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US3636140.Pdf Jan. 18, 1972 A. F. INGULLI ETA 3,636,140 THERMOPLASTIC RESIN BLEND OF POLY SULFONE WITH ABS Filed Aug. 4, 1969 5. Sheets-Sheet, 2. R O /O 20 30 40 0 60 22 80 20 M22 (7, AOA. Yuo/MAOM/A /W AA S adze wa /MVA MV7 OAS Air 7- 4. a Zafa AA A. MM/G/ZZ / A/a. Mary A. at 7A air 2- 9% agew, Jan. 18, 1972 A. F. NGULL ET All- 3,636,140 "I HERMOPLASTIC RESIN BLEND OF POLYSULFONE WITH ABS Filed Aug. 4, 1969 5. Sheets-Sheet 3 S | | | | | | \ / | | | | |\ 1 \ | | | | | | | | \ | | | | | | | N TTTTTTTT O 3O 20 O SO 70 so 90 /OO 7. AozYuva /owa w Aaj azawo 2g z 7-5 MM/a M72A S. AAAAAA M. MMMGO/4 AM AyAAMA 1 A... a A. JAA larus 9.4 AG AW 7 Jan. 18, 1972 A. F. NGULL FT All- 3,636,140 TERMOPLASTIC RESIN BLEND OF POLYSULFONE WITH ABS Filed Aug. 4, 1969 5 Sheets-Sheet 4. 24.0 -- -T 22.ol | | | || 20.0 I Y Mas t SR I W. n w /4.0 | -- N - S v 2.0 HI N | n N S s S. v O /O 20 30 10 60 60 70 &0 70 /00 7./oz ruz/z/-owa //v4 as aza/v4 MM VAM/OA 27zz7 a AAAMAA A. MM6t/44/ A/AMMA)1 A. az Zafa 9ers /.4- a 47AM/7 Jan. 18, 1972 A. F. NGULL ET All- 3,636,140 THERMOPLASTIC RESIN BLEND OF POLYSULFONE WITH ABS Filed Aug. 4, 1969 5 Sheets-Sheet 5 JO J00 290 28 O 270 28 O 25 O 24 O 2.3 O O O 20 JO 40 50 60 70 8 O 3 O LOO % AOZyura/4 MoM2 //v 44, aza/V2 , , , . aZAaaa a, Mya Az // //a///? Y M. 1/7 a.a. 3,636,140 United States Patent Office Patented Jan. 18, 1972 2 3,636,40 time possess good flow characteristics and impact strength. THERMOLASTC RESIN BLEND OF The present invention provides such a compound in the POLYSULFONE WITH ABS form of a blend of from 10 to 90 parts (all quantities Alfred F. ingulli, Warren, Mich., and Henry L. Alter, are expressed by weight herein) of a thermoplastic poly West Haven, Conn., assignors to Uniroyal, Inc., New Sulfone plastic and correspondingly from 90 to 10 parts York, N.Y. Continuation-in-part of application Ser. No. 827,766, May of ABS plastic. The resulting blends exhibit unexpected 26, 1969, which is a continuation-in-part of applica thermoplastic properties including improved flow, heat tion Ser. No. 67,654, Sept. 29, 1967, which in turn, distortion temperature, impact resistance and flexural is a contination-in-part of application Ser. No. 866,068, strength. Sept. 30, 1969, now Patent No. 3,555,119. This appli O cation Aug. 4, 1969, Ser. No. 847,070 DESCRIPTION OF THE DRAWINGS The portion of the term of the patent subsequent to In the accompanying drawings: an. 2, 1988, has been disclaimed FIG. 1 is a purely diagrammatic representation, based nt. C. C08f 41/12 on electron microscopy, of the morphology of a typical U.S. C. 260-876 R 9 Claims 15 ABS plastic; FIG. 2 is a similar representation of the morphology of the polysulfone plastic; ABSTRACT OF THE DISCLOSURE FIG. 3 is a similar representation of the blend of ABS Blends of thermoplastic polysulfone resin with ABS with polysulfone; plastic are characterized by an unusually useful combi 20 FIGS. 4, 5, 6 and 7 are graphs showing variations in nation of properties, particularly high heat distortion tem heat distortion temperature, impact strength, and appar perature in combination with good flow and processing ent Viscosity, with the percentage of polysulfone resin in characteristics, as well as impact resistance, flexural blends of the invention. strength and self-extinguishing characteristics. 25 DESCRIPTION OF PREFERRED EMBODIMENTS The expression “ABS plastic' is used herein in its con CROSS REFERENCE TO RELATED APPLICATIONS ventional sense as referring to a thermoplastic polymer This application is a continuation-in-part of our co composition containing combined acrylonitrile, butadiene, and styrene. As is well known to those skilled in the art, pending application Ser. No. 827,766, filed May 26, 1969, 30 the ABS plastic may be of the graft copolymer type, or of and now abandoned, which is in turn a continuation-in the physical blend type (polyblend), or a combination of part of our copending application Ser. No. 671,654, filed the two. The conventional ABS graft copolymers are made Sept. 29, 1967 also now abandoned. Said abandoned ap by graft copolymerizing resin-forming monomers, namely, plication Ser. No. 671,654 was replaced by our stream styrene and acrylonitrile, on a previously prepared poly lined continuation application Ser. No. 866,068, filed butadiene rubber spine, or a butadiene-styrene copolymer Sept. 30, 1969, now U.S. Pat. 3,555,119 issued Jan. 12, rubber spine; in the final graft copolymer the resinous por 1971. tion and the rubbery portion are in part chemically com BACKGROUND OF THE INVENTION bined (typically 40-70% chemically combined). The graft (1) Field of the invention copolymer may be made by an emulsion polymerization This invention relates to synthetic thermoplastic resin 40 technique, in which a previously prepared latex of poly compositions. More particularly, the invention relates to butadiene or similar rubber, which serves as a spine, is the resin which