Compositions containing polyarylene (ether) sulfones

Abstract

The present invention relates to compositions comprising polyarylene (ether) sulfones, as well as articles made from said compositions.

Description

[Technical Field]

[0001] The present invention relates to compositions comprising polyarylene (ether) sulfones, as well as articles made from said compositions.

[0002] Polyarylene (ether) sulfones belong to a group of high-temperature-resistant polymers that exhibit high heat resistance, excellent mechanical properties, and inherent flame retardancy (E.M. Koch, H.-M. Walter, Kunststoffe 80 (1990) 1146; E. Doering, Kunststoffe 80, (1990) 1149; N. Inchaurondo-Nehm, Kunststoffe 2008 190). Polyarylene (ether) sulfones are amorphous polymers used in automotive lighting to mold reflectors and lamp bezels. In such applications, the flowability of the materials used, as well as the surface quality of the resulting parts, are important.

[0003] Blends with polycarbonate have been proposed to improve the properties of polyaryl ether and polycarbonate polymers, respectively. U.S. Pat. No. 3,365,517 relates to blends of polyarylene ether and polycarbonate, which are reported to have improved thermal stress and crack resistance. German Patent Application Publication No. 4208341 relates to blends of copolyarylene ether sulfone and polycarbonate, which have excellent toughness. EP Patent Application Publication No. 658600 proposes hydroxy-functionalized polyarylene ether to improve the blister resistance of polyether sulfone / polycarbonate blends.

[0004] Furthermore, EP 2160440 relates to the use of stearic acid / stearates in a mixture containing at least one specific polyethersulfone and at least one specific polysulfone. The resulting product exhibits improved surface quality.

[0005] In particular, applications in the field of automotive parts such as reflectors have an increasing demand for materials with good flowability and toughness, leading to parts with good surface quality. The problem underlying the present patent application was therefore to provide a composition that addresses the shortcomings of known polymeric materials and combines advantageous properties such as flowability, toughness and surface quality. This problem has been solved by the composition of the present invention. In particular, the present invention provides: A) 50 to 94 wt. % of at least one polyarylene(ether) sulfone; B) 5 to 45% by weight of at least one polycarbonate; C) 0.15 to 1% by weight of stearic acid, and D) 0 to 40% by weight of at least one additive wherein the total weight percent based on the composition is 100 weight percent.

[0006] As used herein, "at least one" may generally mean one, two, or more, e.g., three, four, five, or more. "More than" may mean a plurality or an unlimited number (no upper limit). For example, it may mean one, or a mixture of two or more. When used in reference to a compound, "at least one" means that one or more compounds that differ in their chemical makeup, i.e., chemical properties, are described.

[0007] The compositions of the present invention comprise 50 to 94% by weight of at least one polyarylene(ether) sulfone (component A).

[0008] 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.

[0009] The polyarylene (ether) sulfone may preferably be composed of units of general formula II. [ka] (wherein the symbols t, q, Q, T, Y, Ar and Ar 1 The definition is as follows: t and q are independently 0, 1, 2 or 3; Q, T, and Y are each independently a chemical bond or -O-, -S-, -SO2-, S=O, C=O, -N=N-, and -CR a R b -, where R a and R b are each independently a hydrogen atom, (C1 to C 12 ) alkyl, (C1-C 12 )Alkoxy, (C3-C 12 ) cycloalkyl or (C6-C 18 ) an aryl group, where at least one of Q, T, and Y is present and is —SO—; Ar and Ar 1 are independent of each other (C6~C 18 ) arylene)

[0010] When Q, T or Y is a chemical bond, this means that the left adjacent group and the right adjacent group are directly connected to each other through a chemical bond.

[0011] According to one preferred embodiment, t and q are independently 0 or 1.

