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Patent US6127465 - Polycarbonate resin composition - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsDisclosed is a polycarbonate resin composition comprising an aromatic polycarbonate (PC), a high-impact polystyrene resin (HIPS) and a non-halogen phosphate, and also talc and/or polytetrafluoroethylene (PTFE). Optionally, the composition may contain a core/shell-type, grafted, rubber-like elastic material....http://www.google.com/patents/US6127465?utm_source=gb-gplus-sharePatent US6127465 - Polycarbonate resin compositionAdvanced Patent SearchPublication numberUS6127465 APublication typeGrantApplication numberUS 08/923,089Publication dateOct 3, 2000Filing dateSep 4, 1997Priority dateSep 4, 1997Fee statusPaidPublication number08923089, 923089, US 6127465 A, US 6127465A, US-A-6127465, US6127465 A, US6127465AInventorsAkio NoderaOriginal AssigneeIdemitsu Petrochemical Co., Ltd.Export CitationBiBTeX, EndNote, RefManPatent Citations (14), Non-Patent Citations (3), Referenced by (30), Classifications (16), Legal Events (5) External Links: USPTO, USPTO Assignment, EspacenetPolycarbonate resin composition
US 6127465 AAbstract
1. A polycarbonate resin composition, consisting essentially of:(A) from 68-93% by weight of an aromatic polycarbonate (PC), (B) from 5-30% by weight of a high-impact polystyrene resin (HIPS) containing from 2-30% by weight of a rubbery elastic material, (C) from 2-15% by weight of a non-halogen phosphate, the percentages based on the sum of components (A), (B) and (C), (D) talc in an amount of from 3-25 parts by weight and (E) a core/shell grafted, rubbery elastic material prepared by polymerizing at least one monomer selected from the group consisting of alkyl acrylates, alkyl methacrylates and dimethylsiloxane as the main component of the monomers polymerized in an amount of 1 to not greater than 5 parts by weight, each of (D) and (E) relative to 100 parts by weight of the sum of components (A), (B) and (C). 2. The polycarbonate resin composition as claimed in claim 1, wherein the content of rubbery polymer in the core/shell grafted, rubbery elastic material of component (E) is not less than 20% by weight.
7. A polycarbonate resin composition, consisting essentially of:(A) from 68 of 93% by weight of an aromatic polycarbonate (PC), (B) from 5-30% by weight of a high-impact polystyrene resin (HIPS) containing from 2-30% by weight of a rubbery elastic material, (C) from 2-15% by weight of a non-halogen phosphate, the percentage amounts based on the sum of (A), (B) and (C), (D) talc in an amount of from 3-25 parts by weight, (E) a core/shell grafted, rubbery elastic material prepared by polymerizing at least one monomer selected from the group consisting of alkyl acrylates, alkyl methacrylates and dimethylsiloxane as the main component of the monomers polymerized in an amount of 1 to not greater than 5 parts by weight and (F) polytetrafluoroethylene (PTFE) in an amount of not greater than 2 parts by weight, each of (D), (E) and (F) relative to 100 parts by weight of the sum of components (A), (B) and (C). 8. The polycarbonate resin composition as claimed in claim 7, wherein the content of rubbery polymer in the core/shell grafted, rubbery elastic material of component (E) is not less than 20% by weight.
15. A polycarbonate resin composition, consisting essentially of:(A) from 70-93% by weight of an aromatic polycarbonate (PC), (B) from 5-30% by weight of a high-impact polystyrene resin (HIPS) having a melt index ranging from 2.2 to 7.2 and containing from 2-30% by weight of a rubbery elastic material, and (C) from 2-15 parts by weight of a non-halogen phosphate, the percentages based on the sum of (A), (B) and (C), and (F) polytetrafluoroethylene in an amount of not greater than 2 parts by weight relative to 100 parts by weight of the sum of components (A), (B), and (C). 16. The polycarbonate resin composition as claimed in claim 15, wherein (F) polytetrafluoroethylene (PTFE) has a number average molecular weight of not less than 500,000.
19. A polycarbonate resin composition, consisting essentially of:(A) from 70-93% by weight of an aromatic polycarbonate (PC), (B) from 5-30% by weight of a high-impact polystyrene resin (HIPS) containing from 2-30% by weight of a rubbery elastic material, and (C) from 2-15 parts by weight of a non-halogen phosphate, the percentages based on the sum of (A), (B) and (C), (E) a core/shell grafted, rubbery elastic material prepared by polymerizing at least one monomer selected from the group consisting of alkyl acrylates, alkyl methacrylates and dimethylsiloxane as the main component of the monomers polymerized in an amount of 1 to not greater than 5 parts by weight, and (F) polytetrafluoroethylene in an amount of not greater than 2 parts by weight relative to 100 parts by weight of the sum of components (A), (B), and (C). 20. The polycarbonate resin composition as claimed in claim 1, wherein component (B) is a high impact polystyrene resin (HIPS) which is prepared by polymerizing a monovinyl aromatic monomer in the presence of polybutadiene dissolved or mixed in the monomer.
