Tough thermoplastic nylon compositions

Claim 2

A toughened multiphase thermoplastic composition consisting essentially of one phase containing 60 to 99 percent by weight of a polyamide matrix resin of number average molecular weight of at least 5,000, and 1 to 40 percent by weight of at least one other phase containing particles of at least one polymer taken from the class consisting of branched and straight chain polymers having a particle size in the range of 0.01 to 1.0 microns and having sites which adhere to the polyamide matrix resin, and said at least one polymer having a tensile modulus in the range of about 1.0 to 20,000 psi, the ratio of the tensile modulus of the polyamide matrix resin to tensile modulus of said at least one polymer being greater than 10 to 1 wherein said at least one polymer comprises at least 20 percent by weight of said at least one other phase and is represented by the formula: A.sub.(a) -B.sub.(b) -C.sub.(c) -D.sub.(d) -E.sub.(e) -F.sub.(f) -G.sub.(g) -H.sub.(h) derived in any order from monomers A to H wherein A is ethylene; B is CO; C is an unsaturated monomer taken from the class consisting of α,β-ethylenically unsaturated carboxylic acids having from 3 to 8 carbon atoms, and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms and the dicarboxylic acids and anhydrides of the dicarboxylic acids and the metal salts of the monocarboxylic, dicarboxylic acids and the monoester of the dicarboxylic acid having from 0 to 100 percent of the carboxylic acid groups ionized by neutralization with metal ions and dicarboxylic acids and monoesters of the dicarboxylic acid neutralized by amine-ended caprolactam oligomers having a DP of 6 to 24; D is an unsaturated epoxide of 4 to 11 carbon atoms; E is the residue derived by the loss of nitrogen from an aromatic sulfonyl azide substituted by carboxylic acids taken from the class consisting of monocarboxylic and dicarboxylic acids having from 7 to 12 carbon atoms and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms and the dicarboxylic acids and anhydrides of the dicarboxylic acids and the metal salts of the monocarboxylic, dicarboxylic acids and the monoester of the dicarboxylic acid having from 0 to 100 percent of the carboxylic acid groups ionized by neutralization with metal ions; F is an unsaturated monomer taken from the class consisting of acrylate esters having from 4 to 22 carbon atoms, vinyl esters of acids having from 1 to 20 carbon atoms, vinyl ethers of 3 to 20 carbon atoms, vinyl and vinylidene halides, and nitriles having from 3 to 6 carbon atoms; G is an unsaturated monomer having at least one substituent selected from the group consisting of pendant hydrocarbon chains of 1 to 12 carbon atoms and pendant aromatic groups which may have 1 to 6 substituent groups having a total of 14 carbon atoms; and H is an unsaturated monomer taken from the class consisting of branched, straight chain and cyclic compounds having from 4 to 14 carbon atoms and at least one additional unsaturated carbon-carbon bond capable of being grafted with a monomer having at least one reactive group of the type defined in C, D and E; monomers A to H being present in the following mole fraction: (a) 0 to 0.95, (b) 0 to 0.30, (c) 0 to 0.5, (d) 0 to 0.5, (e) 0 to 0.5, (f) 0 to 0.99, (g) 0 to 0.99, and (h) 0 to 0.99; said at least one polymer having present at least one of monomers B, C, D and E with the proviso that when monomer A is present, in addition to at least one of monomers B, C, D and E, at least one of monomers F, G and H is also present, and further provided that when said at least one polymer is present as part of a mixture, that the components of the mixture co-exist in the same discrete particles in the polyamide matrix.

Claim 3

A composition according to claim 1 wherein the tensile modulus of said at least one polymer is about 5.0 to 20,000 p.s.i. and the ratio of tensile modulus is greater than 20 to 1.

Claim 4

A composition according to claim 1 wherein said at least one polymer is present as part of a mixture.

Claim 5

A composition according to claim 1 wherein the ratio of tensile modulus is greater than 20 to 1.

Claim 6

A composition according to claim 1 wherein the polyamide matrix resin melts above 200° C.

Claim 7

A composition according to claim 5 wherein the polyamide matrix resin is taken from the class consisting of straight chain and branched chain polyamides.

