CA1262496A - Polycarbonate/condensation polymer blends - Google Patents

Abstract

POLYCARBONATE/CONDENSATION POLYMER BLENDS
ABSTRACT OF THE DISCLOSURE
A thermoplastic composition includes compatible blends of a mixed polycarbonate comprising units derived from a first dihydric phenol, which is a bis(hydroxyaryl) sulfone, a second dihydric phenol; and one or more thermo-plastic condensation polymers containing hereto groups.

Description

~62~91~

POLYCARBONATE/CONDENSATION POLYMER BLENDS
This invention relates to thermoplastic compositions containing a mixed polycarbonate and thermo-plastic condensation polymers containing hereto groups which are admixed to provide compatible blends. More particularly, it relates to compositions comprising a mixed polycarbonate which comprises units derived from a first dihydric phenol which is a bis(hydroxyaryl) sulfone and a second dihydric phenol, and one or more thermoplastic polymers containing hereto groups to provide a compatible blend.
BACKGROUND OF THE INVENTION
. . _ At present, it is known to prepare a copolymer consisting of the reaction product of bis(3,5-dimethyl-4-hydroxyphenyl) sulfone; 2,2-bis(4-hydroxyphenyl) propane and a carbonate pxecursor. U.S. Patent No. 3,737,409 issued June 5, 1973 to Fox describes a process for making such a copolymer, which is disclosed to lend itself to the preparation of textile fibers.
U.5. Patent No. 4,286,057 issued August 25, 1981 to Wulff describes a molding composition comprising blends of polyarylates derived from a dihydric phenol and mixtures of terephthalic acid and isophthalic acid, and at least one thermoplastic polymer compatible therewith.
A blend of the polyarylates and an aromatic polycarbonate, where a thermoplastic compatible polymer is optionally added is also mentioned.
Polyethylene terephthalate films modified with ~'

- 2 - 08CT0-3959 a minor amount of preferably no more than 10~ bisphenol A
polycarbonate resin are disclosed in U.S. Patent 3,720,732 issued March 13, 1973 to sevenich. Processing difficulties were encountered when higher amounts of the resin were included. In any event, when the working composition of the aforementioned U.S. Patent 3,720,732 are made, a compatible composition in the sense contemplated by the present invention is not obtained when the amount of polycarbonate resin exceeds as little as 5% by weight of the combined amounts of polycarbonate and polyester.
In applicants' Canadian Application Serial No.
~41,969, filed November 25, 1983, there are disclosed and claimed novel compositions comprising mixed polycarbonate and thermoplastic addition polymers containing hereto groups which are admixed to provide compatible compositions.
SUMMARY OF THE INVENTION
Compatible mixtures of polycarbonates and thermoplastic resins have generally not been produced over a broad range of component proportions.
It is an object of this invention to provide blends of polycarbonate and thermoplastic condensation polymers which are compatible in mixtures having widely varying ratios of components and which have improved properties.
When used herein and in the appended claims, "compatible" refers to blends or compositions of polymers in which the component polymers do not undergo phase separation, thus helping to avoid stratification of the components during or after processing. Compatibility is of great significance for an admixture of different resins, because it ensures homogeneity, and a unity of properties, which greatly facilitates subsequent processing and use of the composition. Incompatible blends separate into phases containing predominantly their own separate components, and thus may be considered to be immiscible.

1~62~96

- 3 - 08CTO-3959 This characteristic, combined with the often low physical attraction forces across the phase boundaries, usually causes immiscible/incompatible blend systems to have poor mechanical properties, thus preventing the preparation of useful polymer blends.
When blends of two polymers exhibit a single glass transition temperature (Tg), it generally signifies the resin components are compatible. However, a single Tg is not a necessary condition for a compatible blend.
In accordance with the present invention, there are provided thermoplastic compositions comprising a poly-carbonate resin and a thermoplastie condensation polymer resin which have been melt admixed to provide a compatible composition.
Polycarbonates useful in accordance with the present invention are well known and any, especially the aromatic polycarbonates, may be employed. Intrinsic viscosities of from 0.40 to 0.80 dl./g (as measured in phenol/trichloroethylene) are preferred. Such resins may be formed from dihydric phenol, such as hydrocarbon bisphenol monomer, ordinarily by condensation with a carbonate precursor, such as carbonyl chloride, to provide a linear polymer consisting of units of the dihydrie phenol linked to one another through earbonate linkages.
The polycarbonate of the invention ineludes units derived from a dihydrie phenol and a dihydrie aryl sulfone.
In an espeeially preferred embodiment, a polycarbonate eopolymer ineludes a diphenyl sulfone as deseribed in U.S. Patent 3,737,409 issued June 5, 1973 to Fox. For these eopolymers a mole or unit ratio of 1:5 to 5:1 is desirable. The preferred diphenyl sulfone monomer for these resins is bis(3,5-dimethyl-4-hydroxy~
phenyl)sulfone, also known as dixylenol sulfone, whieh may be formed from 2,6-xylenol. The other preferred monomer is 2,2-bis(4-hydroxyphenyl)propane, also known as bisphenol A.

i~:6~9~

- 4 - 08CT0-3959 The condensation polymers which are mixed with the polycarbonate to form the compatible composition are comprised of units derived from repeat groups including a heterogroup. Heterogroups are groups containing atoms besides carbon and hydrogen; such atoms are designated heteroatoms.
The polymers containing heterogroups can have the heterogroups (A) as pendant groups on the polymer chain or as linkages in the polymer chain:
A

C--C
- C A C
Typical examples of heteroatoms are oxygen, sulfur, nitrogen, halogen, etc. Examples of heterogroups are O O O
.. .. -esters (R-C-O-R'); nitrile (R-CN); anhydride (R-C-O-C-R');
O O
ll ll ll imide (R-C-N-C-R"), carbonate (R-O-C-O-R') and the like.
R' From the foregoing, it follows that polymers within the scope of this invention, without limitation, are illustrated by polyesters, polyamides, polyimides, polyethers, polysulfones, polycarbonates, polyacrylates, and the like.
Outside the scope of the invention are polyolefins, poly(vinyl aromatics), and the like.
Once formed, the product composition may be employed (or further processed) in conventional manner.
Its applications include, for example, tough films useful in packaging. It may also be injection molded or extruded to produce a variety of useful thermoplastic articles.
In addition to at least two polymeric components, the present compositions may contain any of the conventional additives, for the purposes for which they are known. These additives include fire-retardants, impact modifiers, pigments, tints, reinforcing materials such as glass fiber, antioxidants and the like. They may be - ~262~6

