Low gloss non-coating thermoplastic resin composition, method for manufacturing molded article by using the same, and molded article manufactured through the same

Patent metadata

Field	Value
Publication number	US-12060485-B2
Application number	US-202017108839-A
Country	US
Kind code	B2
Filing date	Dec 1, 2020
Priority date	Apr 27, 2020
Publication date	Aug 13, 2024
Grant date	Aug 13, 2024

Abstract

The present invention relates to a non-coating thermoplastic resin composition, a method for manufacturing a molded article by using the same, and a molded article manufactured by the same. More specifically, the present invention is characterized by providing the thermoplastic resin composition which contains polycarbonate, polysiloxane-polycarbonate copolymer, polyester, master-batched carbon black, and additives in specific contents and the molded article, which has excellent chemical resistance, mechanical properties, light resistance, hydrolysis resistance, and low glossiness, manufactured by using the same.

First claim

What is claimed is:

1. A thermoplastic resin composition comprising:
a polycarbonate;
a polysiloxane-polycarbonate copolymer;
a polyester;
a gloss-reducing agent;
an impact-reinforcing agent; and
a carbon black,
wherein the carbon black is compounded into a master batch (MB),
the master batch comprises the carbon black and the polycarbonate, and
the master batch comprises an amount of about 10% by weight to 40% by weight of the carbon black and an amount of about 60% by weight to 90% by weight of the polycarbonate, based on the total weight of the master batch,

wherein the thermoplastic resin composition comprises,
an amount of about 10% by weight to 65% by weight of the polycarbonate,
an amount of about 10% by weight to 45% by weight of the polysiloxane-polycarbonate copolymer,
an amount of about 10% by weight to 45% by weight of the polyester,
an amount of about 5% by weight to 25% by weight of the gloss-reducing agent,
an amount of about 1% by weight to 10% by weight of the impact-reinforcing agent, and
an amount of about 1.5% by weight to 8.5% by weight of the carbon black, based on the total weight of the thermoplastic resin composition,
wherein the gloss-reducing agent comprises an ASA(acrylonitrile styrene acrylate)-based graft copolymer having a core-shell structure,
wherein the impact-reinforcing agent comprises an MBS(methyl methacrylate butadiene styrene)-based graft copolymer having a core-shell structure.

2. The thermoplastic resin composition of claim 1 ,
wherein the polycarbonate is a thermoplastic aromatic polycarbonate having a viscosity average molecular weight (Mv) of about 15,000 to 40,000.

3. The thermoplastic resin composition of claim 1 ,
wherein the polycarbonate comprises a polymer of Formula 1 below:

where in Formula 1, X comprises a straight, branched, or cyclic alkylene group, or a straight, branched, or cyclic alkylene group comprising one functional group selected from the group consisting of sulfide, ether, sulfoxide, sulfone, ketone, naphthyl, isobutyl phenyl, and combinations thereof, R 1 and R 2 each independently comprise a hydrogen atom, a halogen atom, or an alkyl group, and n and m each comprise an integer of 0 to 4.

4. The thermoplastic resin composition of claim 1 ,
wherein the polysiloxane-polycarbonate copolymer has a viscosity average molecular weight (Mv) of about 15,000 to 200,000, and
comprises hydroxy terminal siloxane and the polycarbonate at a weight ratio of about 50:50 to 99:1.

5. The thermoplastic resin composition of claim 1 ,
wherein the polysiloxane-polycarbonate copolymer comprises polymers of Formulas 2 and 3 below:

where in Formula 2, R 3 independently comprises a hydrogen atom, a halogen atom, a hydroxy group, an alkyl group having 1 to 20 carbon atoms, an alkoxy group having 1 to 13 carbon atoms, or an aryl group having 6 to 10 carbon atoms, and R 4 independently comprises a hydrocarbon group having 1 to 13 carbon atoms or a hydroxy group, R 5 independently comprises an alkylene group having 2 to 8 carbon atoms, A refers to X or NH-X-NH, where X is a linear or branched aliphatic group having 1 to 20 carbon atoms, a cycloalkylene group having 3 to 6 carbon atoms, or a mononuclear or polynuclear arylene group having 6 to 30 carbon atoms unsubstituted or substituted with a halogen atom, an alkyl group, an alkoxy group, an aryl group, or a carboxyl group, m comprises an integer from 0 to 10, independently, and independently comprises an integer from 2 to 1,000:

