WO2001042356A1 - Abs resin compositions containing metallic particles - Google Patents

Abs resin compositions containing metallic particles Download PDF

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Publication number
WO2001042356A1
WO2001042356A1 PCT/US2000/031606 US0031606W WO0142356A1 WO 2001042356 A1 WO2001042356 A1 WO 2001042356A1 US 0031606 W US0031606 W US 0031606W WO 0142356 A1 WO0142356 A1 WO 0142356A1
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Prior art keywords
abs
composition
copolymer
metal particles
group
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PCT/US2000/031606
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French (fr)
Inventor
Joseph Marsh Cameron
Christian Maier
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General Electric Company
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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L55/00Compositions of homopolymers or copolymers, obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in groups C08L23/00 - C08L53/00
    • C08L55/02ABS [Acrylonitrile-Butadiene-Styrene] polymers
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/01Use of inorganic substances as compounding ingredients characterized by their specific function
    • C08K3/013Fillers, pigments or reinforcing additives
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/02Elements
    • C08K3/08Metals

Definitions

  • the present invention relates to lower opacity ABS resin compositions containing special-effect colorants and articles molded from such resin compositions. More particularly, the invention relates to metallic particle containing ABS resin compositions and articles displaying reflective sparkle appearance.
  • ABS Acrylonitrile-butadiene-styrene
  • ABS acrylic-butadiene-styrene
  • Most ABS products consist of a two phase system of a grafted terpolymer, acrylonitrile-butadiene-styrene, dispersed in a glassy continuous matrix of styrene-acrylonitrile (SAN) copolymer.
  • the graft terpolymer typically consists of a polybutadiene rubber core and grafted SAN shell, small amounts of styrene and acrylonitriie being grafted onto the rubber particles to compatibilize the two phases.
  • the broad versatility of ABS results from the many compositional and structural variables that can be selected to achieve a desired property balance.
  • the elastomeric (rubber) component either butadiene homopolymer, a styrene-but ⁇ diene or an acrylonitrile- butadiene copolymer
  • This phase can be carried out either in a water-based emulsion or in a solution polymerization process.
  • the styrene and acrylonitriie 50-90/10-50 are copolymerized optionally with other monomers and grafted onto the elastomeric phase to achieve the desired compatibility.
  • the rubber content of an ABS graft may range from 10 to 90 weight percent.
  • This stage can be performed either in emulsion, bulk/ mass or via suspension and/ or the emulsion-suspension process route.
  • styrene and acrylonitriie and, optionally, other olefin monomers are copolymerized either simultaneously with the grafting stage or separately in an independent operation to form the rigid matrix.
  • this step may involve one or more of the following processes: emulsion, bulk or suspension polymerization.
  • the SAN matrix may range from 10 to 90 weight percent of the ABS graft composition.
  • ABS materials may be produced by various process techniques known as batch, semi-batch or continuous polymerization for reasons of either manufacturing economics, product performance or both.
  • ABS plastics vary somewhat with their method of manufacture but more so with their composition.
  • various particle pigments such as metal particles and flakes, pearlescents, granites, fluorescents, phosphorescents, luminescents and other such pigments have c°en utilized as special effect colorants for polymeric materials.
  • Metallic flake particles or pigments are opaque to visible light, typically reflective and are usually conductors of electricity. They are used in formulations to provide metallic finishes having many functions, for example appearance, greater durability, moisture proofing, heat resistance or economical coverage.
  • the metallic pigments utilized most frequently in plastics are aluminum, for silvery colors, followed by copper and copper alloys, the last known as bronzes or gold bronzes.
  • Both bronze and aluminum flake can be colored by several different methods or used with conventional transparent colorants.
  • Metallic pigments are typically marketed in a spheroidal or flake form. Leafing and non-leafing grades are available.
  • Aluminum flake may be utilized in damp powder or paste form, which minimizes the hazards of dust and fire, in plasticizers or mineral oil in a 5 to 80 percent metallic pigment concentration, with or without color concentrates.
  • Gold bronzes may be coated with stearic acid (less than 1 percent) to provide lubricity during milling.
  • U.S. Patent No. 5,324,472 (1994) to Page et al. discloses a process for preparing metal flake plastics comprising multiplane rotational molding of thermoplastic polymers such as polyolefins (preferably polyethylene) with additives such as emulsifiers, surfactants, dispersants, pigments and metal flakes in such a manner as to evenly distribute the metal flakes.
  • thermoplastic polymers such as polyolefins (preferably polyethylene) with additives such as emulsifiers, surfactants, dispersants, pigments and metal flakes in such a manner as to evenly distribute the metal flakes.
  • additives such as emulsifiers, surfactants, dispersants, pigments and metal flakes