Claim 8

A toughened multiphase thermoplastic composition consisting essentially of one phase containing 60 to 99 percent by weight of a polyamide matrix resin of number average molecular weight of at least 5,000, and 1 to 40 percent by weight of at least one other phase containing particles of at least one polymer taken from the class consisting of branched and straight chain polymers having a particle size in the range of 0.01 to 1.0 microns and having sites which adhere to the polyamide matrix resin, and said at least one polymer having a tensile modulus in the range of about 1.0 to 20,000 psi, the ratio of the tensile modulus of the polyamide matrix resin to tensile modulus of said at least one polymer being greater than 10 to 1 wherein the polyamide melts below 200° C. and the said at least one polymer comprises at least 20 percent by weight of said at least one other phase and is a polyurethane which is the reaction product of at least one glycol taken from the class consisting of polyester glycol having an average molecular weight of 300 to 6,000 and a polyether glycol having an average molecular weight of 300 to 6,000, and optionally at least one diol having a molecular weight of less than 300, and at least one diisocyanate having 4 to 21 carbon atoms.

Claim 9

A toughened multiphase thermoplastic composition consisting essentially of one phase containing 60 to 99 percent by weight of a polyamide matrix resin of number average molecular weight of at least 5,000, and 1 to 40 percent by weight of at least one other phase containing particles of at least one polymer taken from the class consisting of branched and straight chain polymers having a particle size in the range of 0.01 to 1.0 microns and having sites which adhere to the polyamide matrix resin, and said at least one polymer having a tensile modulus in the range of about 1.0 to 20,000 psi, the ratio of the tensile modulus of the polyamide matrix resin to tensile modulus of said at least one polymer being greater than 10 to 1 wherein the polyamide melts below 200° C. and the said at least one polymer comprises at least 20 percent by weight of said at least one other phase and is a polyurethane which is the reaction product of at least one glycol taken from the class consisting of polyester glycol having an average molecular weight of 300 to 6,000 and a polyether glycol having an average molecular weight of 300 to 6,000, and optionally at least one diol having a molecular weight of less than 300, and at least one diisocyanate having 4 to 21 carbon atoms.

Claim 10

A toughened multiphase thermoplastic composition consisting essentially of one phase containing 60 to 99 percent by weight of a polyamide matrix resin of number average molecular weight of at least 5,000, and 1 to 40 percent by weight of at least one other phase containing particles of at least one polymer taken from the class consisting of branched and straight chain polymers having a particle size in the range of 0.01 to 1.0 microns and having sites which adhere to the polyamide matrix resin, and said at least one polymer having a tensile modulus in the range of about 1.0 to 20,000 psi, the ratio of the tensile modulus of the polyamide matrix resin to tensile modulus of said at least one polymer being greater than 10 to 1 wherein the polyamide melts below 225° C. and the said at least one polymer comprises at least 20 percent by weight of said at least one other phase and is a polymer containing polyether repeat units taken from the class consisting of the reaction product of epoxide-containing monomers having 2 to 3 carbon atoms, an epoxide-containing monomer having pendant groups taken from the class consisting of methyl or chloromethyl groups, and mixtures of said epoxide monomers.

Claim 11

A toughened multiphase thermoplastic composition consisting essentially of one phase containing 60 to 99 percent by weight of a polyamide matrix resin of number average molecular weight of at least 5,000, and 1 to 40 percent by weight of at least one other phase containing particles of at least one polymer taken from the class consisting of branched and straight chain polymers having a particle size in the range of 0.01 to 1.0 microns and having sites which adhere to the polyamide matrix resin, and said at least one polymer having a tensile modulus in the range of about 1.0 to 20,000 psi, the ratio of the tensile modulus of the polyamide matrix resin to tensile modulus of said at least one polymer being greater than 10 to 1 wherein the polyamide melts below 225° C. and the said at least one polymer comprises at least 20 percent by weight of said at least one other phase and is a polymer containing polyether repeat units taken from the class consisting of the reaction product of epoxide-containing monomers having 2 to 3 carbon atoms, an epoxide-containing monomer having pendant groups taken from the class consisting of methyl or chloromethyl groups, and mixtures of said epoxide monomers.

Claim 12

A composition according to claim 6 wherein the notched Izod in the dry as molded condition is at least the values represented by the formulae: B+0.2 C.sub.1 B+2.0+0.5 (C.sub.2 -10), B+12.0 where B is the notched Izod of the polyamide matrix resin, C 1 is 2 to 10 percent by weight of the at least one polymer, and C 2 is 10 to 30 percent by weight of the at least one polymer, and the notched Izod is at least B+12.0 when the concentration of the at least one polymer is between 30 and 40 percent by weight.

Claim 13

A composition according to claim 6 wherein the notched Izod value, dry as molded, is greater than 8 ft. lbs./inch when the concentration of said at least one polymer is from 5 to 20 percent by weight.