where in Formula 3, R 6 comprises an alkyl group having 1 to 20 carbon atoms, a cycloalkyl group having 3 to 6 carbon atoms, an alkenyl group having 2 to 13 carbon atoms, an alkoxy group having 1 to 13 carbon atoms, an aromatic hydrocarbon group having 6 to 30 carbon atoms substituted or unsubstituted with a halogen atom, or a nitro.

6. The thermoplastic resin composition of claim 1 ,
wherein the polyester has a melt temperature of about 215 to 235° C. and an intrinsic viscosity (IV) of about 0.45 to 1.6 /g.

7. The thermoplastic resin composition of claim 1 ,
wherein the polyester comprises one or more selected from the group consisting of polyethylene terephthalate, polypropylene terephthalate, and polybutylene terephthalate.

8. The thermoplastic resin composition of claim 1 ,
wherein the ASA-based graft copolymer comprises an amount of about 30% by weight to 80% by weight of a core and an amount of about 20% by weight to 70% by weight of a shell, based on the total weight of the ASA-based graft copolymer,
wherein the core of the ASA-based graft copolymer comprises an acrylic rubber, and
wherein the shell of the ASA-based graft copolymer comprises a vinyl-based graft copolymer.

9. The thermoplastic resin composition of claim 1 ,
wherein the core of the MBS-based graft copolymer comprises polybutadiene, and
wherein the shell of the MBS-based graft copolymer comprises one or more selected from the group consisting of alkyl methacrylate and alkyl acrylate.

10. The thermoplastic resin composition of claim 1 , further comprising an additive,
wherein the additive further comprises: one or more auxiliary agents selected from the group consisting of inorganic fillers, lubricants, antioxidants, light stabilizers, hydrolysis stabilizers, mold release agents, colorants, ultraviolet stabilizers, antistatic agents, conductivity imparting agents, magnetism imparting agents, cross-linking agents, antibacterial agents, processing aids, anti-frictional agents, anti-wear agents, and coupling agents.

11. The thermoplastic resin composition of claim 10 ,
wherein the thermoplastic resin composition comprises the auxiliary agent in an amount of about 0.1 parts by weight to 2 parts by weight based on 100 parts by weight of the polycarbonate.

12. A method for manufacturing a molded article, the method comprising:
manufacturing a pellet by melting and extruding a thermoplastic resin composition of claim 1 ; and
manufacturing a molded article by molding the pellet.

13. A molded article manufactured by the manufacturing method of claim 12 , wherein a 20° specular glossiness based on ISO 2813 is about 2.5 to 3.0.

14. A vehicle comprising a molded article of claim 12 .

Assignees

• Hyundai Motor Co Ltd
• Kia Motors Corp
• Samyang Corp

Inventors

• Yi Seul
• An Boo Youn
• Kim Dae Sik
• Jang Kyeong Hoon
• Kwon Min Woo
• Han In Soo
• Ahn Jin Gi
• Bae Do Young
• Roh Hyung Jin
• An Tae Jin
• Han Jung Kyu
• Jo Chul Jin
• Cheon Si Uk
• Kang Suk Woo

Classifications

• C08L2310/00

  Masterbatches · CPC title

• C08L2207/53

  Core-shell polymer · CPC title

• C08L2205/035

  containing four or more polymers in a blend · CPC title

• C08L83/14

  in which at least two but not all the silicon atoms are connected by linkages other than oxygen atoms (C08L83/10 takes precedence) · CPC title

• C08L67/02

  Polyesters derived from dicarboxylic acids and dihydroxy compounds (C08L67/06 takes precedence) · CPC title