[0012] According to a preferred embodiment, Q, T and Y in formula II are independently a chemical bond, -O-, -SO2- and -CR a R b -, with the proviso that at least one of Q, T, and Y is present and is -SO2-. a and R b are preferably, independently of each other, hydrogen or (C1-C4) alkyl.

[0013] -CR a R b -In R aand R b are preferably independently hydrogen, (C1 to C 12 ) alkyl, (C1-C 12 ) alkoxy and (C6-C 18 ) aryl.

[0014] (C1~C 12 )Alkyl refers to a linear or branched saturated hydrocarbon group having 1 to 12 carbon atoms. The following moieties are included: (C1-C6)alkyl, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, 2- or 3-methylpentyl, and (C7-C 12 ) Alkyl, such as unbranched heptyl, octyl, nonyl, decyl, undecyl, lauryl, and their mono- or poly-branched analogs are specifically included.

[0015] "C1~C 12 The term "-alkoxy" refers to a straight or branched alkyl group having 1 to 12 carbon atoms, for example, methoxy, ethoxy, n-propoxy, 1-methylethoxy, butoxy, 1-methyl-propoxy, 2-methyl-propoxy, or 1,1-dimethylethoxy, attached through an oxygen at any position within the alkyl group.

[0016] (C3~C 12 ) Cycloalkyl refers to a monocyclic saturated hydrocarbon group having 3 to 12 carbon ring members, and includes in particular (C3-C8)cycloalkyl, such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclopropylmethyl, cyclopropylethyl, cyclopropylpropyl, cyclobutylmethyl, cyclobutylethyl, cyclopentylethyl, -propyl, -butyl, -pentyl, -hexyl, cyclohexylmethyl, -dimethyl, and -trimethyl.

[0017] Ar and Ar 1 are independent of each other (C6~C 18 ) arylene groups. According to a particular embodiment, Ar 1 is unsubstituted (C6-C12 ) arylene group in some cases.

[0018] Ar and Ar 1 are preferably independently selected from phenylene, bisphenylene, and naphthylene groups, and arylene groups derived from anthracene, phenanthrene, or naphthacene. For example, Ar and Ar 1 are 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-dihydroxynaphthylene and 4,4'-bisphenylene.

[0019] In particular, Ar and Ar 1 are independently selected from phenylene and naphthylene groups, for example, 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, and more particularly independently selected from 1,4-phenylene, 1,3-phenylene, and naphthylene. Furthermore, 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 further embodiments, Ar and Ar 1 is independently selected from 2,7-dihydroxynaphthylene and 4,4'-bisphenylene.

[0020] It may be preferred that the polyarylene (ether) sulfone according to component A) comprises at least one of the following repeat units IIa to IIo: [ka] [ka]

[0021] In addition to units IIa to IIo, which may preferably be present, other repeating units are those in which one or more 1,4-phenylene units derived from hydroquinone are replaced by 1,3-phenylene units derived from resorcinol or naphthylene units derived from dihydroxynaphthalene.

[0022] Particularly preferred units of general formula II are units IIa, IIg and / or IIk. According to a particular embodiment, it is particularly preferred that component A) polyarylene(ether)sulfone essentially consists of one type of unit of general formula II, said one type being in particular selected from IIa, IIg and IIk.

[0023] 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. This polyarylene(ether)sulfone is also called polyphenylene sulfone (PPSU) (formula IIg).

[0024] According to a further preferred embodiment, component A) polyarylene(ether)sulfone is composed of repeating units where Ar is 1,4-phenylene, t is 1, q is 0, T is C(CH3)2, and Y is SO2. This polyarylene(ether)sulfone is also called polysulfone (PSU) (formula IIa).

[0025] According to an even more 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. This polyarylene (ether) sulfone is also called polyether sulfone (PESU) (formula IIk).

[0026] According to a further preferred embodiment, the composition of the present invention comprises one polyarylene(ether)sulfone as component A) in the amounts or preferred amounts detailed herein. In particular, component A) is one polyarylene(ether)sulfone selected from any of the polymers described above, in particular selected from polymers comprising at least one of the repeating units IIa to IIo.

