyrene - the polystyrene of example II 506 - a styrene acrylic about 78:22 (no impact modifier) sold by the Plastics Group of Polysar Inc. under the trade mark POLYSAR grade 506. HIPS - high impact polystyrene of Example II. PPO - 2,6 dimethyl polyphenylene ether (sometimes referred to as PPO) from General Electric. The blends were prepared and tested for transmission and falling dart impact as described above. The compositions as the results are set forth in table II. * trademark Composition Transparency Percent Falling Dart Impact kg/cm/cm (Ft lb./inch) 1) SAN 50% ABS 1.1% Block copolymer 48.9 % 92 78.8 (14.6) 2) (control see 1) SAN 50% Block copolymer 50% 96 7.6 (1.4) 3) 77-3 50% Block copolymer 50% 96 744.1 (137.8) 4) 77-5 50% Block copolymer 50% 96 306.7 (56.8) 5) Polystyrene 50% ZYLAR 90 1.1% Block copolymer 48.9% 88 14.6 (2.7) 6) Polystyrene 50% ZYLAR 92 1.1% Block copolymer 48.9% 91 7.6 (1.4) 7) (control see 3 or 4) 506 50% Block copolymer 50% 98 56.7 (10.5) 8) (control Ex. II, 5 & 6) Polystyrene 50% Block copolymer 50% 96 7.0 (1.3) 9) (control 11) PPO 50% Block copolymer 50% 82 - 10) PPO 50% HIPS 1.1% Block copolymer 48.9% 80 - In the present application, any numerical value includes the precise value and any value "about" or "substantially" the same as the precise value.

Claims: An impact modified thermoplastic blend, characterised by having a transparency of not less than 80 percent as measured using sheet material 0.1cm (0.040 inches) thick comprising: a) from 10 to 99 weight percent of a transparent block copolymer which when blended with one or more clear glassy polymers gives a transparent blend, wherein said block copolymer comprises: 60 to 85 weight percent of at least one block polymer of at least one C₈₋₁₂ vinyl aromatic monomer which is unsubstituted or substituted by a C₁₋₄ alkyl radical and from 40 to 15 weight percent of at least one block polymer of at least one C₄₋₆ conjugated diolefin, or said block copolymer comprises from 70 to 80 weight percent of styrene and 30 to 20 weight percent of butadiene; and wherein said glassy polymer is selected from: (i) poly C₈₋₁₂ vinyl aromatic polymers; (ii) styrene acrylates (iii) copolymers of a C₈₋₁₂ vinyl aromatic monomer and a C₃₋₈ alkenyl nitrile; (iv) polyphenylene ethers (v) polyphenylene sulfides; (vi) polysulfones; and (vii ) polycarbonates. (b) from 0.01 to 1 weight percent of rubber in a particulate form having a volume moment average particle diameter from 100 to 10000nm (0.1 to 10 microns), wherein said rubber is selected from: (i) homopolymer of C₄₋₆ conjugated diolefins; (ii) homogeneous homo and copolymers of C₄₋₈ alkyl esters of acrylic and methacrylic acids, which homo and copolymers having a Tg of less than 20°C; (iii) heterogeneous polymers comprising 40 to 60 weight percent of a first domain comprising 100 to 70 weight percent of one or more C₄₋₈ acrylate or methacrylate esters which form homopolymer having a Tg less than 0°C, and from 0 to 30 weight percent of one or more monomers selected from: methyl acrylate, ethyl acrylate, methyl methacrylate, and ethyl methacrylate; and from 60 to 40 weight percent of a subsequent domain comprising a homopolymer or a copolymer of one or more monomers selected from: methyl acrylate, ethyl acrylate, methyl methacrylate, and ethyl methacrylate; (iv) linear and radial block copolymers having a molecular weight of not less than 75,000 and a styrene content from 20 to 50 weight percent selected from: styrene-butadiene diblock copolymers, styrene-butadiene-styrene triblock copolymers, styrene-isoprene diblock copolymers, styrene-isoprene-styrene triblock copolymers, partially hydrogenated styrene-butadiene-styrene