results from the physical blending of a Subject to emulsion polymerization conditions with a mon polysulfone thermoplastic resin with an ABS polymer. omeric mixture of styrene and acrylonitrile emulsified therein. Alternatively, graft copolymer may be prepared (2) Description of the prior art by solution polymerization methods, or by so-called mass ABS resins of the kind employed in the invention are bead technique. On the other hand, the physical blend type disclosed in U.S. Pats. 2,439,202, L. E. Daly, Apr. 6, 1948; of ABS is typically a mixture of butadieneacrylonitrile 2,600,024 H. Romeyn, Jr. et al., June 10, 1952; 2,820,773, rubber with separately prepared styrene-acrylonitrile res C. W. Childers, Jan. 21, 1958; 3,111,501, M. S. Thomp in. Frequently the graft polymer type of ABS includes son, Nov. 18, 1963; 3,198,853, R. L. Bergen, Jr., Aug. 3, 50 additional separately prepared styrene-acrylonitrile resin 1965; and 3,261,887, J. U. Mann, July 19, 1966, for blended with the graft copolymer. Any such type of ABS example. resin is suitable for blending with the thermoplastic poly Thermoplastic polysulfone resin of the kind employed sulfone resin in accordance with the invention. Moreover, in the invention is disclosed in U.S. Pat. 3,264,536, H. B. if desired, other styrene-type monomer (such as alpha Robinson et al., Aug. 2, 1966, and British Pat. 1,060,546, methylstyrene) may be substituted for some or all of the Minnesota. Mining and Manufacturing Co., published Mar. styrene itself and other acrylic monomers (such as metha 8, 1967; also Cornell Ser. No. 847,427 filed herewith, crylonitrile, ethyl acrylate, methyl methacrylate) may be now U.S. Pat. 3,554,972, issued Jan. 12, 1971. substituted for some or all of the acrylonitrile-type mono Blends of ABS with various other polymers are known, C. but not with thermoplastic polysulfone resins. For exam 60 Since the ABS material has both a rubbery component ple, blends of ABS with polycarbonate resins are dis (e.g., polybutadiene or butadiene-styrene spine or bu closed in U.S. Pat. 3,130,177, T. S. Garbowski, Apr. 21, tadieneacrylonitrile copolymer component) and a resinous 1964. component (styrene-acrylonitrile), it may therefore be re Blends of thermosetting polysulfone resins with thermo garded as a "gum plastic' type of material. Usually the setting phenolic resins (U.S. Pats. 3,245,947, N. D. Hanson proportion of the rubbery component in the ABS is from et al., Apr. 12, 1966 and 3,256,361, J. Harding et al., June 5 to 35%, while the proportion of resin is correspondingly 14, 1966) are known, but such blends are quite unlike from 95 to 65%. The overall proportion of acrylonitrile, the blends of the present invention. butadiene and styrene-type monomer usually falls within the ranges: 10 to 40% acrylonitrile; 5 to 65% butadiene; SUMMARY OF THE INVENTION and 25 to 85% styrene. There is a need for reasonably priced plastic compounds O The polysulfone resin component of the blend of the with resistance to high temperatures which at the same invention may be described as a linear, thermoplastic 3,636,140 3 4. polyarylene polyether polysulfone, wherein the arylene phenyl)-3-(4 - hydroxyphenylcyclohexane), or 4,4'-dihy units are interspersed with ether and sulfone linkages. droxydiphenyl sulfone (see Examples 1, 3, 4, 5 and 7 These resins may be obtained by reaction of an alkali of Robinson et al.), or alpha, alpha'-bis(4-hydroxyphen metal double salt of a dihydric phenol and a dihalobenze yl)-p-diisopropylbenzene (see copending application Ser. noid compound, either or both of which contain a sulfone No. 847.427 of R. J. Cornell filed of even date herewith), linkage -SO2- between arylene groupings, to provide now U.S. Pat. 3,554,972, issued Jan. 12, 1971. sulfone units in the polymer chain in addition to arylene Further useful discussion of the polysulfone resins units and ether units. The polysulfone polymer has a basic which may be used is to be found in British Pat. 1,060,- structure composed of recurring units of the formula 546, referred to above. Ordinarily at least about 10% O and preferably at least about 20% of the linkages between -O-E-O-E- the arylene groups are sulfone groups wherein E is the residuum of the dihydric phenol and E' is the residuum of the benzenoid compound having an O inert electron withdrawing group such as sulfone, car / bonyl, vinyl sulfoxide, azo, and saturated fluorocarbon 5 Vij group in at least one of the positions ortho and para to Apart from the ether and sulfone linkages, arylene groups the valence bonds; both of said residua are valently bond may be bonded directly to each other or may be separated ed to the ether oxygens through aromatic carbon atoms; by inert groups, e.g., alkylidene groups such as isopropyl at least one of said residua (E or E' or both) provides a idene groups, which latter appear in the chain which bis sulfone linkage between aromatic carbon atoms.
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