[0027] According to an even more preferred embodiment, component A) polyarylene(ether) sulfone is PPSU, PSU or PESU.

[0028] For the purposes of this disclosure, abbreviations such as PPSU, PESU and PSU comply with DIN EN ISO 1043-1:2001.

[0029] The amount of component A) present in the composition of the present invention is 50 to 94% by weight.

[0030] According to a preferred embodiment, the amount of component A) is 50 to 90% by weight of the composition, in particular 50 to 85% by weight, more particularly 50 to 80% by weight, and even more particularly 50 to 75% by weight. More particularly, one embodiment uses 50 to 70% by weight, and even 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, in particular 53 to 94% by weight, more particularly 54 to 94% by weight, and even more particularly 55 to 94% by 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 a further embodiment, an amount of 54 to 70% by weight may be suitable.

[0031] The weight average molecular weight M of the polyarylene (ether) sulfone A) of the present invention wis preferably 25,000 to 120,000 g / mol, particularly 30,000 to 100,000 g / mol, and particularly preferably 32,000 to 90,000 g / mol, and is determined by gel permeation chromatography using dimethylacetamide as a solvent and polymethyl methacrylate with a narrow molecular weight distribution as a standard substance.

[0032] The preparation processes leading to the above-mentioned polyarylene(ether) sulfones are known per se to those skilled in the art and are described, for example, in "Encyclopedia of Polymer Science and Technology" by Herman F. Mark, 3rd Edition, Volume 4, 2003, Chapter "Polsulfones", pages 2-8, and also in "Aromatic Polyethers" by Hans R. Kricheldorf in Handbook of Polymer Synthesis, 2nd Edition, 2005, pages 427-443.

[0033] The synthesis of polyarylene (ether) sulfones can generally be carried out by polycondensation of suitable monomers in dipolar aprotic solvents at elevated temperatures (RN Johnson et al., J. Polym. Sci. A-1 5 (1967) 2375; JE McGrath et al., Polymer 25 (1984) 1827). To achieve a desired VN, the molecular weight of the polyarylene (ether) sulfone must be controlled, which can be done, for example, by monitoring the torque level during the condensation, requiring a calibration curve between the torque level in the reaction mixture and the corresponding final product. Furthermore, by using general knowledge about adjusting the molecular weight by using an appropriate stoichiometric ratio between the monomers during polycondensation, the molecular weight can be controlled so that the required viscosity of the polyarylene (ether) sulfone is achieved (see, for example, McGrath et al., Polym. Eng. Sci. 17, 647 (1977)). In this case too, the molecular weight M n A correlation between VN and NIH must be established.

[0034] Particularly preferred is the reaction between at least one aromatic compound having two halogen substituents and at least one aromatic compound having two functional groups reactive with said halogen substituents 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. One particularly preferred combination is N-methyl-2-pyrrolidone as the solvent and potassium carbonate as the base.

[0035] The polyarylene(ether)sulfones as component A) usually have halogen end groups, in particular -Cl, or phenolic OH or phenolate end groups, the latter of which may be present as such or in reacted form, in particular in the form of -OCH3 end groups.

[0036] The polyarylene(ether)sulfone A) preferably has a maximum of 0.05% by weight, particularly preferably a maximum of 0.02% by weight, of phenol end groups, based on the weight of component A).

[0037] The respective upper limit of the content of phenolic end groups in component A) is a function of the number of available end groups per molecule (which is 2 for linear polyarylene ethers) and the number-average chain length. Those skilled in the art are aware of these calculations.

[0038] The average number of phenol end groups per polymer chain in component A) is preferably 0 to 0.05, in particular 0 to 0.02, particularly preferably 0 to 0.01. The content of OH or phenolate end groups, determined by potentiometric titration, is preferably at most 0.05% by weight.

