Note: Descriptions are shown in the official language in which they were submitted.
8CL-3558
NITROGEN-CONTAINING POLYMER AND
POLYESTER-CARBONATE BLENDS
This invention is directed to a thermoplastic com-
position comprised of a blend of polymers. More particularly
it is directed to a blend of (a) a polyester-carbonate resin,
and (b) at least one polymer selected from the group consisting
of (i) polyamides, (ii) polyimides, and (iii) polyamideimides.
BACKGROUND OF THE IWVEWTION
Polyester-carbonates are known thermoplastic resins
whose many excellent physical properties allow them to be
used successfully in many commercial and industrial applications.
This is especially true of aromatic polyester-carbonates.
However, in some applications a material having a high heat
distortion temperature, higher flexural strength and greater
tensile strength than aromatic polyester-carbonate resin is
re~uired.
The addition of various additives in attempting
to provide an aromatic polyester-carbonate resin which has
a higher heat distortion temperature, higher flexural strength
and greater tensile strength have produced mixed results.
In some instances there was no improvement in the heat
distortion temperature, flexural strength, or the tensile
strength o~ the polymer. In other instances the addition
of certain additives to the aromatic polyester-carbonate
resulted in a polymer having a higher heat distortion
temperature, higher flexural strength and grea-ter tensile
strength, but this was accomplished only at the expense
of some of the other valuable properties of the polyester-
carbonate.
This is due to the fact, well known to those
skilled in the art, that the area of modification of the
physical properties of a polymer by the addition of various
additives thereto is largely an empirical art rather than
~ 8CL-3558
a predictable science with little, if any, predictability
on the effects a particular additive will have in a
particular polymer.
Thus, while a particular additive may have
one effect in one polymer system the same additive may
well produce entirely different results when used in
another and different polymer system. Likewise, two
rather closely related additives may produce entirely
different results when added to the same polymer system.
There thus exists a need for an aromatic
polyester-carbonate resin which has a higher heat dis-
tortion temperature, greater tensile and flexural strength,
and yet retains all of the advantageous physical properties
of an unmodified aromatic polyester-carbonate.
DESCRIPTION OF THE INVENTION
The instant invention is directed to novel
thermoplastic compositions containing a blend of (a)
an aromatic polyester-carbonate resin, and (b) at least
one resin selected from the group consisting of (i) poly-
amides, (ii) polyimides, and (iii) polyamideimides.
These compositions have improved heat distortion temper-
atures, flexural strength and tensile strength compared
to unmodified aromatic polyester-carbonates.
The polyester-carbonates which find use in the
instant invention and the methods for their preparation
are well known in the art as disclosed in U.S. Patent Nos.
3,303,331 to Donald R. Biegel, issued February 7, 1967;
3,169,121 to Eugene P. Goldberg, issued February 9, 1965;
4,194,038 to Josefina T. Baker et al, issued March 18, 1980;
and 4,156,069 to Dusan C. Prevorsek et al, issued ~ay 22,
1979; as well as in Canadian application Serial No. 350,529
filed April 24, 1980 and assigned to the same assignee as
the instant application.
-- 2 --
~ 8CL-3558
The polyester-carbonates can generally be
termed copolyesters containing carbonate groups, carboxy-
late groups, and aromatic carbocyclic groups in the
polymer chain, in which at least some of the carboxylate
groups and at least some of the carbonate groups are
bonded directly to ring carbon atoms of the aromatic
carbocyclic groups. These polyester-carbonates are,
in general, prepared by reacting a difunctional carboxylic
acid or a reactive derivative of the acid such as the acid
dihalide, a dihydric phenol and a carbonate precursor.
