Novel compatibilizer compositions and blends thereof

Abstract

Described herein are compatibilizer compositions having improved impact and tensile properties and thermoplastic blends thereof. The compatibilizer composition consists of a non-reactive component and a reactive component selected to improve the miscibility of the matrix resin component and to improve the physical properties of the resulting thermoplastic blend. In addition, methods of improving the physical properties of thermoplastic blends are described.

Description

Technical Field

[0001] The present disclosure relates to materials and methods for improving the properties of polymeric materials. More specifically, the present disclosure relates to compatibilizer compositions, and methods of using the compatibilizer compositions to improve the physical properties of thermoplastic resins including post-consumer resin. Background Art

[0002] Thermoplastics having high stiffness, high thermal stability, and balanced impact resistance are desirable for many industries including consumer electronics, automotive components, and device housings. Polycarbonate blends, such as blends of polycarbonate (PC) and acrylonitrile butadiene-styrene (ABS), can provide the desired properties for these applications. Due to the desirable properties of PC blends such as PC-ABS, these materials have high annual consumption, thus greatly contributing to the alarming amount of plastic waste present in landfills around the world.

[0003] Although thermoplastics can be recycled, many post-consumer resins (PCRs) lose their mechanical properties over time (usually due to degradation), and thus the post-consumer resins are landfilled rather than recycled. Currently, efforts to reuse PCRs include combining virgin thermoplastics with PCRs, and incorporating impact modifiers to produce blends having improved impact resistance compared to unmodified PCRs. Many attempts have been made to effectively recycle and reuse PC / ABS at the end of its useful life. However, products made with high recycle content typically have poor properties, and blends with low recycle content cannot consume enough waste material to mitigate the environmental impact of PC-ABS scrap.

[0004] Improving the physical properties of thermoplastics, especially PCRs, not only provides materials with desired properties for a large number of applications, but also reduces the amount of post-consumer resin in landfills. Summary of the Invention

[0005] Accordingly, the present disclosure describes materials and methods for improving the physical properties of thermoplastic blends.

[0006] In one aspect, a compatibilizer composition for a thermoplastic blend is disclosed. The compatibilizer composition comprises: at least one reactive component, and at least one non-reactive component. The compatibilizer composition is configured to modify a matrix resin, the matrix resin comprising a first component having a first solubility parameter and a second component having a second solubility parameter; and wherein the solubility parameter of the reactive component is between the first solubility parameter and the second solubility parameter.

[0007] In some embodiments of the first aspect, at least one reactive component of the compatibilizer composition comprises an acrylonitrile-styrene-acrylate and maleic anhydride copolymer. In some embodiments of the first aspect, at least one reactive component of the compatibilizer composition comprises an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer.

[0008] In some embodiments of the first aspect, at least one non-reactive component of the compatibilizer composition comprises ethyl methacrylate. In some embodiments of the first aspect, at least one non-reactive component of the compatibilizer composition comprises ethyl butyl acrylate. In some embodiments of the first aspect, at least one non-reactive component of the compatibilizer composition comprises a non-reactive silicone-acrylic rubber.

[0009] In some embodiments of the first aspect, the ratio of at least one reactive component to at least one non-reactive component in the compatibilizer composition is from 1:2.3 to 2.3:1.

[0010] In some embodiments of the first aspect, at least one reactive component comprises an acrylonitrile-styrene-acrylate and maleic anhydride copolymer, and at least one non-reactive component comprises ethyl methacrylate.

[0011] In some embodiments of the first aspect, at least one reactive component is an acrylonitrile-styrene-acrylate and maleic anhydride copolymer, and the non-reactive component is ethyl butyl acrylate.

[0012] In some embodiments of the first aspect, at least one reactive component comprises an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer, and at least one non-reactive component comprises ethyl methacrylate.

[0013] In some embodiments of the first aspect, at least one reactive component comprises an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer, and at least one non-reactive component comprises ethyl butyl acrylate.

[0014] In some embodiments of the first aspect, at least one reactive component comprises an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer and an acrylonitrile-styrene-acrylate and maleic anhydride copolymer; and at least one non-reactive component comprises ethyl methacrylate.

[0015] In some embodiments of the first aspect, at least one reactive component comprises an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer and an acrylonitrile-styrene-acrylate and maleic anhydride copolymer; and at least one non-reactive component comprises a non-reactive silicone-acrylic rubber.

[0016] In a second aspect, a thermoplastic blend is disclosed. The thermoplastic blend comprises: a matrix resin and a compatibilizer composition according to the first aspect above, wherein the matrix resin comprises a first component and a second component.

[0017] In some embodiments of the second aspect, the matrix resin comprises a post-consumer resin. In some embodiments of the second aspect, the matrix resin comprises polycarbonate. In some embodiments of the second aspect, the matrix resin comprises polycarbonate and acrylonitrile butadiene-styrene.

[0018] In some embodiments of the second aspect, based on the total weight of the thermoplastic blend, the matrix resin comprises 50 wt% to 80 wt% of polycarbonate.

[0019] In some embodiments of the second aspect, based on the total weight of the thermoplastic blend, the thermoplastic comprises 3 wt% to 7 wt% of the compatibilizer composition.

[0020] In some embodiments of the second aspect, at least one reactive component comprises an acrylonitrile-styrene-acrylate and maleic anhydride copolymer. In some embodiments of the second aspect, at least one reactive component comprises an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer.