Polytetrafluoroethylene with fibril-forming ability may be prepared, for example, by polymerizing tetrafluoroethylene in the presence of sodium, potassium or ammonium peroxydisulfide in an aqueous solvent, under a pressure of from 1 to 100 psi and at a temperature of from 0 to 200� C., preferably from 20 to 100� C.
The resin composition of the invention can be produced by formulating each component optionally along with any desired additives in suitable proportions, followed by kneading them. To formulate and knead the components, employable are any ordinary devices, such as ribbon blenders, Henschel mixers, Bumbury mixers, drum tumblers, single-screw extruders, double-screw extruders, co-kneaders, multi-screw extruders, etc. The heating temperature for the kneading may fall generally between 240 and 300� C.
The components shown in Table 1 below were formulated in the proportions indicated therein, fed into an extruder (VS40 manufactured by Tanabe Plastic Machine CO.), kneaded therein at 260� C., and pelletized. In all Examples and Comparative Examples, antioxidants of 0.1 parts by weight of Irganox 1076 (manufactured by Ciba Specialty Chemicals K.K. Japan) and 0.1 parts by weight of Adekastab C (manufactured by Asahi Denka Co.) were added to the compositions. The resulting pellets were dried at 80� C. for 12 hours, and then molded through injection molding at a molding temperature of 260� C. to prepare test pieces. The thus-prepared test pieces were tested for their properties, and the test data obtained are shown in Table 1. The materials used herein and the methods employed for evaluating the test pieces are referred to after Table 1.
TABLE 1__________________________________________________________________________                            Comparative                                  Comparative                                        Comparative    Example 1 Example 2 Example 3 Example 4 Example 1 Example 2 Example__________________________________________________________________________                                        3  C (A) PC 75% 76% 85% 71% 75% 85% 59%  o (B) HIPS  m HIPS 1 20% 16% -- -- 20% -- 33%  p HIPS-2 -- -- 10% 21% -- 10% --  o SBS -- -- -- -- -- -- --  s (outside  i the  t invention)  i (C) Phosphate  o P-1 5% -- -- -- 5% -- --  n P-2 -- 8% -- -- -- -- --   P-3 -- -- 5% 8% -- 5% 8%   (D) Talc 20 parts 5 parts 15 parts 10 parts -- -- 10 parts   (E) Rubber-like   Elastic Material   G-1 -- 5 parts -- -- -- -- --   G-2 -- -- 3 parts 3 parts -- 3 parts 3 parts   (F) PTFE -- 0.2 parts 0.1 parts 0.1 parts -- 0.1 parts 0.1 parts                                         T (1) IZOD 15 60 65 55 25                                        70 5  e (2) Modulus of Bending 4500 3400 4100 3900 2800 2700 3700  s Elasticity  t (3) HDT (height) 100� C. 100� C. 105� C.                                        95� C. 95� C.                                        105� C. 90� C.  M (4) SFL (260� C.) 60 cm 65 cm 55 cm 60 cm 65 cm 60 cm 70 cm                                         e (5) LOI 35% 34% 34% 37%                                        29% 28% 32%  t (6) 1/16-inches UL94 V-1 V-0 V-0 V-0 V-2 V-2 V-1  h  o  d  s__________________________________________________________________________          Comparative                Comparative                      Comparative                            Comparative                                  Comparative                                        Comparative    Example 4 Example 5 Example 6 Example 7 Example 8 Example 9__________________________________________________________________________  C (A) PC 93% 76% 62% 75% 75% 80%  o (B) HIPS  m HIPS 1 -- -- 17% 20% -- 20%  p HIPS-2 2% --  -- 16% --  o SBS -- 16% -- -- -- --  s (outside  i the  t invention)  i (C) Phosphate  o P-1 5% -- 21% 5% -- --  n P-2 -- 8% -- -- -- --   P-3 -- -- -- -- 9% --   (D) Talc 19 parts 5 parts 15 parts 30 parts 10 parts 20 parts   (E) Rubber-like   Elastic Material   G-1 -- 5 parts 3 parts -- -- --   G-2 -- -- -- -- 8 parts --   (F) PTFE 0.1 parts 0.2 parts 0.1 parts 0.1 parts 0.1 parts --  T (1) IZOD 15 55 5 5 50 20  e (2) Modulus of Bending 4200 2800 4300 4800 3700 4300  s Elasticity  t (3) HDT (height) 105� C. 90� C. 70� C. 105.degree                                        . C. 85� C. 115.degree                                        . C.  M (4) SFL (260� C.) 45 cm 70 cm 80 cm 50 cm 60 cm 50 cm  e (5) LOI 36% 32% 37% 37% 36% 27%  t (6) 1/16-inches UL94 V-0 V-1 V-0 V-0 V-0 HB  h  o  d  s__________________________________________________________________________ *) In Table, "%" is "% by weight", and "parts" is "parts by weight" relative to 100 parts by weight of (A) + (B) + (C).
