Aliphatic polyketone and acrylonitrile butadiene styrene polymer blends

Abstract

Embodiments of this disclosure relate to polymer blends comprising 55% by weight and 90% by weight of aliphatic polyketone; and 10% by weight and 40% by weight of acrylonitrile butadiene styrene (ABS), wherein the melt flow rate of the aliphatic polyketone is greater than or equal to 1 g / 10 min and less than or equal to 90 g / 10 min, as measured according to ASTM D1238 at 240°C and 2.16 kg by weight.

Description

[0001] Priority Statement

[0002] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 071,919, filed August 28, 2020, Agent's File No. 12020009, which is incorporated herein by reference in its entirety. Technical Field

[0003] Embodiments of this disclosure generally relate to polymer blends, and more specifically to polymer blends of aliphatic polyketones and acrylonitrile butadiene styrene (ABS) with improved chemical resistance. Background Technology

[0004] Polymer blends of acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) are widely used in healthcare, automotive, and electronics applications due to their relatively high heat resistance and combination of tensile strength and toughness. ABS improves the processability and flexibility of the polymer blends, but its upper glass transition temperature limit of approximately 95 to 105 °C restricts its use in high-temperature applications. To balance ABS, PC is added to improve the heat resistance of the polymer blends.

[0005] While ABS imparts resistance to aqueous solutions to ABS and PC blends, their chemical resistance is relatively poor, particularly to organic solvents, hydrocarbons, and select alcohols, which may be insufficient for certain applications in the healthcare, automotive, and electronics sectors.

[0006] Therefore, there is a continued need for improved polymer blends that provide the required chemical resistance, while also offering improved heat resistance and sufficient tensile and flexural strength and stiffness for the aforementioned applications. Summary of the Invention

[0007] Embodiments of this disclosure relate to polymer blends of aliphatic polyketones and ABS that meet the required chemical resistance while providing improved heat resistance and sufficient tensile and flexural strength and stiffness. Furthermore, these polymer blends can exhibit improved impact strength.

[0008] According to one embodiment, a polymer blend is provided. The polymer blend comprises 55% by weight and 90% by weight of aliphatic polyketone; and 10% by weight and 40% by weight of acrylonitrile butadiene styrene (ABS), wherein the melt flow rate of the aliphatic polyketone, measured according to ASTM D1238 at 240°C and 2.16 kg by weight, is greater than or equal to 1 g / 10 min and less than or equal to 90 g / 10 min.

[0009] Other features and advantages of the invention are set forth in the following detailed description, some of which will be readily apparent to those skilled in the art from the description, or will be recognized by practicing the invention as described herein, including the following detailed description and the claims. Attached Figure Description

[0010] Figure 1 These are photographs of sample strips formed using the comparative and example formulations according to the embodiments described herein, in a strain gauge. Detailed Implementation

[0011] Reference will now be made in detail to various embodiments of polymer blends, specifically polymer blends comprising: greater than or equal to 55% by weight and less than or equal to 90% by weight of aliphatic polyketone; and greater than or equal to 10% by weight and less than or equal to 40% by weight of acrylonitrile butadiene styrene (ABS), wherein the melt flow rate of the aliphatic polyketone, measured according to ASTM D1238 at 240°C and 2.16 kg by weight, is greater than or equal to 1 g / 10 min and less than or equal to 90 g / 10 min.

[0012] This disclosure should not be construed as being limited to the embodiments set forth herein. These embodiments are provided, of course, to make this disclosure thorough and complete, and to fully convey the subject matter to those skilled in the art.

[0013] definition

[0014] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used in this disclosure is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0015] In this document, a range may be expressed as from "about" a specific value and / or to "about" another specific value. When expressing such a range, another implementation includes from said one specific value and / or to said other specific value. Similarly, when a numerical value is expressed as an approximation using the preposition "about," it can be understood that the specific value constitutes another implementation. It should also be understood that the endpoints of each range are important both in relation to and unrelated to another endpoint.

[0016] Unless otherwise expressly stated, no method described herein should be construed as requiring its steps to be performed in a specific order, or requiring any device to have a particular orientation. Therefore, if a method claim does not actually describe the order in which its steps are to be followed, or if any device does not actually describe the order or orientation of its components, or if the claims or description do not otherwise specifically state that the steps are limited to a specific order, or do not describe a specific order or orientation of the device components, then in no way should the order or orientation be inferred. This applies to any possible non-expressive basis of interpretation, including: logical questions concerning the arrangement of steps, operational flow, the order of components, or the orientation of components; questions of obvious meaning derived from grammatical organization or punctuation; and questions of the number or type of embodiments described in the description.

[0017] In this specification and the appended claims, unless the context explicitly indicates otherwise, the singular forms "a," "an," and "the / said" also include the plural forms. Thus, for example, unless the context explicitly indicates otherwise, reference to "a" component includes aspects having two or more such components.

[0018] When the terms "0% by weight," "free of," and "substantially free of" are used to describe the weight of a particular component in a polymer blend and / or to describe its absence, it means that the component was not intentionally added to the polymer blend. However, the polymer blend may contain trace amounts of the component as contaminants or impurities, in amounts less than 0.05% by weight.

[0019] The weight-average molecular weight (Mw) described in this article was measured using conventional gel permeation chromatography.

[0020] Unless otherwise stated, the term "% by weight" as used herein refers to a weight percentage based on the weight of the polymer blend.

[0021] The term "heat distortion temperature" as used herein refers to the temperature at which an article formed from the polymer blends described herein deforms, as measured according to ASTM D648 under a load of 0.45 MPa.

[0022] The terms "tensile modulus" or "tensile stiffness" as used herein refer to the ratio of stress along an axis to strain along that axis, as measured according to ASTM D638 at 23°C and a strain rate of 0.85 mm / s.

[0023] The term "yield" as used in this paper refers to the point on the stress-strain curve that represents the limit of elastic behavior and the beginning of plastic behavior.

[0024] The term "yield tensile strength" as used herein refers to the maximum stress that a material can withstand when stretched, before it begins permanent deformation, at 23°C and a strain rate of 0.85 mm / s, according to ASTM D638.

[0025] The term "yield tensile elongation" as used herein refers to the ratio between the increased length at the yield point and the initial length, as measured according to ASTM D638 at 23°C and a strain rate of 0.85 mm / s.

[0026] The term "tensile strength at break" as used herein refers to the maximum stress that a material can withstand under tension before fracture, as measured according to ASTM D638 at 23°C and a strain rate of 0.85 mm / s.

[0027] The term "elongation at break" as used herein refers to the ratio between the length after fracture and the initial length, as measured according to ASTM D638 at 23°C and a strain rate of 0.85 mm / s.

[0028] The terms "flexural modulus" or "flexural stiffness" as used herein refer to the ratio of stress to strain in flexural deformation as measured according to ASTM D790 at 23°C and a strain rate of 0.21 mm / s.

[0029] The term "bending strength" as used herein refers to the maximum bending stress that can be applied to a material before it yields, as measured according to ASTM D790 at 23°C and a strain rate of 0.21 mm / s.

[0030] As described herein, the term “sufficient tensile and flexural strength and stiffness” means a tensile modulus greater than or equal to 1100 MPa, a yield tensile strength greater than or equal to 35 MPa, a yield tensile elongation greater than or equal to 8%, a tensile strength at break greater than or equal to 35 MPa, a tensile elongation at break greater than or equal to 8%, a flexural modulus greater than or equal to 1200 MPa, and a flexural strength greater than or equal to 45 MPa.

[0031] The term "melt flow rate" as used herein refers to the ability of a material melt to flow under pressure, as measured according to ASTM D1238, at a given temperature and a given weight of applied pressure.

[0032] The term "Notched Izod Impact strength" as used herein refers to the kinetic energy required for an article formed from the polymer blends described herein to begin cracking and continue cracking until it breaks, as measured according to ASTM D256 at 23°C and 2.75J.

[0033] The term "specific gravity" as used in this article refers to the ratio of the density of a material to the density of water, as measured at 23°C according to ASTM D792.

[0034] The term “particle size distribution D50” as used in this article refers to 50% of the particles having a diameter smaller than a given size.

[0035] The term “Shore D hardness” as used in this article refers to the material hardness measured according to ASTM D2240.

[0036] As described in this article, the term "acid value" refers to the mass of potassium hydroxide (KOH) in milligrams (mg) required to neutralize one gram of a chemical substance, as measured according to ASTM D3644.

[0037] As described in this article, the term "glass transition temperature" refers to the temperature range in which a polymer transitions from a hard, glassy material to a soft, rubbery material, as measured by dynamic mechanical analysis according to ASTM D4440.

[0038] The contents (wt%) of P2O5 and CaO in the hydroxyapatite stabilizer were determined by X-ray fluorescence (XRF).

[0039] As described in this article, the term "loss on ignition" refers to the mass loss of a combustion residue when heated to 800°C in an air / oxygen atmosphere, as measured according to ASTM D7348.

[0040] As mentioned above, conventional ABS and PC blends offer the heat resistance and tensile stiffness (i.e., a heat deflection temperature of approximately 90°C and a tensile modulus of approximately 2700 MPa) required for a wide range of applications, including healthcare, automotive, and electronics. PC is a rigid, amorphous thermoplastic that imparts heat resistance to polymer blends. ABS is also an amorphous thermoplastic, but its tensile and flexural stiffness is lower than that of PC. Therefore, ABS reduces tensile and flexural stiffness, thereby increasing flexibility and improving the processability of conventional ABS and PC blends. However, conventional ABS and PC blends have relatively low chemical resistance, particularly to organic solvents, hydrocarbons, and selected alcohols, which may be insufficient for certain applications in the healthcare, automotive, and electronics sectors.