Claim 14

A composition according to claim 1 wherein the polyamide is the condensation reaction product of a dicarboxylic acid of 4 to 12 carbon atoms and a diamine of 4 to 14 carbon atoms.

Claim 15

A composition according to claim 1 wherein the polyamide is polycaprolactam.

Claim 16

A composition according to claim 1 wherein there is present up to 5.0 percent by weight, based on the weight of the composition, of at least one colorant.

Claim 17

A composition according to claim 1 wherein there is present up to 50 percent by weight, based on the weight of the composition, of glass fibers.

Claim 18

A composition according to claim 1 wherein there is present up to 50 percent by weight, based on the weight of the composition, of fibrous and particulate mineral fillers and reinforcements.

Claim 19

A composition according to claim 1 wherein there is present up to 1.0 percent by weight, based on the weight of polyamide, of a stabilizer.

Claim 20

A composition according to claim 1 wherein said at least one polymer has present carbon monoxide.

Claim 21

A composition according to claim 1 wherein said at least one polymer has present an unsaturated monomer taken from the class consisting of α,β-ethylenically unsaturated carboxylic acids having from 3 to 8 carbon atoms, and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms and the dicarboxylic acids and anhydrides of the dicarboxylic acids and the metal salts of the monocarboxylic, dicarboxylic acids and the monoester of the dicarboxylic acid having from 0 to 100 percent of the carboxylic acid groups ionized by neutralization with metal ions and dicarboxylic acids and monoesters of the dicarboxylic acid neutralized by amine-ended caprolactam oligomers having a DP of 6 to 24.

Claim 22

A composition according to claim 1 wherein said at least one polymer has present an unsaturated epoxide of 4 to 11 carbon atoms.

Claim 23

A composition according to claim 1 wherein said at least one polymer has present the residue derived by the loss of nitrogen from an aromatic sulfonyl azide substituted by carboxylic acids taken from the class consisting of monocarboxylic and dicarboxylic acids having from 7 to 12 carbon atoms and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms and the dicarboxylic acids and anhydrides of the dicarboxylic acids and the metal salts of the monocarboxylic, dicarboxylic acids and the monoester of the dicarboxylic acid having from 0 to 100 percent of the carboxylic acid groups ionized by neutralization with metal ions.

Claim 24

A composition according to claim 6 wherein said at least one polymer has present carbon monoxide.

Claim 25

A composition according to claim 6 wherein said at least one polymer has present an unsaturated monomer taken from the class consisting of α,β-ethylenically unsaturated carboxylic acids having from 3 to 8 carbon atoms, and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms and the dicarboxylic acids and anhydrides of the dicarboxylic acids and the metal salts of the monocarboxylic, dicarboxylic acids and the monoester of the dicarboxylic acid having from 0 to 100 percent of the carboxylic acid groups ionized by neutralization with metal ions and dicarboxylic acids and monoesters of the dicarboxylic acid neutralized by amine-ended caprolactam oligomers having a DP of 6 to 24.

Claim 26

A composition according to claim 6 wherein said at least one polymer has present an unsaturated epoxide of 4 to 11 carbon atoms.

Claim 27

A composition according to claim 6 wherein said at least one polymer has present the residue derived by the loss of nitrogen from an aromatic sulfonyl azide substituted by carboxylic acids taken from the class consisting of monocarboxylic and dicarboxylic acids having from 7 to 12 carbon atoms and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms and the dicarboxylic acids and anhydrides of the dicarboxylic acids and the metal salts of the monocarboxylic, dicarboxylic acids and the monoester of the dicarboxylic acid having from 0 to 100 percent of the carboxylic acid groups ionized by neutralization with metal ions.

Claim 28

A composition according to claim 1 wherein said at least one polymer has present an unsaturated monomer taken from the class consisting of acrylate esters having from 4 to 22 carbon atoms, vinyl esters of acids having from 1 to 20 carbon atoms, vinyl ethers of 3 to 20 carbon atoms, vinyl and vinylidene halides, and nitriles having from 3 to 6 carbon atoms.

Claim 29

A composition according to claim 1 wherein said at least one polymer has present an unsaturated monomer having pendant hydrocarbon chains of 1 to 12 carbon atoms capable of being grafted with monomers having at least one reactive group of the type defined in C, D and E, and pendant aromatic groups which may have 1 to 6 substituent groups having a total of 14 carbon atoms.

Claim 30

A composition according to claim 1 wherein said at least one polymer has present an unsaturated monomer taken from the class consisting of branched, straight chain and cyclic compounds having from 4 to 14 carbon atoms and at least one additional nonconjugated unsaturated carbon-carbon bond capable of being grafted with a monomer having at least one reactive group of the type defined in C, D and E.

