Compositions comprising polyarylene (ether) sulfones

Abstract

The present invention relates to a composition comprising a polyarylene (ether) sulfone and a product made from said composition.

Description

[0001] The present invention relates to compositions comprising polyarylene (ether) sulfones and products made from the compositions.

[0002] Polyarylene (ether) sulfones belong to the group of high-temperature resistant polymers which exhibit high heat resistance, excellent mechanical properties and inherent flame retardancy (EM Koch, H.-M. Walter, Kunststoffe 80 (1990) 1146; E. Kunststoffe 80, (1990) 1149, N. Inchaurondo-Nehm, Kunststoffe 2008 190). Polyarylene (ether) sulfones are amorphous polymers and are used in automotive lighting to mold reflectors and lamp housings. In this application, the flow of the material used and the surface quality of the resulting parts are important.

[0003] Blending with polycarbonate has been proposed to improve the properties of polyarylene ether and polycarbonate polymers, respectively. US Pat. No. 3,365,517 relates to blends of polyarylene ether and polycarbonate, which are reported to have improved thermal stress resistance and crack resistance. DE 4208341 relates to blends of copolyarylene ether sulfone and polycarbonate having excellent toughness. To improve the blister resistance of polyethersulfone / polycarbonate blends, hydroxyl-functionalized polyarylene ethers are proposed in EP 658600.

[0004] Furthermore, EP 2 160 440 relates to the use of stearic acid / stearates in mixtures comprising at least one specific polyethersulfone and at least one specific polysulfone. The corresponding products exhibit improved surface qualities.

[0005] For applications in the field of automotive parts (such as reflectors), there is an increasing need for materials with good flow and toughness properties and resulting in parts with good surface quality. Therefore, the underlying problem of this patent application is to address the shortcomings of known polymer materials and provide a composition with a combination of advantageous properties such as flow characteristics, toughness and surface quality. This problem is solved by the composition of the present invention. In particular, the present invention provides a composition comprising:

[0006] A) 50 to 94% by weight of at least one polyarylene (ether) sulfone;

[0007] B) 5% to 45% by weight of at least one polycarbonate;

[0008] C) 0.15% to 1% by weight of stearic acid; and

[0009] D) 0% to 40% by weight of at least one additive; wherein the sum of the % by weight based on the composition is 100% by weight

[0010] As used herein, "at least one" generally refers to one or two or more, such as three or four or five or more, where more may refer to a plurality or uncountable number of compounds. For example, it may refer to a mixture of one or two or more compounds. If used with a compound, "at least one" means describing one or two or more compounds that differ in chemical composition (i.e., chemical properties).

[0011] The composition of the invention comprises 50% to 94% by weight of at least one polyarylene (ether) sulfone (component A)).

[0012] Polyarylene (ether) sulfones are generally known to those skilled in the art. In principle, for component A), polyarylene (ether) sulfones of any structure are encompassed by the present invention.

[0013] It may be preferred that the polyarylene (ether) sulfone is composed of units of the general formula II

[0014]

[0015] The symbols t, q, Q, T, Y, Ar and Ar 1 is defined as follows:

[0016] t and q are independently 0, 1, 2 or 3;

[0017] Q, T, and Y are independently a chemical bond or selected from -O-, -S-, -SO2-, S=O, C=O, -

[0018] N=N- and -CR a R b - group, wherein R a and R b are independently hydrogen atoms,

[0019] (C1-C 12 )alkyl, (C1-C 12 ) alkoxy, (C3-C 12 )cycloalkyl or (C6-C 18 ) an aryl group, and wherein at least one of Q, T and Y is present and is -SO2-;

[0020] and

[0021] Ar and Ar 1 Independently of each other (C6-C 18 )arylene group.

[0022] If Q, T or Y is a chemical bond, this means that the adjacent group on the left and the adjacent group on the right are directly connected to each other via a chemical bond.

[0023] According to a preferred embodiment, t and q are independently 0 or 1.

[0024] According to a preferred embodiment, Q, T and Y in formula II are independently selected from a chemical bond, -O-, -SO2- and -CR a R b -, provided that at least one of Q, T and Y is present and is -SO2-. In addition, if R a and R b Independently of each other, hydrogen or (C1-C4)alkyl may be preferred.

[0025] In-CR a R b -Middle, R a and R b Preferably independently selected from hydrogen, (C1-C 12 )alkyl, (C1-C 12 ) alkoxy and (C6-C 18 )aryl.