[0021] In some embodiments of the second aspect, at least one non-reactive component comprises ethyl methacrylate. In some embodiments of the second aspect, at least one non-reactive component comprises ethyl butyl acrylate. In some embodiments of the second aspect, at least one non-reactive component includes a non-reactive silicone-acrylic rubber.

[0022] In some embodiments of the second aspect, the ratio of at least one reactive component to at least one non-reactive component comprised in the compatibilizer composition is from 1:2.3 to 2.3:1.

[0023] In a third aspect, a method of improving the physical properties of a thermoplastic blend is disclosed. The method comprises adding a compatibilizer composition according to the first aspect above to a matrix resin to obtain a thermoplastic blend having improved physical properties.

[0024] In some embodiments of the third aspect, at least one reactive component comprises an acrylonitrile-styrene-acrylate and maleic anhydride copolymer. In some embodiments of the third aspect, at least one reactive component comprises an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer.

[0025] In some embodiments of the third aspect, at least one non-reactive component comprises ethyl methacrylate. In some embodiments of the third aspect, at least one non-reactive component comprises ethyl butyl acrylate. In some embodiments of the third aspect, at least one non-reactive component comprises non-reactive silicone-acrylic rubber.

[0026] In some embodiments of the third aspect, the ratio of at least one reactive component to at least one non-reactive component is from 1:2.3 to 2.3:1.

[0027] In some embodiments of the third aspect, at least one reactive component comprises acrylonitrile-styrene-acrylate and maleic anhydride copolymer and at least one non-reactive component comprises ethyl methacrylate.

[0028] In some embodiments of the third aspect, at least one reactive component is acrylonitrile-styrene-acrylate and maleic anhydride copolymer and the non-reactive component is ethyl butyl acrylate.

[0029] In some embodiments of the third aspect, at least one reactive component comprises acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer and at least one non-reactive component comprises ethyl methacrylate.

[0030] In some embodiments of the third aspect, at least one reactive component comprises acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer and at least one non-reactive component comprises ethyl butyl acrylate.

[0031] In some embodiments of the third aspect, at least one reactive component comprises acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer and acrylonitrile-styrene-acrylate and maleic anhydride copolymer; and at least one non-reactive component comprises ethyl methacrylate.

[0032] In some embodiments of the third aspect, at least one reactive component comprises acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer and acrylonitrile-styrene-acrylate and maleic anhydride copolymer; and at least one non-reactive component comprises non-reactive silicone-acrylic rubber.

[0033] In some embodiments of the third aspect, the matrix resin comprises post-consumer resin. In some embodiments of the third aspect, the matrix resin comprises polycarbonate. In some embodiments of the third aspect, the matrix resin comprises polycarbonate and acrylonitrile butadiene-styrene. In some embodiments of the third aspect, based on the total weight of the thermoplastic blend, the matrix resin comprises 50 wt% to 80 wt% of polycarbonate.

[0034] In some embodiments of the third aspect, based on the total weight of the thermoplastic blend, the thermoplastic comprises 3 wt% to 7 wt% of a compatibilizer composition.

[0035] This summary is not intended to limit the scope of the present invention. Additional features and advantages will become apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The drawings described herein are for illustrative purposes of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0037] Figure 1 is a representative graph illustrating the impact properties of a thermoplastic blend according to an embodiment of the present invention.

[0038] Figure 2 is a representative graph illustrating the impact properties of a thermoplastic blend according to an embodiment of the present invention.

[0039] Figure 3 is a representative graph illustrating the elastic properties of a thermoplastic blend according to an embodiment of the present invention.

[0040] Figure 4 is a representative graph illustrating the tensile strength of a thermoplastic blend according to an embodiment of the present invention.

[0041] Figure 5 is a representative graph illustrating the elongation properties of a thermoplastic blend according to an embodiment of the present invention.

[0042] Figure 6 is a representative graph illustrating the elastic properties of a thermoplastic blend according to an embodiment of the present invention.

[0043] Figure 7 is a representative graph illustrating the tensile strength of a thermoplastic blend according to an embodiment of the present invention.

[0044] Figure 8 is a representative graph illustrating the impact strength of a thermoplastic blend according to an embodiment of the present invention at low temperatures.

[0045] Figure 9 is a representative graph illustrating the impact properties of a thermoplastic blend having post-consumer resin and post-industrial resin according to an embodiment of the present invention.

[0046] Figure 10 is a representative graph illustrating the impact properties of a thermoplastic blend having post-industrial resin according to an embodiment of the present invention. Detailed implementation manners

[0047] The figures and descriptions provided herein may have been simplified to illustrate aspects relevant to the materials, compositions, and methods described herein clearly. At the same time, for the sake of clarity, other aspects that can be found in typical similar materials, compositions, and methods have been omitted. Those of ordinary skill in the art can thus recognize that other elements and / or operations may be desirable and / or necessary for implementing the materials, compositions, and methods described herein. However, because such elements and operations are known in the art and because they do not facilitate a better understanding of the present disclosure, discussions of such elements and operations may not be provided herein for the sake of brevity. Nevertheless, it is considered that the present disclosure still includes all such elements, variations, and modifications of the described aspects that are known to those of ordinary skill in the art.