- 5 - 08CT0-3959 combined with the compositions either before or after melt mixing~
Condensation polymers suitable for admixing with the polycarbonate are selected from the group consisting of a copolyestercarbonate, a polyarylate, a poly(aryl ether), a copolyetherester block polymer, a polyhydroxyether, a polyimide, or combinations thereof.
(a) Polyesters Polyesters which are suitable for use herein are derived from an aliphatic or cycloaliphatic diol, or mixtures thereof, containing from 2 to about 10 carbon atoms and at least one aromatic dicarboxylic acid. The polyesters which are derived from an aliphatic diol and an aromatic dicarboxylic acid have repeated units of the following general formula:
(I) O ~
O (CH2) n-- OC~~C --wherein n is an integer of from 2 to 4.
The preferred polyester is poly(ethylene terephthalate).
Also contemplated herein are the above polyesters with minor amounts, e.g., from 0.5 to about 2 percent by weight, of units derived from aliphatic acid and/or aliphatic polyols, to form copolyesters. The aliphatic polyols include glycols, such as poly(ethylene glycol). These can be made following the teachings of, for example, U.S. Patent Nos. 2,465,319 and 3,047,539 issued July 31, 1962 to Pengilly.
The polyesters which are derived from a cyclo-aliphatic diol and an aromatic dicarboxylic acid are prepared by condensing either the cis- or trans-isomer (or mixtures thereof) of, for example, 1,4-cyclohexane-dimethanol with an aromatic dicarboxylic acid so as to produce a polyester having recurring units of the ~;Z6~496

- 6 - 08CT0-3959 following formula:
(II) ~CH2- CH2 o o wherein the cyclohexane ring is selected from the cis- and trans-isomers thereof and R represents an aryl radical containing 6 to 20 carbon atoms and which is the decarboxyl-ated residue derived from an aromatic dicarboxylic acid.
Examples of aromatic dicarboxylic acids represented by the decarboxylated residue R in formula II
are isophthalic or terephthalic acid; 1,2-di(p-carboxy-phenyl)ethane, 4,4'-dicarboxydiphenyl ether, etc., and mixtures of these. A11 of these acids contain at least one aromatic nucleus. Acids containing fused rings can also be present, such as in 1,4- or 1,5-naphthalene-dicarboxylic acids. The preferred dicarboxylic acids are terephthalic acid or a mixture of terephthalic and isophthalic acids.
Another preferred polyester may be derived from the reaction of either the cis- or trans-isomer (or a mixture thereof) of 1,4-cyclohexanedimethanol with a mixture of isophthalic and terephthalic acids. Such a polyester would have repeating units of the formula:
(III) O
C
~CH2- CH2~ 0 /=<
\CH2- CH2~ ~

Still another preferred polyester is a copoly-ester derived from a cyclohexane dimethanol, an alkylene glycol and an aromatic dicarboxylic acid. These copoly-esters are prepared by condensing either the cis- or trans-isomer (or mixtures thereof) of, for example, 1,4-cyclo-hexane-dimethanol and an alkylene glycol with an aromatic lZ~;Z~9~

- 7 - 08CT0-3959 dicarboxylic acid so as to produce a copolyester having repeating units of the following formula:
(IV) r ~CH2 2~ 1~ ~1 r ~) \CH -CH~ ~O-(CH2)n-OC-R-C----5 wherein the cyclohexane xing is selected from the cis-and trans-isomers thereof, R is as previously defined, n is an integer of 2 to 4, the x units comprise from about 10 to about 90 percent by weight and the y units comprise from about 90 to about 10 percent by weight.
Such a preferred copolyester may be derived from the reaction of either the cis- or trans-isomer (or mixtures thereof) of 1,4-cyclohexanedimethanol and ethylene glycol with terephthalic acid in a molar ratio of 1:2:3. These copolyesters have repeating units of the 15 following formula:
(V) 2 c~ >~H--CH ~--:~(CH2)2--oc~c_~

wherein x and y are as previously defined.
The polyesters described herein are either 20 commercially available or can be produced by methods well known in the art, such as those set forth in, for example, U.S. Patent No. 2,901,466, issued August 25, 1959 to Kibler et al.
The polyesters used herein have an intrinsic 25 viscosity of from about 0.4 to about 2.0 dl/g. as measured in a 60:40 phenol/tetrachloroethane mixture or similar solvent at 23-30C.

126Z~lC~;

- 8 - 08CT0-3959 (b) Aromatie Polycarbonate ; Thermoplastie aromatie polycarbonates that ean be employed as the thermoplastic heterogroup containing polymer herein are homopolymers and copolymers and mixtures thereof, which have an intrinsic viscosity of from about 0.4 to about 1.0 dl/~. as measured in methylene chloride at 25C. The polycarbonat~s are prepared by reacting a dihydric phenol with a carbonate precursor.
; Typical of some of the dihydric phenols that may be employed are bisphenol-A, bis(4-hydroxyphenyl)methane, 2,2-bis(4-hydroxy-3-methylphenyl)propane, 4,4-bis(4-hydroxyphenyl)-heptane, 2,2(3,5,3',5'-tetrabromo-4,4'-dihydroxydiphenyl)-propane, (3,3'-dichloro-4,4'-dihydroxydiphenyl)methane, and the like. Other dihydric phenols of the bisphenol type are described in, for example, U.S. Patent Nos. 2,999,835 issued September 12, 1961 to Goldberg, 3,028,365 issued April 3, 1962 to Sehnell et al and 3,334,154 issued August 1, 1967 to Kim.
It is, of course, possible to employ two or more different dihydric phenols, or a copolymer of a dihydric phenol, with a glyeol or with hydroxy or acid terminated polyesters, or with a dibasic acid, in the event a carbonate copolymer or inter-polymer rather than a homopolymer is desired for use in the preparation of the aromatie earbonate polymer containing heterogroup.
The earbonate precursor may be either a earbonyl halide, a earbonate ester, or a haloformate.
The earbonyl halides whieh ean be employed herein are earbonyl bromide, earbonyl ehloride and mixtures thereof.
Typieal of the earbonate esters whieh may be employed herein are diphenyl earbonate, di-(halophenyl)carbonates, sueh as di-(ehlorophenyl)earbonate or di-(bromophenyl)-earbonate, ete., di-(alkylphenyl)earbonates such as di-(tolyl)earbonate, di-(naphthyl)earbonate, di-(ehloro-naphthyl)earbonate, ete. or mixtures thereof. The halo-formates suitable for use herein inelude bishaloformates 126;~36

- 9 - 08CT0-3959 of dihydric phenols, for example: bischloroformates of bisphenol-A, of hydroquinone, etc.; of glycols, for example: bis-haloformates of ethylene glycol, neopentyl glycol, polyethylene glycol, etc. While other carbonate precursors will be apparent to those skilled in the art, carbonyl chloride, also known as phosgene, is preferred.
The aromatic polycarbonate polymers may be prepared by methods well known in the art, by using phosgene or haloformate and by employing a molecular weight regulator, an acid acceptor and a catalyst. The molecular weight regulators which can be employed in carrying out the process include monohydric phenols, such as phenol, paratertiary-butylphenol, para-bromophenol, primary and secondary amines, etc. Preferably, a phenol is employed as the molecular weight regulator.
A suitable acid acceptor may be either an organic or an inorganic acid acceptor. A suitable organic acid acceptor is a tertiary amine and includes materials, such as pyridine, triethylamine, dimethylaniline, tributylamine, etc. The inorganic acid acceptor may be one which can be either a hydroxide, a carbonate, a bicarbonate, or a phosphate of an alkali or alkaline earth metal.
The catalysts which are employed herein can be any of the suitable catalysts that aid the polymerization of, for example, bisphenol-A with phosgene. Suitable catalysts include tertiary amines, such as triethylamine, tripropylamine, N,N-dimethylanaline, quaternary ammonium compounds, such as tetraethylammonium bromidel cetyl triethyl ammonium bromide, tetra-n-heptylammonium iodide, and quaternary phosphonium compounds, such as n-butyl-triphenyl-phosphonium bromide and methyl-triphenyl phosphonium bromide~
The polycarbonates can be prepared in one-phase (homogeneous solution) or two-phase (interfacial) systems when phosgene or a haloformate are used. Bulk reactions are possible when the diarylcarbonate precursors are used.