[0026] (C1-C 12 )alkyl refers to a straight-chain or branched saturated hydrocarbon group having 1 to 12 carbon atoms. In particular, the following moieties are encompassed: (C1-C6)alkyl, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, 2-methylpentyl or 3-methylpentyl, and (C7-C 12 ) alkyl groups such as unbranched heptyl, octyl, nonyl, decyl, undecyl, lauryl, and their singly or multiply branched analogs.

[0027] The term "C1-C 12 "-Alkoxy" refers to a straight-chain or branched alkyl group having 1 to 12 carbon atoms, which is bonded via oxygen at any position of the alkyl group (for example methoxy, ethoxy, n-propoxy, 1-methylethoxy, butoxy, 1-methyl-propoxy, 2-methylpropoxy or 1,1-dimethylethoxy).

[0028] (C3-C 12 )cycloalkyl refers to a monocyclic saturated hydrocarbon radical having 3 to 12 carbon ring members and includes in particular (C3-C8)cycloalkyl, for example cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclopropylmethyl, cyclopropylethyl, cyclopropylpropyl, cyclobutylmethyl, cyclobutylethyl, cyclopentylethyl, cyclopentylpropyl, cyclopentylbutyl, cyclopentylpentyl, cyclopentylhexyl, cyclohexylmethyl, cyclohexyldimethyl and cyclohexyltrimethyl.

[0029] Ar and Ar 1 Independently of each other (C6-C 18)-arylene group. It may be preferred that, according to a specific embodiment, Ar 1 For unsubstituted (C6-C 12 ) arylene group.

[0030] It is preferable that Ar and Ar 1 are independently selected from phenylene, biphenylene and naphthylene, and arylene groups derived from anthracene, phenanthrene or naphthacene. For example, Ar and Ar 1 Independently selected from 1,2-phenylene, 1,3-phenylene, 1,4-phenylene, 1,6-naphthylene, 1,7-naphthylene, 2,6-naphthylene and 2,7-naphthylene, 2,7-dihydroxynaphthalene and 4,4'-bisphenylene.

[0031] In particular, it may be preferred that Ar and Ar 1 is independently selected from phenylene groups and naphthylene groups, such as independently selected from 1,2-phenylene, 1,3-phenylene, 1,4-phenylene, 1,6-naphthylene, 1,7-naphthylene, 2,6-naphthylene and 2,7-naphthylene, more specifically independently selected from 1,4-phenylene, 1,3-phenylene and naphthylene. In addition, according to another embodiment of the present invention, Ar and Ar 1 are independently selected from arylene groups derived from anthracene, phenanthrene or naphthacene. According to yet another embodiment, Ar and Ar 1 Independently selected from 2,7-dihydroxynaphthalene and 4,4'-bisphenylene.

[0032] It may be preferred that the polyarylene (ether) sulfone according to component A) comprises at least one of the following repeating units IIa to IIo:

[0033]

[0034]

[0035] In addition to the units IIa to IIo which may preferably be present, further repeating units are repeating units in which one or more 1,4-phenylene units derived from hydroquinone have been replaced by 1,3-phenylene units derived from resorcinol or by naphthylene units derived from dihydroxynaphthalene.

[0036] Particularly preferred units of the general formula II are units IIa, IIg and / or IIk. According to a specific embodiment, it is particularly preferred that component A) polyarylene (ether) sulfone consists essentially of one type of units of the general formula II, wherein the one type can in particular be selected from IIa, IIg and IIk.

[0037] According to a preferred embodiment, component A) polyarylene (ether) sulfone is composed of repeating units in which Ar is 1,4-phenylene, t is 1, q is 0, T is a chemical bond, and Y is SO 2. Such polyarylene (ether) sulfones are also known as polyphenylene sulfone (PPSU) (Formula IIg).

[0038] According to a further preferred embodiment, component A) polyarylene (ether) sulfone is composed of repeating units in which Ar is 1,4-phenylene, t is 1, q is 0, T is C(CH 3 ) 2 , and Y is SO 2 . Such polyarylene (ether) sulfones are also known as polysulfones (PSU) (Formula IIa).

[0039] According to a further preferred embodiment, component A) polyarylene (ether) sulfone is composed of repeating units in which Ar is 1,4-phenylene, t is 1, q is 0, and T and Y are SO 2. Such polyarylene (ether) sulfones are also known as polyethersulfones (PESU) (Formula IIk).

[0040] According to a further preferred embodiment, the composition of the invention comprises as component A a polyarylene (ether) sulfone in the amounts or preferred amounts as detailed herein. In particular, component A) is a polyarylene (ether) sulfone selected from any of the above-mentioned polymers, in particular from polymers comprising at least one of the repeating units IIa to IIo.