[0048] Regarding the disclosed methods, the order of the presented steps is illustrative in nature. Therefore, the order of the steps can be different in various embodiments. As used herein, "a" and "an" mean "at least one / kind" of the item exists; when possible, there can be multiple / kinds of such items. Unless otherwise clearly stated, when describing the broadest scope of the present technology, all numerical values in this specification are understood to be modified by the word "about", and all geometric and spatial descriptors are understood to be modified by the word "substantially". When applied to a numerical value, "about" means some slight inaccuracy in the calculated or measured allowable value (there are some methods close to the accurate value; approximate or reasonably close to the value; close). If for some reason, the inaccuracy provided by "about" and / or "substantially" cannot be understood in the ordinary meaning of the art, then "about" and / or "substantially" as used herein at least represent the variations that may be caused by ordinary methods of measurement or use of these parameters.

[0049] As used herein, regarding a list of more than two items, elements, components, or materials, the term "or" does not mean complete separation such that the listed items, elements, components, or materials are mutually exclusive. For example, "X, Y, or Z" does not mean that each of X, Y, and Z is mutually exclusive. Two or more of X, Y, and Z can overlap partially or completely with each other, or at least one of X, Y, or Z can be included in at least one of the others of X, Y, or Z or be a subgenus of at least one of the others of X, Y, or Z.

[0050] Although open-ended terms such as "comprising", which is synonymous with, for example, the non-limiting terms "including", "containing", or "having", are used herein to describe and claim embodiments, the embodiments may optionally be described using more restrictive terms such as "consisting of" or "consisting essentially of". Thus, for any given embodiment that lists materials, components, or process steps, the present technology also specifically includes embodiments consisting of or consisting essentially of: these materials, components, or process steps excluding additional materials, components, or processes (for "consisting of"), and these materials, components, or process steps excluding additional materials, components, or processes that affect the significant properties of the embodiment (for "consisting essentially of"), even if these additional materials, components, or processes are not explicitly listed in the present application. For example, a recitation of a composition or process having elements A, B, and C specifically contemplates embodiments consisting of and consisting essentially of A, B, and C, excluding element D that may be recited in the art, even if element D is not explicitly described as being excluded herein.

[0051] Concentrations, amounts, and other numerical data may be expressed or presented herein in a range format. It should be understood that this range format is used merely for convenience and brevity and should therefore be interpreted flexibly to include not only the explicitly recited numerical values that are the limits of the range, but also all the individual numerical values or sub-ranges subsumed within the range, as if each numerical value and sub-range were explicitly recited. By way of illustration, a numerical range of "about 1 to 5" should be interpreted to include not only the explicitly recited values of about 1 to about 5, but also the individual values and sub-ranges within the indicated range. Thus, the numerical range includes the individual values, such as 2, 3, and 4, and sub-ranges, such as 1-3, 2-4, and 3-5, etc., as well as the individual values of 1, 2, 3, 4, and 5. The same principle applies to ranges that merely list one numerical value as the minimum or maximum. In addition, this interpretation should apply regardless of the breadth of the range or feature being described.

[0052] As used herein, the term "thermoplastic" is used to refer to any material that can be softened or melted when heat is applied and solidifies or hardens when cooled. Examples of thermoplastics include polycarbonate or PC, polyethylene or PE, acrylics, polyamide or PA (also known as nylon), polymethyl methacrylate or PMMA, polystyrene or PS, polypropylene or PP, acrylonitrile butadiene styrene or ABS, acrylonitrile styrene - acrylic or ASA, polyesters, poly(vinyl chloride) or PVC, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytetrafluoroethylene or PTFE (also known as Teflon), blends thereof, and derivatives thereof. Thermoplastic polycarbonate blends include, but are not limited to: polycarbonate / acrylonitrile butadiene styrene (PC - ABS), polycarbonate / methyl methacrylate acrylonitrile butadiene styrene (PC - MABS), polycarbonate / styrene acrylonitrile (PC - SAN), polycarbonate / polyethylene terephthalate (PC - PETP), polycarbonate / polybutylene terephthalate (PC - PBT), polycarbonate / polyethylene (PC - PE), polycarbonate / poly(vinyl chloride) (PC - PVC), polycarbonate / polyurethane (PC - PUR), polycarbonate / poly(methyl methacrylate) (PC - PMMA), polycarbonate / acrylonitrile styrene - acrylic (PC - ASA), and polycarbonate / polystyrene (PC - PS).

[0053] As used herein, the term "post - consumer resin" is defined as a polymeric resin obtained from post - consumer recycle components (i.e., finished products that have been used and then recycled). As used herein, the term "post - industrial resin" is defined as a polymeric resin obtained from post - industrial waste (i.e., waste generated during the manufacturing process). These two terms will be used interchangeably throughout the specification.

[0054] As is known in the art, additives, such as impact modifiers, can be combined with post - consumer resins in an effort to regain many of the mechanical properties of the original resin. As an example, PCR polycarbonate / acrylonitrile butadiene - styrene (PC - ABS) is modified via the incorporation of functionalized block copolymers. Examples of modifiers include maleic anhydride grafted styrene - ethylene - butene - styrene or SEBS - MAH, which provides a polycarbonate - reactive MAH block and a styrene block compatible with ABS, resulting in a thermoplastic blend with slightly greater toughness than post - consumer PC - ABS. Additional modifiers include combinations of reactive and non - reactive modifiers to improve the dispersion and domain size of the modified particles; examples include glycidyl methacrylate functionalized ethylene methyl acrylate (EMA - GMA), also known by the trade name and non - functionalized ethylene methyl acrylate (EMA), also known by the trade name

[0055] In the case of reactive / non-reactive modifier combinations, the surface energy and solubility parameters of the polymer drive the increase in blend properties. Due to the covalent linkages generated between the modifier and the polycarbonate, the reactive species are dispersed in the blend. The non-reactive species are not miscible with PC / ABS and thus will diffuse into the domains of the reactive modifier. This conservation of surface energy is the driving force for domain growth that provides improved impact properties.