  • ABS plastics containing special effect colorants such as metal flake and particle pigments. It is particularly desirable that the metal particles display a bright, reflective metallic sparkle appearance rather than appearing dull. It is further desirable that the look and consistency a the finished product can be controlled.
  • the present invention utilizes an ABS resin based on a styrene-butadiene copolymer rubber (SBR) substrate grafted with styrene-acrylonitrile or methyl methacrylate-styrene-acrylonitrile (MMASAN) and optionally blended with additional SAN, MMASAN or other copolymers to achieve the desired rubber content.
  • SBR styrene-butadiene copolymer rubber
  • MMASAN methyl methacrylate-styrene-acrylonitrile
  • Three or more metal particle sizes (average size) are be employed.
  • Organic dyes or pigments that are soluble in the resin matrix may be used to provide further advantages.
  • the present invention generally provides for an acrylonitrile- butadiene-styrene type composition
  • an acrylonitrile- butadiene-styrene type composition comprising: a) a copolymer derived from both a vinyl aromatic monomer and a vinyl cyanide monomer wherein the copolymer is present at a weight percent level of from about 40 to about 80 percent by weight based on the total weight of the composition; b)a graft copolymer comprising a substrate copolymer and a superstrate copolymer wherein the substrate copolymer comprises a copolymer derived from a vinyl aromatic monomer and a di-olefin monomer and wherein the superstrate copolymer comprises a copolymer derived from both a vinyl aromatic monomer and a vinyl cyanide monomer wherein the graft copolymer is present at a level of from about 20 to about 60 weight percent of the total weight of the composition; and c)
  • an acrylonitrile-butadiene-styrene type (ABS) composition comprising: a) a copolymer derived from both a vinyl aromatic monomer and a vinyl cyanide monomer wherein the copolymer is present at a weight percent level of from about 40 to about 80 percent by weight based on the total weight of the composition; b) a graft copolymer comprising a substrate copolymer and a superstrate copolymer wherein the substrate copolymer comprises a copolymer derived from a vinyl aromatic monomer and a di- olefin monomer and wherein the superstrate copolymer comprises a copolymer derived from both a vinyl aromatic monomer and a vinyl cyanide monomer wherein the graft copolymer is present at a level of from about 20 to about 60 weight percent of the total weight of the composition; and c) metal particles wherein the metal particles have at least three different average sizes.
  • ABS acrylonit
  • ABS type thermoplastic resins utilized by the present invention are graft copolymers of vinyl cyanide monomers, di-olefins and vinylaromatic monomers.
  • ABS type or acrylonitriie butadiene styrene type to include the group of polymers derived from vinyl cyanide monomers, di-olefins, and vinyl aromatic monomers as hereinafter defined.
  • Vinyl cyanide monomers are herein defined by the following structural formula:
  • R is selected from the group consisting of hydrogen, alkyl groups of from 1 to 5 carbon atoms, bromine and chlorine.
  • vinyl cyanide monomers include acrylonitriie, ethacrylonitrile, methacrylonitrile, ⁇ - chloroacrylonitrile and ⁇ -bromoacrylonitrile.
  • the di-olefins utilized in the present invention are herein defined by the following structural formula:
  • each Q is independently selected from the group consisting of hydrogen, alkyl groups of from 1 to 5 carbon atoms, bromine and chlorine.
  • di-olefins include butadiene, isoprene, 1,3-heptadiene, methyl- 1,3-pentadiene, 2,3-dimethylbutadiene, 2-ethyl-l,3-pentadiene, 1,3 hexadiene, 2,4-hexadiene, dichlorobutadiene, dibromobutadiene, chlorobutadiene, bromobutadiene and mixtures thereof.
  • Vinyl aromatic monomers are herein defined by the following structural formula:
  • each X is independently selected from the group consisting of hydrogen, alkyl groups of from 1 to 5 carbon atoms, cycloalkyl, aryl, alkaryl, aralkyl, alkoxy, aryloxy and halogen and where R is selected from the group consisting of hydrogen, alkyl groups of from 1 to 5 carbon atoms, bromine and chlorine.
  • substituted vinyl aromatic monomers examples include styrene, 4-methylstyrene, vinyl xylene, 3,5-diethylstyrene, p-tert-butyl- styrene, 4-n-propylstyrene, -methyl-styrene, -ethyl-styrene, ⁇ -methyl-p- methylstyrene, p-hydroxy-styrene, methoxy-styrenes, chloro-styrene, 2- methyl-4-chloro styrene, bromo-styrene, ⁇ -chloro-styrene, ⁇ -bromo-styrene, dichloro-styrene, 2,6-dichloro-4-methyl-styrene, dibromo-styrene, tetrachloro- styrene and mixtures thereof.
  • Various monomers may be further utilized in addition to or in place of those listed above to further modify various properties of the compositions disclosed herein.
  • the components of the present invention may be compounded with a copolymerizable monomer or monomers within a range not damaging the objectives and advantages of this invention.
  • the rubber phase may in addition to or in place of SBR may be comprised of polybutadiene, butadiene-acrylonitrile copolymers, polyisoprene, EPM and EPR rubbers (ethylene/ propylene rubbers), EPDM rubbers (ethylene/ propylene/ non-conjugated diene rubbers) and crosslinked alkylacrylate rubbers based on C ⁇ -C 8 alkylacrylates, in particular ethyl, butvl and ethylhexylacrylates, either alone or as a mixture of two or more kinds.
  • the rubber may comprise either a block or random copolymer.
  • monomers including vinyl naphthalene, vinyl anthracene, vinyl carboxylic acids such as acrylic acid and methacrvlic acid, acrylamides such as acrylamide, methacrylamide and n-butyl acrylamide, alpha-, beta-unsaturated dicarboxylic anhydrides such as maleic anhydride and itaconic anhydride, imides of alpha-, beta-unsaturated dicarboxylic acids such as maleimide, N-methylmaleimide, N-ethylmaleimide, N-Aryl maleimide and the halo substituted N-alkyl N-aryl maleimides, imidized polymethyl methacrylates (polyglutarimides), unsaturated ketones such as vinyl methyl ketone and methyl isopropenyl ketone, alpha-olefins such as ethylene and