[0041] According to a still further preferred embodiment, component A), the polyarylene (ether) sulfone, is PPSU, PSU or PESU.

[0042] For the purposes of this disclosure, abbreviations such as PPSU, PESU and PSU conform to DIN EN ISO 1043-1:2001.

[0043] Component A) is present in the composition of the invention in an amount of 50% to 94% by weight.

[0044] According to a preferred embodiment, the amount of component A) is 50% to 90% by weight, particularly 50% to 85% by weight, more particularly 50% to 80% by weight, and even more particularly 50% to 75% by weight, based on the weight of the composition. More specifically, one embodiment uses 50% to 70% by weight, more particularly 50% to 65% by weight of component A). According to a very specific embodiment, the amount of component A) is 51% to 94% by weight. In a further preferred embodiment, the amount of component A) is 52% to 94% by weight, particularly 53% to 94% by weight, more particularly 54% to 94% by weight, and even more particularly 55% to 94% by weight, based on the weight of the composition. A very specific embodiment of the present invention uses 56% to 94% by weight, more particularly 57% to 94% by weight, and even more particularly 58% to 94% by weight of component A). According to another embodiment, an amount of 54% to 70% by weight may be suitable.

[0045] The weight average molar mass M of the polyarylene (ether) sulfone A) of the present invention is w Preferably 25,000 to 120,000 g / mol, in particular 30,000 to 100,000 g / mol, particularly preferably 32,000 to 90,000 g / mol, determined by gel permeation chromatography in dimethylacetamide as solvent with narrowly distributed polymethyl methacrylate as standard.

[0046] The preparation processes for obtaining the above-mentioned polyarylene (ether) sulfones are known per se to the person skilled in the art and are described by way of example in Herman F. Mark, “Encyclopedia of Polymer Science and Technology”, 3rd edition, volume 4, 2003, chapter “Polysulfones”, pages 2-8, and in Hans R. Kricheldorf, “Aromatic Polyethers” in Handbook of Polymer Synthesis, 2nd edition, 2005, pages 427-443.

[0047] The synthesis of polyarylene (ether) sulfones can generally be carried out by polycondensing suitable monomers in a dipolar aprotic solvent at elevated temperatures (RN Johnson et al., J. Polym. Sci. A-1 5 (1967) 2375, JEM McGrath et al., Polymer 25 (1984) 1827). In order to achieve the preferred VN, the molecular weight of the polyarylene (ether) sulfone must be controlled, for example, by monitoring the torque level during the condensation process, which requires a calibration curve between the torque level in the reaction mixture and the corresponding final product. In addition, by using general knowledge about regulating the molecular weight using an appropriate stoichiometric ratio between monomers during the polycondensation process, the molecular weight can be controlled so as to achieve the desired viscosity of the polyarylene (ether) sulfone (see, for example, McGrath et al., Polym. Eng. Sci. 17, 647 (1977)). In this case as well, the molecular weight M must be established. n Correlation between VN.

[0048] The reaction between at least one aromatic compound having two halogen substituents and at least one aromatic compound having two functional groups reactive toward the aforementioned halogen substituents is particularly preferably carried out in an aprotic polar solvent and in the presence of an anhydrous alkali metal carbonate, in particular sodium carbonate, potassium carbonate, calcium carbonate or a mixture thereof, very particularly preferably potassium carbonate. A particularly suitable combination is N-methyl-2-pyrrolidone as solvent and potassium carbonate as base.

[0049] The polyarylene (ether) sulfones as component A) generally have halogen end groups, in particular -Cl, or phenolic OH end groups or phenolate end groups, the latter being present as such or in reacted form, in particular in the form of -OCH3 end groups.

[0050] It is preferred that the polyarylene (ether) sulfone A) has phenolic end groups in an amount of at most 0.05% by weight, particularly preferably at most 0.02% by weight, based on the weight of component A).

[0051] The respective upper limit for the content of phenolic end groups in component A) is a function of the number of available end groups per molecule (two in the case of linear polyarylene ethers) and the number-average chain length. Those skilled in the art are aware of these calculations.

[0052] Preferably, the average number of phenolic end groups per polymer chain in component A) is 0 to 0.05, in particular 0 to 0.02, particularly preferably 0 to 0.01. The content of OH or phenoxide end groups is preferably up to 0.05% by weight, as determined by potentiometric titration.

