Aromatic Polycarbonate Composite Resin Composition
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Solution Overview
Problem
Existing aromatic polycarbonate resin compositions used in portable terminal housings lack sufficient impact resistance, particularly at low temperatures, and residence heat resistance, which are critical for durability and performance in varying environmental conditions.
Innovation Solution
Aromatic polycarbonate composite resin composition comprising 60-90 parts by mass of aromatic polycarbonate resin, 10-40 parts by mass of polyester resin, 3-20 parts by mass of a graft copolymer with specific sulfur content and average particle diameter, and 0.005-0.1 parts by mass of an organic phosphate stabilizer, along with an optional silicate salt compound, to enhance impact resistance and heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If aromatic polycarbonate resin is compounded with polyester resin to improve chemical resistance, then chemical resistance is improved, but impact resistance especially low-temperature impact resistance deteriorates
Solution Approach 1:
The patent uses a composite material system comprising aromatic polycarbonate resin, polyester resin, and rubber particles to achieve synergistic effects. The rubber particles (5-50 parts by mass per 100 parts by mass of aromatic polycarbonate resin) provide impact resistance while the polyester resin (10-40 parts by mass per 100 parts by mass of aromatic polycarbonate resin) provides chemical resistance, resolving the contradiction between these two properties.
Solution Approach 2:
The patent specifies precise parameter ranges for the rubber particles including particle size (0.01-10 μm), sulfur content (10-500 ppm), and graft copolymer content (5-50 parts by mass per 100 parts by mass of aromatic polycarbonate resin). By controlling these parameters, the invention optimizes both impact resistance and chemical resistance simultaneously.
2Object-affected harmful factors
If aromatic polycarbonate resin is compounded with polyester resin to improve chemical resistance, then chemical resistance is improved, but residence heat resistance deteriorates
Solution Approach 1:
The patent creates a composite material system where rubber particles (5-50 parts by mass per 100 parts by mass of aromatic polycarbonate resin) with specific properties (sulfur content 10-500 ppm, particle size 0.01-10 μm) are combined with polyester resin (10-40 parts by mass per 100 parts by mass of aromatic polycarbonate resin). This composite structure provides both chemical resistance from the polyester and residence heat resistance from the rubber-modified polycarbonate matrix.
Solution Approach 2:
The patent controls specific parameters including rubber particle size (0.01-10 μm), sulfur content (10-500 ppm), and the ratio of polyester resin (10-40 parts by mass per 100 parts by mass of aromatic polycarbonate resin). By optimizing these parameters, the invention achieves both improved chemical resistance and maintained residence heat resistance.
3Volume of moving object
If housing size and thickness are reduced to meet portable terminal requirements, then portability is improved, but impact resistance deteriorates
Solution Approach 1:
The patent employs a composite material system with rubber particles (5-50 parts by mass per 100 parts by mass of aromatic polycarbonate resin) dispersed in the aromatic polycarbonate-polyester resin matrix. This composite structure enhances impact resistance at the material level, allowing thinner and smaller housing designs to maintain adequate impact protection.
Solution Approach 2:
The patent specifies precise parameter ranges for rubber particle size (0.01-10 μm), sulfur content (10-500 ppm), and rubber content (5-50 parts by mass per 100 parts by mass of aromatic polycarbonate resin). By controlling these parameters, the invention achieves high impact resistance in the resin composition, enabling reduced housing thickness while maintaining impact protection.
Data Source
AI summary
A resin composition is provided which is excellent in impact resistance, heat resistance, moldability, and chemical resistance and which is suitable, for example, as a molding material for a portable terminal housing. An aromatic polycarbonate composite resin composition contains, with respect to 100 parts by mass of a resin component formed of 60 to 90 parts by mass of an aromatic polycarbonate resin (A) and 10 to 40 parts by mass of a polyester resin (B), 3 to 20 parts by mass of a graft copolymer (C) formed by graft polymerization of a (meth)acrylic acid ester compound with a diene-based rubber and 0.005 to 0.1 parts by mass of a stabilizer (D). The graft copolymer (C) has a sulfur content of 100 to 1,500 ppm and an average particle diameter of 70 to 240 nm, and the stabilizer (D) is an organic phosphate compound represented by the following general formula (I). O=P(OH)m(OR)3-m (I) R represents an alkyl group or an aryl group. m represents 0 to 2.