~Z~ 96

- 10 - 08CT0-3959 (c) Poly(arylether)s Poly(aryl ether) resin components suitable for use herein are linear, thermoplastic polyarylene polyether polysulEones, wherein the arylene units are interspersed with ether and sulfone linkages. These resins may be obtained by reaction of an alkali metal double salt of a dihydric phenol and a dihalobenzenoid compound, either or both of which contain a sulfone or ketone linkage i.e., -S2 - or --CO - between arylene groupings, to provide sulfone or ketone units in the polymer chain in addition to arylene units and ether units. The polysulfone polymer has a basic structure comprising recurring units of the formula:
-O-E--O--E' -wherein E is the residuum of the dihydric phenol and E' is the residuum of the benzenoid compound having an inert electron withdrawing group in at least one of the positions ortho and para to the valence bonds; both of said residua are valently bonded to the ether oxygens through aromatic carbon atoms. Such polysulfones are included within the class of polyarylene polyether resins described in U.S. Patent Nos. 3,264,536 issued August 2, 1966 to Robinson et al and 4,108,837 issued August 22, 1978 to Johnson et al, for example.
The residuum of a dihydric phenol, E, is derived from dinuclear phenols having the structure:
(A,)r (,l)rl OH(Ar -Rl -Ar)OH
wherein Ar is an aromatic group and preferably is a phenylene group, A and Al may be the same or different inert substituent groups, such as alkyl groups having from 1 to 4 carbon atoms, halogen atoms, i.e., fluorine, chlorine, bromine or iodine or alkoxy radicals having from 1 to 4 carbon atoms, r and rl are integers having a value of from 0 to 4, inclusive, and Rl is representative of a bond between aromatic carbon atoms as in dihydroxydi-phenyl, or is a divalent radical, including, for example, 1262~916 ~ 08CT0-3959 CO, O, S, S -S, SO2 or a divalent organic hydrocarbon radical, such as alkylene, alkylidene, cycloalkylene, or the halogen, alkyl, aryl, or like substituted alkylene, alkylidene and cycloalkylene radicals as well as alkarylene and aromatic radicals and a ring fused to both Ar groups.
Typical preferred polymers have recurring units having the following structure:
(A) (A ) r ~ ~Rl--6~ ~)~R2~--as described in aforementioned U.S. Patent No. 4,108,837.
In the foregoing formula A and Al can be the same or different inert substituent groups such as alkyl groups having from 1 to 4 carbon atoms, halogen atoms (e.g., fluorine, chlorine, bromine or iodine) or alkoxy radicals having from 1 to 4 carbon atoms, r and rl are integers having a value of from 0 to 4, inclusive. Typically, Rl is representative of a bond between aromatic carbon atoms or a divalent connecting radical and R2 represents sulfone, carbonyl, or sulfoxide. Preferably, Rl represents a bond between aromatic carbon atoms. Even more preferred are the thermoplastic poly-sulfones of the above formula wherein r and rl are zero, Rl is a divalent connection radical of the formula:

R"-C -R"
I

wherein R" is selected from lower alkyl, aryl, and the halogen substituted groups thereof, preferably methyl, and R2 is a sulfone group.
The poly(aryl ether)s have a reduced viscosity of from about 0.4 to about 1.5 dl/g as measured in an appropriate solvent at an appropriate temperature depending on the particular polyether, such as in methylene chloride 1'~62~3~

- 12 - 08CT0-3gsg at 25C.
The preferred poly(aryl ether)s have repeating units of the formula:

~ ~ ~ 2 ~

~ ~ , and , 3 (d~ Copolyetherester Block Copolymer Copolyetheresters suitable for use herein are well known in the art and are described in, for example, U.S. Patent Nos. 3,784,520 issued January 8, 1974 to Hoeschele and 3,766,146 issued October 16, 1973 to Witsiepe.
The polyester comprises a multiplicity of recurring intralinear long chain and short chain ester units connected head-to-tail through ester linkages, said long chain ester units being represented by the following structure: O O
(a) -OGO-CR C -and said short chain ester units being represented by the following structure:
O O
ll ll (b) -ODO-CR3C -wherein G is a divalent radical remaining after removal of terminal hydroxy groups from a poly(alkylene oxide) glycol having a molecular weight of from about 400 to about 3500; D is a divalent radical remaining after removal ~Z6Z~96 of hydroxyl groups from a low molecular weight diol having a molecu]ar weight of less than about 250; and R3 is a divalent radical remaining after removal of carboxyl groups from a dicarboxylic acid having a molecular weight of less than about 300, with the proviso that the short chain ester units constitute from about 25 to about 65%
by weight of the copolyester, at least about 70% of the R3 groups are 1,4-phenylene radicals, at least about 70%
of the D groups are 1,4-butylene radicals, and the sum of the percentages of the R3 groups which are not 1,4-phenylene radicals and the D groups which are not 1,4-butylene radicals does not exceed about 30%.
The term "long chain ester units" as applied to units in a polymer chain refers to the reaction product of a long chain glycol with a dicarboxylic acid. Such "long chain ester units," which are repeating units in the copolyester herein, correspond to the structure (a) above. The long chain glycols may be poly(alkylene oxide) glycols having a molecular weight between about 400 and about 3500, preferably between about 600 and about 2000.
Copolyesters prepared from poly(alkylene oxide) glycols having a molecular weight between about 600 to about 2000 are preferred.
The term "short chain ester units" as applied to units in a polymer chain refers to low molecular weight compounds or polymer chain units having molecular weight of less than about 550. They are made by reacting a low molecular weight diol, (below about 250), with a dicar-boxylic acid, to form ester units represented by structure (b) above.
Included among the low molecular weight diols, (other than 1,4-butanediol), which react to form short chain ester units are acyclic, alicyclic and aromatic dihydroxy compounds. Preferred are diols with from 2 to 15 carbon atoms, such as ethylene, propylene, isobutylene, tetramethylene, pentamethylene, 2,2-dimethyl-trimethylene, hexamethylene and decamethylene glycols, 1~62 ~96 dihydroxy cyclohexane, cyclohexanedimethanol, resorcinol, hydroquinone, 1,5-dihydroxy naphthalene, etc. Especially preferred are aliphatic diols containing from 2 to 8 carbon atoms. Included among the bisphenols which can be used are bis(p-hydroxy)diphenyl, bis(p-hydroxyphenyl)-methane, and bis(p-hydroxyphenyl)propane.
Dicarboxylic acids (other than terephthalic acid) which are reacted with the foregoing long chain glycols or low molecular weight diols to produce the copolyesters are aliphatic, cycloaliphatic or aromatic dicarboxylic acids.
Representative aliphatic and cycloaliphatic acids which may be used are sebacic acid, 1,3-cyclohexane dicarboxylic acid, 1,4-cyclohexane dicarboxylic acid, adipic acid, glutaric acid, succinic acid, carbonic acid, cyclopentanedicarboxylic acid, decahydro-1,5-naphthylene dicarboxylic acid and 4,4-bicyclohexyl dicarboxylic acid.
Preferred aliphatic acids are cyclohexane-dicarboxylic acids.
Representative aromatic dicarboxylic acids which may be used include phthalic, terephthalic and isophthalic acids, substituted dicarboxy compounds with two benzene nuclei, such as bis(p-carboxyphenyl)methane and p-carboxyphenyl/oxybenzoic acid. Among the aromatic acids, those with from 8 to 16 carbon atoms are preferred, particularly the phenylene dicarboxylic acids, i.e., terephthalic and isophthalic acids.
Preferably, at least about 70 mole percent of the dicarboxylic acid incorporated into the polymer is terephthalic acid and at least about 70 mole percent of the low molecular weight diol incorporated into the polymer is 1,4-butanediol. Thus, at least 70% of the R3 groups in structures (a) and (b) above are 1,4-phenylene radicals and at least about 70% of the D groups in formula b above are 1,4-butylene radicals.
The most preferred copolyesters are those 1;~62~9~