  • the ABS type thermoplastic resin preferably utilized is based on 5 to 80 weight percent styrene-butadiene (15:85 to 25:75) copolymer rubber substrate grafted with 20 to 95 weight percent styrene-acrylonitrile (90:10 to 60:40) or optionally either poly methylmethacrylate (PMMA) or methyl methacrylate-styrene-acrylonitrile (MMASAN) (35:35:30 to 70:20:10) and optionally blended with additional SAN or MMASAN copolymers to achieve the desired rubber content.
  • PMMA poly methylmethacrylate
  • MMASAN methyl methacrylate-styrene-acrylonitrile
  • the typical ABS type resin has an opacity of 80 to 90 percent or greater.
  • opacity ranging from 5 percent to 90 percent, preferably from 30 percent to 90 percent, more preferably from 55 percent to 90 percent and most preferably from 80 percent to 90 percent opacity.
  • Opacity as herein defined is measured on a 25D Hunter Colorimeter and expressed as a percent wherein the percent opacity is related to the percent by the following relationship:
  • percent opacity 100 -percent transmission.
  • the term metal particles includes flakes, thin film, foil, platelets or spheroids that have a metallic appearance. Preferred metal particles are based on metals of Group I-B, III-A, IV, VI-B and VIII of the periodic table. Also, physical mixtures or alloys of these metals may be employed. Examples of these metals include aluminum, bronze, brass, chromium, copper, gold, iron, lead, molybdenum, nickel, tin, titanium, zinc and the 'ike.
  • a "cornflake” type or corrugated irregularly shaped planar flake of aluminum or bronze is preferred, although a "silver dollar” type or a circular planar type of flake may also be utilized.
  • Use of metal par icles having two or more average flake sizes, i.e. at least two different average particle sizes, has been found to give much better control of the desired appearance and also been found to allow a greater consistency of achieving the desi ⁇ °d appearance.
  • Glitter is a special type of aluminum pigment produced from foil.
  • the foil rolled to gauges of less than 0.001 inch, is cut into square, rectangular or hexagonal shapes in sizes from 0.008 to 0.125 inch and typically coated with a transparent epoxy lacquer to halt oxidative dulling of the foil. Glitter, with its large particle sizes, can produce discrete specular highlights.
  • Gold bronzes are actually brasses—alloys of copper and zinc with a small amount of aluminum to reduce oxidation.
  • the range of gold colors is produced by varying proportions of major alloy components.
  • the green golds contain 70 percent copper, and color becomes redder as the percentage of copper is increased; 90 percent copper produces pale gold; deep golds are made by controlled oxidation of the alloys.
  • Gold bronzes are usually utilized in flake form, with coarser grades giving more brilliance. Copper must be utilized with care, however, as it is susceptible to heat, moisture and corrosives.
  • Lubricants such as ethylene bis stearamide, butyl stearate, glycerin or mineral oils or the like are preferably included in the resin formulation.
  • the preferred dyes ⁇ r pigments are organic dyes or pigment complexes which are, in themselves, soluble in the resin matrix.
  • organic dyes and pigments include the following classes and examples: furnace carbon black, phthalocyanine blues or greens, anthraquinone dyes, scarlet 3b Lake, azo compounds and acid azo pigments, quinacridones, chromophthalocyanine pyrrols, halogenated phthalocyanines, quinolines, heterocyclic dyes, perinone dyes, anthracenedione dyes, thioxanthene dyes, parazolone dyes, polymethine pigments and others.
  • Suitable redox initiators include di-tert-butvl peroxide, benzoyl peroxide, lauroyl peroxide, oleyl peroxide, toluyl peroxide, di-tert-butyl diperphthalate, tert-butyl peracetate, tert-butyl perbenzoate, dicumvl peroxide, tert-butyl peroxide, isopropyl carbonate, 2,5-dimethyl-2,5-dimethyl- 2,5-di(tert-butylperoxy)hexane, 2,5-dimethyl-2,5-di(tertbutylperoxy) hexane-3 or hexyne-3, tert-butyl hydroper
  • additives such as heat and ultraviolet light stabilizers, antioxidants, flow aids, mold or metal release agents ⁇ antistatic agents, flame and fire retardants, plasticizers, fillers, drip suppressants, mineral additives and fillers, reinforcing agents, and the like.
  • This example illustrates the use of an appropriate ABS resin with metal particles of two different sizes and organic dyes.
  • HRG is a SBR/ SAN graft of 50% styrene-butadiene rubber and 50% styrene-acrylonitrile, with the styrene-butadiene rubber being 85% styrene and 15% butadiene and the grafted styrene-acrylonitrile being 75% styrene and 25% acrylonitriie.
  • the graft phase particle size averaged 3000 angstroms (.3 microns).
  • SAN is a copolymer of styrene-acrylonitrile of 72% styrene and 28% acrylonitriie with a weight molecular average of 100,000.
  • This example illustrates the use of n appropriate ABS resin with metal particles of three different average sizes, specifically 17.5, 40 and 70 microns average size, and various inorganic pigments.
  • the invention may be modified with various other monomers including various mo no vinylidene aromatic, ethylenically unsaturated nitrile and aery late monomers and applied to special effect colorants other than metal flake such as pearlescents, granites, fluorescents, phosphorescents, luminescents, thermochromics, photochromies and other such pigments.

