Graft copolymer, production method therefor, resin composition, and molded article

Patent metadata

Field	Value
Publication number	US-9315634-B2
Application number	US-201113977300-A
Country	US
Kind code	B2
Filing date	Dec 27, 2011
Priority date	Dec 28, 2010
Publication date	Apr 19, 2016
Grant date	Apr 19, 2016

Abstract

Disclosed are a method of producing a graft copolymer, comprising polymerizing a vinyl monomer (B) containing a polyfunctional vinyl monomer (b1) in the presence of a polyorganosiloxane rubber (A) comprising more than 20% by mass of a toluene-insoluble matter, wherein a mass percentage of the polyfunctional vinyl monomer (b1) is 11 to 19% by mass based on 100% by mass of a total amount of the polyorganosiloxane rubber (A) and the vinyl monomer (B); a graft copolymer obtained by the method; a resin composition being prepared by blending the graft copolymer with a resin and having high impact resistance and heat resistance and sufficient flame retardancy; and a molded article obtained by molding the resin composition.

First claim

The invention claimed is:

1. A method of producing a graft copolymer, comprising polymerizing a vinyl monomer (B) containing a polyfunctional vinyl monomer (b1) in the presence of a polyorganosiloxane rubber (A) comprising more than 20% by mass of a toluene-insoluble matter,
wherein a mass percentage of the polyfunctional vinyl monomer (b1) is 11 to 19% by mass based on 100% by mass of a total amount of the polyorganosiloxane rubber (A) and the vinyl monomer (B).

2. The method of producing a graft copolymer according to claim 1 , wherein the polyfunctional vinyl monomer (b1) is allyl methacrylate.

3. The method of producing a graft copolymer according to claim 1 , wherein the mass percentage of the polyfunctional vinyl monomer (b1) is 13 to 17% by mass based on 100% by mass of the total amount of the polyorganosiloxane rubber (A) and the vinyl monomer (B).

4. A graft copolymer obtained by the production method according to claim 1 .

5. A resin composition comprising 100 parts by mass of a resin and 0.5 to 20 parts by mass of the graft copolymer according to claim 4 .

6. The resin composition according to claim 5 , wherein the resin is polycarbonate.

7. A molded article obtained by molding the resin composition according to claim 5 .

8. The molded article according to claim 7 , wherein the molded article is a casing for home appliances.

9. The molded article of claim 7 , wherein a total burning time of the molded article having a thickness of 1.6 mm in a UL94V test is 40 s or less.

10. The graft copolymer according to claim 4 , wherein when 5 parts by mass of the graft copolymer is blended with 100 parts by mass of a polycarbonate having a viscosity average molecular weight of 22000, 0.3 parts by mass of a phenol antioxidant represented by the following formula (1), 0.3 parts by mass of a phosphorus antioxidant represented by the following formula (2), and 0.5 parts by mass of a polytetrafluoroethylene having a mass average molecular weight of 8000000 to 15000000,
(1) Charpy impact strength at −30° C. is 20 kJ/m 2 or more, and
(2) a total burning time of a molded article having a thickness of 1.6 mm in a UL94V test is 40 s or less:

11. The graft copolymer according to claim 10 , wherein
(3) a deflection temperature under load at a load of 1.8 MPa is 118° C. or more.

12. A resin composition comprising 100 parts by mass of a resin and 0.5 to 20 parts by mass of the graft copolymer according to claim 10 .

13. The resin composition according to claim 12 , wherein the resin is polycarbonate.

14. A molded article obtained by molding the resin composition according to claim 12 .

15. The molded article according to claim 14 , wherein the molded article is a casing for home appliances.

16. The graft copolymer of claim 4 , having a Charpy impact strength at −30° C. is 20 kJ/m 2 or more.

17. The method of claim 1 , wherein the graft copolymer has a Charpy impact strength at −30° C. is 20 kJ/m 2 or more.

18. A method of increasing heat resistance and impact resistance in a graft copolymer, the method comprising:
polymerizing a vinyl monomer (B) containing a polyfunctional vinyl monomer (b1) in the presence of a polyorganosiloxane rubber (A) comprising more than 20% by mass of a toluene-insoluble matter,
wherein a mass percentage of the polyfunctional vinyl monomer (b1) is 11 to 19% by mass based on 100% by mass of a total amount of the polyorganosiloxane rubber (A) and the vinyl monomer (B), thereby providing increased heat resistance and impact resistance at −30° C., with respect to heat resistance and impact resistance of a graft copolymer wherein a mass percentage of the polyfunctional vinyl monomer (b1) is 10% by mass.

Assignees

• Otonari Hiroaki
• Miura Takashi
• Kasai Toshihiro
• Mitsubishi Rayon Co

Inventors

• Otonari Hiroaki
• Miura Takashi
• Kasai Toshihiro

Classifications

• C08L2201/02

  Flame or fire retardant/resistant · CPC title

• C08G77/442 Primary

  containing vinyl polymer sequences · CPC title

• C08L69/00

  Compositions of polycarbonates; Compositions of derivatives of polycarbonates · CPC title

• C08F283/12 Primary

  on to polysiloxanes · CPC title

• C08L51/085

  on to polysiloxanes · CPC title