prepared from dimethylterephthalate, 1,4-butanediol and poly(tetramethylene oxide) glycol having a molecular weight of from about 600 to about 1500.
The copolyetheresters described herein can be made conveniently by a conventional ester interchange reaction by methods well known in the art and as described in, for example, aforementioned U.S. Patent Nos. 3,784,520 and 3,766,146.
(e) Polyhydroxyether The thermoplastic polyhydroxyethers which may be used herein have the following general formula:

--~F--O -D"--O ~
where F is the radical residuum of a dihydric phenol, D"
is a radical residuum of an epoxide selected from mono-and diepoxides and which contain from 1 to 2 hydroxylgroups, and n is an integer which represents the degree of polymerization and is at least about 30 and preferably is above about 80.
In general, thermoplastic polyhydroxyethers are prepared by contacting, under polymerization conditions, a dihydric phenol and an epoxide containing from 1 to 2 epoxide groups in substantially equimolar amounts by methods well known in the art.
Any dihydric phenol can be used in forming polyhydroxyethers. Illustrative dihydric phenols are mononuclear dihydric phenols such as hydroquinone, resorcinol, and the like as well as the polynuclear phenols. The dihydric polynuclear phenols have the general formula:

r (B)a 1 r- l)al 1 H ~ R ~ ~ t R ~ H

wherein R4 is an aromatic divalent hydrocarbon radical, such as naphthylene and phenylene, with phenylene 1~6;~

being preferredi B and B1 may be the same or different and are selected from alkyl radicals, such as methyl, n-propyl, n-butyl, n-hexyl/ n-octyl and the like, preferably alkyl radicals having 1 to 4 carbon atoms; a and al are independently integers of 0 to 4, and R' is alkylene, alkylidene cycloalkylene or a saturated divalent group. Particularly preferred are dihydric polynuclear phenols having the general formula:
(7) a (71) al ~ R6~H

wherein B, Bl, a and al are as previously defined, and R6 is an alkylene or alkylidene group, preferably having from 1 to 3 carbon atoms, or cycloalkylene having 6 to 12 carbon atoms.
Diepoxides useful for the preparation of polyhydroxyethers may be represented by repeating units of the following formula:

H - C ~ R7 - C ~ H
wherein R7 is representative of a bond between adjacent carbon atoms or a divalent organic radical such as an aliphatic, aromatic, cyclic, heterocyclic or acyclic arrangement of atoms.
Other diepoxides which can be mentioned include those wherein two oxirane groups are linked through an aromatic ether, i.e., compounds having the grouping -C -O-W - O-(R8O)d -C -wherein R8 is a divalent organic radical, W is a divalent aromatic radical residuum of a dihydric phenol, such as those listed above in the description of dihydric phenols, and d is an integer from 0 to 1 inclusive.

1;Z62~9~

Still other diepoxides include ethers wherein the oxirane groups are connected to vicinal carbon atoms, at least one pair of which is a part of a cycloaliphatic hydrocarbon.
These polyhydroxy ethers are prepared by methods well known in the art, such as those described in, for example, U.S. Patent Nos. 3,238,087 issued March 1, 1966 to Norwalk et ali 3,305,528 issued February 21, 1967 to Wynstra et al; 3,294,747 issued December 27, 1966 to Fry;
and 3,277,051 issued October 4, 1966 to Wynstra.
( f ) Polyimides Polyimides prepared from the reaction between substantially e~ual molar amounts of aromatic bis(ether anhydride)s of the formula, (I) ., O

o /\ ~ ~o O O
and organic diamine of the formula, (II) H2NR NH2 in the presence of a phenolic solvent which produce a solution which remains homogeneous when the mixture is allowed to cool to room temperature. There is obtained a solution of polyimide in the phenolic solvent which can be used directly as a wire coating enamel or for applying polyimide onto various substrates. If desired, the polyimide can be recovered by effecting its separation from the phenolic solvent mixture with a non-solvent for polyimide, such as methanol.
As shown in formula I, R is a member selected from the class consisting of (a) the following divalent organic radicals:

~262~ct~

~'~' ~
~'~

CH Br Br CH CH3 3 B

, and ~ C(CH3) CH3 Br Br CH3 Br Br and (b) divalent organic radicals of the general formula ~ (X)m ~

where X is a member selected from the class consisting of divalent radicals of the formulas O O
ll ll Cy 2y ~ -C-, -S-, -O-o and -S-, where m is 0 or 1, y is a whole number from 1 to 5, and Rl is a divalent organo radical selected from the class consisting of (a) aromatic hydrocarbon radicals having from 6-20 carbon atoms and halogenated derivatives thereof, (b) alkylene radicals, C(2 8) alkylene terminated polydiorganosiloxane, cycloalkylene radicals having from 2-20 carbon atoms, and (c) divalent radicals included by the formula, ~Z62~3~
- lg - 08CT0-3959 ~ (Q)m ~

where Q is a member selected from the class consisting of O O
-O-, -C-, -S-, -S-, -CxH2 -o and x is a whole number from 1 to 5 inclusive, and 5 m is as pre~iously defined.
These polyimide are prepared by methods well known in the art such as those described in, for example, U.S. Patent No.s. 3,917,643 issued November 4, 1975 to Takekoshi; 3,852,242 issued December 3, 1974 to White;
3,855,176 issued December 17, 1974 to Skidmore; and ¦ 3,833,546 issued September 3, 1974 to Takekoshi.
~ The polyimide can be a polyetherimide having ¦ repeating units of the formula:

O O

~ \N-R-N< --RO O

where R is a divalent organic radical selected from the class consisting of (a) aromatic hydrocarbon radicals having from 6-20 carbon atoms and halogenated derivatives thereof, (b) alkylene radicals, C(2 8) alkylene terminated polydiorganosiloxane cycloalkylene radicals having from 2-20 carbon atoms, and (c) divalent radicals included by the formula ~;262~9~;
- l9a - 08CTO-3959 ~ ~ Q ~ ~
where Q is a member selected from the class consisting of O O
-O-, -C-, -S-, -S-, and -CXH2x, o and x is a whole number from 1 to 5, inclusive and Rl is an aromatic radieal having from 6-30 earbon atoms. Rl is more partieularly aromatie radieals seleeted from the class eonsisting of (a) the following divalent organie radieals: CH3 ~ '~'~, and CH3 Br Br CH3 i26249~
- l9b - 08CTO-3959 Br Br C(CH3) Br Br and (b) divalent organic radicals of the general formula ~ ( X ) m ~
where x is a mem~er selected from the class consisting of divalent radicals of the formulas O O
-CyH2y -, -C-, ,, -O- and -S-, where m is o or 1, and y is a whole number from 1 to 5.
` The following examples are given by way of . illustration only and are not intended as a limitation of ; 10 the scope of this invention. Many variations are possible without departing from its spirit and scope. Unless other-wise specified herein, all proportions are provided on a weight basis. The intrinsic viscosities (I.V.) are all determined in a solvent mixt~re comprising 60-40 w/w phenol-tetrachloroethene at 30C.

