CA1258332A - Stabilized polycarbonate-polyester compositions - Google Patents

Stabilized polycarbonate-polyester compositions

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Publication number
CA1258332A
CA1258332A CA000484604A CA484604A CA1258332A CA 1258332 A CA1258332 A CA 1258332A CA 000484604 A CA000484604 A CA 000484604A CA 484604 A CA484604 A CA 484604A CA 1258332 A CA1258332 A CA 1258332A
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CA
Canada
Prior art keywords
composition
poly
resin
parts
polyester
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000484604A
Other languages
French (fr)
Inventor
Donald B.G. Jaquiss
Russell J. Mccready
John A. Tyrell
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
General Electric Co
Original Assignee
General Electric Co
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Filing date
Publication date
Application filed by General Electric Co filed Critical General Electric Co
Priority to CA000484604A priority Critical patent/CA1258332A/en
Application granted granted Critical
Publication of CA1258332A publication Critical patent/CA1258332A/en
Expired legal-status Critical Current

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Abstract

STABILIZED POLYCARBONATE-POLYESTER COMPOSITIONS

ABSTRACT OF THE DISCLOSURE
Compositions comprising predominately a poly-carbonate resin, e.g., poly(bisphenol A carbonate), and a polyester resin, e.g., poly(1,4-butylene terephthalate), alone, or in combination with one or more second resins, are melt stabilized with monosodium phosphate and/or monopotassium phosphate.

Description

~ ` ~2583~ 8CV 04178 O
. STABILIZED POLYCARBONATE-POLYESTER
, - COMPOSITIONS
This invention relates generally to polycarbon-ate-polyester resin compositions, alone, or in further combination with other resins, and more particularly to methods f~r stabilizing blends of high molecular weight linear thermoplastic polycarbonates and polyesters against undesirable changes in melting point.
BACKGROUND OF THE INVENTION
10Polyester resins derived from terephthalic acid and reactive derivatives thereof, such as dimethyl terephthalate, and alkanediols of from e.g., 1 to 10 inclusive carbon atoms, e.g., ethylene glycol and 1,4-butanediol, as well as related diols, such as 1,6-cyclohexane dimethanol, and mixture-s of such resins have been known for some time and have become impor~ant constituents in iniection moldable compositions. Work-pieces molded from such polyester resin compositions, alone, or combined with reinforcements, offer a high degree of surface hardness and abrasion resistance, high gloss, and lower surface friction. More recently, blends of such polyester resins with one or more second resins have become of significant commercial interest because such second resins, carefully selected, can greatly improve impact strength, as well as tensile strength, modulus and distortion temperature under load in parts molded from such compositions. ~y way of illustration, such second resins can comprise minor proportions aro-matic polycarbonate resins, as described for example, in ~awase et al, U.S. 3,953,539. Also known are such blends in further combination with other resins, such as polyacrylate resins. See, for example, Cohen and Dieck, U.S. 4,257,937.
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~, ''' , ~ Z 5~ 33 ~ 8CV 4178 All such polycarbonate-polyester resin compo-sitions have, however, a tendency to-be unstable in the molten states as evidenced by a change in melting point.
Especially troublesome in this respect are polycarbonate resin compositions containing minor proportions of poly-ester resins. Such compositions seem to undergo a chemical reaction commonly referred to as "jumbling".
The "jumbling" reaction may be due to catalyst residues remaining in the polyester resin because some success has been achieved in using organic phosphites as melt stabilizers, see, e.g., Hofrichter, Jr., U.S. 2,6~0,213;
and W. German Offen 2,710,729; and as color stabilizers in polycarbonate resins, Fritz et al, U.S. 3,305,520.
However, considerable variability in the effectiveness of jumbling suppression has been observed with such phosphites, and more reliable melt stabilizers are needed.
It has now been discovered that two specific inorganic phosphorus reagents, monosodium phosphate and monopotassium phosphate, alone, or in combination, are highly effective to stabilize such polycarbonate-poly-ester resin compositions containing, predominantly, polycarbonate, especially if the polyester is made with a titanium compound catalyst, e.g., tetra octyl titanate.
Monosodium phosphate and monopotassium phosphate, both rather innocuous, mildly acidic reagents, are surpris-ingly effective as stabilizers for polycarbonate-polyester compositions. The stabilizers can be used in various manners, including prior incorporation as a concentrate in the polycarbonate resin, or in the polyester resin.
ln addition to the high degree of reliability as stabil-izers in such compositions, monosodium phosphate andl or monopotassium phosphate do notdetrimentally ` ~Z5833Z
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affect any of the resinous components in the composi-tion, e. 9., the polycarbonates, or the polyesters, because the prior art mono ammoni~m phosphates, as will be shown later, at the same levels degrade the individual polymers. In addition, monosodium phosphate appears to be unique as a stabilizer for polycarbonate-polyester blends comprising predominantly polycarbonate because it is superior to the chemically closely related disodium phosphate, as will be shown later.
Especially difficult to melt stabilize are combinations of polycarbonates and polyester resins with third resins such as polyacrylates, as well as flame retarded blends of polycarbonates and polyesters. Such formulations are rendered reliably melt stable with monosodium phosphate and/or monopotassium phosphate, according to the present invention.~ In addition to the specific instances noted above, melt stabilization can also be induced in other combinations of polycarbonates with polyesters and other resins, especially those in which an active catalyst was used to prepare one or all of the polymers in the blend.
SUMMARY OF THE INVENTION
; According to the present invention, there are provided thermoplastic compositions comprising predomi-nantly a polycarbonate and at least one polyester resin derived from terephthalic acid or a reactive derivative thereof- and an alkanediol, alone, or in further combina-tion with at least one additional resin, melt stabilized with monosodium phosphate and/or monopotassium phosphate.