The dihydric phenols useful in Eormulating
the polyester-carbonates which are of use in the practice
of the present invention are in general, represented by
the general formula :
r ~ r
HO ¦ A - _ -E I - A ~ ~ OH
- L_ _ t _ ~ s _ _ u
wherein A represents an aromatic group such as phenylene,
biphenylene, napthylene, etc. E may be an alkylene or
alkylidene group such as methylene, ethylene, propylene,
propylidene~ isopropylidene, butylene, butylidend, iso-
butylidene, amylene, isoamylene, amlidene, isoamylidene,
etc. Where E is an alkylene or alkylidene group, it may
also consist of two or more alkylene or alkylidene groups
connected by a non-alkylene or non-alkylidene group such
as an aromatic linkage, a tertiary amino linkage, an
ether linkage, a carbonyl linkage, a silicon-containing
linkage, or by a sulfur-containing linkage such as sulfide,
sulfoxide, sulfone, etc. In addition, E may be a cyclo-
aliphatic group (e.g., cyclopentyl, cyclohexyl, etc.); a
sulfur-containing linkage, such as sulfide, sulfoxide or
sulfone; an ether linkage; a carbonyl group; a -tertiary
-- 3
8CL-3558
ni-trogen group; or a silieon-containing linkage sueh as
silane or siloxy. Other groups whieh E may represent will
oceur to those skilled in the art. R represents hydrogen
or a monovalent hydrocarbon group such as alkyl (methyl,
ethyl, propyl, etc.), aryl (phenyl, naphthyl, etc.)/
aralkyl (benzyl, ethylphenyl, etc.), or eycloaliphatie
(cyclopentyl, cyclohexyl, etc.). _ may be an inorganic
atom such as halogen (fluorine, bromine, chlorine, iodine),
an inorganic group such as the nitro group, an organic
group sueh as R above, or an oxy group such as OR, it
being only necessary that Y be inert to and unaffected
by the reaetants and reaction conditions. The letter _
represents any integer from and including zero through
the number of positions on A available for substitu-tion;
p represents an integer from and including zero through
the number of positions on E available for substitution;
t represents an integer equal to at least one; s is either
zero or one; and u represents an integer including zero.
In the dihydric phenol compound represented
by Formula I above, when more than one Y substituent is
present, they may be the same or different. The same
holds true for the R substituent. Where s is zero in
Formula I and _ is not zero, the aromatie rings are
direetly joined with no intervening alkylene or o-ther
bridge. The positions of the hydroxyl groups and Y on
the aromatie nuelear residues A ean be varied in the
ortho,me-ta r or para positions and the groupings ean be
in a vieinal, asymmetrieal or symmetrical relationship,
where two or more ring carbon atoms of the hydrocarbon
residue are substituted with Y and hydroxyl groups.
Some nonlimiting examples of dihydric phenols
falling within the seope of Formula I inelude:
~ 8CL-3558
2,2-bis(4-hydroxyphenyl)propane (bisphenol A);
2,4'-dihydroxydiphenylmethane;
bis(2-hydroxyphenyl)methane;
bis(4-hydroxyphenyl)methane;
bis(4-hydroxy-5-nitrophenyl)methane;
bis(4-hydroxy-2,6-dimethyl-3-methoxyphenyl)methane;
1,1-bis(4-hydroxyphenyl)ethane;
1,1-bis(4-hydroxy-2-chlorophenyl)ethane;
2,2-bis(3-phenyl-4-hydroxyphenyl)propane;
bis-(4-hydroxyphenyl)-cyclohexylmethane; and
2,2-bis(4-hydroxyphenyl)-1-phenykpropane.
These dihydric phenols may be used alone or
as mixtures of two or more different dihydric phenols.
In general, any difunctional carboxylic acid,
or its reactive derivative such as the acid dihalide,
conventionally used in the preparation of polyesters
may be used for the preparation of the polyester-
carbonates useful in formulating the compositions of
the prepsent invention. In general~ the carboxylic acids
which may be used are aliphatic carboxylic acids,
aliphatic~aromatic carboxylic acids, or aromatic car-
boxylic acids. The aromatic dicarboxylic acids or
their reactive derivatives such as the aromatic acid
dihalides are preferred as they produce the aromatic
polyester-carbonates which are most useful in the
practice of the present invention.