A resin blend is provided by admixing poly-(ethylene terephthalate) resin with 45 percent by total res.in weight of polycarbonate resin formed from dixylenol sulfone (sulfone) and bisphenol A (bisphenol) in a mole ratio of 1:4.
This admixture is melt mixed at a temperature of about 325C for 30 minutes in a Brabender mixing bowl , to form a melt admixed composition. Comparative properties of the resins and the melt admixed composition are as follows:

i~6;2~

Polycarbonate Poly(ethylene terephthalate) Composition I.V. = 0.61 I.V. = 0.72 I.V. = 0.52 Tg = 172C Tg = 67C (amorphous) Tg = 108C
The resolution of the distinct glass transition points of the two component resins to the single point for the melt admixed composition shows formation of a homo-geneous resin solution.

The process of Example 1 is repeated substituting 50 per cent by weight of a polycarbonate having a 1:1 mole ratio of sulfone to bisphenol. Comparative properties after melt admixture at about 325C for 5 minutes are as follows:
Polycarbonate Poly(ethylene terephthalate) Composition I.V. = 0.48 I.V. = 0.72 I.V. = 0.46 Tg = 202C Tg = 67C (amorphous) Tg = 120C

The process of Example 1 is repeated substituting 45 per cent by weight of polycarbonate having a 3:1 mole ratio of sulfone to bisphenol. Comparative properties after melt admixture at about 325C for 10 minutes are as follows:
Polycarbonate Poly(ethylene terephthalate) Composition I.V. = 0.58 I.V. = 0.72 I.V. = 0.48 Tg = 227C Tg = 67C (amorphous) Tg = 117C

A poly(ethylene terephthalate) is admixed with 50 per cent by total weight of polycarbonate resin formed from sulfone and bisphenol A in a mole ratio of 1:1.
This admixture is melt mixed at a temperature of about 270C for 3-5 minutes in an l-inch single screw extruder. Comparative properties of the resultant composi-tion are as follows:
Polycarbonate Poly(ethylene terepht_ late) Composition I.V. = 0.58 I.V. = 0.72 I.V. = 0.54 Tg = 202C Tg = 67C (amorphous Tg = 103C

1~6~9~i EXAMPLE S
The process of Example 4 is repeated substituting 40 per cent by weight of a polycarbonate having 1:1 mole ratio of sulfone to bisphenol. Comparative properties after extruding are as follows:
Polycarbonate Poly(ethylene terephthalate Composition I.V. = 0.58 I.V. = 0.72 I.V. = 0.60 Tg = 202C Tg = 67C (~lorphous) Tg = 97C

The process of Example 4 is repeated substituting 90 per cent by weight of a polycarbonate having a 1:1 mole ratio of sulfone to bisphenol. Comparative properties after extruding are as follows:
Polycarbonate Poly(ethylene-terephthalate) Composition I.V. = 0.45 I.V. = 0.72 I.V. = 0.41 Tg = 197C Tg = 67C (amorphous) Tg = 169C

The process of Example 1 is repeated substituting 80 per cent by weight of polycarbonate having a 4:1 mole ratio of sulfone to bisphenol. Comparative properties after melt admixture at about 335C for 5 minutes are as follows:
Polycarbohate Poly(ethylene terephthalate) Composition I.V. = 0.68 I.V. = 0.72 I.V. = 0.65 Tg = 245C Tg = 67C (amorphous) Tg = 192C

The process of Example 1 is repeated substituting 80 per cent by weight of polycarbonate having a 1:1 mole ratio of sulfone to bisphenol. Comparative properties after melt admixture at about 300C for 5 minutes are as follows:
Polycarbonate Poly(ethylene terephthalate) Composition I.V. = 0.73 I.V. = 0.72 I.V. = 0.68 Tg = 210C Tg = 67C (amorphous) Tg = 180C

62~9~;

~rl The process of Example 1 is repeated substituting ~ 80 per cent by weight of polycarbonate having a 3:7 mole : ratio of sulfone to bisphenol. Comparative properties after melt admixture at about 280C for 5 minutes are as follows:
Polycarbonate Poly(ethylene terephthalate) Composition I.V. = 0.62 I.V. = 0.72 I.V. = 0.61 Tg = 171C Tg = 67C (amorphous) Tg = 138C

The process of Example 1 is repeated substituting 60 per cent by weight of polycarbonate having a 4:1 mole ratio of sulfone to bisphenol. Comparative properties after , melt admixture at about 325~C for 5 minutes are as follows:
" 15 Polycarbonate Poly(ethylene terephthalate) Composition ,~ I.V. = 0.68 I.V. = 0.72 I.V. = 0.63 . Tg = 235C Tg = 67C (amorphous) Tg = 147C
.:~ EXAMPLE 11 The process of Example 1 is repeated substituting : 20 60 per cent by weight of polycarbonate having a 1:1 mole : ratio of sulfone to bisphenol. Comparative properties after melt admixture at about 300C for 5 minutes are as follows:
Polycarbonate Poly(ethylene terephthalate) Composition I.V. = 0.73 I.V. = 0.72 I.V. = 0.68 Tg = 210C Tg = 67C (amorphous) Tg = 135C

The process of Example 1 is repeated substituting 60 per cent by weight of polycarbonate having a 3:7 mole . 30 ratio of sulfone to bisphenol. Comparative properties after melt admixture at about 275C for 5 minutes are as follows:
.~. Polycarbonat.e~ Poly(ethylene terephthalate) Composition I.V. = 0.62 I.V. = 0.72 I.V. = 0.64 Tg = 171C Tg = 67C (amorphous Tg = 99C

lZ6;2~9~

The process of Example 1 is repeated substituting 40 per cent by weight of polycarbonate having a 4:1 mole ratio of sulfone to bisphenol. Comparative properties after melt admixture at about 310C for 5 minutes are as follows:
Polycarbonate Poly(ethylene' ter'ephthalate) Composition I.V. = 0.68 I.V. = 0.72 I.V. = 0.66 Tg = 235C Tg = 67C (amorphous) Tg = 112C
EXAMPl;E~ 14 The process of Example 1 is repeated substituting 40 per cent by weight of polycarbonate having a 1:1 mole ratio of sulfone to bisphenol. Comparative properties after melt admixture at about 285C for 5 minutes are as follows:
Polycarbonate Poly(ethylene terephthalate) Composition I.V. = 0.73 I.V. = 0.72 I.V. = 0.70 Tg = 210C Tg = 67C (amorphous) Tg = 105C