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DESCRIPTION OF THE INVENTION
Any amount of the monosodium and/or monopo-tassium phosphate will melt stabilize a polycarbonate-polyester resin blend. Preferably, however, from about 0.01 parts to about 7.5 parts by weight of the phosphate should be used, and most preferably, from about O.l parts to about 4.0 parts by weight should be used, based on lO0 parts by weight of the total polyester resinous component (b) in the composition. Although the phos-10 phates are, as mentioned, relatively innocuous, amountslarger than about lO.O parts by weight should be used with caution since such larger amounts will provide melt stability, but might also deleteriously affect the mechanical properties of one or more of the resins in 15 the composition.
The phosphate of the invention may be mixed with the polymers by any suitable means. Since most phosphates are solids, they can be most expeditiously mixed with the resin either as a precompounded concen-20 trate, or directly into the melt, e.g., in an extruder.
Generally, all thermoplastic resins made withactive catalysts, e.g., titanium catalysts, are melt unstable, and all such resins can be treated with in-organic phosphates according to this invention. The 25 polycarbonate resins can be produced from a diphenol and phosgene or a phosgene precursor, such as from a dihydroxy diaryl alkane, e.g., bisphenol-A and phosgene or a diester of carbonic acid, see, e.g., Schnell et al, Canadian Patent No. 578,585. As indicated above, the 30 polyester resins can be produced from terephthalic acid or a reactive derivative thereof and an alkanediol or cyclohexane dimethanol, such as, for example, processes described in Whinfield and Dickson, U.S. 2,465,319.