These carboxylic acids may be represented by
the general formula:
II. R2 [Rl ~ - COOH
wherein R represents an alkylene, alkylidene or
cycloaliphatic group in the same manner as se-t out above
-- 5
~CL-3553
for E in Formula I; an alkylene, alkylidene, or cyclo-
aliphatic group containing ethylenic unsaturation; an
aromatic radical such as phenylene, naphthylene, sub-
stituted phenylene, etc.; two or more aromatic groups
connected through non-aromatic linkages such as those
defined by E in Formula I; or an aralkyl radical such
as tolylene, xylene r etc. R2 is either a carboxyl or
a hydroxyl group. The letter q represents one where
R is a hydroxyl group and either zero or one wherein
R2 is a carboxyl group. Thus the difunctional acid
will either be a monohydroxy monocarboxylic acid or a
dicarboxylic acid. For purposes of the present invention
the dicarboxylic acids or their reactive derivatives
such as the acid dihalides are preferred, with the aromatic
dicarboxylic acids or their dihalides being more
preferred. Thus, in these more preferred acids R is a
carboxyl groups and R is an aromatic radical such as
phenylene, naphthylene, biphenylene, substituted phenylene,
etc; two or more aromatic groups connected through non
aromatic linkages; or an aralkyl group. Some nonlimiting
examples of suitable preferred aromatic and aliphatic-
aromatic dicarboxylic acids which may be used in preparing
the polyester-carbonates useful in the practice of the
present invention include phthalic acid, isophthalic acid,
terephthalic acid, homophthalic acld, o-, m- and p-
phenylenediacetic acid; the polynuclear aromatic acids
such as diphenic acid, and 1,4-naphthalic acid.
These acids may be used either individually
or as a mixture of two or more different acids.
The carbonate precursor may be either a
carbonyl halide, a carbonate es-ter or a haloformate.
The carbonyl halides which can be employed are carbonyl
~6~ 8CL-3558
chloride, carbonyl bromide and mixtures -thereof.
Typical of carbonate esters which may be employed herein
are diphenyl carbonate, di(halophenyl) carbonates such
as di(chlorophenyl)carbonate, di(bromophenyl)carbonates,
di(trichlorophenyl)earbonate, di(tribromophenyl)carbonate,
etc., di(al]cylphenyl)earbonates such as di(tolyl)carbonate,
etc., di(naphthyl)carbonate, di(chloronathyl)carbonate,
phenyl tolyl carbonate, chlorophenyl chloronaphthyl
carbonate, etc., or mixtures thereof. The haloformates
suitable for use herein include bishaloformates of
dihydric phenols (bischloroformates of hydroquinone, etc)
or glyeols (bishaloformates of ethylene glycol, neopentyl
glycol, polyethylene glyeol, ete.). Carbonyl ehloride,
also known as phosgene, is preferred.
Also present during the eo-reaetion between
the dihydrie phenol, the earbonate preeursor and the
diearboxylie aeid or its reaetive derivative are catalysts,
molecular weight regulators, and acid aceeptors.
Examples of suitable moleeular weight regulators include
phenol, tertiary butyl phenol ete. Examples of suitable
eatalysts inelude tertiary amines, quaternary ammonium
eompounds, quaternary phosphonium eompounds, ete.
Examples of suitable aeid aeeeptors inelude tertiary amines,
alkali or alkaline earth metal hydroxides, e-tc.
The polyester-carbonates which are useful in
-the practiee of the present invention are the aromatie
polyester-earbonates derived from dihydrie phenols,
aromatie diearboxylie aeids or thier reaetive derivatives
such as the aromatic aeid dihalides, e.g., diehlorides
and phosgene. A quite useful elass of aromatie polyester-
carbonates are those derived from bisphenol A; terephthalic
acid, isopthalic acid, or a mixture of isphthalic and
-- 7
~6~ 8CL-3558
terephthalic acids or isophthaloyl chloride, terephthaloyl
chloride, or a mixture of isophthaloyl and terephthaloyl
chloride; and phosgene. If a mixture of terephthaloyl
and isophthaloyl dichloride is present the ratio by
weight of terephthaloyl dichloride to isophthaloyl
dichloride is from about 5:95 to 95:5.
The instant invention is direc-ted to novel
compositions, more particularly novel thermoplastic
molding compositions, containing polymer blends comprised
Of
(a) an aromatic polyester-carbonate resin; and
(b) at least one polymer selected from the
group consisting of (i) polyamides,
(ii) polyimides, and (iii) polyamideimides.