[0056] The compatibility of components can be determined using the Hildebrand solubility parameter with Equation 1 below. This equation shows that the polymer solubility parameter is a function of its molar attraction constant (F) divided by its molar volume (V). These attraction constants and volumes can be determined using group contribution theory. Group contribution theory allows one to break down the polymer repeat unit into discrete functional groups with well-defined attraction constants and volumes. The sum of these groups allows for the determination of the polymer solubility parameter.

[0057]

[0058] The compatibility of polymers can be determined by comparing their solubility parameters. As a general rule, if the difference between the solubility parameters of two polymers is less than or equal to 1, the blend is miscible. If the difference is greater than 1, the blend is presumably immiscible. Of course, there are exceptions to this rule based on specific interactions that can improve miscibility, such as the pi-pi complexes that can be found between the benzene rings of the styrene units in ABS and the aromatic rings of bisphenol A in polycarbonate. Table 1 lists the solubility parameters calculated using Equation 1.

[0059] Table 1.

[0060]

[0061] As shown in Table 1, the solubility parameter of PC is 21.7 MPa 1 / 2 and the value of ABS is 19.6 MPa 1 / 2 . The difference between these values is 2.1 MPa 1 / 2 , confirming the known immiscibility between PC and ABS. It can also be seen that the solubility parameters of both EMA and its reactive derivative EMA-GMA are in the low 16 MPa 1 / 2Within this range, this would lead people to believe that it is not compatible with any component of the PC / ABS blend. Although a large difference in solubility parameters between the modifier and the matrix would lead people to expect a decrease in properties, the observed situation is exactly the opposite. The notched Izod impact properties of several PC / ABS blends with different modifiers were evaluated. The uninstrumented linear resilience of the thermoplastic blend containing PCR PC-ABS 70 / 30 modified with 7.5% of a composition (containing 30% EMA-GMA and 70% EMA) was approximately 627, which is better than that of the thermoplastic blend containing PCR PC-ABS 70 / 30 modified with 7.5% SEBS-MAH, with a linear resilience of approximately 530. This demonstrates the ability of the reactive substance (in this case, EMA-GMA) to disperse well with PC and grow in size to improve impact strength due to the similarity in solubility parameters between the reactive and non-reactive modifiers.

[0062] Although the impact strength is indeed significantly improved compared to the pure reactive modifier, the tensile properties are indeed affected. The tensile properties of these same blends were evaluated. The same thermoplastic blend containing PCR PC-ABS 70 / 30, which provides excellent impact performance, and a combination of EMA-GMA and EMA has substandard tensile properties, with an ultimate tensile strength of 46.1. The tensile modulus is approximately 200 MPa lower than expected, the ultimate tensile strength is approximately 10 MPa lower than normal, and the elongation at break is 8.3%, far lower than the expected value of 50%.

[0063] The suspected cause of the undesirable tensile properties is the incompatibility of the EMA-based modifier with ABS. The reactive EMA-GMA substance only reacts with the polycarbonate part of the PC / ABS blend. Therefore, the non-reactive EMA will try to find domains inside the PC phase and will not toughen the ABS part. Although the PC domains will experience increased impact performance, any "free" EMA that cannot migrate to the reactive EMA domains will reside at the interface between PC and ABS, weakening their adhesion. This explains the extreme loss of elongation at break and the weakening of other tensile properties.

[0064] To overcome the loss of tensile properties, theoretically reducing the difference in solubility parameters between the modifier and the matrix resin can improve compatibility and thus improve the physical properties.

[0065] For the purpose of improving not only the impact properties but also the tensile properties, the compatibilizer compositions described herein comprise a reactive component having a solubility parameter between the solubility parameters of two immiscible polymers of the thermoplastic blend. Based on the solubility parameters listed in Table 1, it can be seen that due to the similarity of the solubility parameters, acrylonitrile-styrene-acrylate (ASA) is expected to be miscible with both PC and ABS. The compatibilizer composition further comprises a non-reactive component. Since the acrylate component of ASA is typically methyl acrylate or butyl acrylate, ethylene methacrylate (EMA) or ethylene butyl acrylate (EBA) will serve well as the non-reactive component. In some embodiments, the reactive component of the compatibilizer composition comprises ASA. Additionally or alternatively, the reactive component of the compatibilizer composition is ASA-MAH. In other embodiments, the reactive component of the compatibilizer composition is ASA-GMA. Additionally or alternatively, the reactive component can be a combination of ASA-GMA and ASA-MAH. In some embodiments, ASA-GMA comprises from about 1% to about 10% GMA. Additionally or alternatively, ASA-GMA can comprise from about 3% to about 5% GMA. In some embodiments, ASA-MAH comprises from about 1% to about 10% MAH. Additionally or alternatively, ASA-MAH can comprise from about 3% to about 5% MAH. Non-limiting examples of the reactive component are listed in Table 2.