The process of Example 1 is repeated substituting 40 per cent by weight of polycarbonate having a 3:7 mole ratio of sulfone to bisphenol. Comparative properties after melt admixture at about 270C for 5 minutes are as follows:
Polycarbonate Poly(ethylene terephthalate) Composition 25 I.V. = 0.62 I.V. = 0.72 I.V. = 0.66 Tg = 171C Tg = 67C (amorphous) Tg = 90C

The process of Example 1 is repeated substituting 20 per cent by weight of polycarbonate having a 4:1 mole ratio of sulfone to bisphenol. Comparative properties after melt admixture at about 310C for 5 minutes are as follows:
Polycarbonate P'oly(e'thy'l'ene_terephtha'late) Composi'tion I.V. = 0.68 I.V. - 0.72 I.V. = 0.67 Tg = 235OC Tg = 67C (amorphous) Tg = 85C

~262~9~;

The process of Example 1 is repeated substituting " 20 per cent by weight of polycarbonate having a 1:1 mole ratio of sulfone to bisphenol. Comparative properties af-ter melt admixture at about 275C for 5 minutes are as follows:
, Polycarbonate Poly(ethylene terephthalate) Composition I.V. = 0.73 I.V. = 0.72 I.V. = 0.65 Tg = 210C Tg = 67C (amorphous) Tg = 83C
EXAMPLE'18 The process of Example 1 is repeated substituting 20 percent by weight of polycarbonate having a 3:7 mole ratio of sulfone to bisphenol. Comparative properties after melt admixture at about 270C for 5 minutes are as follows:
Polycarbonate P'oly('e'thy'len'e terephthalate) Composition I.V. = 0.62 I.V. = 0.72 I.V. = 0.63 = 171C Tg = 67C (amorphous) Tg = 82C
' EXAMPLE 19 The procedure of Example 1 is repeated substituting 50 per cent by weight of polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 50 per cent by weight ', poly(butylene terephthalate). Comparative properties after melt admixture at about 300C are as follows:
Polycarbonate Poly(butylene terephthalate) Composition I.V. = 0.62 I.V. = 1.02 I.V. = 0.73 Tg = 210C Tg = 45C Tg = 102C

The procedure of Example 1 is repeated substitu-ting 50 per cent by weight of polycarbonate having a 4:1 mole ratio of sulfone to bisphenol and 50 per cent by weight poly(butylene terephthalate). The results after melt admixture at about 310C are as follows:
Polycarbonate Poly(butylene terephthal'ate) Composition I.V. = 0.65 I.V. = 1.02 I.V. = 0.75 Tg = 235C Tg = 45C Tg = 112C

i262~96 _AMPLE 21 The procedure of Example 1 is repeated substitu-ting 50 per cent by weight of polycarbonate having a 3:7 mole ratio of sulfone to bisphenol and 50 per cent by weight of 1 poly(butylene terephthalate). The results after melt admixture at about 290C are as follows:
.. l Polycarbonate Poly(butylene terephthalate) C~omposition I.V. = 0.73 I.V. = 1.02 I.V~ = 0.84 Tg = 171C Tg = 45C Tg = 97C
;~
:~ 10 EXAMPLE 22 A physical mixture of 50 per cent by weight of dry polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 50 per cent by weight poly(butylene terephthalate) (manufactured by General Electric Company under the trademark Valox 310) are melt mixed in an extruder operating under the following conditions:
' ' ' Temperature RPM Zone Zone Zone Die Amp 1 2 3 Melt 30 530F 565F 565F 540F 3.0 The extruded, blended polymer strands are chopped into pellets which are dried and injection-molded (into .- specimens suitable for testing) in a 3 ounce/75 ton Newbury injection molding machine operating under the following conditions:
Barrel Temperature 530F
Mold Temperature 150F
Molding Pre.ss.ure . 10,00.0 psi -The specimens were evaluated for fluxural properties (ASTM D790) and heat distortion temperature (ASTM D256).
Comparative data is presented in Table I.

1~:62 ~

Z TABLE I
Flexural Flexural Heat Distortion Modulus Strength Temperature (piS) (pSl)( C) Valox 310 340,000 12,800 54 poly(butylene terephthalate) Specimen 381,000 14,300 73 A physical mixture of 50 per cent by weight of dry polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 50 per cent by weight of a copolyester derived from ethylene glycol, cyclohexane dimethanol and terephthalic acid (manufactured by Eastman Kodak Co. under the trademark Kodar PETG) is extruder blended, and injection molded, and tested for properties substantially as described in Example 22. Comparative results are as follows:
Property _ecimens Kodar PETG Copolyester Tg, C 131 80 HDT, C 106 65 Notched Izod, 0.8 0.8-1.9 ft-lb/in Flex. Mod., psi 370,000 308,000 Flex. Str., psi 17,100 11,400 A physical mixture of 50 per cent by weight of dry polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 50 per cent by weight of a copolyester derived from cyclohexane dimethanol and iso/terephthalic acids (manufactured by Eastman Kodak Company under the trademark Kodar A-150) is extruder blended, injection molded, and tested for properties substantially as described in Example 22. Comparative results are as follows:

lZ~i2 ~9~

Property SpecimensKodar A-150 Copolyester Tg, C 137 87 HDT, C 114 71 Notched Izod, 1.0 1.4 Ft-lb/in Flex. Mod., psi330,000 241,000 Flex. Str., psi15,600 9,800 The process of Example 1 is repeated substituting 60 per cent by weight of polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 40 per cent by weight of Bisphenol A polycarbonate (manufactured by General Electric Company under the trademark Lexan). Comparative results after melt admixture at about 300C are as follows:
Sulfone/Bisphenol Polycarbonate Lexan Polycarbonate Composition ' Tg = 210C 150C 172C

The procedure of Example 1 is repeated substituting 60 per cent by weight polycarbonate having a 3:7 mole ratio of sulfone to bisphenol and 40 per cent by weight of Lexan polycarbonate. Comparative results after melt admixture at about 300C are as follows:
Sulfone/Bisphenol Polycarbonate Lexan Polycarbon te Composition Tg = 171C 150C 162C

EXAMPLE'27 The procedure of Example 1 is repeated ; substituting 40 per cent by weight of polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 60 per cent by weight of Lexan polycarbonate. Comparative results after melt admixture at about 300C are as follows:
Sulfone/BispAenol Polycarbona~e Lexan P'olyc'arbonate C'ompos'ition Tg = 210~C 150C 168C

~;26~

The procedure of Example 1 is repeated substitu-ting 40 per cent by weight of polycarbonate having a 3:7 mole ratio of sulfone to bisphenol and 60 per cent by weight of Lexan polycarbonate~ Comparative results after melt admixture at about 300C are as follows:
, Sulfone/Bisphenol Polycarbonate _xan'PolycarbonateComposition Tg = 171C 150C 159C

he procedure of Example l is repeated substitu-ting 20 per cent by weight of polycarbonate having a l:l mole ratio of sulfone to bisphenol and 80 per cent by weight of Lexan polycarbonate. Comparative results after melt admixture at about 300~C are as follows:
Sulfone/Bisphenol Polxca_bonateLexan Polycarbonate Composition Tg = 210C 150C 155C
t `~ EXAMPLE 30 ; 20 The procedure of Example 1 is repeated substitu-ting 20 per cent by weight of polycarbonate having a 3:7 mole ratio of sulfone to bisphenol and 80 per cent by weight of Lexan polycarbonate. Comparative results after melt ' admixture at about 300C are as follows:
25 Sulfone/Bisphenol Polycarbonate Lexan Polycarbonate Composition Tg = 171C 150C 154C