Abstract

Lower opacity ABS resins with special effect colorants such as metal flake are disclosed. The finished products have a bright, reflective sparkle appearance. Lower opacity ABS resins based on styrene-butadiene copolymer rubber substrate and grafted with styrene-acrylonitrile or methyl methacrylate-styrene-acrylonitrile are utilized. Improved control of finished color, look and consistency may be achieved through the use of two or more metal particles sizes and/or organic dyes and pigments.

Description

ABS RESIN COMPOSITIONS CONTAINING METALLIC PARTICLES
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The present invention relates to lower opacity ABS resin compositions containing special-effect colorants and articles molded from such resin compositions. More particularly, the invention relates to metallic particle containing ABS resin compositions and articles displaying reflective sparkle appearance.
DESCRIPTION OF THE RELATED ART
Acrylonitrile-butadiene-styrene (ABS) plastics, which are rubber and thermoplastic composites, comprise a broad, versatile family of graft copolymers. Most ABS products consist of a two phase system of a grafted terpolymer, acrylonitrile-butadiene-styrene, dispersed in a glassy continuous matrix of styrene-acrylonitrile (SAN) copolymer. The graft terpolymer typically consists of a polybutadiene rubber core and grafted SAN shell, small amounts of styrene and acrylonitriie being grafted onto the rubber particles to compatibilize the two phases. The broad versatility of ABS results from the many compositional and structural variables that can be selected to achieve a desired property balance.
In the ABS manufacturing process, three distinct polymerization reactions or stages are involved. First the elastomeric (rubber) component, either butadiene homopolymer, a styrene-butάdiene or an acrylonitrile- butadiene copolymer, is produced. This phase can be carried out either in a water-based emulsion or in a solution polymerization process. In the second stage, the styrene and acrylonitriie (50-90/10-50) are copolymerized optionally with other monomers and grafted onto the elastomeric phase to achieve the desired compatibility. The rubber content of an ABS graft may range from 10 to 90 weight percent. This stage can be performed either in emulsion, bulk/ mass or via suspension and/ or the emulsion-suspension process route. In the third stage, styrene and acrylonitriie and, optionally, other olefin monomers are copolymerized either simultaneously with the grafting stage or separately in an independent operation to form the rigid matrix. Again, this step may involve one or more of the following processes: emulsion, bulk or suspension polymerization. The SAN matrix may range from 10 to 90 weight percent of the ABS graft composition.
In addition, the ABS materials may be produced by various process techniques known as batch, semi-batch or continuous polymerization for reasons of either manufacturing economics, product performance or both.
To alter specific properties of the resulting polymers, other monovinylidene aromatic, ethylenically unsaturated nitrile and acrylate monomers may be incorporated. The physical properties of ABS plastics vary somewhat with their method of manufacture but more so with their composition.
In order to improve the appearance, various particle pigments such as metal particles and flakes, pearlescents, granites, fluorescents, phosphorescents, luminescents and other such pigments have c°en utilized as special effect colorants for polymeric materials.
Metallic flake particles or pigments are opaque to visible light, typically reflective and are usually conductors of electricity. They are used in formulations to provide metallic finishes having many functions, for example appearance, greater durability, moisture proofing, heat resistance or economical coverage. The metallic pigments utilized most frequently in plastics are aluminum, for silvery colors, followed by copper and copper alloys, the last known as bronzes or gold bronzes.
Both bronze and aluminum flake can be colored by several different methods or used with conventional transparent colorants. Metallic pigments are typically marketed in a spheroidal or flake form. Leafing and non-leafing grades are available. Aluminum flake may be utilized in damp powder or paste form, which minimizes the hazards of dust and fire, in plasticizers or mineral oil in a 5 to 80 percent metallic pigment concentration, with or without color concentrates. Gold bronzes may be coated with stearic acid (less than 1 percent) to provide lubricity during milling.
Among the problems to be solved when utilizing ABS resins and metallic pigments to produce metallic particle containing ABS resin compositions and molded articles are those related to composition coloring and those related to producing a very bright, metallic reflective sparkle appearance in molded articles. Metal particles typically appear dull or lacking in a bright reflective sparkle appearance in ABS products because the ABS resins utilized are fairly opaque. The opacity of the resin in which Tie metal flake or metal particles are dispersed interferes with reflectivity oi the metallic particles unless the particles are at the surface of the of the polymer. Thus, the highly opaque nature of the ABS resin dulls the metallic luster of the metal flake or metal particles dispersed in the ABS resin.
Previous approaches to producing metal pigmented polymers of having a high reflective appearance have primarily concentrated on improving the dispersion of the metal particles in the polymer matrix in order to prevent visible blotches and agglomerations of particles and on improving the shelf life and stability of metallic color concentrates. For example, U.S. Patent No. 4,544,600 (1985) to Kern discloses metal filled polymers showing improved dispersion in polymeric matrices, exhibiting reduced agglomeration and improved shelf life. Products containing metallic pigments were prepared by using a terpene phenol resin coating with either a polyethylene resin or other hydrocarbon resin or an organic additive like mineral oil or organic ester plasticizers over the metallic particles. While reducing agglomeration, this approach does not solve the problem of metal particles which appear dull or are lacking in a bright reflective sparkle appearance when utilized in ABS plastics.
U.S. Patent No. 5,324,472 (1994) to Page et al. discloses a process for preparing metal flake plastics comprising multiplane rotational molding of thermoplastic polymers such as polyolefins (preferably polyethylene) with additives such as emulsifiers, surfactants, dispersants, pigments and metal flakes in such a manner as to evenly distribute the metal flakes. For various reasons, probably relating to factors such as prolonged heat exposure and shear, ABS resins are not well suited for use in rotational molding and sucr an approach has not yet proven successful with ABS plastics.
SUMMARY OF THE INVENTION
It is therefore seen that there is a particular need for low cost, lower opacity ABS plastics containing special effect colorants such as metal flake and particle pigments. It is particularly desirable that the metal particles display a bright, reflective metallic sparkle appearance rather than appearing dull. It is further desirable that the look and consistency a the finished product can be controlled.
To achieve these advantages, the present invention utilizes an ABS resin based on a styrene-butadiene copolymer rubber (SBR) substrate grafted with styrene-acrylonitrile or methyl methacrylate-styrene-acrylonitrile (MMASAN) and optionally blended with additional SAN, MMASAN or other copolymers to achieve the desired rubber content. Three or more metal particle sizes (average size) are be employed. Organic dyes or pigments that are soluble in the resin matrix may be used to provide further advantages.