triblock copolymers, and partially hydrogenated styrene-isoprene-styrene triblock copolymers; and (v) copolymers comprising 100-60 weight percent of a C₄₋₆ conjugated diolefin and 0-40 weight percent of one or more monomers seleated frow C₂₋₆ alkenyl nitrile monomers, C₈₋₁₂ vinyl aromatic monomers; C₁₋₄ alkyl esters of acrylic acid; C₁₋₄ esters of methacrylic acid; and (c) the balance said one or more clear glassy polymers. A blend as in claim 1, characterised by said rubber has a volume moment average particle size from 0.2 to 3 µm. A blend as in claim 1 or 2, characterised by said block polymer is a radial block polymer. A blend as in claim 3, characterised by said rubber has a volume moment average diameter from 0.5 to 1.5 µm. A blend as in claim 4, characterised by said rubber is introduced into the transparent block copolymer in the form of an impact modified polymer blend comprising from about 0.1 to 20 weight percent of said rubber in particulate form and from 99.9 to 80 weight percent of a clear glassy polymer. A blend as in claim 5, characterised by said impact modified polymer blend is selected from: (i) high impact polystyrene comprising 90 to 95 weight percent of styrene and 5 to 10 weight percent of a cis- poly C₁₋₄ conjugated diolefin; (ii) a styrene acrylate copolymer comprising: (a) 10 to 50 weight percent of one or more acrylate or methacrylate esters which form homopolymers having a Tg greater than 35°C, 50 to 90 weight percent of one or more C₈₋₁₂ vinyl aromatic monomers which are unsubstituted or substituted by a C₁₋₄ alkyl radical; 0 to 9.9 weight percent of one or more acrylate or methacrylate esters which form homopolymers having a Tg of less than 20°C; (b) either (i) grafted to from 0.1 to 10 weight percent of a cis-polymer of one or more C₄₋₆ conjugated diolefins or (ii) having from 0.1 to 40 weight percent of a dispersed polymer phase selected from: homopolymers of butyl acrylate and core shell polymers comprising 40 to 60 weight percent of a core comprising 100 to 70 weight percent of butyl acrylate and 0 to 30 weight percent of one or more monomers selected from: methyl acrylate, ethyl acrylate, methyl methacylate, and ethyl methacrylate; and 60 to 40 weight percent of a shell consisting of one or more monomers selected from: methyl acrylate, ethyl acrylate, methyl methacylate, and ethyl methacrylate; (iii) a graft copolymer comprising: from 2 to 20 parts by weight of linear and radial di and tri block copolymers having a molecular weight of 75,000 and a styrene content from 20 to 50 weight percent selected from: styrene-butadiene diblock copolymers, styrene-butadiene-styrene triblock copolymers, styrene-isoprene diblock copolymers, styrene-isoprene-styrene triblock copolymers, partially hydrogenated styrene-butadiene-styrene triblock copolymers, and partially hydrogenated styrene-isoprene-styrene triblock copolymers onto which is grafted a polymer comprising: (a) 25 to 75 parts by weight of a C₈₋₁₂ vinyl aromatic monomer which is unsubstituted or substituted at the vinyl radical by a C₁₋₂ alkyl radical and which is unsubstituted or substituted in the aromatic ring by up to two alkyl radicals (b) from 70 to 30 parts by weight of a copolymerizable C₁₋₈ alkyl or hydroxyalkyl ester of a C₃₋₆ ethylenically unsaturated acid provided that such esters have a Tg of less than 40°C; (c) from 10 to 50 parts by weight of methyl methacrylate; and (iv) an impact modified polymer comprising: from 10 to 5 weight percent of a copolymer comprising: 100-60 weight percent of a C₄₋₆ conjugated diolefin and 0-40 weight percent of at least one monomer selected from: C₃₋₆ alkenyl nitrile monomers; C₈₋₁₂ vinyl aromatic