The procedure of Example l is repeated substitu-ting 90 per cent by weight of polycarbonate having a l:l mole ratio of sulfone to bisphenol and 10 per cent by weight Lexan polycarbonate. Comparative results after melt admixture at about 310C are as followc:
Sulfone/Bisphenol Polycarbonate 'Lexan Polycarbonate Composition Tg = 210C 150C 193C

6'~96 The procedure of Example 1 is repeated substitu-ting 70 per cent by weight of polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 30 per cent by weight of Lexan polycarbonate. Comparative results after melt admixture at about 310C are as follows:
Sulfone/Bisphenol Polycarbonate Lexan Polycarbonate Composition Tg = 210C 150C 187C

The procedure of Example 1 is repeated substitu-ting 55 per cent by weight of polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 45 per cent by weight of Lexan polycarbonate. Comparative results after melt admixture at about 300C are as follows:
Sulfone/Bisphenol Polycarbo _te Lexan Polycarbonate Composition Tg = 210C 150C 177C
;

A physical mixture of 5 per cent by weight of dry polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 95 per cent by weight Lexan polycarbonate are extruder blended, injection molded, and tested for properties substantially as described in Example 22. The results of this Example are presented in Table II below.
_AM LE 35 A physical mixture of 10 per cent by weight of dry polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 90 per cent by weight of Lexan polycarbonate are extruder blended, injection molded, and tested for properties substantially as described in Example 22. The results of this Example are presented in Table II below.

A physical mixture of 15 per cent by weight of dry polycarbonate having a 1:1 mole ratio of sulfone to i2~2 ~96 , bisphenol and 85 per cent by weight Lexan polycarbonate are extruder blended, injection molded, and tested for ~i properties substantially as described in Example 22.
The results of this Example are presented in Table Ii -~ 5 below.
::
: .

A physical mixture of 20 parts of dry poly-carbonate having a 1:1 mole ratio of sulfone to bisphenol and 80 parts Lexan polycarbonate are extruder blended, injection molded, and tested for properties substantially as described in Example 22. The results of this Example are presented in Table II below.
- TABLE II
Tg HDT Notched Izod C C ft lbs/in Lexan Polycarbonate 151 140 ~15 Example 34 153 143 ~15 Example 35 155 147 ~15 Example 36 157 149 ~15 Example 37 159 152 ~15 :.

The injection molded composition of Example 37 were further evaluated according to the tests for the ; specimens of Examples 22 and 23. Comparative results are set forth in Table III.
TABLE III
LEXAN
Property (Polycarbonate) Composition Tensile Modulus, psi 345,000 370,000 Tensile Strength, psi 9,000 9,100 30 Yield Elongation, % 10 7 Elongation at Break, ~ 110 46 Flexural Modulus, psi 340,000 396,000 Flexural Strength, psi 13,500 15,900 HDT, F 270 305 Notched Izod, ft-lbs/in320 320 Gardner Impact, in-lbs.~320 >320 iZ62~

A physical mixture of 33.3 per cent by weight of dry polycarbonate having a 1:1 mole ratio of sulfone to bisphenol, 33.3 percent by weight Lexan polycarbonate, and 33.3 per cent by weight Kodar A-150 polyester are extruder blended, injection molded, and tested for properties substantially as described in Example 22. The results are presented below:
HDT, C 117 Flex. Mod. psi 342,000 Flex. Str., psi 15,100 A physical mixture of 40 per cent by weight of dry polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 60 per cent by weight of polyester-carbonate (manufactured by General Electric Company under the trademark Lexan 3250) are extruder blended, injection molded, and tested for properties substantially as described in Example 22. The results are presented in Table IV
below.

A physical mixture of 40 per cent by weight of dry polycarbonate having a 7:3 mole ratio of sulfone to bisphenol and 60 per cent by weight of Lexan 3250 poly-estercarbonate are extruder blended, injection molded, andtested for properties substantially as described in Example 22. The results are presented in Table IV below.
ABLE IV
Property Example 39 Example 40 Tg, C 190 195 HDT, C 161 176 HDT, F 322 349 Notched Izod 3.0 3.2 ft-lbs/in.

6,~ 36 The procedure of Example 1 is repeated substitu-ting 40 per cent by weight of polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 10 per cent by weight of a polyarylate (sold by Union Carbide Corporation under the designation Ardel D-100). Comparative results after melt admixture at about 300C are as follows:
~ Sulfone/Bisphenol " Polycarbonate Ardel D-100 Polyarylate Composition ', 10 Tg = 210C 192C 207C

The procedure of Example 1 is repeated substitu-ting 70 per cent by weight of polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 30 per cent by weight of Ardel D-100 polyarylate. Comparative results after melt admixture at about 300C are as follows:
; Sulfone/sisphenol Polycarbonate Ardel D-100 Polyarylate Composition Tg = 210C 192C 203C
', 20 EXAMPLE 44 The procedure of Example 1 is repeated substitut-ing 50 per cent by weight of polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 50 per cent by weight of Ardel D-100 polyarylate. Comparative results after melt admixture at about 300C are as follows:
Sulfone/Bisphenol Polycarbonate Ardel D-lOC Polyaryla'te _mposition Tg = 210C 192C 197C

The procedure of Example 1 is repeated substitut-ing 30 per cent by weight of polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 70 per cent by weight of Ardel D-100 polyarylate. Comparative results after melt admixture at about 300C are as follows:
Sulfone/Bisphenol --Polycarbonate Ardel D'-lOO Polyarylate Composition Tg = 210C 192C 196C

6Z~

-The procedure of Example 1 is repeated substitu-ting 10 per cent by weight of polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 90 per cent by weight of Ardel D-100 polyarylate. Comparative results after melt admixture at about 300C are as follows:
Sulfone/Bisphenol Polycarbonate Ardel D-100 Polyarylene Composition Tg = 210C 192C 193C

A physical mixture of 50 per cent by weight of dry polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 50 per cent by weight of Ardel D-100 poly-arylate are extruder blended, injection molded, and tested for properties substantially as described in Example 22.
The results are as follows:
Property Composition HDT, C 167 Flex Mod., psi 347,000 Flex Str., psi 16,300 The procedure of Example 1 is repeated substitu-ting 50 per cent by weight of polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 50 per cent by weight of polyetherimide (manufactured by General Electric Company under the trademark Ultem). Comparative results after melt admixture at about 330C are as follows:
Sulfone/Bisphenol PolycarbonateUltem PolyetherimideComposition 30Tg = 210C 217C 214C
~ =~
~
\

, . . .. , ~

~Z62~96 The procedure of Example l is repeated substituting 50 per cent by weight of polycarbonate having a 8:2 mole ratio of sulfone to bisphenol and 50 per cent by weight of Ultem polyetherimide.
Comparative results after melt admixture at about 330C
are as follows:
Sulfone/Bisphenol Polycarbonate' Ultem PolyetherimideComposition lOTg = 235C 214C 223C