The present invention generally provides for an acrylonitrile- butadiene-styrene type composition comprising: a) a copolymer derived from both a vinyl aromatic monomer and a vinyl cyanide monomer wherein the copolymer is present at a weight percent level of from about 40 to about 80 percent by weight based on the total weight of the composition; b)a graft copolymer comprising a substrate copolymer and a superstrate copolymer wherein the substrate copolymer comprises a copolymer derived from a vinyl aromatic monomer and a di-olefin monomer and wherein the superstrate copolymer comprises a copolymer derived from both a vinyl aromatic monomer and a vinyl cyanide monomer wherein the graft copolymer is present at a level of from about 20 to about 60 weight percent of the total weight of the composition; and c) a special effect colorant selected from the group consisting of metal particles, pearlescents, granites, fluorescents, phosphorescents and luminescents. More particularly the present invention provides for an acrylonitrile-butadiene-styrene type (ABS) composition comprising: a) a copolymer derived from both a vinyl aromatic monomer and a vinyl cyanide monomer wherein the copolymer is present at a weight percent level of from about 40 to about 80 percent by weight based on the total weight of the composition; b) a graft copolymer comprising a substrate copolymer and a superstrate copolymer wherein the substrate copolymer comprises a copolymer derived from a vinyl aromatic monomer and a di- olefin monomer and wherein the superstrate copolymer comprises a copolymer derived from both a vinyl aromatic monomer and a vinyl cyanide monomer wherein the graft copolymer is present at a level of from about 20 to about 60 weight percent of the total weight of the composition; and c) metal particles wherein the metal particles have at least three different average sizes.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
It has been found that combining a low cost, lower opacity ABS type thermoplastic with metallic particles results in a lower opacity polymer composite with a very bright, metallic reflective sparkle appearance coupled with the performance advantages of ABS polymers. It has further been found that by utilizing metallic particles of two or more different sizes, both more consistency and more control of the final appearance may be achieved.
The ABS type thermoplastic resins utilized by the present invention are graft copolymers of vinyl cyanide monomers, di-olefins and vinylaromatic monomers. Thus applicants define herein the phrase ABS type or acrylonitriie butadiene styrene type to include the group of polymers derived from vinyl cyanide monomers, di-olefins, and vinyl aromatic monomers as hereinafter defined. Vinyl cyanide monomers are herein defined by the following structural formula:
Figure imgf000007_0001
where R is selected from the group consisting of hydrogen, alkyl groups of from 1 to 5 carbon atoms, bromine and chlorine. Examples of vinyl cyanide monomers include acrylonitriie, ethacrylonitrile, methacrylonitrile, α- chloroacrylonitrile and α-bromoacrylonitrile. The di-olefins utilized in the present invention are herein defined by the following structural formula:
Figure imgf000008_0001
where each Q is independently selected from the group consisting of hydrogen, alkyl groups of from 1 to 5 carbon atoms, bromine and chlorine. Examples of di-olefins include butadiene, isoprene, 1,3-heptadiene, methyl- 1,3-pentadiene, 2,3-dimethylbutadiene, 2-ethyl-l,3-pentadiene, 1,3 hexadiene, 2,4-hexadiene, dichlorobutadiene, dibromobutadiene, chlorobutadiene, bromobutadiene and mixtures thereof. Vinyl aromatic monomers are herein defined by the following structural formula:
Figure imgf000008_0002
where each X is independently selected from the group consisting of hydrogen, alkyl groups of from 1 to 5 carbon atoms, cycloalkyl, aryl, alkaryl, aralkyl, alkoxy, aryloxy and halogen and where R is selected from the group consisting of hydrogen, alkyl groups of from 1 to 5 carbon atoms, bromine and chlorine. Examples of substituted vinyl aromatic monomers include styrene, 4-methylstyrene, vinyl xylene, 3,5-diethylstyrene, p-tert-butyl- styrene, 4-n-propylstyrene, -methyl-styrene, -ethyl-styrene, α-methyl-p- methylstyrene, p-hydroxy-styrene, methoxy-styrenes, chloro-styrene, 2- methyl-4-chloro styrene, bromo-styrene, α-chloro-styrene, α-bromo-styrene, dichloro-styrene, 2,6-dichloro-4-methyl-styrene, dibromo-styrene, tetrachloro- styrene and mixtures thereof. It will be understood that by the use of "monomers" are included all of the polymerizable species of monomers and copolymers typically utilized in polymerization reactions, including by way of example monomers, homopolymers of primarily a single monomer, copolymers of two or more monomers, terpolymers of three monomers and physical mixtures thereof.
Various monomers may be further utilized in addition to or in place of those listed above to further modify various properties of the compositions disclosed herein. In general, the components of the present invention may be compounded with a copolymerizable monomer or monomers within a range not damaging the objectives and advantages of this invention. For example, the rubber phase may in addition to or in place of SBR may be comprised of polybutadiene, butadiene-acrylonitrile copolymers, polyisoprene, EPM and EPR rubbers (ethylene/ propylene rubbers), EPDM rubbers (ethylene/ propylene/ non-conjugated diene rubbers) and crosslinked alkylacrylate rubbers based on Cι-C8 alkylacrylates, in particular ethyl, butvl and ethylhexylacrylates, either alone or as a mixture of two or more kinds. Furthermore, the rubber may comprise either a block or random copolymer. In addition to or in place of styrene and acrylonitriie monomer used in the grafted or free rigid resins, monomers including vinyl naphthalene, vinyl anthracene, vinyl carboxylic acids such as acrylic acid and methacrvlic acid, acrylamides such as acrylamide, methacrylamide and n-butyl acrylamide, alpha-, beta-unsaturated dicarboxylic anhydrides such as maleic anhydride and itaconic anhydride, imides of alpha-, beta-unsaturated dicarboxylic acids such as maleimide, N-methylmaleimide, N-ethylmaleimide, N-Aryl maleimide and the halo substituted N-alkyl N-aryl maleimides, imidized polymethyl methacrylates (polyglutarimides), unsaturated ketones such as vinyl methyl ketone and methyl isopropenyl ketone, alpha-olefins such as ethylene and propylene, vinyl esters such as vinyl acetate and vinyl stearate, vinyl and vinylidene halides such as the vinyl and vinylidene chlorides and bromides and pyridine monomers may be used, either alone or as a mixture of two or more kinds.
The ABS type thermoplastic resin preferably utilized is based on 5 to 80 weight percent styrene-butadiene (15:85 to 25:75) copolymer rubber substrate grafted with 20 to 95 weight percent styrene-acrylonitrile (90:10 to 60:40) or optionally either poly methylmethacrylate (PMMA) or methyl methacrylate-styrene-acrylonitrile (MMASAN) (35:35:30 to 70:20:10) and optionally blended with additional SAN or MMASAN copolymers to achieve the desired rubber content.
The typical ABS type resin has an opacity of 80 to 90 percent or greater.