monomers, C₁₋₄ alkyl esters of acrylic acid and C₁₋₄ alkyl esters of methacrylic acid onto which is grafted a copolymer comprising 90 to 95 weight percent of a copolymer comprising 70 to 90 weight percent of a C₈₋₁₂ vinyl aromatic monomer which is unsubstituted or substituted by a C₁₋₄ alkyl radical 30 to 10 weight percent of a C₃₋₆ alkenyl nitrile. A blend as in claim 6, characterised by comprising per 40 to 60 weight percent of said blend of block copolymer and rubber from 60 to 40 weight percent of a clear glassy polymer selected from: polystyrene, styrene-alkenyl nitrile copolymers, polyphenylene ethers, polyphenyl sulfides; polysulfones and polycarbonates. A blend as in claim 7, characterised by said rubber is introduced into the blend in the form of a high impact polystyrene comprising 90 to 95 weight percent of styrene grafted to 5 to 10 weight percent of a cis-poly C₄₋₆ conjugated diolefin. A blend as in claim 8, characterised by said cis-poly C₄₋₆ conjugated diolefin is a cis-polybutadiene. A blend as in claim 9, characterised by said clear glassy polymer is polystyrene. A blend as in claim 10, characterised by comprising 39.5 to 58.5 weight percent of polystyrene; 60 to 40 weight percent of radial block copolymer comprising 70 to 80 weight percent styrene and 30 to 20 weight percent of polybutadiene and 0.05 to 0.7 weight percent of high impact polystyrene. A blend as in claim 11, characterised by said rubber is introduced into the blend in the form of an impact modified acrylate copolymer comprising: from 0.1 to 10 weight percent of a high cis-polymer of one or more C₄₋₆ conjugated diolefins onto which is grafted a polymer comprising: (a) 10 to 50 weight percent of one or more acrylate or methacrylate esters which form homopolymers having a Tg greater than 35°C; (b) 50 to 90 weight percent of one or more C₈₋₁₂ vinyl aromatic monomers which are unsubstituted or substituted by a C₁₋₄ alkyl radical; and (c) 0 to 9.9 weight percent of one or more acrylate or methacrylate esters which form homopolymers having a Tg of less than 20°C. A blend as in claim 12, characterised by said impact modified acrylate comprises from 0.1 to 10 weight percent of a high cis-polybutadiene onto which is grafted a polymer comprising: (a) 10 to 30 weight percent of one or more monomers selected from: methyl methacrylate; ethyl methacrylate and a mixture thereof; (b) 70 to 90 weight percent of one or more monomers selected from: styrene, alpha-methyl styrene; and para-methyl styrene; and (c) from 5 to 9.9 weight percent of one or more monomers selected from: ethyl acrylate, propyl acrylate, butyl acrylate, and ethylhexyl acrylate. A blend as in claim 13, characterised by said clear glassy polymer is polystyrene. A blend as in claim 13, characterised by said clear glassy polymer comprises 50 to 90 weight percent of one or more monomers selected from: styrene, alpha-methyl styrene and para-methyl styrene; and 10 to 50 weight percent of one or more monomers selected from: methyl methacrylate, ethyl acrylate and a mixture thereof. A blend as in claim 7, characterised by said rubber is introduced into the blend in the form of an impact modified acrylate comprising: (a) 60 to 90.5 weight percent of a polymer comprising one or more monomers selected from: C₁₋₂ alkyl esters of acrylic and methacrylic acid; and (b) from 0.5 to 40 weight percent of a dispersed polymer phase selected from: homopolymers of butyl acrylate and core shell polymers comprising 40 to 60 weight percent of a core comprising 100 to 70 weight percent of butyl acrylate and 0 to 30 weight percent of one or more monomers selected from: methyl acrylate, ethyl acrylate, methyl