Polyester/Polycarbonate Alloy Resin Composition
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Solution Overview
Problem
Polybutylene terephthalate resin has low impact resistance and thermal distortion temperature, leading to instability in polyester/polycarbonate blends when additives are used without compatibilizers, resulting in mechanical property deterioration and color changes during injection molding.
Innovation Solution
A polyester/polycarbonate alloy resin composition is developed, comprising a mixed resin with a polycarbonate resin, a polyester resin, an acryl-based resin, and an impact-reinforcing agent, along with optional additives, to enhance impact resistance, heat resistance, and injection molding appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ethylene-propylene copolymer (EPR), ethylene-propylene-diene copolymer (EPDM), or methylmethacrylate-butadiene-styrene copolymer (MBS) are added to polyester resin to improve impact resistance, then impact resistance is improved, but the phases of polyester and polycarbonate become unstable and mechanical properties deteriorate
Solution Approach 1:
The patent introduces a compatibilizer as an intermediary substance that facilitates stable blending between polyester resin and polycarbonate resin. The compatibilizer has molecular structures that are compatible with both resin types, acting as a bridge to maintain phase stability while allowing the addition of impact-reinforcing agents. This resolves the contradiction by enabling improved impact resistance without compromising phase stability.
Solution Approach 2:
The patent creates a composite resin composition comprising polyester resin, polycarbonate resin, and a compatibilizer. This composite structure allows the synergistic combination of materials to achieve both improved impact resistance and maintained phase stability. The compatibilizer ensures homogeneous distribution and stable interfaces between the different polymer phases.
2Strength
If functional groups are introduced into polyester resin or terminal groups are cross-linked to increase compatibility and impact resistance, then impact resistance and compatibility are improved, but un-reacted functional groups cause color change and gas generation during injection molding
Solution Approach 1:
The patent removes or eliminates functional groups that cause harmful side reactions (color change and gas generation) while retaining the beneficial compatibility and impact resistance properties. By selecting polyester resins with appropriate functional group content and using compatibilizers, the invention achieves improved mechanical properties without the harmful effects of un-reacted functional groups.
Solution Approach 2:
The patent optimizes the concentration and type of functional groups in the polyester resin to achieve the desired balance. By controlling parameters such as intrinsic viscosity, functional group content, and molecular weight distribution, the invention maximizes compatibility and impact resistance while minimizing harmful reactions during injection molding.
3Ease of manufacture
If polybutylene terephthalate resin is used to achieve rapid crystallization and excellent molding characteristics, then molding characteristics are improved, but thermal distortion temperature and impact resistance at room temperature are low
Solution Approach 1:
The patent combines polybutylene terephthalate resin with polycarbonate resin and a compatibilizer to create a composite material that leverages the advantages of each component. The polybutylene terephthalate provides rapid crystallization and excellent molding characteristics, while the polycarbonate component enhances impact resistance and thermal distortion temperature. The compatibilizer ensures stable phase distribution and maintains the beneficial properties of both resins.
Data Source
AI summary
Disclosed are a polyester/polycarbonate alloy resin composition that includes: (A) a mixed resin including (A-1) a polycarbonate resin having a weight average molecular weight ranging from about 30,000 to about 200,000 g/mol and (A-2) a polyester resin having an intrinsic viscosity of about 0.85 to about 1.52 dl/g; (B) an acryl-based resin; and (C) an impact-reinforcing agent, and a molded product made using the polyester/polycarbonate alloy resin composition.