[0053] The proportion of phenolic end groups is preferably determined by potentiometric titration. To this end, the polymer is dissolved in dimethylformamide and titrated with a toluene / methanol solution of tetrabutylammonium hydroxide. The endpoint is recorded potentiometrically. The proportion of halogen end groups is preferably determined by elemental analysis.

[0054] One skilled in the art can use known methods to determine the average number of phenolic end groups per polymer chain (n OH ), under the assumption of a strictly linear polymer chain, the following formula is used: OH =m OH [% by weight] / 100*M n P [in g / mol]*1 / 17, starting from the weight proportion of the phenolic end groups based on the total weight of the polymer (m OH ) and starting from the number average molecular weight (M n P ).

[0055] Alternatively, the average number of phenolic end groups per polymer chain (n OH ) can be calculated as follows: n OH =2 / (1+(17 / 35.45*m Cl / m OH )), assuming that the only end groups present are OH groups and Cl groups, and assuming a strictly linear polymer chain, if the weight proportion of Cl end groups (m Cl ) are also known. In the presence of terminal groups other than Cl, a person skilled in the art knows how to adjust the calculation method.

[0056] As component B), 5% to 45% by weight of at least one polycarbonate is present in the composition of the present invention. Polycarbonates are known to those skilled in the art and can be prepared by known methods. Polycarbonates derived from bisphenols or biphenols are preferred. Suitable biphenols or bisphenols are, for example, selected from 2,2-bis(4-hydroxyphenyl)propane, 2,4-bis(4-hydroxyphenyl)-2-methylbutane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 2,2-bis(4-hydroxyphenyl)pentane, 2,6-dihydroxynaphthalene, 4,4'-dihydroxydiphenyl sulfone, 4,4'-dihydroxydiphenyl ether, 4,4'-dihydroxydiphenyl sulfite, 4,4'-dihydroxydiphenylmethane, 1,1-bis(4-hydroxyphenyl)ethane and 4,4-dihydroxybiphenyl, as well as mixtures of any of these compounds. A preferred example of bisphenol is 2,2-bis(4-hydroxyphenyl)propane, also known as bisphenol A.

[0057] Homopolycarbonates or copolycarbonates can be used. According to one embodiment of the present invention, bisphenol A and copolycarbonates of bisphenol A homopolycarbonate are particularly preferred.

[0058] Preference is also given to polycarbonates based on bisphenol A or bisphenol A and up to 30 mol % of any of the aforementioned compounds. Also suitable are copolycarbonates as described in US Pat. No. 3,737,409, in particular copolycarbonates based on bisphenol A and bis-(3,5-dimethyl-dihydroxyphenyl)sulfone. According to another preferred embodiment, the polycarbonate is based on bisphenol A with up to 50 mol % of 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane.

[0059] See also, for example, DE-B 13 00 266 and / or DE-A. 14 95 730. For polycarbonates containing polydiorganosiloxanes, see DE-A 33 34 782.

[0060] The polycarbonates used as component B) may have branching as is generally known in the art. Branching can be achieved, for example, by incorporating 0.05 to 2.0 mol % of at least trifunctional compounds, for example those having three or more phenolic OH groups, based on the total amount of bisphenols used.

[0061] Particularly suitable polycarbonates are those having a melt volume index (MVR) of 5 ml / 10 min to 40 ml / 10 min or 6 ml / 10 min to 35 ml / 10 min, in particular 7 ml / 10 min to 30 ml / 10 min, more particularly 8 ml / 10 min to 27 ml / 10 min (measured at 300° C. / 1.2 kg in accordance with ISO 1133). This corresponds to an average molecular weight M of 10,000 g / mol to 200,000 g / mol, preferably 20,000 g / mol to 80,000 g / mol. w (weight average).

[0062] Polycarbonates can be prepared, for example, by reacting the corresponding bisphenols or diphenols with phosgene in an interfacial process or in a homogeneous process (known as the pyridine process). Chain terminators can be used to achieve the desired molecular weight. This is generally known to those skilled in the art. Examples of suitable chain terminators are phenol, p-tert-butylphenol, and long-chain alkylphenols such as 4-(1,3-tetramethylbutyl)phenol (see, for example, DE-A 28 42 005). Mono- or dialkylphenols having alkyl substituents containing 8 to 20 carbon atoms can also be used (see DE-A 35 06 472). Examples are p-nonylphenol, 3,5-di-tert-butylphenol, p-tert-octylphenol, p-dodecylphenol, 2-(3,5-dimethylheptyl)phenol, and 4-(3,5-dimethylheptyl)phenol.