The procedure of Example 1 is repeated substituting 30 per cent by weight of polycarbonate having a 8:2 mole ratio of sulfone to bisphenol and 70 per cent by weight of Ultem polyetherimide.
Comparative results after melt admixture at about 330C
are as follows:
Sulfone/Bisphenol PolycarbonateUltem PolyetherimideComposition 20Tg = 235C 217C 220C

A physical mixture of 25 per cent by weight of dry polycarbonate having a l:l mole ratio of sulfone to bisphenol and 75 per cent by weight Udel polysulfone ~5 (P-1700, Union Carbide) are extruder blended, injection molded, and tested for properties substantially as described in Example 22. The results are presented in Table V below:

EXAMP'LE'52 A physical mixture of 75 per cent by weight of dry polycarbonate having a l:l mole ratio of sulfone to bisphenol and 25 per cent by weight Victrex (I.C.I.) poly-ethersulfone are extruder blended, injection molded, and tested for properties substantially as described in Example 22. The results are presented in Table V below:

~2~2~96 A physical mixture of 30 per cent by weight of dry polycarbonate having a 1:1 mole ratio of sulfone to bisphenol and 70 per cent by weight phenoxy resin are extruder blended, injection molded, and tested for properties substantially as described in Example 22.
The results are presented in Table V below:
TABLE V
EXAMPLE FLEX. MOD , PSI FLEX. STR., PSI
51 388,00017,000 52 375,00018,000 53 389,00015,800 A physical mixture of 60 per cent by weight of dry polycarbonate having a 1:1 mole ratio of sulfone to bisphenol, 30 per cent by weight poly(ethylene terephthalate), and 10 per cent by weight of an acrylate based polymer called KM 330 (sold by Rohn & Haas) are extruder blended, injection molded, and tested for properties substantially as described in Example 22.
; The results are presented below:
HDT, C 122 Flex. mod., psi327,000 Flex. str., psi14,700 Tensile. mod., psi 295,000 Tensile. str., psi 8,800 Notched Izod. ft-lbs/in. 3.8 . ~
,~ \
,',,.' ~

"

2 ~96 A physical mixture of 50 per cent by weight of dry polycarbonate having a 1:1 mole ratio of sulfone to bisphenol, 25 per cent by weight poly(ethylene terephthalate), and a copolyether ester block copolymer (sold under the trade name Hytrel 5555 by E.I. du Pont de Nemours) are extruder blended, injection molded, and tested for properties substantially as described in Example 22. The results are presented below:
Flex mod., psi 291,000 Flex strength, psi 14,250 A physical mixture of 50 per cent by weight of dry polycarbonate having a 1:1 mole ratio of sulfone to bisphenol, 40 per cent by weight poly(butylene terephthalate), and 10 per cent by weight of an acrylate based polymer called KM 330 (sold by Rohm & Haas) are extru-der blended, injection molded, and tested for properties substantially as described in Example 22. The results 20 are presented below:
Flex. mod., psi328,000 Flex. str., psi13,300 Notched Izod ft-lbs/in. 11 Polymer Synthesis The dixylenol sulfone/bisphenol A (DXS/BPA) described in the foregoing examples were prepared employing interfacial polymerization, in which a rapidly stirred two phase mixture of aqueous caustic, polymer solvent, bisphenols, a phase transfer catalyst, and monofunctional chain terminators is phosgenated. The growing polymer dissolves in polymer solvent, unreacted bisphenols dissolve in the aqueous caustic phase and the polymer forms at the interface. The polymer is isolated by precipitation in methanol and dried. The applicable technology of the synthesis of polycarbonates is described Z~96 in "Chemistry and Physics of Polycarbonates" by H. Schnell (Interscience, 1964).
Preferred blends are admixtures of a polycarbonate resin including units derived from a first dihydric phenol, which is a bis(hydroxyaryl)sulfone and a second dihydric phenol, and a thermoplastic which is the resin product of a condensation polymerization reaction.
Obviously, other modifications and variations of the present invention are possible in the light of the above teachings. It is, therefore, to be understood that ; changes may be made in the particular embodiments of the invention described which are within the full intended scope of the invention as defined by the appended claims.

Claims (17)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A thermoplastic resin composition comprising:
(a) a mixed polycarbonate consisting of units derived from a first dihydric phenol, which is a bis(hydroxyaryl)sulfone, and a second dihydric phenol, said first and second dihydric phenols being in a mole ratio of 1:5 to 7:3; and (b) a thermoplastic condensation polymer comprising an aromatic polycarbonate, said composition having been admixed to produce a compatible composition.

2. The composition of claim 1, wherein mixed polycarbonate comprises from about 1 to about 99 percent by weight of total resin weight.

3. The composition of claim 2, wherein said mixed polycarbonate comprises from about 10 to about 90 percent by weight of total resin weight.

4. A thermoplastic resin composition comprising:
(a) from about 20 to about 80 percent by weight of a mixed polycarbonate consisting of units derived from a first dihydric phenol, which is a bis(hydroxyaryl)sulfone, and a second dihydric phenol, said first and second dihydric phenols being in a mole ratio of 1:5 to 7:3; and (b) from 80 to about 20 percent by weight of a thermoplastic condensation polymer, said composition having been admixed to produce a compatible composition.

5. The composition of claim 2, wherein said thermoplastic condensation polymer comprises from about 99 to 1 percent by weight of the total resin weight.

6. The composition of claim 3, wherein said thermoplastic condensation polymer comprises from about 90 to about 10 percent by weight of total resin weight.

7. The composition of claim 4, wherein said thermoplastic condensation polymer comprises an aromatic polycarbonate.

8. The composition of claim 1, wherein said mixed polycarbonate comprises units derived from bis(3,5-dimethyl-4-hydroxyphenyl)sulfone.

9. The composition of claim 8, wherein said mixed polycarbonate also comprises units derived from 2,2'-bis(4-hydroxyphenyl)propane.

10. The composition of claim 9, wherein said bis(3,5-dimethyl-4-hydroxyphenyl)sulfone and said 2,2'-bis(4-hydroxyphenyl)propane units are in a mole ratio of from about 1:99 to about 99:1.

11. The composition of claim 1, wherein said mixed polycarbonate comprises units of 2,2'-bis(4-hydroxyphenyl)propane.

12. The composition of claim 1, wherein said mixed polycarbonate comprises units derived from bis(3,5-dimethyl-4-hydroxyphenyl)sulfone.

13. A composition as defined in claim 1, wherein said thermoplastic condensation polymer also includes a polymer selected from the group consisting of a polyester, a copolyestercarbonate, a polyarylate, a poly(aryl ether), a copolyetherester block copolymer, a polyhydroxyether, and a polyimide.

14. A composition as defined in claim 13, which also includes a thermoplastic addition polymer resin.

15. A composition as defined in claim 14, wherein said thermoplastic addition polymer resin is selected from a styrene resin, an alkyl acrylate resin, a vinyl halide resin, or a mixture of any of the foregoing.

16. A composition as defined in claim 13, wherein said aromatic polycarbonate (b) is the reaction product of a dihydric phenol and a carbonate precursor.

17. A composition as defined in claim 16, wherein the dihydric phenol is bisphenol-A and the carbonate precursor is carbonyl chloride.