[0039] The proportion of phenolic end groups is preferably determined by potentiometric titration. For this, the polymer is dissolved in dimethylformamide and titrated with a toluene / methanol solution of tetrabutylammonium hydroxide. The end point is recorded potentiometrically. The proportion of halogen end groups is preferably determined by elemental analysis.

[0040] Those skilled in the art can determine the average number of phenolic end groups per polymer chain (n OH ) is assumed to be a strictly linear polymer chain, the following formula, n OH =m OH [Weight%] / 100×M n P [g / mol] × 1 / 17, i.e., the weight fraction of phenol end groups (m OH ) and the number average molecular weight (M n P ), it can be determined.

[0041] Alternatively, the average number of phenolic end groups per polymer chain (n OH ) is the weight fraction of Cl end groups (m Cl ) are publicly known at the same time, OH =2 / (1+(17 / 35.45×m Cl / m OH )) The skilled person knows how to adapt the calculation method when terminal groups other than Cl are present.

[0042] 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-di(4-hydroxyphenyl)propane, 2,4-di(4-hydroxyphenyl)-2-methylbutane, 1,1-di(4-hydroxyphenyl)cyclohexane, 1,1-di(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 2,2-di(4-hydroxyphenyl)pentane, 2,6-dihydroxynaphthalene, 4,4'-dihydroxydiphenylsulfone, 4,4'-dihydroxydiphenylether, 4,4'-dihydroxydiphenylsulfite, 4,4'-dihydroxydiphenylmethane, 1,1-di(4-hydroxyphenyl)ethane, and 4,4-dihydroxybiphenyl, as well as mixtures of any of the aforementioned compounds. A preferred example of a bisphenol is 2,2-di(4-hydroxyphenyl)propane, also known as bisphenol A.

[0043] Either homopolycarbonates or copolycarbonates can be used, with copolycarbonates of bisphenol A and bisphenol A homopolycarbonate being particularly preferred according to one embodiment of the invention.

[0044] Also preferred are polycarbonates based on bisphenol A or bisphenol A and up to 30 mol% of any one of the above compounds. Also suitable are the copolycarbonates described in U.S. Pat. No. 3,737,409 A, in particular those based on bisphenol A and di-(3,5-dimethyl-dihydroxyphenyl) sulfone. According to a further preferred embodiment, the polycarbonate is based on bisphenol A containing up to 50 mol% of 1,1-di(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane.

[0045] See, for example, DE-B 1 300 266 (B) and / or DE-B 1 495 730 (A). For polydiorganosiloxane-containing polycarbonates, see DE-A 3 334 782 (A).

[0046] The polycarbonates used as component B) may be branched as is generally known in the art, for example, by incorporating 0.05 to 2.0 mol % of at least trifunctional compounds, for example compounds having three or more phenolic OH groups, based on the total bisphenols used.

[0047] Polycarbonates that have proven particularly suitable are those having a melt volume index (MVR) of 5 to 40 ml / 10 min, or 6 to 35 ml / 10 min, in particular 7 to 30 ml / 10 min, and more particularly 8 to 27 ml / 10 min (measured at 300°C / 1.2 kg according to ISO 1133). These have an average molecular weight M of 10,000 to 200,000, preferably 20,000 to 80,000 g / mol. w (weighted average).

[0048] Polycarbonates can be prepared, for example, by reacting the respective bisphenols or biphenols with phosgene in an interfacial process or in a homogeneous phase process (known as the pyridine process). Chain terminators can be used to achieve the desired molecular weight, as 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, German Patent Application Publication No. 2842005A). Mono- or dialkylphenols with alkyl substituents having 8 to 20 carbon atoms can also be used (see, for example, German Patent Application Publication No. 3506472A). 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.