[0041] This document discloses polymer blends that alleviate the aforementioned problems. Specifically, the polymer blends disclosed herein comprise blends of aliphatic polyketones and ABS, resulting in chemically resistant polymer blends with improved heat resistance and sufficient tensile and flexural strength and stiffness. Aliphatic polyketones are semi-crystalline thermoplastics, similar to PC, which enhance the heat resistance of the polymer blends. Contrary to their function in conventional ABS and PC blends, ABS imparts tensile and flexural stiffness to aliphatic polyketone and ABS blends. While not wishing to be bound by theory, it is believed that the resistance of aliphatic polyketones to non-aqueous solutions and the resistance of ABS to aqueous solutions lead to an overall improved chemical resistance in aliphatic polyketone and ABS polymer blends. Furthermore, it is believed that the semi-crystalline structure of aliphatic polyketones, compared to the amorphous structure of PC, results in improved chemical resistance. Additionally, by adding rubber-containing impact modifiers, chemically resistant aliphatic polyketone and ABS polymer blends can exhibit improved impact strength.

[0042] The polymer blends disclosed herein can generally be described as containing aliphatic polyketides and acrylonitrile butadiene styrene (ABS).

[0043] Aliphatic polyketide

[0044] As mentioned above, aliphatic polyketones increase the heat resistance of polymer blends. Compared to conventional ABS and PC blends, the combination of aliphatic polyketones and ABS results in improved chemical resistance in the polymer blends. While not wishing to be bound by theory, this improved chemical resistance is believed to be due to the resistance of aliphatic polyketones to non-aqueous solutions and the resistance of ABS to aqueous solutions. Furthermore, the semi-crystalline structure of aliphatic polyketones is believed to contribute to the improved chemical resistance compared to the amorphous structure of PC.

[0045] Therefore, in some embodiments, the content of aliphatic polyketone is greater than or equal to 55% by weight, such that the aliphatic polyketone can improve heat resistance and yield elongation, and contribute to the overall chemical resistance of the polymer blend. In some embodiments, the amount of aliphatic polyketone may be limited (e.g., less than or equal to 90% by weight) and balanced with ABS, such that the tensile and flexural stiffness of the polymer blend is not reduced below the desired amounts (e.g., greater than or equal to 1100 MPa and greater than or equal to 1200 MPa, respectively) due to the presence of aliphatic polyketone. In some embodiments, the amount of aliphatic polyketone in the polymer blend may be greater than or equal to 55% by weight, greater than or equal to 60% by weight, greater than or equal to 65% by weight, or even greater than or equal to 68% by weight. In some embodiments, the amount of aliphatic polyketone may be less than or equal to 90% by weight, less than or equal to 85% by weight, less than or equal to 80% by weight, less than or equal to 75% by weight, or even less than or equal to 70% by weight. In some embodiments, the amount of aliphatic polyketone in the polymer blend may be greater than or equal to 55% by weight and less than or equal to 90% by weight, greater than or equal to 55% by weight and less than or equal to 85% by weight, greater than or equal to 55% by weight and less than or equal to 80% by weight, greater than or equal to 55% by weight and less than or equal to 75% by weight, greater than or equal to 55% by weight and less than or equal to 70% by weight, greater than or equal to 60% by weight and less than or equal to 90% by weight, greater than or equal to 60% by weight and less than or equal to 85% by weight, greater than or equal to 60% by weight and less than or equal to 80% by weight, greater than or equal to 60% by weight and less than or equal to 75% by weight, greater than or equal to 60% by weight and less than or equal to 70% by weight. , greater than or equal to 65% by weight and less than or equal to 90% by weight, greater than or equal to 65% by weight and less than or equal to 85% by weight, greater than or equal to 65% by weight and less than or equal to 80% by weight, greater than or equal to 65% by weight and less than or equal to 75% by weight, greater than or equal to 65% by weight and less than or equal to 70% by weight, greater than or equal to 68% by weight and less than or equal to 90% by weight, greater than or equal to 68% by weight and less than or equal to 85% by weight, greater than or equal to 68% by weight and less than or equal to 80% by weight, greater than or equal to 68% by weight and less than or equal to 75% by weight, or even greater than or equal to 68% by weight and less than or equal to 70% by weight, or any and all subranges formed by any of these endpoints.

[0046] In some implementations, the melt flow rate of aliphatic polyketones, measured at 240°C and 2.16 kg by weight, can be greater than or equal to 1 g / 10 min, greater than or equal to 10 g / 10 min, greater than or equal to 20 g / 10 min, greater than or equal to 30 g / 10 min, or even greater than or equal to 40 g / 10 min, according to ASTM D1238. While not wishing to be bound by theory, although aliphatic polyketones with higher melt flow rates (e.g., greater than 90 g / 10 min) improve the flowability of polymer blends, higher melt flow rates may prevent adequate dispersion of ABS, potentially negatively impacting the chemical resistance and impact strength of the polymer blends. Therefore, in some embodiments, the melt flow rate of aliphatic polyketone, measured at 240°C and 2.16 kg weight according to ASTM D1238, may be less than or equal to 90 g / 10 min, less than or equal to 80 g / 10 min, less than or equal to 60 g / 10 min, less than or equal to 40 g / 10 min, or even less than or equal to 20 g / 10 min.In some embodiments, according to ASTM D1238, at 240°C and 2.16 kg, the melt flow rate of aliphatic polyketide can be greater than or equal to 1 g / 10 min and less than or equal to 90 g / 10 min, greater than or equal to 1 g / 10 min and less than or equal to 80 g / 10 min, greater than or equal to 1 g / 10 min and less than or equal to 60 g / 10 min, greater than or equal to 1 g / 10 min and less than or equal to 40 g / 10 min, greater than or equal to 1 g / 10 min and less than or equal to 9 ... 90 g / 10 min, greater than or equal to 1 g / 10 min and less than 90 g / 10 min, greater than or equal to 1 g / 10 min and less than 90 g / 10 min, greater than or equal to 1 g / 10 min and less than 90 g / 10 min, greater than or equal to 1 g / 10 min and less than 90 g / 10 min, greater than or equal to 1 g / 10 min and less than 90 g / 10 min, Or equal to 20 grams / 10 minutes, greater than or equal to 10 grams / 10 minutes and less than or equal to 90 grams / 10 minutes, greater than or equal to 10 grams / 10 minutes and less than or equal to 80 grams / 10 minutes, greater than or equal to 10 grams / 10 minutes and less than or equal to 60 grams / 10 minutes, greater than or equal to 10 grams / 10 minutes and less than or equal to 40 grams / 10 minutes, greater than or equal to 10 grams / 10 minutes and less than or equal to 20 grams / 10 minutes, greater than or equal to 20 grams / 10 minutes. 90 grams / 10 minutes or less, 20 grams / 10 minutes or more but less than or equal to 80 grams / 10 minutes, 20 grams / 10 minutes or more but less than or equal to 60 grams / 10 minutes, 20 grams / 10 minutes or more but less than or equal to 40 grams / 10 minutes, 30 grams / 10 minutes or more but less than or equal to 90 grams / 10 minutes, 30 grams / 10 minutes or more but less than or equal to 80 grams / 10 minutes, 30 grams / 10 minutes or more ... 0 g / 10 min and less than or equal to 60 g / 10 min, greater than or equal to 30 g / 10 min and less than or equal to 40 g / 10 min, greater than or equal to 40 g / 10 min and less than or equal to 90 g / 10 min, greater than or equal to 40 g / 10 min and less than or equal to 80 g / 10 min, or even greater than or equal to 40 g / 10 min and less than or equal to 60 g / 10 min, or any and all subranges formed by any of these endpoints. In some embodiments, aliphatic polyketides may comprise at least two different aliphatic polyketides (e.g., one with a relatively high melt flow rate and one with a relatively low melt flow rate) to achieve an intermediate melt flow rate (e.g., greater than or equal to 60 g / 10 min).

[0047] In some embodiments, the heat distortion temperature of aliphatic polyketone can be greater than or equal to 180°C, or even greater than or equal to 190°C. In some embodiments, the heat distortion temperature of aliphatic polyketone can be less than or equal to 225°C, or even less than or equal to 210°C. In some embodiments, the heat distortion temperature of aliphatic polyketone can be greater than or equal to 180°C and less than or equal to 225°C, greater than or equal to 180°C and less than or equal to 210°C, greater than or equal to 190°C and less than or equal to 225°C, or even greater than or equal to 190°C and less than or equal to 210°C, or any and all subranges formed by any of these endpoints.

[0048] In some embodiments, the tensile modulus of aliphatic polyketone may be greater than or equal to 1300 MPa, or even greater than or equal to 1400 MPa. In some embodiments, the tensile modulus of aliphatic polyketone may be less than or equal to 1800 MPa, or even less than or equal to 1700 MPa. In some embodiments, the tensile modulus of aliphatic polyketone may be greater than or equal to 1300 MPa and less than or equal to 1800 MPa, greater than or equal to 1300 MPa and less than or equal to 1700 MPa, greater than or equal to 1400 MPa and less than or equal to 1800 MPa, or even greater than or equal to 1400 MPa and less than or equal to 1700 MPa, or any and all subranges formed by any of these endpoints.

[0049] In some embodiments, the yield tensile strength of aliphatic polyketone can be greater than or equal to 45 MPa, or even greater than or equal to 55 MPa. In some embodiments, the yield tensile strength of aliphatic polyketone can be less than or equal to 75 MPa, or even less than or equal to 65 MPa. In some embodiments, the yield tensile strength of aliphatic polyketone can be greater than or equal to 45 MPa and less than or equal to 75 MPa, greater than or equal to 45 MPa and less than or equal to 65 MPa, greater than or equal to 55 MPa and less than or equal to 75 MPa, or even greater than or equal to 55 MPa and less than or equal to 65 MPa, or any and all subranges formed by any of these endpoints.