[0066] In some embodiments, the non-reactive component of the compatibilizer composition can be an acrylate. In some embodiments, the non-reactive component is EMA. Additionally or alternatively, the non-reactive component is EBA. Additionally or alternatively, the non-reactive component can be a non-reactive silicone-acrylic rubber. Although acrylates are described herein, it is to be understood that other non-reactive impact modifiers can be used as the non-reactive component of the compatibilizer. Non-limiting examples of the non-reactive component are listed in Table 2.

[0067] Table 2.

[0068]

[0069] The compatibilizer composition can comprise from 25 wt% to 85 wt% of the non-reactive component. Additionally, the compatibilizer composition can comprise from 25% wt to 85% wt of the reactive component. In some embodiments, the ratio of the reactive component to the non-reactive component is 1:2.3. In some embodiments, the ratio of the reactive component to the non-reactive component is 1:1.5. In some embodiments, the ratio of the reactive component to the non-reactive component is 1:1. In some embodiments, the ratio of the reactive component to the non-reactive component is 1.5:1. In some embodiments, the ratio of the reactive component to the non-reactive component is 2.3:1.

[0070] The compatibilizer composition can be added to the matrix resin as a modifier resin to obtain a thermoplastic blend having improved physical properties. The compatibilizer composition can be added to the matrix resin in an amount of about 1% to about 20%. Optionally, the compatibilizer composition can be added to the matrix resin in an amount of about 1% to about 10%. In some embodiments, the compatibilizer composition is added to the matrix resin in an amount of about 3% to about 7%.

[0071] In some embodiments, the compatibilizer composition is added to post-consumer resin (PCR) to improve the physical properties of the PCR. By improving the physical properties of the PCR, the PCR can be recycled. This will reduce the amount of PCR in landfills. Additionally or alternatively, the compatibilizer composition is added to virgin resin to improve the physical properties, thereby preparing an engineering resin having better physical properties.

[0072] In some embodiments, the compatibilizer composition is added to a thermoplastic blend. In some embodiments, the compatibilizer composition is added to a polycarbonate blend. In some embodiments, the compatibilizer is added to a polycarbonate blend containing 90% PC. Additionally or alternatively, the compatibilizer composition is added to a polycarbonate blend containing 80% PC. In some embodiments, the compatibilizer composition is added to a polycarbonate blend containing 70% PC. In other embodiments, the compatibilizer composition is added to a polycarbonate blend containing 60% PC. In other embodiments, the compatibilizer composition is added to a polycarbonate blend containing 50% PC. In some embodiments, the compatibilizer composition is added to a polycarbonate blend containing PC-ABS.

[0073] The compatibilizer composition can be added to the matrix resin to obtain a thermoplastic blend having better impact strength. Additionally or alternatively, the compatibilizer composition can be added to the matrix resin to obtain a thermoplastic blend having improved elasticity or elastic modulus. In some embodiments, the compatibilizer composition can be added to the matrix resin to obtain a thermoplastic blend having improved tensile strength or ultimate tensile strength (UTS). Additionally or alternatively, the compatibilizer can be added to the matrix resin to obtain a thermoplastic blend having improved elongation at break (EAB).

[0074] Working Examples

[0075] In the following working examples, a compatibilizer composition was added to various PC / ABS blends. The compatibilizer composition included 30% reactive components and 70% non-reactive components. In the case of two reactive components, each was added at 15% of the compatibilizer composition. A Leistritz ZSE 27MAXX co-rotating intermeshing twin screw extruder with an L / D ratio of 40 / 1 was used to compound the PC / ABS formulations. A loss-in-weight feeder was used to supply all components of the formulation at the feed port. The screw speed of the extruder was between 400 and 600 rpm, and the melt temperature was between 250 and 290 degrees Celsius. To evaluate the mechanical properties, ASTM D638 Type I tensile bars and ASTM D790 flexural bars were injection molded using a Milacron Roboshot S-2000i100A injection molding machine. Before molding, the compounded pellets were dried to less than 0.02% moisture. The specimens were molded at a melt temperature of 490 to 530 degrees Fahrenheit and a mold temperature of 180 to 200 degrees Fahrenheit.

[0076] As Figure 1 and Figure 2 shown, adding 5% of the compatibilizer composition to the 50 / 50 virgin PC-ABS blend improved the impact properties. Additionally, as Figure 1 also shown, when the compatibilizer composition was added to the 60 / 40 PC / ABS blend, the impact properties were improved. Specifically, 3% ASA-GMA / EMA increased the impact properties from 79 J / m to 353 J / m, while 3% of the standard impact modifier EMA-GMA / EMA increased the impact properties from 79 J / m to 128 J / m. When 5% of the compatibilizer composition ASA-GMA / EMA was added to the PC-ABS blend, the impact properties were further increased to 379 J / m compared to the standard impact modifier EMA-GMA / EMA which only increased the impact properties to 166 J / m. More surprisingly, 5% of the compatibilizer composition containing ASA-GMA / ASA-MAH / EMA improved the impact properties to 352 J / m. The Figure 1 and Figure 2 results shown are presented in Table 3. The impact test data obtained in Figure 1 and 2 was obtained using ASTM D256 with an Instron Ceast 9,050 impact testing machine. Not shown in the figure, when 7.5% SEBS-MAH / EMA was added to the 70% PC blend, the impact resistance was 530 J / m.