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; The ratio of polycarbonate resin to polyester resin is also important, if not critical to the present invention. For every 100 parts of polycarbonate resin component (a) there must be present no less than 5 and no more than 95, and preferably between 10 and 70 parts by weight of polyester resin component (b).
Those embodiments of the invention which are melt-stabilized flame retardant thermoplastic polycar-bonate-polyester resin compositions are made by including 10 the monosodium and/or monopotassium phosphate in composi-tions rendered flame retardant with an effective amount of one or more flame retardant additives, in conventional ways. Such additives are, for example, bromine- or chlorine-containing compounds, e.g., decabromodiphenyl 15 ether, a polycarbonate of tetrabromob~isphenol A
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_ 6 _ - or a copolycarbonate of tetrabromobisphenol A and bisphenol A, and the li~e, ~lone, or preferably, combined with a synergist, such as antimDny trioxide.
The examples which follow will show melt stabilization of a number of s~c~ compositions according to the present invention.
DESCRIPTION O~ THE PREFERRED 1~K30DIME~T5 The following examples illustrate the present invention, but are not intended to limit the scope-of the claims in any manner whatsoever All parts are by weiqht unless otherwise specified.
EX~HPLES 1-2 Compositions are prepared by co-extr~ding poly(bisphenol A) carbonate (General Electric Com3any LEXA~ 145) and poly~l,4-butylene terephthalate)~Gener21 Electric Company VALOX6 315) in a vacuum-vented 1-3/4 in.
Sterling extruder operated at 400D ~. ~zone 1); 425~.
zone 2); 450'~. ~zone 3); and 475~ (at the èie).
; 20 Helt viscositles were measureo in a Tinlu5-~lsen E~rusion Plastomete.. ~or control and comparison purposes, a composition omitting stabilizing additives, and three containing additives proposed by the prior art were also made and tested. The ~ormul~tions used, ~nd the re~sults obtaines are set forth in Tabl e 1:
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o o o ~ o , C~ o o , , o, , , , _1 a~ ~ '`
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~O ~ 0~ 2~ 0 O ~1 O ~ ^ ~ 2 0 S C- 2 ~ 2 ~n ~ v c~ O Z ~ _ `' Zo v Sa, ~ ~
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,' ~ ~ ~ ~ _~ P o ~0 0 ~ ~ o ~ ~ C P c Ec O ~ l v ~ o Ei V ~ _l a c c v, c ~60 ~ o v v *

x o o o ~ " 8 e ~ 8 ~ o ~ 6 E

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The combination of high melting points and high melt viscosities demonstrate the advantages of monosodium phosphate and monopotassium phosphate (Examples 1 and 2). The lowering of melting point demonstrates 5 the jumbling effect (Control lA and Comparison Example 2A). The loss in melt viscosity aemonstrates degrada-tion of at least one of the polymeric components by the ammonium compounds (Comparison Examples 2~ and 2C).

EX~MPLE 3 The general procedure of Example 1 was used to prepare and test a formulation of poly(bisphenol A
carbonate)/poly(1,4-butylene terephthalate) impact 15 modified with a polyacrylate resin (RDhm & Haas ACRYLOID
KM 653). The formulations used and the results obtained are set forth in TABLE 2:
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g o TABLE 2: IMPACT-MODIFIED POLYCARBONATE
POLYESTER COMPOSI~IONS

EXAMPLE 3A* 3 -5 COMPOSITIO~ (parts) Poly(bisphenol A carbonate) 2500 2500 Poly(1,4-butylene terephthalate) 1200 1200 Polyacrylate resin - 500 500 Antioxidant 40 40 10 Monosodium phosphate (NaH PO ) 0 20 PROPERTIES
Melting point, C. 210 219 * Control The stabilizing effect of monosodium phosphate is demonstrated by the higher melting point of Example 3 in comparison to the control.