In contrast to ABS type resins based on grafted polybutadiene (PBD), wτhere the reported refractive index of the polybutadiene is 1.515, styrene butadiene rubbers have a slightly higher refractive index. At a copolymer composition of 85 weight percent butadiene 15 weight percent styrene for the rubber phase (SBR), the calculated refractive index is 1.526. This is a value of the refractive index that is closer to that calculated for the matrix polymer derived from styrene acrylonitriie which is 1.572. This slight difference in the refractive inde> between the components makes an ABS built on an SBR graft core slightly less opaque than an ABS built on a PBD graft core. This slightly lower opacity contributes to a greater depth of field in the polymer matrix and allows a higher reflectivity of any dispersed metal particles contained in the ABS resin. Generally the less opaque the ABS resin is, the more enhanced the reflective the appearance of the metal particles dispersed in the ABS resin when it contains metallic or metal flake particles. This effect occurs over a broad range of opacity values for the ABS resin from values for the opacity that are close to transparent to values slightly below the usual commercial grades of ABS resins. Thus this effect occurs at an opacity ranging from 5 percent to 90 percent, preferably from 30 percent to 90 percent, more preferably from 55 percent to 90 percent and most preferably from 80 percent to 90 percent opacity. Opacity as herein defined is measured on a 25D Hunter Colorimeter and expressed as a percent wherein the percent opacity is related to the percent by the following relationship:
percent opacity = 100 -percent transmission.
Metal particles ranging in size between 17.5 and 650 microns used in loadings of 0.01 to 20. 0 weight percent, preferably 0.10 to 15.0 weight percent, more preferably 0.25 to 10.0 weight percent, and most preferably 0.5 to 5.0 weight percent are preferred. The term metal particles includes flakes, thin film, foil, platelets or spheroids that have a metallic appearance. Preferred metal particles are based on metals of Group I-B, III-A, IV, VI-B and VIII of the periodic table. Also, physical mixtures or alloys of these metals may be employed. Examples of these metals include aluminum, bronze, brass, chromium, copper, gold, iron, lead, molybdenum, nickel, tin, titanium, zinc and the 'ike. For most applications, a "cornflake" type or corrugated irregularly shaped planar flake of aluminum or bronze is preferred, although a "silver dollar" type or a circular planar type of flake may also be utilized. Use of metal par icles having two or more average flake sizes, i.e. at least two different average particle sizes, has been found to give much better control of the desired appearance and also been found to allow a greater consistency of achieving the desiι°d appearance.
Aluminum flakes produce a satiny silver luster. In general, smaller particle sizes tend to have greater opacity and hiding power with a grayish effect, while larger flake sizes show greater brightness and reflectivity with increased metallic sparkle. Combination of particle sizes are utilized to balance tinctorial strength and specular effects in addition to providing control of look and consistency. Glitter is a special type of aluminum pigment produced from foil. The foil, rolled to gauges of less than 0.001 inch, is cut into square, rectangular or hexagonal shapes in sizes from 0.008 to 0.125 inch and typically coated with a transparent epoxy lacquer to halt oxidative dulling of the foil. Glitter, with its large particle sizes, can produce discrete specular highlights.
Gold bronzes are actually brasses—alloys of copper and zinc with a small amount of aluminum to reduce oxidation. The range of gold colors is produced by varying proportions of major alloy components. The green golds contain 70 percent copper, and color becomes redder as the percentage of copper is increased; 90 percent copper produces pale gold; deep golds are made by controlled oxidation of the alloys. Gold bronzes are usually utilized in flake form, with coarser grades giving more brilliance. Copper must be utilized with care, however, as it is susceptible to heat, moisture and corrosives.
Lubricants such as ethylene bis stearamide, butyl stearate, glycerin or mineral oils or the like are preferably included in the resin formulation.
The preferred dyes ■ r pigments, if desired, are organic dyes or pigment complexes which are, in themselves, soluble in the resin matrix. These organic dyes and pigments include the following classes and examples: furnace carbon black, phthalocyanine blues or greens, anthraquinone dyes, scarlet 3b Lake, azo compounds and acid azo pigments, quinacridones, chromophthalocyanine pyrrols, halogenated phthalocyanines, quinolines, heterocyclic dyes, perinone dyes, anthracenedione dyes, thioxanthene dyes, parazolone dyes, polymethine pigments and others. It may be necessary to use small quantities of inorganic pigments such as Ti02, iron oxide, cadmium-mercury compounds, cadmium-lithium compounds, etc. to achieve certain colors, but such inorganic pigments are generally not used. Suitable redox initiators include di-tert-butvl peroxide, benzoyl peroxide, lauroyl peroxide, oleyl peroxide, toluyl peroxide, di-tert-butyl diperphthalate, tert-butyl peracetate, tert-butyl perbenzoate, dicumvl peroxide, tert-butyl peroxide, isopropyl carbonate, 2,5-dimethyl-2,5-dimethyl- 2,5-di(tert-butylperoxy)hexane, 2,5-dimethyl-2,5-di(tertbutylperoxy) hexane-3 or hexyne-3, tert-butyl hydroperoxide, cumene hydroperoxide, p-menthane hydroperoxide, cyclopentane hydroperoxide, pinane hydroperoxide, 2,5- dimethylhexane-2,5-dihydroperoxide and mixtures thereof.
There may optionally be added to the resin phases, during or after formation, such additives as heat and ultraviolet light stabilizers, antioxidants, flow aids, mold or metal release agents^ antistatic agents, flame and fire retardants, plasticizers, fillers, drip suppressants, mineral additives and fillers, reinforcing agents, and the like.
The following examples are presented as illustrations of the preparation and utility of the ^resent ABS compositions. The examples are not intended in any way to limit the spirit and scope of the invention.
All United States patents refere iced herein are hereby and herewith specifically incorporated by reference.
EXAMPLE 1
This example illustrates the use of an appropriate ABS resin with metal particles of two different sizes and organic dyes.
HRG is a SBR/ SAN graft of 50% styrene-butadiene rubber and 50% styrene-acrylonitrile, with the styrene-butadiene rubber being 85% styrene and 15% butadiene and the grafted styrene-acrylonitrile being 75% styrene and 25% acrylonitriie. The graft phase particle size averaged 3000 angstroms (.3 microns). SAN is a copolymer of styrene-acrylonitrile of 72% styrene and 28% acrylonitriie with a weight molecular average of 100,000.
Table I
Parts by weight
HRG 32.0
SAN 68.0
EBS wax lubricant 0.5
Magnesium oxide acid stabilizer 0.1
Metallic particles: 95 microns 0.05
Metallic particles: 225 microns 1.1
Titanium Dioxide 0.100
Carbon Black 0.009
Perinone dye 0.045
Chloropthalo ' 0.038
Anthraquinone 0.140
EXAMPLE 2
This example illustrates the use of n appropriate ABS resin with metal particles of three different average sizes, specifically 17.5, 40 and 70 microns average size, and various inorganic pigments.
Table II
Parts by weight
HRG 48.0
SAN 52.0
EBS wax lubricant 1.0
Magnesium Stearate lubricant 0.5
Magnesium oxide acid stabilizer 0.1
Metallic particles: 17.5 microns 0.25
Metallic particles: 40 microns 0.25
Metallic particles: 70 microns 3.0
Black iron oxide 0.003
Sodium aluminum silicate 0.004
Rutile titanium nickel antimonv chromium oxide 0.014
No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred. As those skilled in the art, upon attaining an understanding of the invention, may readily conceive of alterations to, modifications of, and equivalents to the preferred embodiments without departing from the principles of the invention, it is intended to cover all these alternatives, modifications and equivalents. By way of example, but not of limitation, it would be obvious to those skilled in the ai that the invention may be modified with various other monomers including various mo no vinylidene aromatic, ethylenically unsaturated nitrile and aery late monomers and applied to special effect colorants other than metal flake such as pearlescents, granites, fluorescents, phosphorescents, luminescents, thermochromics, photochromies and other such pigments.