[0063] In particular, according to the present invention, preference is given to halogen-free polycarbonates, such as, for example, polycarbonates based on biphenols or the aforementioned bisphenols. For the purposes of the present invention, halogen-free polycarbonates are polycarbonates derived from halogen-free biphenols (diphenols), halogen-free chain terminators, and, where appropriate, halogen-free branching agents. Small amounts of hydrolyzable chlorine (in the ppm range) can result, for example, from the use of phosgene in the preparation of polycarbonates. For the purposes of the present invention, such polycarbonates with small amounts (in the ppm range) of such hydrolyzable chlorine are still considered halogen-free polycarbonates.

[0064] Component B) is present in the composition of the present invention in an amount of 5 to 45 wt %. According to a preferred embodiment, the amount of component B) is 10 to 45 wt %, in particular 15 to 45 wt %, more particularly 20 to 45 wt %, even more particularly 25 to 45 wt %. More specifically, one embodiment uses 30 to 45 wt %, more particularly 35 to 45 wt %. According to a very specific embodiment, the amount of component B) is 5 to 44 wt %. In a further preferred embodiment, the amount of component B) is 10 to 43 wt %, in particular 15 to 42 wt %, more particularly 20 to 41 wt %, even more particularly 25 to 40 wt %.

[0065] As component C, 0.15 to 1% by weight of stearic acid is used. Stearic acid is commercially available, for example from KLK Oleo.

[0066] According to a preferred embodiment, the amount of component C) is 0.15% to 0.9% by weight, particularly 0.15% to 0.85% by weight, more particularly 0.15% to 0.8% by weight, even more particularly 0.15% to 0.75% by weight, based on the weight of the composition. More specifically, one embodiment uses 0.15% to 0.7% by weight, more particularly 0.15% to 0.65% by weight of component C). According to a very specific embodiment, the amount of component C) is 0.15% to 0.6% by weight. In another preferred embodiment, the amount of component C) is 0.15% to 0.55% by weight, particularly 0.15% to 0.5% by weight. According to another preferred embodiment, the amount of component C) is 0.2% to 0.9% by weight, particularly 0.2% to 0.85% by weight, more particularly 0.2% to 0.8% by weight, even more particularly 0.2% to 0.75% by weight, based on the weight of the composition. More specifically, one embodiment uses 0.2% to 0.7% by weight, more particularly 0.2% to 0.65% by weight of component C). According to a very specific embodiment, the amount of component C) is 0.2% to 0.6% by weight. In another preferred embodiment, the amount of component C) is 0.2% to 0.55% by weight, particularly 0.2% to 0.5% by weight.

[0067] According to the present invention, the composition may contain at least one additive D) which is different from components A), B) and C) and is present in an amount of 0% to 40% by weight, in particular 0% to 30% by weight, more particularly 0% to 20% by weight, even more particularly 0% to 10% by weight, for example 0% to 5% by weight. In one aspect of the present invention, the composition of the present invention contains at least one additive (component D)) in an amount of greater than 0% to 40% by weight, preferably greater than 0% to 30% by weight, more particularly greater than 0% to 20% by weight of component D). According to this aspect, it can be preferred if component D) is present in an amount of greater than 0% to 15% by weight, in particular greater than 0% to 10% by weight, more particularly greater than 0% to 5% by weight.

[0068] If present, it may be preferred that the composition comprises from 0.01% to 20% by weight, more particularly from 0.1% to 20% by weight, of at least one additive D). It may be more preferred if D) is used in an amount of from 0.1% to 15% by weight, such as from 0.1% to 10% by weight. Perhaps even more preferred is that the composition of the invention comprises from 0.1% to 5% by weight of D).

[0069] The at least one additive may be selected, for example, from processing aids, pigments, stabilizers, impact modifiers and flame retardants and may also be a mixture of various additives. Other examples of conventional additives are oxidation inhibitors, agents for inhibiting thermal or UV-induced decomposition, lubricants and release agents, dyes and plasticizers, which may be used alone or in combination with any other additives.

[0070] According to one embodiment, the composition of the invention comprises at least one pigment as component D). In addition, the composition may also contain one or more further components D). In a specific embodiment, the composition of the invention comprises one or more pigments as component D) and no further additives D).