[0050] In some embodiments, the yield tensile elongation of aliphatic polyketone may be greater than or equal to 15%, or even greater than or equal to 20%. In some embodiments, the yield tensile elongation of aliphatic polyketone may be less than or equal to 30%, or even less than or equal to 25%. In some embodiments, the yield tensile elongation of aliphatic polyketone may be greater than or equal to 15% and less than or equal to 30%, greater than or equal to 15% and less than or equal to 25%, greater than or equal to 20% and less than or equal to 30%, or even greater than or equal to 20% and less than or equal to 25%, or any and all subranges formed by any of these endpoints.

[0051] In some embodiments, the flexural modulus of aliphatic polyketone may be greater than or equal to 1200 MPa, or even greater than or equal to 1300 MPa. In some embodiments, the flexural modulus of aliphatic polyketone may be less than or equal to 1700 MPa, or even less than or equal to 1600 MPa. In some embodiments, the flexural modulus of aliphatic polyketone may be greater than or equal to 1200 MPa and less than or equal to 1700 MPa, greater than or equal to 1200 MPa and less than or equal to 1600 MPa, greater than or equal to 1300 MPa and less than or equal to 1700 MPa, or even greater than or equal to 1300 MPa and less than or equal to 1600 MPa, or any and all subranges formed by any of these endpoints.

[0052] In some embodiments, the flexural strength of aliphatic polyketone can be greater than or equal to 40 MPa, or even greater than or equal to 50 MPa. In some embodiments, the flexural strength of aliphatic polyketone can be less than or equal to 70 MPa, or even less than or equal to 60 MPa. In some embodiments, the flexural strength of aliphatic polyketone can be greater than or equal to 40 MPa and less than or equal to 70 MPa, greater than or equal to 40 MPa and less than or equal to 60 MPa, greater than or equal to 50 MPa and less than or equal to 70 MPa, or even greater than or equal to 50 MPa and less than or equal to 60 MPa, or any and all subranges formed by any of these endpoints.

[0053] In some embodiments, the cantilever beam notched impact strength of aliphatic polyketone can be greater than or equal to 75 J / m, greater than or equal to 100 J / m, greater than or equal to 150 J / m, or even greater than or equal to 200 J / m. In some embodiments, the cantilever beam notched impact strength of aliphatic polyketone can be less than or equal to 250 J / m, or even less than or equal to 225 J / m. In some embodiments, the cantilever beam notched impact strength of the aliphatic polyketone can be greater than or equal to 75 J / m and less than or equal to 250 J / m, greater than or equal to 75 J / m and less than or equal to 225 J / m, greater than or equal to 100 J / m and less than or equal to 250 J / m, greater than or equal to 100 J / m and less than or equal to 225 J / m, greater than or equal to 150 J / m and less than or equal to 250 J / m, greater than or equal to 150 J / m and less than or equal to 225 J / m, greater than or equal to 200 J / m and less than or equal to 250 J / m, or even greater than or equal to 200 J / m and less than or equal to 225 J / m, or any and all subranges formed by any of these endpoints.

[0054] In some embodiments, the specific gravity of aliphatic polyketone may be greater than or equal to 1.15, or even greater than or equal to 1.2. In some embodiments, the specific gravity of aliphatic polyketone may be less than or equal to 1.3, or even less than or equal to 1.25. In some embodiments, the specific gravity of aliphatic polyketone may be greater than or equal to 1.15 and less than or equal to 1.3, greater than or equal to 1.15 and less than or equal to 1.25, greater than or equal to 1.2 and less than or equal to 1.3, or even greater than or equal to 1.2 and less than or equal to 1.25, or any and all subranges formed by any of these endpoints.

[0055] Suitable commercial implementations of aliphatic polyketides are available from Hyosung's POKETONE brand, such as grades M330, M630, and M930, which contain various additives (indicated by "A", "F", "S", or others) or do not contain additives (indicated by "P"). In addition to another grade of aliphatic polyketide (e.g., POKETONE M630A), the polymer blends described herein may also include powder grades of aliphatic polyketides, such as POKETONE M630P, to ensure easier incorporation of additional components into the blend. Table 1 shows some properties of POKETONE M330A, M630A, and M930A.

[0056] Table 1

[0057]

[0058] Acrylonitrile butadiene styrene (ABS)

[0059] As mentioned above, ABS increases the tensile and flexural stiffness of polymer blends, and the combination of ABS and aliphatic polyketone results in improved chemical resistance compared to conventional ABS and PC blends. While not wishing to be bound by theory, this improved chemical resistance is believed to be due to the resistance of aliphatic polyketone to non-aqueous solutions and the resistance of ABS to aqueous solutions.

[0060] Therefore, in some embodiments, the ABS content is greater than or equal to 10% by weight, so that ABS can increase tensile and flexural stiffness and contribute to the overall chemical resistance of the polymer blend. In some embodiments, the amount of ABS may be limited (e.g., less than or equal to 40% by weight) so that the heat resistance is not reduced below the desired amount due to the presence of ABS (e.g., heat distortion temperature greater than or equal to 100°C). In some embodiments, the amount of ABS in the polymer blend can be greater than or equal to 10% by weight, greater than or equal to 14% by weight, greater than or equal to 18% by weight, greater than or equal to 20% by weight, greater than or equal to 24% by weight, or even greater than or equal to 28% by weight. In some embodiments, the amount of ABS in the polymer blend can be less than or equal to 40% by weight, less than or equal to 35% by weight, or even less than or equal to 30% by weight. In some embodiments, the amount of ABS in the polymer blend may be greater than or equal to 10% by weight and less than or equal to 40% by weight, greater than or equal to 10% by weight and less than or equal to 35% by weight, greater than or equal to 10% by weight and less than or equal to 30% by weight, greater than or equal to 14% by weight and less than or equal to 40% by weight, greater than or equal to 14% by weight and less than or equal to 35% by weight, greater than or equal to 14% by weight and less than or equal to 30% by weight, greater than or equal to 18% by weight and less than or equal to 40% by weight, greater than or equal to 18% by weight and less than or equal to 35% by weight, greater than or equal to 18% by weight and less than or equal to 30% by weight. Greater than or equal to 20% by weight and less than or equal to 40% by weight, greater than or equal to 20% by weight and less than or equal to 35% by weight, greater than or equal to 20% by weight and less than or equal to 30% by weight, greater than or equal to 24% by weight and less than or equal to 40% by weight, greater than or equal to 24% by weight and less than or equal to 35% by weight, greater than or equal to 24% by weight and less than or equal to 30% by weight, greater than or equal to 28% by weight and less than or equal to 40% by weight, greater than or equal to 28% by weight and less than or equal to 35% by weight, or even greater than or equal to 28% by weight and less than or equal to 30% by weight, or any and all subranges formed by any of these endpoints.

[0061] In some embodiments, ABS may include emulsion ABS produced by an emulsion polymerization process. In some embodiments, ABS may include bulk ABS, a purer type of ABS produced by bulk polymerization with minimal additives.

[0062] In some embodiments, the melt flow rate of ABS, measured at 230°C and 3.8 kg weight according to ASTM D1238, can be greater than or equal to 1 g / 10 min, greater than or equal to 3 g / 10 min, or even greater than or equal to 5 g / 10 min. In some embodiments, the melt flow rate of ABS, measured at 230°C and 3.8 kg weight according to ASTM D1238, can be less than or equal to 20 g / 10 min, or even less than or equal to 10 g / 10 min. In some implementations, the melt flow rate of ABS, measured at 230°C and 3.8 kg weight according to ASTM D1238, can be greater than or equal to 1 g / 10 min and less than or equal to 20 g / 10 min, greater than or equal to 1 g / 10 min and less than or equal to 10 g / 10 min, greater than or equal to 3 g / 10 min and less than or equal to 20 g / 10 min, greater than or equal to 3 g / 10 min and less than or equal to 10 g / 10 min, greater than or equal to 5 g / 10 min and less than or equal to 20 g / 10 min, or even greater than or equal to 5 g / 10 min and less than or equal to 10 g / 10 min, or any and all subranges formed by any of these endpoints.

[0063] In some embodiments, the tensile modulus of ABS can be greater than or equal to 2000 MPa, or even greater than or equal to 2500 MPa. In some embodiments, the tensile modulus of ABS can be less than or equal to 3500 MPa, or even less than or equal to 3000 MPa. In some embodiments, the tensile modulus of ABS can be greater than or equal to 2000 MPa and less than or equal to 3500 MPa, greater than or equal to 2000 MPa and less than or equal to 3000 MPa, greater than or equal to 2500 MPa and less than or equal to 3500 MPa, or even greater than or equal to 2500 MPa and less than or equal to 3000 MPa, or any and all subranges formed by any of these endpoints.

[0064] In some embodiments, the yield tensile strength of ABS can be greater than or equal to 30 MPa, greater than or equal to 35 MPa, or even greater than or equal to 40 MPa. In some embodiments, the yield tensile strength of ABS can be less than or equal to 50 MPa, or even less than or equal to 45 MPa. In some embodiments, the yield tensile strength of ABS can be greater than or equal to 30 MPa and less than or equal to 50 MPa, greater than or equal to 30 MPa and less than or equal to 45 MPa, greater than or equal to 35 MPa and less than or equal to 45 MPa, greater than or equal to 40 MPa and less than or equal to 50 MPa, or even greater than or equal to 40 MPa and less than or equal to 45 MPa, or any and all subranges formed by any of these endpoints.

[0065] In some embodiments, the yield tensile elongation of ABS may be greater than or equal to 1%, or even greater than or equal to 1.5%. In some embodiments, the yield tensile elongation of ABS may be less than or equal to 5%, or even less than or equal to 4%. In some embodiments, the yield tensile elongation of ABS may be greater than or equal to 1% and less than or equal to 5%, greater than or equal to 1% and less than or equal to 4%, greater than or equal to 1.5% and less than or equal to 5%, or even greater than or equal to 1.5% and less than or equal to 4%, or any and all subranges formed by any of these endpoints.