[0049] In particular, halogen-free polycarbonates are preferred according to the present invention, such as polycarbonates based on biphenols or bisphenols as detailed above. For the purposes of the present invention, halogen-free polycarbonates are polycarbonates derived from halogen-free bis(s)phenols, halogen-free chain terminators, and, where appropriate, halogen-free branching agents. Small amounts of hydrolyzable chlorine (ppm range) can result, for example, from the preparation of polycarbonates using phosgene. For the purposes of the present invention, polycarbonates of this type having small amounts (ppm range) of such hydrolyzable chlorine are still considered halogen-free polycarbonates.

[0050] The amount of component B) present in the composition of the present invention is 5 to 45% by weight. According to a preferred embodiment, the amount of component B) is 10 to 45% by weight, in particular 15 to 45% by weight, more particularly 20 to 45% by weight, and even more particularly 25 to 45% by weight of the composition. More particularly, one embodiment uses 30 to 45% by weight, more particularly 35 to 45% by weight, of component B). According to a very specific embodiment, the amount of component B) is 5 to 44% by weight. In a further preferred embodiment, the amount of component B) is 10 to 43% by weight, in particular 15 to 42% by weight, more particularly 20 to 41% by weight, and even more particularly 25 to 40% by weight of the composition.

[0051] As component C) 0.15 to 1% by weight of stearic acid is used, which is commercially available, for example, from KLK Oleo.

[0052] According to a preferred embodiment, the amount of component C) is 0.15 to 0.9% by weight, in particular 0.15 to 0.85% by weight, more particularly 0.15 to 0.8% by weight, and even more particularly 0.15 to 0.75% by weight of the composition. More particularly, 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 a further preferred embodiment, the amount of component C) is 0.15 to 0.55% by weight, in particular 0.15 to 0.5% by weight. According to a further preferred embodiment, the amount of component C) is 0.2 to 0.9% by weight, in particular 0.2 to 0.85% by weight, more particularly 0.2 to 0.8% by weight, and even more particularly 0.2 to 0.75% by weight of the composition. More particularly, 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 particular embodiment, the amount of component C) is 0.2 to 0.6% by weight. In a further preferred embodiment, the amount of component C) is 0.2 to 0.55% by weight, in particular 0.2 to 0.5% by weight.

[0053] According to the present invention, the composition may comprise at least one additive D), which is different from components A), B), and C), and is present in an amount of 0 to 40 wt%, in particular 0 to 30 wt%, more particularly 0 to 20 wt%, even more particularly 0 to 10 wt%, for example 0 to 5 wt%. In one embodiment of the present invention, the composition of the present invention comprises at least one additive (component D)) in an amount of component D) greater than 0 to 40 wt%, preferably greater than 0 to 30 wt%, more particularly greater than 0 to 20 wt%. According to this embodiment, it may be preferred that component D) is present in an amount greater than 0 to 15 wt%, in particular greater than 0 to 10 wt%, more particularly greater than 0 to 5 wt%.

[0054] When present, it may be preferred that the composition comprises 0.01 to 20% by weight, more particularly 0.1 to 20% by weight, of at least one additive D). It may be more preferred that D) is used in an amount of 0.1 to 15% by weight, for example 0.1 to 10% by weight. It may be even more preferred that the composition of the invention comprises 0.1 to 5% by weight of D).

[0055] The at least one additive may be selected from, for example, processing aids, pigments, stabilizers, impact modifiers and flame retardants, or may be a mixture of various additives. Other examples of conventional additives are oxidation retardants, agents that inhibit degradation caused by heat or ultraviolet light, lubricants and mold release agents, dyes and plasticizers, which may be used alone or in any combination with any other additive.

[0056] According to one embodiment, the composition of the present invention comprises at least one pigment as component D). In addition, the composition may also contain one or more other components D). In a particular embodiment, the composition of the present invention comprises one or more pigments as component D) and does not contain further additives D).