[0077] Table 3.

[0078]

[0079] Additional properties of the modified original polycarbonate blend are shown in Figures 3 - 7 . Figure 3 Improved modulus of elasticity is shown after addition of the compatibilizer compositions described herein. Figure 4 Improved tensile strength is shown after addition of the compatibilizer compositions described herein. Figure 5 Improved elongation at break (EAB) properties are shown after addition of the compatibilizer compositions described herein. The improved properties are also listed in Table 4. Figure 6 Measurements of the elasticity for a PC / ABS blend having 57% PC and 23% ABS are shown. In the absence of a compatibilizer, the modulus of elasticity was 2946 MPa. In the case of 0.75% ASA-GMA / 0.75% ASA-MAH as reactive components and 3.5% of a non-reactive silicone-acrylic rubber as a non-reactive component (ASA-GMA / ASA-MAH), the modulus of elasticity decreased to 2674 MPa. When 1.5% of an epoxy-reactive silicone-acrylic rubber was added as a reactive component and 3.5% of a non-reactive silicone acrylic rubber as a non-reactive component (Silicone Acrylic Coreshell), the modulus of elasticity was further decreased to 2488 MPa. Figure 7 Shown are from Figure 6 the same samples. Figures 3 - 7 The data from

[0080] Table 4

[0081]

[0082] The compatibilizer compositions were further tested at low temperatures. Figure 8The impact strength at -30 °C and 23 °C is shown for the following compatibilizer compositions each added to a PC / ABS blend having 57% PC and 23% ABS: a compatibilizer composition having 0.75% ASA-GMA / 0.75% ASA-MAH as reactive components and 3.5% of a non-reactive silicone-acrylic rubber as non-reactive component (labeled ASA-GMA / ASA-MAH), and a compatibilizer composition having 1.5% of an epoxy-reactive silicone-acrylic rubber as reactive component and 3.5% of a non-reactive silicone acrylic rubber as non-reactive component (labeled silicone acrylic core-shell). At both -30 °C and 23 °C, each compatibilizer composition improved the impact strength compared to the untreated PC / ABS.

[0083] The compatibilizer compositions described herein were added to post-consumer resins and the impact properties were measured, as shown in Table 5 and Figure 9 and Figure 10 as shown. The compatibilizer compositions described herein improve the impact properties of post-consumer resins (PCR) and post-industrial resins (PIR). As Figure 9 shown, when no compatibilizer composition (or impact modifier) was added to a PC / ABS prepared from 60% post-consumer resin and 40% post-industrial resin, the impact strength was 145 J / m. When a compatibilizer composition having only one component, ASA-GMA, was added to the resin, the impact strength increased to 351. When a compatibilizer composition having two components as described herein was added, the impact strength increased to 418 J / m. As Figure 10 shown, when the compatibilizer composition as described herein was added to 100% post-industrial PC / ABS, the impact strength increased from 542 to 731 compared to the resin without the compatibilizer composition.

[0084] Table 5.

[0085]

[0086] It has been found that combining a reactive polymer having a solubility parameter between two immiscible polymers with a non-reactive impact modifier can improve the impact, tensile, and thermal properties of PC / ABS blends. Without being bound by theory, it is hypothesized that applying this reactive / non-reactive additive combination to the original PC / ABS blend can further improve the blend properties and allow its extension to even higher demanding applications. The compatibilizer compositions described herein can be used to modify the original PC blend as well as PCR or post-industrial resin (PIR) blends.

[0087] This test data indicates that the ASA-GMA / ASA-MAH combination of reactive components for the compatibilizer composition shows more improved properties compared to the unmodified PC-ABS blend and the current standard EMA-GMA / EMA impact modifier. Without wishing to be bound by theory, it is believed that this is because the free carboxyl groups generated by MAH grafting freely react with the free hydroxyl groups formed by GMA grafting to form a branched PC network.

[0088] The compatibilizer compositions described herein not only improve the impact properties of the thermoplastic blend but also reduce the standard deviation of the properties. When comparing the tensile properties, it can be seen that not only are the tensile strength and modulus restored to the optimal material properties, but the elongation at break also jumps to nearly twice that of the commercially available grades.

[0089] The thermoplastic blends described herein may further comprise additional additives including, but not limited to, flame retardants. Examples of flame retardants include, but are not limited to CO6000 and CO3000 (poly(phosphonate-co-carbonate)), 600 (non-halogenated phosphorus flame retardant), APP-MC (melamine-coated ammonium polyphosphate), Sol-DP (oligomeric, free-flowing solid ingot phosphate flame retardant), Metablen TM S-2030 (non-reactive silicone-acrylic rubber) and Metablen TM SX-005 (silicone-acrylic rubber flame retardant).

[0090] In the foregoing detailed description, for the purposes of brevity of this disclosure, various features may be grouped into separate embodiments. The methods of this disclosure should not be construed as reflecting an intention that any subsequently claimed embodiment requires more features than are expressly recited.

[0091] Furthermore, the description of this disclosure is provided so that any person skilled in the art can make or use the embodiments of this disclosure. Various modifications to this disclosure will be apparent to those skilled in the art, and the general principles defined herein can be applied to other variations without departing from the spirit or scope of this disclosure. Therefore, this disclosure is not intended to be limited to the examples and designs described herein, but rather to embrace the broadest scope consistent with the principles and novel features disclosed herein.