[0066] In some embodiments, the elongation at break of ABS can be greater than or equal to 5%, or even greater than or equal to 10%. In some embodiments, the elongation at break of ABS can be less than or equal to 40%, or even less than or equal to 35%. In some embodiments, the elongation at break of ABS can be greater than or equal to 5% and less than or equal to 40%, greater than or equal to 5% and less than or equal to 35%, greater than or equal to 10% and less than or equal to 40%, or even greater than or equal to 10% and less than or equal to 35%, or any and all subranges formed by any of these endpoints.

[0067] In some embodiments, the flexural modulus of ABS can be greater than or equal to 2400 MPa, or even greater than or equal to 2500 MPa. In some embodiments, the flexural modulus of ABS can be less than or equal to 2800 MPa, or even less than or equal to 2700 MPa. In some embodiments, the flexural modulus of ABS can be greater than or equal to 2400 MPa and less than or equal to 2800 MPa, greater than or equal to 2400 MPa and less than or equal to 2700 MPa, greater than or equal to 2500 MPa and less than or equal to 2800 MPa, or even greater than or equal to 2500 MPa and less than or equal to 2700 MPa, or any and all subranges formed by any of these endpoints.

[0068] In some embodiments, the flexural strength of ABS can be greater than or equal to 60 MPa, or even greater than or equal to 70 MPa. In some embodiments, the flexural strength of ABS can be less than or equal to 90 MPa, or even less than or equal to 80 MPa. In some embodiments, the flexural strength of ABS can be greater than or equal to 60 MPa and less than or equal to 90 MPa, greater than or equal to 60 MPa and less than or equal to 80 MPa, greater than or equal to 70 MPa and less than or equal to 90 MPa, or even greater than or equal to 70 MPa and less than or equal to 80 MPa, or any and all subranges formed by any of these endpoints.

[0069] In some embodiments, the cantilever beam notched impact strength of ABS can be greater than or equal to 200 J / m, greater than or equal to 300 J / m, or even greater than or equal to 350 J / m. In some embodiments, the cantilever beam notched impact strength of ABS can be less than or equal to 500 J / m, or even less than or equal to 400 J / m. In some embodiments, the cantilever beam notched impact strength of ABS can be greater than or equal to 250 J / m and less than or equal to 500 J / m, greater than or equal to 250 J / m and less than or equal to 400 J / m, greater than or equal to 300 J / m and less than or equal to 500 J / m, greater than or equal to 300 J / m and less than or equal to 400 J / m, greater than or equal to 350 J / m and less than or equal to 400 J / m, or even greater than or equal to 350 J / m and less than or equal to 400 J / m, or any and all subranges formed by any of these endpoints.

[0070] Suitable commercial implementations of ABS are available from INEOS Styrolution under the LUSTRAN brand, such as grades 348 and 433, and from Trinseo under the MAGNUM brand, such as grade 8391MED. Table 2 shows some characteristics of LUSTRAN 348 and 433 and MAGNUM 8391MED.

[0071] Table 2

[0072]

[0073] polymer blends

[0074] As mentioned above, aliphatic polyketones increase the heat resistance of polymer blends but may decrease their tensile and flexural stiffness. While ABS increases the tensile and flexural stiffness of polymer blends, it may decrease their heat resistance. Therefore, when obtaining polymer blends with improved chemical resistance, the amount of aliphatic polyketone should be balanced with the amount of ABS to maintain improved heat resistance and achieve the desired tensile and flexural stiffness. In some embodiments, the weight ratio of aliphatic polyketone to ABS may be 2:1 to 6:1, 2:1 to 5:1, 2:1 to 4:1, 2:1 to 3:1, 2:1 to 2.5:1, 2:1 to 2.3:1, 2.3:1 to 6:1, 2.3:1 to 5:1, 2.3:1 to 4:1, 2.3:1 to 3:1, 2.3:1 to 2.5:1, 2.5:1 to 6:1, 2.5:1 to 5:1, 2.5:1 to 4:1, 2.5:1 to 3:1, 3:1 to 6:1, 3:1 to 5:1, 3:1 to 4:1, 4:1 to 6:1, 4:1 to 5:1, even 5:1 to 6:1, or any and all subranges formed by any of these endpoints.

[0075] Aliphatic polyketides improve the heat resistance of polymer blends, as evidenced by their heat deflection temperatures. A higher heat deflection temperature indicates an increased ability of the polymer blend to resist deformation under a given load at higher temperatures. Some applications may require a heat deflection temperature (e.g., greater than or equal to 100°C). In some embodiments, the heat deflection temperature of the polymer blend may be greater than or equal to 100°C, or even greater than or equal to 110°C. In some embodiments, the heat deflection temperature of the polymer blend may be less than or equal to 175°C, less than or equal to 150°C, or even less than or equal to 125°C. In some embodiments, the heat distortion temperature of the polymer blend can be greater than or equal to 100°C and less than or equal to 175°C, greater than or equal to 100°C and less than or equal to 150°C, greater than or equal to 100°C and less than or equal to 125°C, greater than or equal to 110°C and less than or equal to 175°C, greater than or equal to 110°C and less than or equal to 150°C, or even greater than or equal to 110°C and less than or equal to 125°C, or any and all subranges formed by any of these endpoints.

[0076] As demonstrated by the tensile modulus of the polymer blend, ABS increases the tensile and flexural stiffness of the polymer blend. Higher tensile and flexural moduli indicate increased stiffness and are therefore associated with stronger polymer blends. In some embodiments, the tensile modulus of the polymer blend can be greater than or equal to 1100 MPa, greater than or equal to 1250 MPa, greater than or equal to 1500 MPa, or even greater than or equal to 1600 MPa. In some embodiments, the tensile modulus of the polymer blend can be less than or equal to 2500 MPa, less than or equal to 2000 MPa, or even less than or equal to 1800 MPa. In some embodiments, the tensile modulus of the polymer blend can be greater than or equal to 1100 MPa and less than or equal to 2500 MPa, greater than or equal to 1100 MPa and less than or equal to 2000 MPa, greater than or equal to 1100 MPa and less than or equal to 1800 MPa, greater than or equal to 1250 MPa and less than or equal to 2500 MPa, greater than or equal to 1250 MPa and less than or equal to 2000 MPa, greater than or equal to 1250 MPa and less than or equal to 1800 MPa, greater than or equal to 1100 MPa and less than or equal to 2500 MPa, greater than or equal to 1250 MPa and less than or equal to 1800 MPa, greater than or equal to 1100 MPa and less than or equal to 2500 MPa, greater than or equal to 1100 MPa and less than or equal to 20 ...100 MPa and less than or equal to 2000 MPa, greater than or equal to 1100 MPa and less than or equal to 1800 MPa, greater than or equal to 1100 MPa and less than or equal to 2500 MPa, greater than or equal to 1100 MPa and less than or equal to 2500 MPa, greater than or equal to 1100 MPa and less than or equal to 2500 MPa, greater than or equal to 1100 MPa and less than or equal to 2500 MPa, greater The flexural modulus can be equal to or less than or equal to 1500 MPa and 2500 MPa, greater than or equal to 1500 MPa and less than or equal to 2000 MPa, greater than or equal to 1500 MPa and less than or equal to 1800 MPa, greater than or equal to 1600 MPa and less than or equal to 2500 MPa, greater than or equal to 1600 MPa and less than or equal to 2000 MPa, or even greater than or equal to 1600 MPa and less than or equal to 1800 MPa, or any and all subranges formed by any of these endpoints. In some embodiments, the polymer blend may have a flexural modulus greater than or equal to 1200 MPa or even greater than or equal to 1300 MPa. In some embodiments, the flexural modulus of the polymer blend may be less than or equal to 2500 MPa, less than or equal to 2250 MPa, or even less than or equal to 2000 MPa. In some embodiments, the flexural modulus of the polymer blend may be greater than or equal to 1200 MPa and less than or equal to 2500 MPa, greater than or equal to 1200 MPa and less than or equal to 2250 MPa, greater than or equal to 1200 MPa and less than or equal to 2000 MPa, greater than or equal to 1300 MPa and less than or equal to 2500 MPa, greater than or equal to 1300 MPa and less than or equal to 2250 MPa, or even greater than or equal to 1300 MPa and less than or equal to 2000 MPa, or any and all subranges formed by any of these endpoints.

[0077] In some embodiments, the yield tensile strength of the polymer blend can be greater than or equal to 35 MPa, greater than or equal to 40 MPa, or even greater than or equal to 42 MPa. In some embodiments, the yield tensile strength of the polymer blend can be less than or equal to 65 MPa, less than or equal to 60 MPa, less than or equal to 55 MPa, less than or equal to 50 MPa, or even less than or equal to 48 MPa. In some embodiments, the yield tensile strength of the polymer blend can be greater than or equal to 35 MPa and less than or equal to 65 MPa, greater than or equal to 35 MPa and less than or equal to 60 MPa, greater than or equal to 35 MPa and less than or equal to 55 MPa, greater than or equal to 35 MPa and less than or equal to 50 MPa, greater than or equal to 35 MPa and less than or equal to 48 MPa, greater than or equal to 40 MPa and less than or equal to 65 MPa, greater than or equal to 40 MPa and less than or equal to 60 MPa, greater than or equal to 40 MPa and less than or equal to 42 MPa. Or equal to 55 MPa, greater than or equal to 40 MPa and less than or equal to 50 MPa, greater than or equal to 40 MPa and less than or equal to 48 MPa, greater than or equal to 42 MPa and less than or equal to 65 MPa, greater than or equal to 42 MPa and less than or equal to 60 MPa, greater than or equal to 42 MPa and less than or equal to 55 MPa, greater than or equal to 42 MPa and less than or equal to 50 MPa, or even greater than or equal to 42 MPa and less than or equal to 48 MPa, or any and all subranges formed by any of these endpoints.