The polyamides and their preparation are well
known to those skilled in the general formula
III. (~ b (R~ c
I C ~ - C _ N ~ Nl6
wherein each R3 and each R5 are independently selected
from alkyl radicals of from 1 to about 12 carbon atoms,
halogen radicals, and substituted alkyl radicals
containing from 1 to about 12 carbon atoms and substi-tuent
grops such as halogen and/or oxy groups such as oR7
wherein R7 is an alkyl group containing from 1 -to about
10 carbon atoms; R~ and R6 are independently selected from
alkyl radicals of from 1 to about 12 carbon atoms,
hydrogen, aryl radicals of from 6 to 18 carbon atoms,
aralkyl radicals of from 7 to 18 carbon atoms, and
~ 8CL-3558
alkaryl radicals of from 7 to 18 carbon atoms; and _
represents a number having a value from 10 to about 500;
_ represents an integer having a value from O to the
number of replaceable hydrogen atoms on the aromatic
ring, i.e, 4, inclusive.
Illustrative of compounds falling within the
scope of Formula III is one wherein b and _ are 0, and
R4 and R6 represent hydrogen. Such polyamides are
marketed by the E.I. DuPont Company under the tradename
Nomex and Kevlar.
The polyamideimides and their preparation are
likewise well known to those skilled in the art. For
purposes of the present invention the aromatic polyamidei-
mides are preferred. These aromatic polyamideimides
are represented by the general formula
_ _
I~ N - R _ N ~ -
O O
wherein each R10 is independently selected from the
yroup consisting of alkyl radicals of from 1 to about
12 carbon atoms, halogen, and substituted alkyl radicals
containing from 1 to about 12 carbon atoms and
substituen-t groups such as halogen and/or oxy groups
represented by the formula ORll wherein Rll is an
alkyl radical of from 1 to about 12 carbon atoms; R is
selected from the group consisting of hydrogen, alky]
radicals of from 1 to about 12 carbon atoms, aryl radicals
of from 6 to 18 carbon atoms, aralkyl radicals of from
~ 8CL-3558
7 to about 18 carbon atoms and aralkyl radicals of
from 7 to about 18 carbon atoms. R in Formula IV is
selected from the group consisting of divalent aromatic
organic radicals having from 6 to bout 30 carbon atoms;
a~kylene radicals having from 2 to about 20 carbon atoms;
alkylidene radicals having from 2 to about 20 carbon
atoms; and cycloalkylene radicals containing from about
3 to about 8 carbon atoms. Radicals included by R8 are,
for example, aromatic hydrocarbon radicals and halogenated
aromatic hydrocarbon radicals, for example, phenylene,
tolylene, chlorophenylene, naphthylene, etc. The letter
e represents an integer having a value from 0 -to the
number of replaceable hydrogen atoms present on the
aromatic ring, i.e., 3, inclusive; and d is a
number having a value from about 10 to about 500.
Illustrative of compounds falling within the
scope of Formula IV is one wherein is 0. R is hydrogen
and R8 is an alkylene or arylene radical. Such poly-
amideimides are marketed by the Amoco Corporation under
the tradename Torlon.
The polyimides are also known compounds whose
preparation and properties are well known to those
skilled in the art. For the purposes of the instant
invention, the polyetherimides are the preferred poly-
imides. The polyetherimides are disclosed in U.S.
Patent Nos. 3,803,085 to Tohru Takehoshi et al, issued
April 9, 1974; and 3,905,942 to Tohru Takehoshi et al,
issued September 16, 1975. These polyetherimides are
represented by the general formula:
-- 10 --
~86~5 8CL-3558
V.
~ o_RlL~ o ~"\
10 wherein f has a value from about 10 to about 500; and R
is a divalent aliphatic hydrocarbon radical containing
from 2 to about 12 carbon atoms, a divalent aromatic
hydrocarbon or halogenated hydrocarbon radical containing
from 6 to 18 carbon atoms, or a divalent cycloaliphatic
hydrocarbon radical containing from 3 to about 10
carbon atoms. Rll is a divalent aromatic organic
radical having rom 6 to 30 carbon atoms. Radicals
included by Rll are, for example, aromatic hydrocarbon
radicals and halogenated aromatic hydrocarbon radicals
for example, phenylene, tolylene, chlorophenylene,
naphthalene, etc.~ and radicals included by the formula:
VI. ~13 (C) -R13-
wherein R ls a divalent aromatic radical haviny from
6-13 carbon atoms selected from hydrocarbon radicals and
halogenated hydrocarbon radicals, and G is a divalent
organo radical selected from:
~l 13 ~14
z 2z ~ C , -IS~ O-, and -Si-
30o l14
-- 11 --
6~
8CL-3558
where g is 0 or 1, z is an integer having a value of
from 1-5 inclusive, and R14 is a monovalent hydrocarbon
radical selected from methyl, phenyl, etc.