Claims

1. A compatibilizer composition for a thermoplastic blend, comprising: at least one reactive component, and at least one non-reactive component, wherein the compatibilizer composition is configured to modify a matrix resin, the matrix resin comprising a first component having a first solubility parameter and a second component having a second solubility parameter; and wherein the solubility parameter of the reactive component is between the first solubility parameter and the second solubility parameter.

2. The compatibilizer composition according to claim 1, wherein the at least one reactive component comprises an acrylonitrile-styrene-acrylate and maleic anhydride copolymer; an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer; or a combination thereof.

3. The compatibilizer composition according to claim 1, wherein the at least one non-reactive component comprises ethyl methacrylate, ethyl butyl acrylate, non-reactive silicone-acrylic rubber, or a combination thereof.

4. The compatibilizer composition according to claim 1, wherein the ratio of the at least one reactive component to the at least one non-reactive component is from 1:2.3 to 2.3:

1.

5. The compatibilizer composition according to claim 1, wherein the at least one reactive component comprises an acrylonitrile-styrene-acrylate and maleic anhydride copolymer, and the at least one non-reactive component comprises ethyl methacrylate.

6. The compatibilizer composition according to claim 1, wherein the at least one reactive component is an acrylonitrile-styrene-acrylate and maleic anhydride copolymer, and the non-reactive component is ethyl butyl acrylate.

7. The compatibilizer composition according to claim 1, wherein the at least one reactive component comprises an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer, and the at least one non-reactive component comprises ethyl methacrylate.

8. The compatibilizer composition according to claim 1, wherein the at least one reactive component comprises an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer, and the at least one non-reactive component comprises ethyl butyl acrylate.

9. The compatibilizer composition according to claim 1, wherein the at least one reactive component comprises an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer and an acrylonitrile-styrene-acrylate and maleic anhydride copolymer; and the at least one non-reactive component comprises ethyl methacrylate.

10. The compatibilizer composition according to claim 1, wherein the at least one reactive component comprises an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer and an acrylonitrile-styrene-acrylate and maleic anhydride copolymer; and the at least one non-reactive component comprises non-reactive silicone-acrylic rubber.

11. A thermoplastic blend, comprising: a matrix resin, wherein the matrix resin comprises a first component and a second component, and the compatibilizer composition according to claim 1.

12. The thermoplastic blend according to claim 11, wherein the matrix resin comprises a post-consumer resin.

13. The thermoplastic blend according to claim 11, wherein the matrix resin comprises polycarbonate.

14. The thermoplastic blend according to claim 11, wherein the matrix resin comprises polycarbonate and acrylonitrile butadiene styrene.

15. The thermoplastic according to claim 11, wherein based on the total weight of the thermoplastic blend, the matrix resin comprises 50 wt% to 80 wt% of polycarbonate.

16. The thermoplastic according to claim 11, wherein based on the total weight of the thermoplastic blend, the thermoplastic comprises 3 wt% to 7 wt% of the compatibilizer composition.

17. The thermoplastic according to claim 11, wherein the at least one reactive component comprises an acrylonitrile styrene acrylate and maleic anhydride copolymer; an acrylonitrile styrene acrylate and glycidyl methacrylate copolymer; or a combination thereof.

18. The thermoplastic according to claim 11, wherein the at least one non-reactive component comprises ethyl methacrylate, ethyl butyl acrylate, non-reactive silicone-acrylic rubber, or a combination thereof.

19. The thermoplastic according to claim 11, wherein the ratio of the at least one reactive component to the at least one non-reactive component comprised in the compatibilizer composition is from 1:2.3 to 2.3:

1.

20. A method of improving the physical properties of a thermoplastic blend, the method comprising adding the compatibilizer composition according to claim 1 to a matrix resin to obtain a thermoplastic blend having improved physical properties.

21. The method according to claim 20, wherein the at least one reactive component comprises an acrylonitrile styrene acrylate and maleic anhydride copolymer; an acrylonitrile styrene acrylate and glycidyl methacrylate copolymer; or a combination thereof.

22. The method according to claim 20, wherein the at least one non-reactive component comprises ethyl methacrylate, ethyl butyl acrylate, non-reactive silicone-acrylic rubber, or a combination thereof.

23. The method according to claim 20, wherein the ratio of the at least one reactive component to the at least one non-reactive component is from 1:2.3 to 2.3:

1.

24. The method according to claim 20, wherein the at least one reactive component comprises an acrylonitrile styrene acrylate and maleic anhydride copolymer, and the at least one non-reactive component comprises ethyl methacrylate.

25. The method according to claim 20, wherein the at least one reactive component is an acrylonitrile styrene acrylate and maleic anhydride copolymer, and the non-reactive component is ethyl butyl acrylate.

26. The method according to claim 20, wherein the at least one reactive component comprises an acrylonitrile - styrene - acrylate and glycidyl methacrylate copolymer, and the at least one non - reactive component comprises ethyl methacrylate.

27. The method according to claim 20, wherein the at least one reactive component comprises an acrylonitrile - styrene - acrylate and glycidyl methacrylate copolymer, and the at least one non - reactive component comprises ethyl butyl acrylate.