[0078] In some embodiments, the yield tensile elongation of the polymer blend can be greater than or equal to 8%, greater than or equal to 10%, or even greater than or equal to 12%. In some embodiments, the yield tensile elongation of the polymer blend can be less than or equal to 30%, less than or equal to 25%, less than or equal to 20%, or even less than or equal to 18%. In some embodiments, the yield tensile elongation of the polymer blend can be greater than or equal to 8% and less than or equal to 30%, greater than or equal to 8% and less than or equal to 25%, greater than or equal to 8% and less than or equal to 20%, greater than 8% and less than or equal to 18%, greater than or equal to 10% and less than or equal to 30%, greater than or equal to 10% and less than or equal to 25%, greater than or equal to 10% and less than or equal to 20%, greater than or equal to 10% and less than or equal to 18%, greater than or equal to 12% and less than or equal to 30%, greater than or equal to 12% and less than or equal to 25%, greater than or equal to 12% and less than or equal to 20%, or even greater than or equal to 12% and less than or equal to 18%, or any and all subranges formed by any of these endpoints. In some embodiments, the polymer blend may not exhibit a defined yield tensile elongation.

[0079] In some embodiments, the tensile strength at break of the polymer blend can be greater than or equal to 35 MPa, greater than or equal to 40 MPa, or even greater than or equal to 42 MPa. In some embodiments, the tensile strength at break of the polymer blend can be less than or equal to 65 MPa, less than or equal to 60 MPa, less than or equal to 55 MPa, less than or equal to 50 MPa, or even less than or equal to 48 MPa. In some embodiments, the tensile strength at break of the polymer blend can be greater than or equal to 35 MPa and less than or equal to 65 MPa, greater than or equal to 35 MPa and less than or equal to 60 MPa, greater than or equal to 35 MPa and less than or equal to 55 MPa, greater than or equal to 35 MPa and less than or equal to 50 MPa, greater than or equal to 35 MPa and less than or equal to 48 MPa, greater than or equal to 40 MPa and less than or equal to 65 MPa, greater than or equal to 40 MPa and less than or equal to 60 MPa, greater than or equal to 40 MPa and less than or equal to 42 MPa. Or equal to 55 MPa, greater than or equal to 40 MPa and less than or equal to 50 MPa, greater than or equal to 40 MPa and less than or equal to 48 MPa, greater than or equal to 42 MPa and less than or equal to 65 MPa, greater than or equal to 42 MPa and less than or equal to 60 MPa, greater than or equal to 42 MPa and less than or equal to 55 MPa, greater than or equal to 42 MPa and less than or equal to 50 MPa, or even greater than or equal to 42 MPa and less than or equal to 48 MPa, or any and all subranges formed by any of these endpoints.

[0080] In some embodiments, the elongation at break of the polymer blend can be greater than or equal to 8%, greater than or equal to 15%, or even greater than or equal to 20%. In some embodiments, the elongation at break of the polymer blend can be less than or equal to 400%, less than or equal to 300%, less than or equal to 200%, or even less than or equal to 100%. In some embodiments, the elongation at break of the polymer blend can be greater than or equal to 8% and less than or equal to 400%, greater than or equal to 8% and less than or equal to 300%, greater than or equal to 8% and less than or equal to 200%, greater than or equal to 8% and less than or equal to 100%, greater than or equal to 15% and less than or equal to 400%, greater than or equal to 15% and less than or equal to 300%, greater than or equal to 15% and less than or equal to 200%, greater than or equal to 15% and less than or equal to 100%, greater than or equal to 20% and less than or equal to 400%, greater than or equal to 20% and less than or equal to 300%, greater than or equal to 20% and less than or equal to 200%, or even greater than or equal to 20% and less than or equal to 100%, or any and all subranges formed by any of these endpoints.

[0081] In some embodiments, the polymer blend may have a flexural strength greater than or equal to 45 MPa or even greater than or equal to 50 MPa. In some embodiments, the flexural strength of the polymer blend may be less than or equal to 85 MPa or even less than or equal to 80 MPa. In some embodiments, the flexural strength of the polymer blend may be greater than or equal to 45 MPa and less than or equal to 85 MPa, greater than or equal to 45 MPa and less than or equal to 80 MPa, greater than or equal to 50 MPa and less than or equal to 85 MPa, or even greater than or equal to 50 MPa and less than or equal to 80 MPa, or any and all subranges formed by any of these endpoints.

[0082] In some embodiments, the polymer blend may have a tensile modulus greater than or equal to 1100 MPa, a yield tensile strength greater than or equal to 35 MPa, a yield tensile elongation greater than or equal to 8%, a tensile strength at break greater than or equal to 35 MPa, a tensile elongation at break greater than or equal to 8%, a flexural modulus greater than or equal to 1200 MPa, and a flexural strength greater than or equal to 45 MPa.

[0083] As illustrated in the following Examples section, the aliphatic polyketone and ABS blends described herein offer improved chemical resistance while providing improved heat resistance and sufficient tensile and flexural strength and stiffness. Therefore, these aliphatic polyketone and ABS blends may be more suitable for certain applications in the healthcare, automotive, and electronics sectors requiring chemical resistance.

[0084] Hydroxyapatite stabilizer

[0085] In some embodiments, the polymer blend may further include a hydroxyapatite stabilizer. While it is not desirable to be bound by theory, in the absence of a hydroxyapatite stabilizer, aliphatic polyketones may crosslink with themselves, resulting in a significant increase in viscosity and thus making processing difficult. When a hydroxyapatite stabilizer is present in the polymer blend, it acts as an acid remover, preventing the self-reaction and crosslinking of the aliphatic polyketone.

[0086] In some embodiments, the hydroxyapatite stabilizer may include pentacalcium tris(orthophosphate) hydroxide, amorphous tricalcium hydroxide phosphate, calcium hydroxide phosphate, or a combination thereof.

[0087] In some embodiments, the amount of hydroxyapatite stabilizer in the polymer blend can be greater than 0% by weight, greater than or equal to 0.1% by weight, greater than or equal to 0.25% by weight, or even greater than or equal to 0.5% by weight. In some embodiments, the amount of hydroxyapatite stabilizer in the polymer blend can be less than or equal to 1% by weight, or even less than or equal to 0.75% by weight. In some embodiments, the amount of hydroxyapatite stabilizer in the polymer blend can be greater than 0% by weight and less than or equal to 1% by weight, greater than 0% by weight and less than or equal to 0.75% by weight, greater than or equal to 0.25% by weight and less than or equal to 1% by weight, greater than or equal to 0.25% by weight and less than or equal to 0.75% by weight, greater than or equal to 0.5% by weight and less than or equal to 1% by weight, or even greater than or equal to 0.5% by weight and less than or equal to 0.75% by weight, or any and all subranges formed by any of these endpoints.

[0088] In some embodiments, the amount of P2O5 in the hydroxyapatite stabilizer may be greater than or equal to 30% by weight, or even greater than or equal to 40% by weight. In some embodiments, the amount of P2O5 in the hydroxyapatite stabilizer may be less than or equal to 60% by weight, or even less than or equal to 50% by weight. In some embodiments, the amount of P2O5 in the hydroxyapatite stabilizer may be greater than or equal to 30% by weight and less than or equal to 60% by weight, greater than or equal to 30% by weight and less than or equal to 50% by weight, greater than or equal to 40% by weight and less than or equal to 60% by weight, or even greater than or equal to 40% by weight and less than or equal to 50% by weight, or any and all subranges formed by any of these endpoints.

[0089] In some embodiments, the amount of CaO in the hydroxyapatite stabilizer may be greater than or equal to 40% by weight, or even greater than or equal to 50% by weight. In some embodiments, the amount of CaO in the hydroxyapatite stabilizer may be less than or equal to 70% by weight, or even less than or equal to 60% by weight. In some embodiments, the amount of CaO in the hydroxyapatite stabilizer may be greater than or equal to 40% by weight and less than or equal to 70% by weight, greater than or equal to 40% by weight and less than or equal to 60% by weight, greater than or equal to 50% by weight and less than or equal to 70% by weight, or even greater than or equal to 50% by weight and less than or equal to 60% by weight, or any and all subranges formed by any of these endpoints.

[0090] In some embodiments, the particle size distribution D50 of the hydroxyapatite stabilizer can be greater than or equal to 1 μm, or even greater than or equal to 2 μm. In some embodiments, the particle size distribution D50 of the hydroxyapatite stabilizer can be less than or equal to 10 μm, or even less than or equal to 5 μm. In some embodiments, the particle size distribution D50 of the hydroxyapatite stabilizer can be greater than or equal to 1 μm and less than or equal to 10 μm, greater than or equal to 1 μm and less than or equal to 5 μm, greater than or equal to 2 μm and less than or equal to 10 μm, or even greater than or equal to 2 μm and less than or equal to 5 μm, or any and all subranges formed by any of these endpoints.

[0091] In some embodiments, the loss on ignition of the hydroxyapatite stabilizer may be greater than or equal to 2%, or even greater than or equal to 4%. In some embodiments, the loss on ignition of the hydroxyapatite stabilizer may be less than or equal to 10%, or even less than or equal to 5%. In some embodiments, the loss on ignition of the hydroxyapatite stabilizer may be greater than or equal to 2% and less than or equal to 10%, greater than or equal to 2% and less than or equal to 5%, greater than or equal to 4% and less than or equal to 10%, or even greater than or equal to 4% and less than or equal to 5%, or any and all subranges formed by any of these endpoints.

[0092] Suitable commercial implementations of hydroxyapatite stabilizers are available from the EPSOLUTE brand in Budenheim, such as grade C13-09. Table 3 shows some characteristics of EPSOLUTE C13-09.

[0093] Table 3

[0094] <![CDATA[P2O5 (wt%)]]> 40.0–42.0 CaO (wt%) 53.0–56.0 Particle size (D50) (μm) 2.9–3.4 Loss on ignition (%) 4.0

[0095] Rubber-containing impact modifiers

[0096] In addition to improved chemical resistance, it may be desirable for the aliphatic polyketone and ABS blends described herein to exhibit improved impact strength, as demonstrated by a cantilever beam notched impact strength greater than or equal to 400 J / m. For example, impact-resistant aliphatic polyketone and ABS blends may be ideal for automotive and industrial applications. Therefore, in some embodiments, a rubber-containing impact modifier may be added to the aliphatic polyketone and ABS blends described herein to increase the cantilever beam notched impact strength of the polymer blend.