HIPS-1: HT52 (trade name of Idemitsu Petrochemical CO., LTD). This is a graft copolymer of a rubber-like elastic material (polybutadiene) as grafted with polystyrene, containing 10% by weight of the rubber-like elastic material. This has a molecular weight of 130,000, and an MI of 2.2 g/10 min (200� C., 5 kg) as measured according to JIS K7210.
H-4: DP611 (ABS resin, manufactured by Nippon Synthetic Rubber CO., LTD). This has an MI of 11.0 (220� C., 10 kg) as measured according to JIS K7210.
In accordance with ASTM D256, each sample of 1/8 inches thick was tested at 23� C. to obtain its Izod impact strength. In general, samples having an Izod impact strength of not smaller than 15 kg-cm/cm are preferred in practical use.
Each sample was tested in accordance with ASTM D790 (test condition: 23� C., 4 mm) to obtain its modulus of bending elasticity (unit: mpa). The data obtained may be the criterion for the stiffness of the resin composition. In general, samples having a modulus of bending elasticity of not smaller than 3000 mpa are preferred in practical use.
Each sample of 1/8 mm thick was tested in accordance with ASTM D648 (load: 18.6 kg/cm2) to obtain its heat deformation temperature (unit: � C.). The data obtained may be the criterion for the heat resistance of the resin composition. Depending on the use of the composition but in general, samples having an HDT of not lower than 80� C. are preferred in practical use.
Each sample was tested in accordance with an Idemitsu method (shaping temperature: 260� C., mold temperature: 60� C., thickness of shaped test piece: 3 mm, width of shaped test piece: 10 mm, injection pressure: 110 MPu) to obtain its SFL (cm). The data obtained may be the criterion for the flowability of the resin composition. In general, samples having an SFL of not smaller than 50 cm are preferred in practical use.
Each sample having a thickness of 3 mm and a width of 6 mm was tested in accordance with ASTM D2863 (test condition: 23� C.) to obtain its LOI (%). The data obtained may be the criterion for the flame retardancy of the resin composition.
The resin composition of Comparative Example 8 is the same as that of Example 4, except that, in the former, the amount of the component (B), high-impact polystyrene resin (HIPS) is reduced while that of the component (E), core/shell-type, grafted, rubber-like elastic material is increased. Though having such a larger amount of the rubber-like elastic material over the defined range, the physical properties of the resin composition of Comparative Example 8 are not improved. Specifically, its impact strength is not improved (IZOD 50), its stiffness is poor (modulus of bending elasticity 3700), and its heat resistance is low (HDT 85� C.)
Of the composition of Comparative Example 6 containing such a large amount of the component (C), the impact strength (IZOD 5) and the heat resistance (HDT 70� C.) are extremely low. On the other hand, the composition of Comparative Example 9 not containing the component (C) has poor flame retardancy with no increase in LOI (LOI 27%; UL-94 HB).