Claims

WHAT IS CLAIMED IS:
1. An acrylonitrile-butadiene-styrene type composition comprising:
a) a copolymer derived from both a vinyl aromatic monomer and a vinyl cyanide monomer wherein the copolymer is present at a weight percent level of from about 40 to about 80 percent by weight based on the total weight of the composition;
b) a graft copolymer comprising a substrate copolymer and a superstrate copolymer wherein the substrate copolymer comprises a copolymer derived from a vinyl aromatic monomer and a di-olefin monomer and wherein the superstrate copolymer comprises a copolymer derived from both a vinyl aromatic monomer and a vinyl cyanide monomer wherein the graft copolymer is present at a level of from about 20 to about 60 weight percent of the total weight of the composition; and
c) a special effect colorant selected from the group consisting of metal particles, pearlescents, granites, fluorescents, phosphorescents and luminescents.
2. An acrylonitrile-butadiene-styrene type (ABS) composition comprising:
a) a copolymer derived from both a vinyl aromatic monomer and a vinyl cyanide monomer wherein the copolymer is present at a weight percent level of from about 40 to about 80 percent by weight based on the total weight of the composition;
b) a graft copolymer comprising a substrate copolymer and a superstrate copolymer wherein the substrate copolymer comprises a copolymer derived from a vinyl aromatic monomer and a di-olefin monomer and wherein the superstrate copolymer comprises a copolymer derived from both a vinyl aromatic monomer and a vinyl cyanide monomer wherein the graft copolymer is present at a level of from about 20 to about 60 weight percent of the total weight of the composition; and
c) metal particles wherein the metal particles have at least three different average sizes.
3. The ABS composition of claim 2 wherein the ABS . .sin is characterized by an opacity of from 80 to 90 percent.
4. The ABS composition of claim 3 wherein the metal particles comprise from 0.01 to 20.0 weight percent of the ABS composition.
5. The ABS composition of claim 4 wherein the metal particles range in size from 17.5 microns to 650 microns.
6. The ABS composition of claim 5 wherein the metal particles are selected from the group consisting of metals of Group I-B, III- A, IV, VI-B and VIII of the periodic table and physical mixtures and alloys of these metals.
7. The ABS composition of claim 6 wherein the metal particles are selected from the group of metals consisting of aluminum, bronze, brass, chromium, copper, gold, iron, lead, molybdenum, nickel, tin, titanium and zinc, alloys of these metals and physical mixtures thereof.
8. The ABS composition of claim 7 wherein the ABS resin further comprises a lubricant.
9. The ABS composition of claim 8 wherein the lubricant is selected from the group consisting of ethylene bis stearamide, butyl stεarate, magnesium stearate, glycerin and mineral oils
10. The ABS composition of claim 9 wherein the ABS resin further comprises an organic dye wherein the organic dye is soluble in the ABS resin.
11. The ABS composition of claim 10 wherein the organic dye is selected from the group consisting of furnace carbon black, phthalocyanine blues, phthalocyanine greens, anthraquinone dyes, scarlet 3b Lake, azo compounds, acid azo pigments, quinacridones, chromophthalocyanine pyrrols, halogenated phthalocyanines, quinolines, heterocyclic dyes, perinone dyes, anthracenedione dyes, thioxanthene dyes, parazolone dyes and polvmethine pigments.
12. The ABS composition of claim 11 wherein the ABS resin further comprises an inorganic pigment.
13. The ABS composition of claim 12 wherein the inorganic pigment is selected from the group consisting of titanium dioxide, iron oxide, cadmium-mercury compounds and cadmium-lithium compounds.
14. An acrylonitrile-butadiene-styrene type (ABS) composition consisting essentially of:
a) a copolymer derived from both a vinyl aromatic monomer and a vinyl cyanide monomer wherein the copolymer is present at a weight percent level of from about 40 to about 80 percent by weight based on the total weight of the composition; b) a graft copolymer comprising a substrate copolymer and a superstrate copolymer wherein the substrate copolymer comprises a copolymer derived from a vinyl aromatic monomer and a di-olefin monomer and wherein the superstrate copolymer comprises a copolymer derived from both a vinvl aromatic monomer and a vinvl cyanide monomer wherein the graft copolymer is present at a level of from about 20 to about 60 weight percent of the total weight of the composition; and
c) metal particles wherein the metal particles have at least three different average sizes.
15. The ABS composition of claim 14 wherein the ABS resin is characterized by an opacity of from 80 to 90 percent.
16. The ABS composition of claim 15 wherein the metal particles comprise from 0.01 to 20.0 weight percent of the ABS composition.
17. The ABS composition of claim 16 wherein the metal particles range in size from 17.5 microns to 650 microns.
18. The ABS composition of claim 17 wherein the metal particles are selected from the group consisting of metals of Group I-B, III- A, IV, VI-B and VIII of the periodic table and physical mixtures and alloys of these metals.
19. The ABS composition of claim 18 wherein the metal particles are selected from the group of metals consisting of aluminum, bronze, brass, chromium, copper, gold, iron, lead, molybdenum, nickel, tin, titanium and zinc, alloys of these metals and physical mixtures thereof.
20. The ABS composition of claim 19 wherein the ABS resin further comprises a lubricant.
21. The ABS composition of claim 20 wherein the lubricant is selected from the group consisting of ethylene bis stearamide, butyl stearate, magnesium stearate, glycerin and mineral oils
22. The ABS composition of claim 21 wherein the ABS resin further comprises an organic dye wherein the organic dye is soluble in the ABS resin.
23. The ABS composition of claim 22 wherein the organic dye is selected from the group consisting of furnace carbon black, phthalocyanine blues, phthalocyanine greens, anthraquinone dyes, scarlet 3b Lake, azo compounds, acid azo pigments, quinacridones, chromophthalocyanine pyrrols, halogenated phthalocyanines, quinolines, heterocyclic dyes, perinone dyes, anthracenedione dyes, thioxanthene dyes, parazolone dyes and polymethine pigments.
24. The ABS composition of claim 23 wherein the ABS resin further comprises an inorganic pigment.
25. The ABS composition of claim 24 wherein the inorganic pigment is selected from the group consisting of titanium dioxide, iron oxide, cadmium-mercury compounds and cadmium-lithium compounds.
PCT/US2000/031606 1999-12-07 2000-11-16 Abs resin compositions containing metallic particles WO2001042356A1 (en)