[0071] Pigments for coloring thermoplastics are well known, see for example R. and H. Müller, Taschenbuch der Kunststoffadditive [Plastics additives handbook], Carl Hanser Verlag, 1983, pp. 494-510. A first group of preferred pigments that may be mentioned are white pigments, such as zinc oxide, zinc sulfide, white lead [2PbCO3·Pb(OH)2], lithopone, antimony white, and titanium dioxide. The most common crystalline forms of titanium dioxide are rutile and anatase, with rutile being particularly useful for white coloring of the compositions according to the invention. Black pigments that can be used according to the invention include iron oxide black (Fe3O4), spinel black [Cu(Cr,Fe)2O4], manganese black (a mixture of manganese dioxide, silicon dioxide, and iron oxide), cobalt black, and antimony black. Carbon black, which is primarily used in the form of furnace black or gas black, is also particularly preferred. A suitable carbon black which can be used as component D) is, for example, Carbon Black Printex EP commercially available from Orion Engineered Carbons. In this connection, see also G. Benzing, Pigmente für Anstrichmittel [Pigments for paints], Expert-Verlag (1988), p. 78 ff.

[0072] Specific shades can be achieved, for example, by using inorganic color pigments such as chromium oxide green or organic color pigments such as azo pigments or phthalocyanines. Pigments of this type are known to those skilled in the art and are widely commercially available.

[0073] Pigments and dyes, if present, may be present in an amount of up to 5% by weight, such as from 0.05% to 5% by weight, in particular from 0.1% to 5% by weight, preferably from 0.5% to 5% by weight, in particular from 0.1% to 3% by weight or from 0.5% to 3% by weight. According to one embodiment, the composition of the invention comprises at least one pigment as component D in an amount of from 0.05% to 5% by weight, in particular from 0.1% to 5% by weight, preferably from 0.5% to 5% by weight, in particular from 0.1% to 3% by weight or from 0.5% to 3% by weight. In addition, the composition may contain one or more further components D). In a very specific embodiment, the composition of the invention contains no further additives D).

[0074] Examples of oxidation inhibitors and heat stabilizers that can be added to the compositions of the invention are halides of metals from Group I of the Periodic Table of the Elements, such as sodium, potassium or lithium halides, exemplified by chlorides, bromides or iodides. Zinc fluoride and zinc chloride can also be used. Sterically hindered phenols, hydroquinone, substituted representatives of these groups, aromatic secondary amines can also be used, if appropriate in combination with phosphorus acids, or their salts, or mixtures of these compounds, preferably in a concentration of up to 1% by weight.

[0075] Examples of UV stabilizers are various substituted resorcinols, salicylates, benzotriazoles and benzophenones, these being used generally in amounts of up to 2% by weight.

[0076] If present, stabilizers may comprise up to 2% by weight, preferably 0.01% to 1% by weight, in particular 0.01% to 0.5% by weight.

[0077] Other possible additives are nucleating agents, an example of which is talc. Component D) may include one or more impact modifiers, wherein the impact modifier may be at least one impact-modifying rubber. Rubbers are typically crosslinkable polymers that have elastomeric properties at room temperature.

[0078] Core-shell graft rubbers are another group of suitable impact modifiers that can be used according to the invention. These are graft rubbers that can be prepared in emulsion and consist of at least one hard component and one soft component. Typically, the hard component is at least one polymer having a glass transition temperature of at least 25° C. and typically the soft component is at least one polymer having a glass transition temperature of not more than 0° C. These products typically have a structure made up of a core (graft base) and at least one shell (graft), and this structure is typically the result of the order in which the monomers are added. The soft component is typically derived from butadiene, isoprene, at least one alkyl acrylate, at least one alkyl methacrylate or at least one siloxane and, if desired, at least one further comonomer. Suitable siloxane cores can be prepared, for example, starting from cyclic oligomeric octamethyltetrasiloxane or from tetravinyltetramethyltetrasiloxane. These can be reacted, for example, with γ-mercaptopropylmethyldimethoxysilane in a ring-opening cationic polymerization, preferably in the presence of sulfonic acid, to give a soft siloxane core. The at least one siloxane can also be crosslinked, for example, by polymerization in the presence of at least one silane having at least one hydrolyzable group, such as a halogen or alkoxy group, such as tetraethoxysilane, methyltrimethoxysilane, or phenyltrimethoxysilane. Examples of suitable at least one comonomer for this purpose are styrene, acrylonitrile, and crosslinking or grafting monomers having more than one polymerizable double bond, such as diallyl phthalate, divinylbenzene, butanediol diacrylate, or triallyl (iso)cyanurate. The hard component is generally derived from styrene, α-methylstyrene, or copolymers thereof, and it may be preferred that the at least one comonomer is acrylonitrile, methacrylonitrile, or methyl methacrylate.