[0057] Pigments for coloring thermoplastics are well known; see, for example, R. Gaechter and H. Muller, Taschenbuch der Kunstststoffadditive [Plastics Additives Handbook], Carl Hanser Verlag, 1983, pp. 494-510. A first preferred group of 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 used for white coloring of the compositions of the present invention. Black pigments that can be used in accordance with the present invention include iron oxide (Fe3O4), spinel black [Cu(Cr,Fe)2O4], manganese black (a mixture of manganese dioxide, silicon dioxide, and iron oxide), cobalt black, and antimony black, and particularly preferably carbon black, most often used in the form of furnace black or gas black. A suitable carbon black that can be used as component D) is, for example, Carbon Black Printex EP, available from Orion Engineered Carbons. In this connection, reference is also made to G. Benzing, Pigmente fuer Anstrichmittel [Pigments for paints], Expert-Verlag (1988), pp. 78 ff.

[0058] Specific shades can be achieved 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 available commercially.

[0059] Pigments and dyes may be present in an amount of up to 5% by weight, for example 0.05 to 5% by weight, and in particular, if present at all, 0.1 to 5% by weight, preferably 0.5 to 5% by weight, and in particular 0.1 to 3% by weight or 0.5 to 3% by weight. According to a specific embodiment, the composition of the present invention comprises, as component D), at least one pigment in an amount of 0.05 to 5% by weight, in particular 0.1 to 5% by weight, preferably 0.5 to 5% by weight, and in particular 0.1 to 3% by weight or 0.5 to 3% by weight. In addition, the composition may also contain one or more other components D). In a very specific embodiment, the composition of the present invention does not contain any further additives D).

[0060] Examples of oxidation retarders and heat stabilizers that can be added to the compositions of the present invention are halide salts of metals from Group I of the Periodic Table, such as sodium halide, potassium halide, or lithium halide, examples being chloride, bromide, or iodide salts.Zinc fluoride and zinc chloride can also be used.It is also possible to use sterically hindered phenols, hydroquinones, substituted representatives of the above groups, secondary aromatic amines, optionally in combination with phosphorus-containing acids, or their salts or mixtures of the above compounds, preferably at a concentration of up to 1% by weight.

[0061] Examples of UV stabilizers are various substituted resorcinols, salicylates, benzotriazoles and benzophenones, commonly used in amounts up to 2% by weight.

[0062] If present, the stabilizer may constitute up to 2% by weight, preferably 0.01 to 1% by weight, especially 0.01 to 0.5% by weight.

[0063] Other possible additives are nucleating agents, for example talc powder. Component D) may contain one or more impact modifiers, which may be at least one impact-modifying rubber. Rubbers are generally crosslinkable polymers that have elastomeric properties at room temperature.

[0064] Core-shell graft rubbers are another group of suitable impact modifiers that can be used in the present invention. These are graft rubbers that can be prepared in emulsion and are composed of at least one hard component and one soft component. The hard component is usually at least one polymer having a glass transition temperature of at least 25°C, and the soft component is usually at least one polymer having a glass transition temperature of 0°C or lower. These products generally have a structure made up of a core (graft base) and at least one shell (graft), and the structure is typically the result of the order of addition of the monomers. The soft component is generally 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 other comonomer. Suitable siloxane cores can be prepared, for example, starting from cyclic oligomeric octamethyltetrasiloxane or tetravinyltetramethyltetrasiloxane. These can be reacted with γ-mercaptopropylmethyldimethoxysilane, for example, in a ring-opening cationic polymerization, preferably in the presence of sulfonic acid, to obtain a soft siloxane core. At least one siloxane can also be crosslinked, for example, by carrying out polymerization in the presence of at least one silane having at least one hydrolyzable group, such as halo or alkoxy, such as tetraethoxysilane, methyltrimethoxysilane, or phenyltrimethoxysilane. Examples of at least one comonomer suitable for this purpose include styrene, acrylonitrile, and crosslinkable or graftable monomers having two or more polymerizable double bonds, such as diallyl phthalate, divinylbenzene, butanediol diacrylate, or triallyl (iso)cyanurate. The hard component is generally derived from styrene, α-methylstyrene, or a copolymer thereof, and the at least one comonomer here may preferably be acrylonitrile, methacrylonitrile, or methyl methacrylate.