methacrylate, and ethyl methacrylate; and 60 to 40 weight percent of a shell comprising one or more monomers selected from: methyl acrylate, ethyl acrylate, methyl methacrylate, and ethyl methacrylate. A blend as in claim 16, characterised by said clear glassy polymer is selected from: polymethyl methacrylate and polyethyl acrylate. A blend as in claim 16, characterised by said clear glassy polymer comprises 70 to 90 weight percent of one or more monomers selected from: styrene, alpha-methyl styrene and para-methyl styrene; and 10 to 30 weight percent of one or more monomers selected from: methyl methacrylate, ethyl acrylate and a mixture thereof. A blend as in claim 7, characterised by said rubber is introduced into the blend in the form of a graft copolymer comprising: from 4 to 12 parts by weight of a di- or triblock copolymer having a molecular weight from 175,000 to 275,000 selected from: styrene-butadiene-styrene triblock copolymers and styrene-isoprene - styrene triblock copolymers onto which is grafted a polymer comprising: (a) from 30 to 65 parts by weight of said vinyl aromatic monomer; (b) from 8 to 20 parts by weight of said copolymerizble C₁₋₈ alkyl or hydroxyl alkyl ester of C₃₋₆ ethylenically unsaturated carboxylic acid, which ester forms a homopolymer having a Tg less than 20°C; and (c) from 15 to 40 parts by weight of methyl methacrylate. A blend as in claim 19, characterised by said clear glassy copolymer comprises polystyrene. A blend as in claim 19, characterised by said clear glassy polymer comprises 70 to 90 weight percent of one or more monomers selected from: styrene, alpha-methyl styrene and para-methyl styrene; and 10 to 30 weight percent of one or more monomers selected from: methyl methacrylate, ethyl acrylate and a mixture thereof. A blend as in claim 7, characterised by said rubber is introduced into the blend in the form of an impact modified polymer comprising: from 10 to 5 weight percent of a copolymer comprising: 100-60 weight percent of a C₄₋₆ conjugated diolefin and 0-40 weight percent of at least one monomer selected from: C₃₋₆ alkenyl nitrile monomers, C₈₋₁₂ vinyl aromatic monomers, C₁₋₄ alkyl esters of acrylic acid and C₁₋₄ alkyl esters of methacrylic acid onto which is grafted a copolymer comprising: 90 to 95 weight percent of a copolymer comprising: 70 to 90 weight percent of a C₈₋₁₂ vinyl aromatic monomer whch is unsubstituted or substituted by a C₁₋₄ alkyl radical; and 30 to 10 weight percent of a C₃₋₆ alkenyl nitrile. A blend as in claim 22, characterised by said clear glassy polymer is a copolymer comprising: 70 to 90 weight percent of a C₈₋₁₂ vinyl aromatic monomer which is unsubstituted or substituted by a C₁₋₄ alkyl radical and from 30 to 10 weight percent of a C₃₋₆ alkenyl nitrile. A blend as in claim 3, characterised by said clear glassy polymer has a backbone of the formula wherein R₁ and R₂ are independantly selected from: hydrogen atoms, chlorine atoms, C₁₋₄ alkyl radicals and a C₆₋₁₀ aromatic radical which is unsubstituted or substituted by a C₁₋₄ alkyl radical; and n is an integer from 300 to 700. A sheet material, characterised by comprising at least one blend as in any one of claims 1 to 24. An article, characterised by comprising at least one blend as in any one of claims 1 to 24. An article as in claim 26, characterised by being a container or a lid for a container.

Inventors: KWOK JOHN CHI-HEE, LAMONT JOHN CRAIG, LUNT JAMES, THOMPSON RONALD JAMES, KWOK, JOHN CHI-HEE, LAMONT, JOHN CRAIG, LUNT, JAMES, THOMPSON, RONALD JAMES
Applicants: NOVACOR CHEM CANADA LTD, NOVACOR CHEMICALS (CANADA) LTD.
Application year: 1990
Main classification: C08L53
IPC codes: C08L53, C08L25, C08L51