Illustrative of a compound falling within the
scope of Formula V is one wherein R12 is phenylene and
Rll iS
CH3
CH3
Such a compound is marketed by the General Electric
Company under the tradename Ultem.
In the practice of the instant invention
the aromatic polyester-carbonates are admixed with at
least one polymer represented by Formula III, Formula
LV, or Formula V to form the novel compositions of the
present invention. The instant compositions can contain,
in addition to the aromatic polyester-carbonate, only
one polymer o~ Formula III, onlv one polymer of Formula
IV, or only one polymer of Formula V; or they may contain
a mixture of two or more polymers. Thus for example,
the instant composition can contain (a) an aromatic
polyester-carbonate, and (b) a polyamide of Formula
III and a polyamideimide of Formula IV; (a) an aromatic
polyester-carbonate, and (b) a polyimide of Formula V;
(a) a polyester-carbonate , and (b) two different polyi-
mides of Formula V; or (a) an aromatic polyester-carbonate
and (b) a polyamide of Formula III and a polyimide of
Formula V and a polyamideimide of Formula IV.
Generally, the instant compositions contain
from about 1 part by weight of the polyester-carbonate
to 99 parts by weight of at least one compound of Formulae
8CL-3558
3~8~
III, IV or V to 99 parts by weight of the axomatic
polyester carbonate to l part by weight of at leas-t one
compound of Formulae III, IV, or V. Preferably the
ratio in parts by weight of the aromatic polyester-
carbonate to the polymer selected from the group
consisting of polyamides, polyimides, polyamideimides,
or mixtures thereof ranges from 30:70 to 70:30, and more
preferably from about 40:60 to 60:40.
The compositions of the instant invention may
also optionally contain the commonly known and used
additives such as antioxidants, antistatic agents, mold
release agents, colorants, impact modifiers, ultra-
violet radiation absorbers, plasticizers, fillers such
as glass, talc, CaSO4, mica, carbon fibers, mineral clay,
etc., color stabilizers, hydrolytic stabilizers, and
flame retardan-ts such as, for example, those described
in U.SO Patents 3,915,926 to Allan D. Wambach issued on
October 28, 1975; and 4,197,232 to Charles A. Bialous et
al, issued on April 8, 1980.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The following examples are set forth to
further illustrate the present invention and are not to
be construed as limiting the invention thereto. Unless
otherwise specified, where parts or percents are mentioned,
they are parts or percents by weight.
EXAMPLE 1
This example illustrates an aromatic polyester-
carbonate resin which is not blended with any of -the
aforedescribed polymers. Thus this example illustrates
a composition falling outside the scope of the instant
invention.
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8CL - 3558
To a ten gallon reactor vessel there are
added 8 liters of methylene chloride, 6 liters of water,
1,906 grams (8.36 moles) of bisphenol A, 20 milliliters
of triethylamine, 4 grams of sodium gluconate, and 65
grams of p-tertiary butylphenol molecular weight regulator.
At a pH of between about 9-10.5 1,089.6 grams (5.37 moles)
of a mixture of 15% by weight of isophthaloyl dichloride
and 85% by weight of terephthaloyl dichloride in 2 liters
of methylene chloride are added over a 10 minu-te interval
while controlling the pH at about 9-10. 5 with 35% aqueous
caus-tic. After the addition oE the diacid chloride
misture phosgene is added at a rate of 36 grams per minute
for 12 minutes while controlling the pH at about 10-11
with 35% aqueous caustic. The polymer mixture is
diluted with 5 liters of methylene chloride and the brine
phase is separated by centrifuge. The resulting polymer
phase is washed with aqueous acid and water and is then
recovered by high pressure steam precipitation to yield
a white powder having an Intrinsic Viscosity of 0. 5 dl/g
20 in methylene chloride at 25C~ To this resin powder is
added a minor amount (about 0.1 parts by weight per
hundred parts by weight of resin) of a stabilizer mixture
con-taining a phosphite color stabilizer and an epoxy
s-tabilizer. This resin product is then fed to an extruder
operating at a temperature of about 600 F to extrude the
resin into strands and the extruded stands are chopped
into pellets. The pellets are then injection molded at
about 650F into test samples measuring abou-t 2-1/2" x
1/" x 1/8".