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US09/456,125 1999-12-07

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2604647A1 (en) * 2011-12-13 2013-06-19 Cheil Industries Inc. Thermoplastic resin composition
CN104530633A (en) * 2014-12-24 2015-04-22 陈程 High-strength ABS (acrylonitrile-butadiene-styrene) conducting composite material and preparation method thereof
CN109880280A (en) * 2019-03-27 2019-06-14 金旸(厦门)新材料科技有限公司 It is a kind of to exempt from spraying ABS material and preparation method thereof with 3D pearl effect
CN111995863A (en) * 2020-07-09 2020-11-27 柏力开米复合塑料(昆山)有限公司 PA/ABS alloy material based on pyrene ketone dye coloring
EP3943546A4 (en) * 2019-10-25 2022-06-22 Lg Chem, Ltd. Thermoplastic resin composition

Citations (3)

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Publication number Priority date Publication date Assignee Title
US4461865A (en) * 1981-08-31 1984-07-24 Denki Kagaku Kogyo Kabushiki Kaisha ABS Resin composition
EP0203635A1 (en) * 1985-05-10 1986-12-03 Akzo N.V. Metallized polymer compositions, processes for their preparation and their uses
EP0549205A2 (en) * 1991-12-27 1993-06-30 Ge Plastics Japan Limited Low-gloss thermoplastic resin compositions

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4461865A (en) * 1981-08-31 1984-07-24 Denki Kagaku Kogyo Kabushiki Kaisha ABS Resin composition
EP0203635A1 (en) * 1985-05-10 1986-12-03 Akzo N.V. Metallized polymer compositions, processes for their preparation and their uses
EP0549205A2 (en) * 1991-12-27 1993-06-30 Ge Plastics Japan Limited Low-gloss thermoplastic resin compositions

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2604647A1 (en) * 2011-12-13 2013-06-19 Cheil Industries Inc. Thermoplastic resin composition
US8962733B2 (en) 2011-12-13 2015-02-24 Cheil Industries Inc. Thermoplastic resin composition
CN104530633A (en) * 2014-12-24 2015-04-22 陈程 High-strength ABS (acrylonitrile-butadiene-styrene) conducting composite material and preparation method thereof
CN109880280A (en) * 2019-03-27 2019-06-14 金旸(厦门)新材料科技有限公司 It is a kind of to exempt from spraying ABS material and preparation method thereof with 3D pearl effect
EP3943546A4 (en) * 2019-10-25 2022-06-22 Lg Chem, Ltd. Thermoplastic resin composition
CN111995863A (en) * 2020-07-09 2020-11-27 柏力开米复合塑料(昆山)有限公司 PA/ABS alloy material based on pyrene ketone dye coloring
CN111995863B (en) * 2020-07-09 2022-12-02 柏力开米复合塑料(昆山)有限公司 PA/ABS alloy material based on pyrene ketone dye coloring

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