EXAMPL~ 4 A flame retardant composition was prepared, molded and tested by the general procedure of Examples 1-2. The $ormulation used and the properties obtained 25 were as set forth in Table 3:

`` . lZ58332 - lq_ t D
TABLE 3: FLAME-RETARDANT POLYCARBONATE-- POLYESTER COMPOSITIONS
EXAMPLE 4A* 4 5 COMPOSITION (Parts) Poly(bisphenol-A)carbonate` 700~ 700 ~
`974 ~974 Poly(tetrabromobisphe carbonate 274 274 Poly(1,4-butylene terephthalate) 900 900 Antimony oxide 82 82 Ethylene/vinyl acetate copolymer 44 44 Poly~tetrafluoroethylene) 8 8 ~onosodium phosphate (Na~2P04) 0 30 Melting p~int, C. 205 219 Flammability rating, Underwriters' Bulletin Flame Test (UL-94), V-O V-O
60 mil sample * Control The high melting point demonstrates the effectiveness of monosodium phosphate to melt stabilize those normally difficult to stabilize flame-retardant ~ compositions, while maintaining the highest flammability : rating.

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- 11 - 08CV 0~178 Obviously, many variations of the present invention will suggest themselves to those skilled in this art in light of the above, detailed description.
For example, instead of poly(l,4-butylene terephthalate) there can be substituted poly(ethylene terephthalate) alone or in a 50:50 admixture with poly(l,4-butylene terephthalate). Conventional additives such as clay, mica, pigments and colorants all can be added in conventional amounts. All such obvious variations are within the full intended scope of the appended claims.

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Claims (15)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A thermoplastic composition comprising:
(a) 100 parts by weight of an aromatic polycarbonate resin;
(b) 5 to 95 parts by weight of at least one polyester resin prepared by reacting terephthalic acid or a reactive derivative thereof and an alkane diol;
and (c) a melt-stabilizing amount of monosodium phosphate, monopotassium phosphate or a mixture thereof.
2. A composition as defined in claim 1 wherein said polyester resin component (b) comprises 10 to 70 parts by weight.
3. A composition as defined in claim 1 wherein said polyester has been polymerized with a titanium compound catalyst.
4. A composition as defined in claim 1 containing from about 0.01 to about 7.5 parts of said phosphate per 100 parts by weight of said polyester (b).
5. A composition as defined in claim 1 containing from about 0.1 to about 4.0 parts of said phosphate per 100 parts by weight of said polyester (b).
6. A composition as defined in claim 1 wherein component (c) is monosodium phosphate.
7. A composition as defined in claim 1 wherein said aromatic polycarbonate resin (a) is derived from a diphenol and phosgene or a phosgene precursor.
8. A composition as defined in claim 7 wherein said aromatic polycarbonate resin (a) is poly(bisphenol A
carbonate).
9. A composition as defined in claim 1 wherein said polyester resin (b) comprises poly(1,4-butylene terephthalate).
10. A composition as defined in claim 1 wherein said polyester resin (b) comprises poly(ethylene terephthalate).
11. A composition as defined in claim 1 wherein said polyester resin (b) comprises an admixture of poly(1,4-butylene terephthalate) and poly(ethylene terephthalate).
12. A composition as defined in claim 1 wherein the polycarbonate resin (a) comprises poly(bisphenol A carbonate) and the polyester resin (b) comprises poly(1,4-butylene terephthalate).
13. A composition as defined in claim 1 which also includes (d) an impact modifier resin.
14. A composition as defined in claim 13 wherein the impact modifier resin comprises a polyacrylate resin.
15. A composition as defined in claim 1 which also includes a flame-retardant amount of a flame retardant additive or combination of such additives.
CA000484604A 1985-06-20 1985-06-20 Stabilized polycarbonate-polyester compositions Expired CA1258332A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA000484604A CA1258332A (en) 1985-06-20 1985-06-20 Stabilized polycarbonate-polyester compositions

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA000484604A CA1258332A (en) 1985-06-20 1985-06-20 Stabilized polycarbonate-polyester compositions

Publications (1)

Publication Number Publication Date
CA1258332A true CA1258332A (en) 1989-08-08

Family

ID=4130776

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000484604A Expired CA1258332A (en) 1985-06-20 1985-06-20 Stabilized polycarbonate-polyester compositions

Country Status (1)

Country Link
CA (1) CA1258332A (en)

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