EXA~PLE 2
This example illustrates a composition of the
present invention which contains a blend of an aromatic
- 14 -
6~ 8CL-3558
polyester-carbonate and a poletherimide.
An aromatic polyester-carbonate resin is
prepared substantially in accordance with the procedure
of Example 1. The powdered polyester-carbonate resin
is mi~ed, in a 50:50 ratio by weight, with a polyetheri-
mide resin represented by formula V wherein R12 is a
phenylene radical and R 1 is the
~ IC
radical. This resin blend is then fed to an extruder
operating at a temperature of about 650F to extrude
the resin into strands and the extruded strands are
chopped into pellets. The pellets are then injection
molded at about 650F into test samples measuring about
2-1/2" x 1/2" x 1/8".
Various physical properties of the test
samples obtained in Examples 1 and 2 were determined
according to the following test procedures;
Heat Distortion Temperature Under Load (DTUL)
of the molded samples was determined according to ASTM
D-647;
Notched Izod (NI) impact on the 1/8" thick
molded samples was determined according to ASTM D-256;
Flexural Yield (FY) and Flexural Modulus (FM)
were determined according to ASTM D-790;
Flame Retardancy (FR) of the molded samples
was determined by subjecting the sample (5 samples for
each Example) to the test procedures set Eorth in
Underwriters' Laboratories, Inc. Bulletin UL-94,
Burning Test for Classifying Materials. In accordance
with this test procedure, materials so investigated
- 15 -
~ S 8CL-3558
are rated either V-O, V-l, or V-II based on the results
of 5 specimens~ The criteria for each V(for ver-tical)
rating per UL-94 is briefly as follows:
"V-O": Average flaming and/or glowing after
removal of the igniting flame shall
not exceed 5 seconds and none of the
specimens shall drip flaming particles
which ignite absorbent cotton.
"V-I": Average flaming and/or glowing after
removal of the igniting flame shall
not exceed 25 seconds and the glowing
does not travel vertically for more
than 1/8" of the specimen after flaming
ceases and glowing is incapable of
igniting absorbent cotton.
"V~ Average flaming and/or glowing after
removal of the igniting flame shall
not exceed 25 seconds and the specimens
drip flaming particles which ignite
absorbent cotton.
In addition, a test bar which continues to burn for more
than 25 seconds after removal of the igniting flame is
classified, not by UL-94 but by the standard of the
present invention, as "burns". Further, UL-94 requires
that all test bars in each test group must meet the
V--type rating to achieve that particular classification.
Otherwise, the 5 bars receive the rating of the worst
single bar.
The results of these tests are set for-th in
Table I~
- 15 -
~6~ 8CL-3558
TABLE 1
Example 1 _ mple _
(FY) in p.s.i. 14,000 17,700
(EM) in p.s.i. 310,0Q0 389,000
(DTUL) at 264 p.s.i., F 325 340
(NI) ft.lb./in. 6.0 2.0
(FR) V-II y-o
In formulating the compositions of the
instant invention the resins are admixed together and
mixed or blended together by generally mechanical means
such as stirring, shaking, blending in a mechanical
blender, etc.
As seen from the data in Table I, the resin
blends of the instant invention, Example 2, have a higher
heat distortion temperature, higher flexural yield and
higher flexural modulus than the unblended aromatic
polyester-carbonate, Example 1. Additionally~ the
compositions of the present invention are more flame
retardant than the unblended aromatic polyester-carbonate.
~ t will thus be seen that the objects set
forth above among those made apparent from the preceding
description, are efficiently attained, and since certain
changes may be made in carrying out the above process
and the compositions set forth without departing from the
scope of the invention, it is intended that all matters
contained in the above description shall be interpreted
as illustrative and not in a limiting sense.
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