[0097] In some embodiments, the amount of rubber-containing impact modifier in the polymer blend can be greater than 0% by weight, greater than or equal to 3% by weight, greater than or equal to 5% by weight, greater than or equal to 7% by weight, or even greater than or equal to 10% by weight. In some embodiments, the amount of rubber-containing impact modifier can be less than or equal to 20% by weight, less than or equal to 18% by weight, less than or equal to 16% by weight, less than or equal to 14% by weight, or even less than or equal to 12% by weight. In some embodiments, the amount of rubber impact modifier in the polymer blend can be greater than 0 wt% and less than or equal to 20 wt%, greater than 0 wt% and less than or equal to 18 wt%, greater than 0 wt% and less than or equal to 16 wt%, greater than 0 wt% and less than or equal to 14 wt%, greater than 0 wt% and less than or equal to 12 wt%, greater than or equal to 3 wt% and less than or equal to 20 wt%, greater than or equal to 3 wt% and less than or equal to 18 wt%, greater than or equal to 3 wt% and less than or equal to 16 wt%, greater than or equal to 3 wt% and less than or equal to 14 wt%, greater than or equal to 3 wt% and less than or equal to 12 wt%, greater than or equal to 5 wt% and less than or equal to 20 wt%, greater than or equal to 5 wt% and less than or equal to 18 wt%, and greater than or equal to 5 wt% and less than or equal to 16 wt%. , greater than or equal to 5% by weight and less than or equal to 14% by weight, greater than or equal to 5% by weight and less than or equal to 12% by weight, greater than or equal to 7% by weight and less than or equal to 20% by weight, greater than or equal to 7% by weight and less than or equal to 18% by weight, greater than or equal to 7% by weight and less than or equal to 16% by weight, greater than or equal to 7% by weight and less than or equal to 14% by weight, greater than or equal to 7% by weight and less than or equal to 12% by weight, greater than or equal to 10% by weight and less than or equal to 20% by weight, greater than or equal to 10% by weight and less than or equal to 18% by weight, greater than or equal to 10% by weight and less than or equal to 16% by weight, greater than or equal to 10% by weight and less than or equal to 14% by weight, or even greater than or equal to 10% by weight and less than or equal to 12% by weight, or any and all subranges formed by any of these endpoints.

[0098] In some embodiments, the rubber-containing impact modifier may comprise another ABS, methyl methacrylate butadiene styrene (MBS), acrylonitrile styrene acrylate (ASA), styrene acrylonitrile (SAN), or a combination thereof. In some embodiments, the other ABS may be a high-rubber (e.g., greater than 50% by weight butadiene) ABS.

[0099] In some embodiments, the cantilever beam notched impact strength of the polymer blend can be greater than or equal to 400 J / m, greater than or equal to 450 J / m, greater than or equal to 500 J / m, or even greater than or equal to 550 J / m. In some embodiments, the cantilever beam notched impact strength of the polymer blend can be less than or equal to 1200 J / m, less than or equal to 1100 J / m, or even less than or equal to 1000 J / m. In some embodiments, the cantilever beam notched impact strength of the polymer blend can be greater than or equal to 400 J / m and less than or equal to 1200 J / m, greater than or equal to 400 J / m and less than or equal to 1100 J / m, greater than or equal to 400 J / m and less than or equal to 1000 J / m, greater than or equal to 450 J / m and less than or equal to 1200 J / m, greater than or equal to 450 J / m and less than or equal to 1100 J / m, or greater than or equal to 450 J / m and less than or equal to 1000 J / m. Greater than or equal to 500 J / m and less than or equal to 1200 J / m, greater than or equal to 500 J / m and less than or equal to 1100 J / m, greater than or equal to 500 J / m and less than or equal to 1000 J / m, greater than or equal to 550 J / m and less than or equal to 1200 J / m, greater than or equal to 550 J / m and less than or equal to 1100 J / m, or even greater than or equal to 550 J / m and less than or equal to 1000 J / m, or any and all subranges formed by any of these endpoints.

[0100] In some embodiments, the melt flow rate of the rubber-containing impact modifier, measured at 230°C and 3.8 kg weight according to ASTM D1238, can be greater than or equal to 1 g / 10 min, greater than or equal to 3 g / 10 min, or even greater than or equal to 5 g / 10 min. In some embodiments, the melt flow rate of the rubber-containing impact modifier, measured at 230°C and 3.8 kg weight according to ASTM D1238, can be less than or equal to 20 g / 10 min, or even less than or equal to 10 g / 10 min. In some embodiments, the melt flow rate of the rubber-containing impact modifier, measured at 230°C and 3.8 kg weight according to ASTM D1238, can be greater than or equal to 1 g / 10 min and less than or equal to 20 g / 10 min, greater than or equal to 1 g / 10 min and less than or equal to 10 g / 10 min, greater than or equal to 3 g / 10 min and less than or equal to 20 g / 10 min, greater than or equal to 3 g / 10 min and less than or equal to 10 g / 10 min, greater than or equal to 5 g / 10 min and less than or equal to 20 g / 10 min, or even greater than or equal to 5 g / 10 min and less than or equal to 10 g / 10 min, or any and all subranges formed by any of these endpoints.

[0101] In some embodiments, the specific gravity of the rubber-containing impact modifier may be greater than or equal to 0.85, or even greater than or equal to 0.9. In some embodiments, the specific gravity of the rubber-containing impact modifier may be less than or equal to 1.05, or even less than or equal to 1. In some embodiments, the specific gravity of the rubber-containing impact modifier may be greater than or equal to 0.85 and less than or equal to 1.05, greater than or equal to 0.85 and less than or equal to 1, greater than or equal to 0.9 and less than or equal to 1.05, or even greater than or equal to 0.9 and less than or equal to 1, or any and all subranges formed by any of these endpoints.

[0102] In some embodiments, the Shore D hardness of the rubber-containing impact modifier may be greater than or equal to 20, or even greater than or equal to 30. In some embodiments, the Shore D hardness of the rubber-containing impact modifier may be less than or equal to 60, or even less than or equal to 50. In some embodiments, the Shore D hardness of the rubber-containing impact modifier may be greater than or equal to 20 and less than or equal to 60, greater than or equal to 20 and less than or equal to 50, greater than or equal to 30 and less than or equal to 60, or even greater than or equal to 30 and less than or equal to 50, or any and all subranges formed by any of these endpoints.

[0103] Suitable commercial implementations of rubber-containing impact modifiers are available from Galata Chemicals under the BLENDEX brand, such as grade 338, and from Arkema under the CLEARSTRENGTH brand, such as grade E-920. Table 4 shows some properties of BLENDEX 338 and CLEARSTRENGTH E-920.

[0104] Table 4

[0105]

[0106] As illustrated in the following Examples section, adding a rubber-containing impact modifier to the blends of aliphatic polyketone and ABS described herein produces polymer blends that exhibit chemical resistance and improved impact strength.

[0107] Compatibilizer

[0108] In addition to improved chemical resistance, it may be desirable to make the components of the polymer blend compatible. Therefore, in some embodiments, compatibilizers may be added to the blends of aliphatic polyketones and ABS described herein. Compatibilizers can react with or be miscible with aliphatic polyketones and / or ABS to alter the different phases and improve the interfacial compatibility of the polymer blends, as evidenced by increased cantilever beam notched impact strength and changes in glass transition temperature determined by dynamic mechanical analysis.

[0109] In some embodiments, the amount of compatibilizer in the polymer blend can be greater than 0% by weight, greater than or equal to 1% by weight, greater than or equal to 1.25% by weight, greater than or equal to 2% by weight, or even greater than or equal to 2.5% by weight. In some embodiments, the amount of compatibilizer in the polymer blend can be less than or equal to 5% by weight, less than or equal to 4% by weight, or even less than or equal to 3% by weight. In some embodiments, the amount of compatibilizer in the polymer blend may be greater than 0 wt% and less than or equal to 5 wt%, greater than 0 wt% and less than or equal to 4 wt%, greater than 0 wt% and less than or equal to 3 wt%, greater than or equal to 1 wt% and less than or equal to 5 wt%, greater than or equal to 1 wt% and less than or equal to 4 wt%, greater than or equal to 1 wt% and less than or equal to 3 wt%, greater than or equal to 1.25 wt% and less than or equal to 5 wt%, greater than or equal to 1.25 wt% and less than or equal to 4 wt%, greater than or equal to 1.25 wt% and less than or equal to 3 wt%, greater than or equal to 2 wt% and less than or equal to 5 wt%, greater than or equal to 2 wt% and less than or equal to 4 wt%, greater than or equal to 2 wt% and less than or equal to 3 wt%, greater than or equal to 2.5 wt% and less than or equal to 4 wt%, or even greater than or equal to 2.5 wt% and less than or equal to 3 wt%, or any and all subranges formed by any of these endpoints.

[0110] In some embodiments, the compatibilizer may comprise styrene-maleic anhydride (SMA), aromatic polyketides, maleic-ABS, polystyrene sulfonates / esters, acrylic copolymers, or combinations thereof.

[0111] In some embodiments, the compatibilizer may have a weight-average molecular weight (Mw) greater than or equal to 4000 g / mol or even greater than or equal to 5000 g / mol. In some embodiments, the compatibilizer may have a weight-average molecular weight (Mw) less than or equal to 7000 g / mol or even less than or equal to 6000 g / mol. In some embodiments, the weight-average molecular weight (Mw) of the compatibilizer may be greater than or equal to 4000 g / mol and less than or equal to 7000 g / mol, greater than or equal to 4000 g / mol and less than or equal to 6000 g / mol, greater than or equal to 5000 g / mol and less than or equal to 7000 g / mol, or even greater than or equal to 5000 g / mol and less than or equal to 6000 g / mol, or any and all subranges formed by any of these endpoints.