[0065] 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, wherein the incorporation of at least one functional group, such as carbonyl, carboxylic acid, anhydride, amide, imide, carboxylic acid ester, amino, hydroxyl, epoxy, oxazoline, urethane, urea, lactam or halobenzyl, may be carried out preferably by adding at least one suitably functionalized monomer during the polymerization of the final shell.

[0066] Examples of suitable functionalized monomers include 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 the functionalized monomer is generally 0.1 to 25 wt %, preferably 0.25 to 15 wt %, 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.

[0067] Rubbers of this type are known per se or are available to the person skilled in the art by utilizing general knowledge and are described, for example, in EP-A-208187.

[0068] Thermoplastic polyester elastomers are another group of suitable impact modifiers. For the purposes of the present invention, polyester elastomers are generally segmented copolyetheresters that may contain long-chain segments derived from poly(alkylene) ether glycols and short-chain segments that may be derived from low-molecular-weight diols 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 commercially available under the trademarks Hytrel® (DuPont), Arnitel® (Akzo), and Pelprene® (Toyobo).

[0069] According to one particular embodiment, the composition of the invention does not contain component D) (0% by weight).

[0070] A detailed embodiment of the present invention comprises: A) 50 to 94 wt. % of at least one polyarylene(ether) sulfone; B) 5 to 45% by weight of at least one polycarbonate; C) 0.15 to 1% by weight of stearic acid, and D) 0 to 40% by weight of at least one additive wherein the total weight percent of components A) to D) is 100 weight percent.

[0071] A further embodiment of the present invention comprises: A) 50 to 70% by weight of at least one polyarylene(ether) sulfone; B) 25 to 45% by weight of at least one polycarbonate; C) 0.15 to 0.8 wt. % stearic acid, and D) 0 to 40% by weight of at least one additive wherein the total weight percent based on the composition is 100 weight percent.

[0072] A further embodiment of the present invention comprises: A) 50 to 70% by weight of at least one polyarylene(ether) sulfone; B) 25 to 45% by weight of at least one polycarbonate; C) 0.15 to 0.8 wt. % stearic acid, and D) 0.1 to 5% by weight of at least one additive wherein the total weight percent based on the composition is 100 weight percent.

[0073] A more detailed embodiment of the present invention comprises: A) 50 to 94% by weight or 54 to 70% by weight of at least one polyarylene(ether) sulfone; B) 5 to 45% by weight of at least one polycarbonate; C) 0.15 to 1% by weight of stearic acid, and D) 0 to 40% by weight of at least one additive wherein the total weight percent based on the composition is 100 weight percent.

[0074] A more detailed embodiment of the present invention comprises: A) 50 to 70% by weight or 54 to 70% by weight of at least one polyarylene(ether) sulfone; B) 25 to 45% by weight of at least one polycarbonate; C) 0.15 to 0.8 wt. % stearic acid, and D) 0 to 40% by weight of at least one additive wherein the total weight percent based on the composition is 100 weight percent.

[0075] A still further embodiment of the present invention comprises: A) 50 to 70% by weight of at least one polyarylene(ether) sulfone; B) 25 to 45% by weight of at least one polycarbonate; C) 0.15 to 0.8 wt. % stearic acid, and D) 0.1 to 5% by weight of at least one additive wherein the total weight percent based on the composition is 100 weight percent.

[0076] The composition can be prepared by methods known in the art, such as extrusion. The components are fed into a melt-mixing device, such as an extruder (single or twin screw), a Brabender or Banbury mixer, or a kneader, mixed, and then extruded. After extrusion, the strands are cooled and pelletized to obtain pellets or granules. The order in which the individual components are fed into the mixing device can be different; for example, two or optionally three components can be premixed, or all components can be mixed together.