28. The method according to claim 20, wherein the at least one reactive component comprises an acrylonitrile - styrene - acrylate and glycidyl methacrylate copolymer and an acrylonitrile - styrene - acrylate and maleic anhydride copolymer; and the at least one non - reactive component comprises ethyl methacrylate.

29. The method according to claim 20, wherein the at least one reactive component comprises an acrylonitrile - styrene - acrylate and glycidyl methacrylate copolymer and an acrylonitrile - styrene - acrylate and maleic anhydride copolymer; and the at least one non - reactive component comprises a non - reactive silicone - acrylic rubber.

30. The method according to claim 20, wherein the matrix resin comprises post - consumer resin.

31. The method according to claim 20, wherein the matrix resin comprises polycarbonate.

32. The method according to claim 20, wherein the matrix resin comprises polycarbonate and acrylonitrile - butadiene - styrene.

33. The method according to claim 20, wherein based on the total weight of the thermoplastic blend, the matrix resin comprises 50 wt% to 80 wt% of polycarbonate.

34. The method according to claim 20, wherein based on the total weight of the thermoplastic blend, the thermoplastic comprises 3 wt% to 7 wt% of the compatibilizer composition.

35. A compatibilizer composition for a thermoplastic blend, comprising: at least one reactive component, and at least one non - reactive component, wherein the compatibilizer composition is configured to modify a matrix resin, the matrix resin comprising a first component having a first solubility parameter and a second component having a second solubility parameter; and wherein the solubility parameter of the reactive component is between the first solubility parameter and the second solubility parameter.

36. The compatibilizer composition according to claim 35, wherein the at least one reactive component comprises an acrylonitrile - styrene - acrylate and maleic anhydride copolymer; an acrylonitrile - styrene - acrylate and glycidyl methacrylate copolymer; or a combination thereof.

37. The compatibilizer composition according to claim 35 or 36, wherein the at least one non - reactive component comprises ethyl methacrylate, ethyl butyl acrylate, a non - reactive silicone - acrylic rubber, or a combination thereof.

38. The compatibilizer composition according to any one of claims 35 to 37, wherein the ratio of the at least one reactive component to the at least one non - reactive component is from 1:2.3 to 2.3:

1.

39. The compatibilizer composition according to any one of claims 35 to 38, wherein the at least one reactive component comprises an acrylonitrile-styrene-acrylate and maleic anhydride copolymer, and the at least one non-reactive component comprises ethyl methacrylate.

40. The compatibilizer composition according to any one of claims 35 to 38, wherein the at least one reactive component is an acrylonitrile-styrene-acrylate and maleic anhydride copolymer, and the non-reactive component is ethyl butyl acrylate.

41. The compatibilizer composition according to any one of claims 35 to 38, wherein the at least one reactive component comprises an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer, and the at least one non-reactive component comprises ethyl methacrylate.

42. The compatibilizer composition according to any one of claims 35 to 38, wherein the at least one reactive component comprises an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer, and the at least one non-reactive component comprises ethyl butyl acrylate.

43. The compatibilizer composition according to any one of claims 35 to 38, wherein the at least one reactive component comprises an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer and an acrylonitrile-styrene-acrylate and maleic anhydride copolymer; and the at least one non-reactive component comprises ethyl methacrylate.

44. The compatibilizer composition according to any one of claims 35 to 38, wherein the at least one reactive component comprises an acrylonitrile-styrene-acrylate and glycidyl methacrylate copolymer and an acrylonitrile-styrene-acrylate and maleic anhydride copolymer; and the at least one non-reactive component comprises a non-reactive silicone-acrylic rubber.

45. A thermoplastic blend comprising: a matrix resin, wherein the matrix resin comprises a first component and a second component, and the compatibilizer composition according to any one of claims 35 to 44.

46. The thermoplastic blend according to claim 45, wherein the matrix resin comprises a post-consumer resin.

47. The thermoplastic blend according to claim 45 or 46, wherein the matrix resin comprises polycarbonate.

48. The thermoplastic blend according to any one of claims 45 to 47, wherein the matrix resin comprises polycarbonate and acrylonitrile butadiene-styrene.

49. The thermoplastic according to any one of claims 45 to 48, wherein based on the total weight of the thermoplastic blend, the matrix resin comprises 50 wt% to 80 wt% of polycarbonate.

50. The thermoplastic according to any one of claims 45 to 49, wherein based on the total weight of the thermoplastic blend, the thermoplastic comprises 3 wt% to 7 wt% of the compatibilizer composition.

51. A method for improving the physical properties of a thermoplastic blend, the method comprising adding a compatibilizer composition according to any one of claims 35 to 44 to a matrix resin to obtain a thermoplastic blend having improved physical properties.

52. The method according to claim 51, wherein the matrix resin comprises a post-consumer resin.

53. The method according to claim 51 or 52, wherein the matrix resin comprises polycarbonate.

54. The method according to any one of claims 51 to 53, wherein the matrix resin comprises polycarbonate and acrylonitrile butadiene styrene.

55. The method according to any one of claims 54 to 54, wherein based on the total weight of the thermoplastic blend, the matrix resin comprises 50 wt% to 80 wt% of polycarbonate.

56. The method according to any one of claims 51 to 55, wherein based on the total weight of the thermoplastic blend, the thermoplastic comprises 3 wt% to 7 wt% of the compatibilizer composition.

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