[0112] In some embodiments, the compatibilizer may have an acid value greater than or equal to 400 mg KOH / g or even greater than 450 mg KOH / g. In some embodiments, the compatibilizer may have an acid value less than or equal to 550 mg KOH / g or even less than or equal to 500 mg KOH / g. In some embodiments, the acid value of the compatibilizer may be greater than or equal to 400 mg KOH / g and less than or equal to 550 mg KOH / g, greater than or equal to 400 mg KOH / g and less than or equal to 500 mg KOH / g, greater than or equal to 450 mg KOH / g and less than or equal to 550 mg KOH / g, or even greater than or equal to 450 mg KOH / g and less than or equal to 500 mg KOH / g.

[0113] In some embodiments, the glass transition temperature of the compatibilizer may be greater than or equal to 100°C, or even greater than or equal to 125°C. In some embodiments, the glass transition temperature of the compatibilizer may be less than or equal to 175°C, or even less than or equal to 150°C. In some embodiments, the glass transition temperature of the compatibilizer may be greater than or equal to 100°C and less than or equal to 175°C, greater than or equal to 100°C and less than or equal to 150°C, greater than or equal to 125°C and less than or equal to 175°C, or even greater than or equal to 125°C and less than or equal to 150°C, or any and all subranges formed by any of these endpoints.

[0114] Suitable commercial implementations of the compatibilizer are available from Polyscope under the XIBOND brand, such as grade 285; from Polyram Group under the BONDYRAM brand, such as 6000; from Mitsubishi Chemical under the METBLEN brand; and from Lotader, France, ethylene-acrylate-based terpolymers. Table 5 shows some properties of XIBOND 285.

[0115] Table 5

[0116] Mw(g / mol) 5000 Acid value (mg KOH / g) 480 Glass transition temperature (°C) 130

[0117] filler

[0118] In some embodiments, the polymer blend may further comprise fillers. In some embodiments, the fillers may comprise adhesion promoters; biocides; antifogging agents; antistatic agents; foaming and blowing agents; binders and bound polymers; dispersants; flame retardants and smoke suppressants; impact modifiers; initiators; lubricants; mica; pigments, colorants and dyes; processing aids; release agents; silanes, titanates / esters and zirconates / esters; slip agents and antiblocking agents; stearates / esters; ultraviolet absorbers; viscosity modifiers; waxes; or combinations thereof.

[0119] In some embodiments, the amount of filler in the polymer blend may be greater than 0% by weight, or even greater than or equal to 0.1% by weight. In some embodiments, the amount of filler in the polymer blend may be less than or equal to 1% by weight, less than or equal to 0.75% by weight, or even less than or equal to 0.5% by weight. In some embodiments, the amount of filler in the polymer blend may be greater than 0% by weight and less than or equal to 1% by weight, greater than 0% by weight and less than or equal to 0.75% by weight, greater than 0% by weight and less than or equal to 0.5% by weight, greater than or equal to 0.1% by weight and less than or equal to 1% by weight, greater than or equal to 0.1% by weight and less than or equal to 0.75% by weight, or even greater than or equal to 0.1% by weight and less than or equal to 0.5% by weight, or any and all subranges formed by any of these endpoints.

[0120] Suitable commercial implementations of the packing material are available from BASF under the IRGAFOS 168 brand, such as grade 168, and from BASF under the IRGANOX brand, such as grades 1098 and 1010.

[0121] Processing

[0122] In some embodiments, the polymer blends described herein can be produced by batch or continuous processes.

[0123] In some embodiments, the components of the polymer blend may be added together into the extruder and mixed. In some embodiments, mixing may be a continuous process carried out at a high temperature (e.g., 230°C–275°C) sufficient to melt the polymer matrix. In some embodiments, fillers may be added at the inlet or via injection or a downstream side feeder. In some embodiments, the extruder output is granulated for subsequent extrusion, molding, thermoforming, foaming, calendering, and / or further processing into polymer articles.

[0124] Example

[0125] Table 6 shows the source of components for the polymer blends of Comparative Examples C1-C8 and Examples 1-5.

[0126] Table 6

[0127]

[0128]

[0129] Environmental Stress Cracking (ESCR)

[0130] Sample strips with formulations of the comparative examples and embodiments shown in Tables 8-10 were formed. To separate the effect of strain from the chemical resistance exhibited by the formulations of the comparative examples and embodiments, the sample strips were placed in a strain fixture and subjected to a fixed strain, such as... Figure 1As shown. For the “1% strain control” example, the sample strips were placed under strain for 72 hours. The tensile modulus, yield tensile strength, and yield tensile elongation of the strain control sample strips were measured and are shown in Table 8-10. For other examples, the sample strips were placed under strain and exposed to chemicals for 72 hours. The sample strips were exposed to chemicals by placing a gauze pad that had been soaked in the chemicals on the sample strip, leaving the gauze pad on the sample strip for 24 hours, removing the gauze pad, and then placing a freshly soaked gauze pad on the sample strip. This operation was repeated twice. The tensile modulus, yield tensile strength, and yield tensile elongation of the chemically exposed sample strips were measured and are shown in Table 8-10. The retention rates of tensile modulus, yield tensile strength, and yield tensile elongation of the chemically exposed sample strips relative to the strain control sample strips were calculated, as shown in Table 8-10. When the retention rates of tensile modulus, yield tensile strength, and tensile elongation properties were between 90% and 110%, the formulation was considered to have “good chemical resistance.” A formulation is considered to have “excellent chemical resistance” when the retention rates of tensile modulus, yield tensile strength, and yield tensile elongation are between 95% and 105%. A formulation is considered to have “poor chemical resistance” when the retention rates of any of these properties are less than 90% or greater than 110%.

[0131] Table 7 shows the chemicals used in the ESCR test.

[0132] Table 7

[0133]

[0134] Table 8 shows the formulations (in weight %), certain properties, and ESCR results for Comparative Examples C1-C4 and Examples 1 and 2. Comparative Examples C1-C4 and Examples 1 and 2 comprise different ratios of POKETONE M330A and LUSTRAN 433, ranging from 1:0 in Comparative Example C1 to 0:1 in Comparative Example C4.

[0135] Table 8

[0136]

[0137]

[0138] As shown in Table 8, the heat distortion temperatures of Example 1 (5.7:1 blend of POKETONE M330A and LUSTRAN 433 polymers) and Example 2 (2.3:1 blend of POKETONE M330A and LUSTRAN 433 polymers) were 163°C and 115°C, respectively. The heat distortion temperatures of Comparative Example C2 (1:1 blend of POKETONE M330A and LUSTRAN 433 polymers), Comparative Example C3 (0.4:1 blend of POKETONE M330A and LUSTRAN 433 polymers), and Comparative Example C4 (0:1 blend of POKETONE M330A and LUSTRAN 433 polymers) were 94°C, 93°C, and 89°C, respectively. As shown in Table 8, the heat distortion temperature increases with increasing aliphatic polyketide and decreasing ABS content. Therefore, the amount of aliphatic polyketone can be balanced with the amount of ABS, for example in Examples 1 and 2, to obtain a desired heat distortion temperature above 100°C. Comparative Examples C2 to C4, with aliphatic polyketone to ABS ratios of 1:1, 0.4:1, and 0:1, respectively, have heat distortion temperatures below 100°C.

[0139] Compared to Comparative Example C1 (0:1 blend of POKETONE M330A and LUSTRAN 433 polymers), Examples 1 (5.7:1 blend of POKETONE M330A and LUSTRAN 433 polymers) and Example 2 (2.3:1 blend of POKETONE M330A and LUSTRAN 433 polymers) exhibit higher tensile and flexural moduli. As shown in Table 8, the tensile and flexural moduli increase with increasing ABS content and decreasing aliphatic polyketone content. Therefore, the amount of ABS can be balanced with the amount of aliphatic polyketone, as in Examples 1 and 2, to obtain higher tensile and flexural moduli.

[0140] In addition to a tensile modulus of 1603 MPa and a flexural modulus of 1602 MPa, Example 1 (a blend of 5.7:1 POKETONE M330A and LUSTRAN 433 polymers) also exhibited sufficient overall tensile and flexural strength and stiffness, with a yield tensile strength of 48 MPa, a yield elongation of 10%, a tensile strength at break of 48 MPa, an elongation at break of 17%, and a flexural strength of 65 MPa. Similarly, in addition to a tensile modulus of 1732 MPa and a flexural modulus of 1783 MPa, Example 2 (a blend of 2.3:1 POKETONE M330A and LUSTRAN 433 polymers) also exhibited sufficient overall tensile and flexural strength and stiffness, with a yield tensile strength of 46 MPa, a yield elongation of 10%, a tensile strength at break of 46 MPa, an elongation at break of 13%, and a flexural strength of 70 MPa.

[0141] In addition to having a heat distortion temperature above 100°C and sufficient tensile and flexural strength and stiffness, Examples 1 and 2 also exhibited excellent chemical resistance to VIREX TB and SPORGON. Comparative Example C1 (1:0 POKETONE M330A and LUSTRAN 433 polymer blend) showed poor chemical resistance to VIREX TB and SPORGON. Comparative Example C4 (0:1 POKETONE M330A and LUSTRAN 433) showed poor chemical resistance to SPORGON. When exposed to VIREX TB, the sample strip of Comparative Example C4 broke in the strain gauge. As shown in the examples in Table 8, polymer blends of aliphatic polyketone and ABS at ratios of 5.7:1 and 2.3:1 exhibited better chemical resistance than blends of aliphatic polyketone alone and blends of ABS alone.