[0079] It may be preferred that the at least one core-shell graft rubber comprises a soft core and a hard shell, or a hard core, a first soft shell and at least one further hard shell. The introduction of at least one functional group, such as a carbonyl, carboxylic acid, anhydride, amide, imide, carboxylate, amino, hydroxyl, epoxy, oxazoline, carbamate, urea, lactam or halobenzyl group, may preferably be carried out by adding at least one appropriately functionalized monomer during the polymerization of the final shell.

[0080] Examples of suitable functionalized monomers are maleic acid, maleic anhydride, half esters or diesters, or maleic acid, tert-butyl (meth)acrylate, acrylic acid, glycidyl (meth)acrylate and vinyloxazoline. The proportion of monomers having functional groups is generally 0.1% to 25% by weight, preferably 0.25% to 15% by weight, based on the total weight of the core-shell graft rubber. The weight ratio of the soft component to the hard component is generally 1:9 to 9:1, preferably 3:7 to 8:2.

[0081] Rubbers of this type are known per se or are obtainable by the person skilled in the art by utilizing general knowledge and are described, for example, in EP-A 208 187.

[0082] Thermoplastic polyester elastomers are another group of suitable impact modifiers. For the purposes of the present invention, polyester elastomers are block copolyetheresters, which may contain long chain segments generally derived from poly(alkylene) ether glycols and short chain segments which may be derived from low molecular weight glycols and dicarboxylic acids. Products of this type are known per se or available to those skilled in the art and are described, for example, in U.S. Pat. No. 3,651,014. Corresponding products are also available as (Du Pont), (Akzo) and (Toyobo Co. Ltd.) was purchased.

[0083] According to one particular embodiment, the composition according to the invention does not comprise component D) (0% by weight).

[0084] A particular embodiment of the present invention relates to a composition comprising:

[0085] A) 50 to 94% by weight of at least one polyarylene (ether) sulfone;

[0086] B) 5% to 45% by weight of at least one polycarbonate;

[0087] C) 0.15% to 1% by weight of stearic acid; and

[0088] D) 0% to 40% by weight of at least one additive;

[0089] The sum of the wt. % of components A) to D) is 100 wt. %.

[0090] Another embodiment of the present invention is directed to a composition comprising:

[0091] A) 50% to 70% by weight of at least one polyarylene (ether) sulfone;

[0092] B) 25 to 45% by weight of at least one polycarbonate;

[0093] C) 0.15% to 0.8% by weight of stearic acid; and

[0094] D) 0% to 40% by weight of at least one additive;

[0095] The sum of the % by weight based on the composition is 100 % by weight.

[0096] Another embodiment of the present invention is directed to a composition comprising:

[0097] A) 50% to 70% by weight of at least one polyarylene (ether) sulfone;

[0098] B) 25 to 45% by weight of at least one polycarbonate;

[0099] C) 0.15% to 0.8% by weight of stearic acid; and

[0100] D) 0.1% to 5% by weight of at least one additive;

[0101] The sum of the % by weight based on the composition is 100 % by weight.

[0102] Another specific embodiment of the present invention relates to a composition consisting of:

[0103] A) 50% to 94% by weight or 54% to 70% by weight of at least one polyarylene

[0104] (Ether)sulfone;

[0105] B) 5% to 45% by weight of at least one polycarbonate;

[0106] C) 0.15% to 1% by weight of stearic acid; and

[0107] D) 0% to 40% by weight of at least one additive;

[0108] The sum of the % by weight based on the composition is 100 % by weight.

[0109] Another embodiment of the present invention relates to a composition consisting of:

[0110] A) 50% to 70% by weight or 54% to 70% by weight of at least one polyarylene (ether) sulfone;

[0111] B) 25 to 45% by weight of at least one polycarbonate;

[0112] C) 0.15% to 0.8% by weight of stearic acid; and

[0113] D) 0% to 40% by weight of at least one additive;

[0114] The sum of the % by weight based on the composition is 100 % by weight.

[0115] Yet another embodiment of the present invention relates to a composition consisting of:

[0116] A) 50% to 70% by weight of at least one polyarylene (ether) sulfone;

[0117] B) 25 to 45% by weight of at least one polycarbonate;

[0118] C) 0.15% to 0.8% by weight of stearic acid; and

[0119] D) 0.1% to 5% by weight of at least one additive;

[0120] The sum of the % by weight based on the composition is 100 % by weight.