Claim 31

A composition according to claim 6 wherein said at least one polymer has present an unsaturated monomer taken from the class consisting of acrylate esters having from 4 to 22 carbon atoms, vinyl esters of acids having from 1 to 20 carbon atoms, vinyl ethers of 3 to 20 carbon atoms, vinyl and vinylidene halides, and nitriles having from 3 to 6 carbon atoms.

Claim 32

A composition according to claim 6 wherein said at least one polymer has present an unsaturated monomer having pendant hydrocarbon chains of 1 to 12 carbon atoms capable of being grafted with monomers having at least one reactive group of the type defined in C, D and E, and pendant aromatic groups which may have 1 to 6 substituent groups having a total of 14 carbon atoms.

Claim 33

A composition according to claim 6 wherein said at least one polymer has present an unsaturated monomer taken from the class consisting of branched, straight chain and cyclic compounds having from 4 to 14 carbon atoms and at least one additional nonconjugated unsaturated carbon-carbon bond capable of being grafted with a monomer having at least one reactive group of the type defined in C, D and E.

Claim 34

A composition according to claim 4 wherein said at least one polymer consists essentially of polymerized ethylene, at least one polymerized α-olefin of 3 to 6 carbon atoms, and at least one polymerized unsaturated monomer taken from the class consisting of branched, straight chain and cyclic compounds having from 4 to 14 carbon atoms and at least one additional nonconjugated unsaturated carbon-carbon bond, and grafted thereto an unsaturated monomer taken from the class consisting of α,β-ethylenically unsaturated dicarboxylic acids having from 3 to 8 carbon atoms, and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms, anhydrides of the dicarboxylic acids, the metal salts of the dicarboxylic acids and the monoesters of said dicarboxylic acid having from 0 to 100 percent of the carboxylic groups ionized by neutralization with metal ions.

Claim 35

A composition according to claim 31 wherein said at least one polymer is a copolymer of ethylene, propylene and 1,4-hexadiene having grafted thereto an unsaturated monomer taken from the class consisting of fumaric acid, maleic acid, maleic anhydride and the monoalkyl ester of said acids in which the alkyl group of the ester has 1 to 3 carbon atoms, said at least one polymer having an after grafting melt flow rate of 0.1 to 100 g./10 minutes, ASTM D 1238 at 280° C. and a total load of 2160 grams.

Claim 36

A composition according to claim 31 wherein said at least one polymer is a tertrapolymer of ethylene, propylene, 1,4-hexadiene and 2,5-norbornadiene having grafted thereto an unsaturated monomer taken from the class consisting of fumaric acid, maleic acid, maleic anhydride and the monoalkyl ester of said acids in which the alkyl group of the ester has 1 to 3 carbon atoms, said at least one polymer having an after grafting melt flow rate of 0.1 to 100 g./10 minutes, ASTM D 1238 at 280° C. and a total load of 2160 grams.

Claim 37

A composition according to claim 32 wherein said polyamide matrix resin is polyhexamethylene adipamide.

Claim 38

A composition according to claim 33 wherein said polyamide matrix resin is polyhexamethylene adipamide.

Claim 39

A composition according to claim 32 wherein said polyamide matrix resin is polycaprolactam.

Claim 40

A composition according to Claim 33 wherein said polyamide matrix resin is polycaprolactam.

Claim 41

A composition according to claim 4 wherein said at least one polymer is a random copolymer consisting essentially of polymerized ethylene, alkyl acrylate selected from methyl and ethyl acrylate, and from about 0.0025-0.077 mole/100 g. polymer of a mono alkyl ester of 1,4-butene-dioic acid in which the alkyl group of the ester has 1 to 6 carbon atoms, said copolymer having from about 0.64-0.80 mole of (-CO 2 -) units per 100 grams of copolymer, and having 0 to 100 percent of the esters of 1,4-butene-dioic acid ionized by neutralization with metal ions selected from lithium, sodium, potassium, calcium and zinc ions, said copolymer having a melt index at 190° C. and a total load of 2160 grams of about 0.3 to 100 grams/10 minutes, and when neutralized having a melt flow rate of 0.04 to 100 grams/10 minutes under condition G of ASTM D 1238.

Claim 42

A composition according to claim 38 wherein said mono alkyl ester of 1,4-butene-dioic acid consists essentially of ethyl hydrogen maleate.

Claim 43

A composition according to claim 39 wherein said polyamide matrix resin is polyhexamethylene adipamide.