TABLE 2__________________________________________________________________________                              Comparative                                    Comparative  Composition No. Example 5 Example 6 Example 7 Example 8 Example 10                                    Example 11__________________________________________________________________________C (A) PC        72%  70%  75%  88%  80%   64%  o (B) HIPS  m H-1  18%  17% -- --  20%  16%  p H-2 -- --  15%  6% -- --  o Polystyrene  n H-3 (outside the invention -- -- -- -- --  e H-4 (outside the invention -- -- -- -- --  n (C) Phosphate Monomer  10%  13%  10%  6% --  20%  t (D) PTFE 0.1 parts 0.5 parts 0.3 parts 0.5 parts 0.1 parts 0.1 parts                                     s  T (1) 1/16-inches UL94 V-0 V-0 V-0 V-0 HB V-0  e (2) IZOD (Kg-cm/cm. 23� C.) 31 24 25 54 26 10  s (3) HDT (�C.) 86 80 85 97 123 72  t (4) SFL (cn. 260� C.) 65 70 72 60 48 75  M  e  t  h  o  d  s__________________________________________________________________________            Comparative                  Comparative                        Comparative                              Comparative                                    Comparative  Composition No. Example 12 Example 13 Example 14 Example 15 Example__________________________________________________________________________                                    16C   (A) PC        50%   88%   72%   75%   88%  o (B) HIPS  m H-1  35%  2% -- -- --  p H-2 -- -- --  15% --  o Polystyrene  n H-3 (outside the invention -- --  18%  18% --  e H-4 (outside the invention -- -- -- --  6%  n (C) Phosphate Monomer  15%  10%  10%  10%  6%  t (D) PTFE 0.5 parts 0.1 parts 0.1 parts -- --  s  T (1) 1/16-inches UL94 V-2 V-0 V-0 V-2 V-0  e (2) IZOD (Kg-cm/cm. 23� C.) 4 65 5 33 50  s (3) HDT (�C.) 76 90 88 86 85  t (4) SFL (cn. 260� C.) 73 43 60 64 45  M  e  t  h  o  d  s__________________________________________________________________________ *) In Table, "%" is "% by weight", and "parts" is "parts by weight" relative to 100 parts by weight of (A) + (B) + (C).
H-1: HT52 (trade name of Idemitsu Petrochemical CO. LTD). This is a graft copolymer of a rubber-like elastic material (polybutadiene) as grafted with polystyrene. This has a molecular weight of 130,000, and an MI of 2.2 g/10 min (200� C., 5 kg) as measured according to JIS K7210.
H-4: DP611 (ABS resin manufactured by Nippon Synthetic Rubber CO. LTD). This has an MI of 11.0 (220� C., 10 kg) as measured according to JIS K7210. H-3 and H-4 are an ordinary polystyrene resin and ABS resin, respectively, not reinforced with any rubber-like elastic material. These were used in comparative samples in place of the component (B), HIPS.
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De C.V.Reactive block copolymersUS8901218Jun 2, 2010Dec 2, 2014Cheil Industries Inc.Branched (meth)acrylate copolymer with high refractive index and method for preparing the sameUS8940836Dec 4, 2009Jan 27, 2015Cheil Industries Inc.Polycarbonate resin composition with improved transparency and scratch-resistanceUS20130289179 *Jun 24, 2013Oct 31, 2013Chell Industries Inc.Polycarbonate Resin Composition and Article Including SameCN101591468BMay 28, 2008Sep 14, 2011上海科领实业有限公司Low-smoke halogen-free flame retardant PC/ABS alloy and preparation method thereofCN101787188BFeb 6, 2009May 23, 2012深圳市科聚新材料有限公司Flame-retardant PC/HIPS composite material and preparation method thereofWO2002046289A1 *Nov 26, 2001Jun 13, 2002Bayer AgFlameproof polycarbonate compositions resistant to thermal deformationWO2008033527A2 *Sep 14, 2007Mar 20, 2008Ambient CorpHousing for inductive coupler for power line communications* Cited by examinerClassifications U.S. Classification524/125, 514/143, 514/127, 514/451, 514/139, 514/141International ClassificationC08L51/04, C08L69/00, C08L27/18, C08K5/523Cooperative ClassificationC08L51/04, C08L27/18, C08L69/00, C08K5/523European ClassificationC08L69/00, C08K5/523Legal EventsDateCodeEventDescriptionMar 7, 2012FPAYFee paymentYear of fee payment: 12Mar 7, 2008FPAYFee paymentYear of fee payment: 8Dec 22, 2004ASAssignmentOwner name: IDEMITSU KOSAN CO.,LTD., JAPANFree format text: CHANGE OF NAME;ASSIGNOR:IDEMITSU PETROCHEMICAL CO., LTD.;REEL/FRAME:015478/0382Effective date: 20040802Owner name: IDEMITSU KOSAN CO.,LTD. 1-1 MARUNOUCHI 3-CHOMECHIYFree format text: CHANGE OF NAME;ASSIGNOR:IDEMITSU PETROCHEMICAL CO., LTD. /AR;REEL/FRAME:015478/0382Mar 10, 2004FPAYFee paymentYear of fee payment: 4Oct 1, 1998ASAssignmentOwner name: IDEMITSU PETROCHEMICAL CO., LTD., JAPANFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:NODERA, AKIO;REEL/FRAME:009497/0271Effective date: 19970827RotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send FeedbackData provided by IFI CLAIMS Patent Services