[0142] Table 9 shows the formulations (in weight percent) of Comparative Examples C5-C8 and Examples 3 and 4, some properties, and ESCR results. Comparative Examples C5 and C7 are blends of aliphatic polyketones only. Examples 3 and 4 are polymer blends of aliphatic polyketones and ABS at a ratio of 2.3:1. Comparative Examples C6 and C8 are polymer blends of aliphatic polyketones and ABS at a ratio of 1:1.

[0143] Table 9

[0144]

[0145]

[0146]

[0147] As shown in Table 9, the heat distortion temperatures of Example 3 (2.3:1 blend of POKETONE M330A and LUSTRAN 433 polymers) and Example 4 (2.3:1 blend of POKETONE M630A and LUSTRAN 433 polymers) are 101°C and 110°C, respectively. The heat distortion temperatures of Comparative Example C6 (1:1 blend of POKETONE M330A and LUSTRAN 433 polymers) and Comparative Example C8 (1:1 blend of POKETONE M630A and LUSTRAN 433 polymers) are 92°C and 96°C, respectively. As shown in the examples in Table 9, the heat distortion temperature increases with increasing aliphatic polyketone and decreasing ABS. Therefore, the amount of aliphatic polyketone can be balanced with the amount of ABS, for example in Examples 3 and 4, to obtain a desired heat distortion temperature above 100°C. Comparative Examples C6 to C8, with an aliphatic polyketone to ABS ratio of 1:1, have heat distortion temperatures below 100°C.

[0148] Compared to Comparative Example C5 (1:0 POKETONE M330A and LUSTRAN 433 polymer blend) and Comparative Example C7 (1:0 POKETONE M630A and LUSTRAN 433 polymer blend), Examples 3 (2.3:1 POKETONE M330A and LUSTRAN 433 polymer blend) and 4 (2.3:1 POKETONE M630A and LUSTRAN 433 polymer blend) exhibit higher tensile and flexural moduli. As shown in Table 9, the tensile and flexural moduli increase with increasing ABS content and decreasing aliphatic polyketone content. Therefore, the amount of ABS can be balanced with the amount of aliphatic polyketone, as in Examples 3 and 4, to obtain higher tensile and flexural moduli.

[0149] In addition to a tensile modulus of 1800 MPa and a flexural modulus of 1682 MPa, Example 3 (a blend of 2.3:1 POKETONE M330A and LUSTRAN 433 polymers) also exhibited sufficient overall tensile and flexural strength and stiffness, with a yield tensile strength of 47 MPa, a yield elongation of 12%, a tensile strength at break of 45 MPa, an elongation at break of 20%, and a flexural strength of 66 MPa. Similarly, in addition to a tensile modulus of 1640 MPa and a flexural modulus of 1719 MPa, Example 4 (a blend of 2.3:1 POKETONE M630A and LUSTRAN 433 polymers) also exhibited sufficient overall tensile and flexural strength and stiffness, with a yield tensile strength of 47 MPa, a yield elongation of 12%, a tensile strength at break of 60 MPa, an elongation at break of 293%, and a flexural strength of 67 MPa.

[0150] In addition to a heat distortion temperature above 100°C and sufficient tensile and flexural strength and stiffness, Example 3 (a 2.3:1 blend of POKETONE M330A and LUSTRAN 433 polymers) also exhibited excellent chemical resistance to VIREX TB and CAVICIDE, and good chemical resistance to BIREX SE. Although Example 3 showed poor chemical resistance to 30% phosphoric acid solution and 10% nitric acid solution, it showed improved chemical resistance to 30% phosphoric acid solution and 10% nitric acid solution compared to Comparative Example C5 (a 1:0 blend of POKETONE M330A and LUSTRAN 433 polymers), as evidenced by the performance retention values. As shown in Table 9, the 2.3:1 blend of aliphatic polyketide and ABS polymers exhibited better chemical resistance than blends containing only aliphatic polyketide.

[0151] In addition to a heat distortion temperature above 100°C and sufficient tensile and flexural strength and stiffness, Example 4 (a 2.3:1 blend of POKETONE M630A and LUSTRAN 433 polymers) also exhibited excellent chemical resistance to CAVICIDE, CIDEXOPA, BIREX SE, and 10% nitric acid solution, and good chemical resistance to VIREX TB, SPORGON, and 30% phosphoric acid solution. Example 4 showed better chemical resistance to SPORGON, CIDEX OPA, 30% phosphoric acid solution, and 10% nitric acid solution than Example 3 (a 2.3:1 blend of POKETONE M330A and LUSTRAN 433 polymers), the latter showing poorer resistance to these chemicals. While not wishing to be bound by theory, it is believed that the different properties of POKETONE M330A and POKETONE M630A contribute to these differences in chemical resistance. For example, compared to blends containing POKETONE M330A, which has a relatively high melt flow rate (i.e., 60 g / 10 min), POKETONE M630A, due to its relatively low melt flow rate (i.e., 6 g / 10 min), can more fully disperse ABS, thus providing a more uniform blend.

[0152] Table 10 shows the formulation (in weight %), certain properties, and ESCR results for Example 5. Example 5 includes a rubber-containing impact modifier (i.e., BLENDEX 338).

[0153] Table 10

[0154]

[0155]

[0156] As shown in Table 10, Example 5 (a 4.7:1 blend of POKETONE M630A and LUSTRAN 433 polymers, including BLENDEX 338) exhibits a heat deflection temperature of 118°C and excellent chemical resistance to VIREX TB, CAVICIDE, and CIDEX OPA. Example 5 also possesses sufficient tensile and flexural strength and stiffness, with a tensile modulus of 1285 MPa, a yield tensile strength of 41 MPa, a yield elongation at break of 21%, a tensile strength at break of 42 MPa, an elongation at break of 193%, a flexural modulus of 1371 MPa, and a flexural strength of 52 MPa. In addition to its improved heat deflection temperature, sufficient tensile and flexural strength and stiffness, and chemical resistance, Example 5 exhibits a cantilever beam notched impact strength of 988 J / m. As shown in Table 10, Example 5 demonstrates that adding a rubber-containing impact modifier to the aliphatic polyketone and ABS blends described herein can produce polymer blends exhibiting increased chemical resistance and impact resistance.

[0157] Obviously, modifications and variations can be made without departing from the scope of the disclosure defined in the appended claims. More specifically, while some embodiments of this disclosure are identified herein as preferred or particularly advantageous, it should be expected that this disclosure is not necessarily limited to these aspects.

[0158] The claims are as appended.

Claims

1. A polymer blend comprising: Greater than or equal to 55% by weight and less than or equal to 90% by weight of aliphatic polyketides; and Greater than or equal to 10% by weight and less than or equal to 40% by weight of acrylonitrile butadiene styrene (ABS), in, According to ASTM D1238, at 240°C and 2.16 kg, the melt flow rate of aliphatic polyketone is greater than or equal to 1 g / 10 min and less than or equal to 90 g / 10 min, and according to ASTM D1238, at 230°C and 3.8 kg, the melt flow rate of ABS is greater than or equal to 3 g / 10 min and less than or equal to 10 g / 10 min. The polymer blend further contains a hydroxyapatite stabilizer of greater than 0% by weight and less than or equal to 1% by weight.

2. The polymer blend of claim 1, wherein, According to ASTM D1238, at 240°C and a weight of 2.16 kg, the melt flow rate of aliphatic polyketone is greater than or equal to 1 g / 10 min and less than or equal to 20 g / 10 min.

3. The polymer blend of claim 1, wherein, According to ASTM D1238, at 240°C and a weight of 2.16 kg, the melt flow rate of aliphatic polyketone is greater than or equal to 40 g / 10 min and less than or equal to 90 g / 10 min.

4. The polymer blend according to any one of claims 1 to 3, wherein, The polymer blend contains 60% or more and 80% or less by weight of aliphatic polyketone.

5. The polymer blend according to any one of claims 1 to 3, wherein, The polymer blend contains 20% or more and 40% or less by weight of ABS.

6. The polymer blend according to any one of claims 1 to 3, wherein, The weight ratio of aliphatic polyketone to ABS in the polymer blend is 2:1 to 6:

1.

7. The polymer blend according to any one of claims 1 to 3, wherein, According to ASTM D648, the heat distortion temperature of the polymer blend is greater than or equal to 100°C when measured under a load of 0.45 MPa.

8. The polymer blend according to any one of claims 1 to 3, wherein, The polymer blend has a tensile modulus greater than or equal to 1100 MPa, as measured according to ASTM D638 at 23°C and a strain rate of 0.85 mm / s.

9. The polymer blend according to any one of claims 1 to 3, wherein, The polymer blend has a yield tensile strength greater than or equal to 35 MPa, measured according to ASTM D638 at 23°C and a strain rate of 0.85 mm / s.

10. The polymer blend according to any one of claims 1 to 3, wherein, According to ASTM D638, the polymer blend has a yield tensile elongation greater than or equal to 8% when measured at 23°C and a strain rate of 0.85 mm / s.

11. The polymer blend according to any one of claims 1 to 3, wherein, According to ASTM D638, the polymer blend has a tensile modulus greater than or equal to 1100 MPa, measured at 23°C and a strain rate of 0.85 mm / s; a yield tensile strength greater than or equal to 35 MPa, measured at 23°C and a strain rate of 0.85 mm / s ... According to ASTM D790, the polymer blend has a flexural modulus greater than or equal to 1200 MPa, measured at 23°C and a strain rate of 0.21 mm / s; and according to ASTM D790, the polymer blend has a flexural strength greater than or equal to 45 MPa, measured at 23°C and a strain rate of 0.21 mm / s.

12. The polymer blend according to any one of claims 1 to 3, wherein, The polymer blend also contains greater than 0% by weight and less than or equal to 20% by weight of a rubber-containing impact modifier.

13. The polymer blend of claim 12, wherein, The cantilever beam notched impact strength of the polymer blend is greater than or equal to 400 J / m.

14. The polymer blend according to any one of claims 1 to 3, wherein, The polymer blend also contains greater than 0% by weight and less than or equal to 5% by weight of compatibilizer.

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