[0121] The preparation of the composition can be carried out by methods known in the art, such as extrusion. The components are fed into a melt mixing device such as an extruder (single screw or twin screw), a Brabender mixer or a Banbury mixer or a kneader, mixed, and then extruded. After extrusion, the wire is usually cooled and granulated to obtain a pellet or granule. The order in which the components are metered into the mixing device can be different, for example two components or optionally three components can be premixed, or all components can be mixed together.

[0122] The components of the composition according to the invention can be mixed in any desired order, and the order in which the components are metered into the mixing apparatus can vary, for example two or optionally three components can be premixed, or all components can be mixed together.

[0123] Homogeneous mixing is important for product performance. For this purpose, mixing times of 0.1 to 30 minutes are typically used at temperatures of 300 to 420°C, preferably 310 to 380°C. After compounding, the resulting strands are cooled and pelletized.

[0124] Surprisingly, the compositions according to the present invention show an excellent combination of desired fluidity and mechanical properties and the very good surface quality of the parts made from the compositions of the present invention. Particularly advantageously, the desired properties such as tensile elongation and yield strength produced by the compositions of the present invention are maintained after aging. These properties make them particularly suitable for applications such as automotive parts, such as reflector fields, where the requirements for fluidity, toughness and surface quality are increasing and particularly desirable heat aging behavior.

[0125] The composition of the invention can be advantageously used to make fibers, films, foams or shaped articles, in particular for making automotive parts such as reflectors, lampshades and mirror housings. According to another aspect, the invention relates to fibers, films or shaped articles, automotive parts such as reflectors, lampshades and mirror housings comprising the composition as described herein. Example

[0126] Preparation and testing of compounds

[0127] Compounding was performed using a twin-screw extruder (ZSK 18) with the barrel temperature set to maintain the melt temperature below 370° C. Molding of the test specimens was performed at a melt temperature of 340° C. and a mold temperature of 120° C.

[0128] The notched impact strength of the materials was tested using an ISO-bar at 23°C according to ISO 179 1eA.

[0129] Tensile tests were performed according to ISO 527 (E-modulus, strength, tensile elongation). For heat aging, the samples were stored in an oven at 150° C. The samples were then removed and stored in dry conditions at room temperature for 24 hours.

[0130] The surface of the samples (molded plates, 60 mm*60 mm) was evaluated visually and qualitatively rated between 1 (very good) and 6 (very poor).

[0131] The solution viscosity of the polyarylether was measured using a 0.01 g / ml N-methyl-pyrrolidone solution at 25°C.

[0132] Component A)

[0133] As component A), polysulfone ( S2010, commercially available from BASF SE).

[0134] Component B)

[0135] As component B), a polycarbonate based on bisphenol A (Makrolon 2605, commercially available from Covestro) with an MVR of 12 ml / 10 min (300° C., 1.2 kg) was used.

[0136] Component C)

[0137] Stearic acid (purity>98%) was used as component C) in a softened state of 55° C. to 60° C. Commercially available from KLK Oleo.

[0138] Component D

[0139] Carbon black Printex EP, commercially available from Orion.

[0140] Table 1 :

[0141]

[0142] C1, C2, C5 and C6 are comparative examples in which no stearic acid is used or stearic acid is used in amounts different from those of the present invention. Compared to the comparative examples, the compounds according to the present invention show a combination of good mechanical properties and improved heat aging stability and surface quality.

Claims

1. A composition comprising: E) 50% to 94% by weight of at least one polyarylene (ether) sulfone; F) 5% to 45% by weight of at least one polycarbonate; G) 0.15% to 1% by weight of stearic acid; and H) 0 to 40% by weight of at least one additive; The sum of the % by weight based on the composition is 100 % by weight. 2 . The composition according to claim 1 , comprising 52 to 75% by weight of component A).

3. The composition according to claim 2, comprising 20% ​​to 45% by weight of component B). 4 . The composition according to claim 1 , comprising 0.1% to 10% by weight of component D).

5. The composition according to claim 4, wherein component D) is at least one pigment.

6. The composition according to any one of claims 1 to 5, wherein component A) is a polyarylene (ether) sulfone.

7. The composition according to any one of claims 1 to 6, wherein component A) is PPSU, PESU or PSU.

8. Use of the composition according to any one of claims 1 to 7 for the production of fibers, films or shaped articles.

9. The use according to claim 8, in the production of automotive parts.

10. The use according to claim 9, wherein the automotive component is a reflector, a lamp housing or a mirror housing.

11. A fiber, film or shaped article comprising the composition according to any one of claims 1 to 7.

12. An automotive part comprising the composition according to any one of claims 1 to 7.

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