[0077] The components of the compositions of the present invention can be mixed in any desired order, and the order in which the individual components are added to the mixing device can vary; for example, two or optionally three components can be premixed, or all components can be mixed together.

[0078] Homogeneous mixing is important for product performance. To achieve this, temperatures of 300 to a maximum of 420°C, preferably 310 to 380°C, and mixing times of 0.1 to 30 minutes are generally used. After compounding, the resulting strands are cooled and pelletized.

[0079] Surprisingly, the compositions according to the present invention exhibit an excellent combination of desirable flowability and mechanical properties, as well as a very good surface quality of the pieces made from the compositions according to the present invention. Particularly advantageously, the desired properties obtained from the compositions according to the present invention, such as tensile elongation and yield strength, are maintained after aging. These properties are particularly useful in applications such as in the field of automotive parts, such as reflectors, where the requirements for flow, toughness and surface quality are increasing and where heat aging behavior is particularly desirable.

[0080] The compositions of the present invention can be advantageously used in the manufacture of fibers, films, foams or molded articles, in particular in the manufacture of automotive parts such as reflectors, lamp bezels and mirror housings. According to a further aspect, the present invention relates to fibers, films or molded articles, automotive parts such as reflectors, lamp bezels and mirror housings, comprising the compositions described herein. [Example]

[0081] Compound production and testing Compounding was carried out using a twin-screw extruder (ZSK 18), with barrel temperatures set to keep the melt temperature below 370° C. Test samples were molded at a melt temperature of 340° C. and a mold temperature of 120° C.

[0082] The notched impact strength of the materials was tested according to ISO 179 1eA at 23°C using an ISO bar.

[0083] 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 at room temperature under dry conditions for 24 hours.

[0084] The surface of the sample (molded plate, 60 mm x 60 mm) was visually evaluated and qualitatively rated from 1 (very good) to 6 (very poor).

[0085] The solution viscosity of the polyarylether was determined using a 0.01 g / ml solution in N-methyl-pyrrolidone at 25°C.

[0086] Ingredient A) As component A) a polysulfone was used (Ultrason® S 2010, commercially available from BASF SE) with an MVR of 90 ml / 10 min (360° C., 10 kg, ISO 1133).

[0087] ·Component B) As component B) a polycarbonate based on bisphenol A with an MVR of 12 ml / 10 min (300° C., 1.2 kg) was used (Makrolon 2605, commercially available from Covestro).

[0088] ·Component C) Component C) used was stearic acid (purity over 98%), with a softening range of 55-60°C. Available from KLK Oleo.

[0089] ·Ingredient D Carbon Black Printex EP, commercially available from Orion Engineered Carbons.

[0090] [Table 1]

[0091] C1, C2, C5 and C6 are comparative examples in which stearic acid is not used or in amounts different from those of the present invention. The compounds according to the present invention show better mechanical performance and an improved combination of heat aging stability and surface quality compared to the comparative examples.

Claims

1. A) 50 to 94 wt. % of at least one polyarylene(ether) sulfone; B) 5 to 45% by weight of at least one polycarbonate; C) 0.15 to 1% by weight of stearic acid, and D) 0 to 40% by weight of at least one additive wherein the total weight percentages based on the composition is 100 weight percent.

2. The composition of claim 1 comprising 52 to 75 weight percent of component A).

3. The composition of claim 2 comprising 20 to 45 wt. % of component B).

4. The composition of any one of claims 1 to 3, comprising 0.1 to 10 wt. % of component D).

5. The composition of claim 4 wherein component D) is at least one pigment.

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

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

8. Use of a composition according to any one of claims 1 to 7 in the manufacture of fibres, films or moulded articles.

9. 9. Use according to claim 8 in the manufacture of automotive parts.

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

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

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

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