Claim 44

A composition according to claim 39 wherein said polyamide matrix resin is polycaprolactam.

Claim 45

A process according to claim 45 wherein said at least one polymer is taken from the class consisting of branched and straight chain polymers.

Claim 46

A process according to claim 45 wherein the tensile modulus of said at least one polymer is about 5.0 to 20,000 p.s.i. and the ratio of tensile modulus is greater than 20 to 1.

Claim 47

A process according to claim 45 wherein said at least one polymer is present as part of a mixture.

Claim 48

A process for the preparation of a toughened multi-phase thermoplastic composition which comprises, in a closed system, (a) admixing (1) 60 to 99 percent by weight of a polyamide matrix resin of number average molecular weight of at least 5000, and (2) 1 to 40 percent by weight of at least one polymer at a temperature in the range of about 5° to 100° C. above the melting point of said polyamide matrix resin and (b) shearing to disperse said at least one polymer in said matrix to contain particles in the range of 0.01 to 1.0 microns, said at least one polymer having sites which adhere to said matrix, and having a tensile modulus in the range of 1.0 to 20,000 p.s.i., the ratio of the tensile modulus of said matrix to tensile modulus of said at least one polymer being greater than 10 to 1 wherein said at least one polymer comprises at least 20 percent by weight of said at least one other phase and is represented by the formula: A.sub.(a) -B.sub.(b) -C.sub.(c) -D.sub.(d) -E.sub.(e) -F.sub.(f) -G.sub.(g) -H.sub.(h) derived in any order from monomers A to H wherein A is ethylene; B is CO; C is an unsaturated monomer taken from the class consisting of α,β-ethylenically unsaturated carboxylic acids having from 3 to 8 carbon atoms, and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms and the dicarboxylic acids and anhydrides of the dicarboxylic acids and the metal salts of the monocarboxylic, dicarboxylic acids and the monoester of the dicarboxylic acid having from 0 to 100 percent of the carboxylic acid groups ionized by neutralization with metal ions and dicarboxylic acids and monoesters of the dicarboxylic acid neutralized by amine-ended caprolactam oligomers having a DP of 6 to 24; D is an unsaturated epoxide of 4 to 11 carbon atoms; E is the residue derived by the loss of nitrogen from an aromatic sulfonyl azide substituted by carboxylic acids taken from the class consisting of monocarboxylic and dicarboxylic acids having from 7 to 12 carbon atoms and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms and the dicarboxylic acids and anhydrides of the dicarboxylic acids and the metal salts of the monocarboxylic, dicarboxylic acids and the monoester of the dicarboxylic acid having from 0 to 100 percent of the carboxylic acid groups ionized by neutralization with metal ions; F is an unsaturated monomer taken from the class consisting of acrylate esters having from 4 to 22 carbon atoms, vinyl esters of acids having from 1 to 20 carbon atoms, vinyl ethers of 3 to 20 carbon atoms, vinyl and vinylidene halides, and nitriles having from 3 to 6 carbon atoms; G is an unsaturated monomer having at least one substituent selected from the group consisting of pendant hydrocarbon chains of 1 to 12 carbon atoms and pendant aromatic groups which may have 1 to 6 substituent groups having a total of 14 carbon atoms; and H is an unsaturated monomer taken from the class consisting of branched, straight chain and cyclic compounds having from 4 to 14 carbon atoms and at least one additional unsaturated carbon-carbon bond capable of being grafted with a monomer having at least one reactive group of the type defined in C, D and E; monomers A to H being present in the following mole fraction: (a) 0 to 0.95, (b) 0 to 0.30, (c) 0 to 0.5, (d) 0 to 0.5, (e) 0 to 0.5, (f) 0 to 0.99, (g) 0 to 0.99, and (h) 0 to 0.99; said at least one polymer having present at least one of monomers B, C, D and E with the proviso that when monomer A is present, in addition to at least one of monomers B, C, D and E, at least one of monomers F, G and H is also present, and further provided that when said at least one polymer is present as part of a mixture, that the components of the mixture co-exist in the same discrete particles in the polyamide matrix.

Claim 49

A process for the preparation of a toughened multi-phase thermoplastic composition which comprises, in a closed system, (a) admixing (1) 60 to 99 percent by weight of a polyamide matrix resin of number average molecular weight of at least 5000, and (2) 1 to 40 percent by weight of at least one polymer at a temperature in the range of about 5° to 100° C. above the melting point of said polyamide matrix resin and (b) shearing to disperse said at least one polymer in said matrix to contain particles in the range of 0.01 to 1.0 microns, said at least one polymer having sites which adhere to said matrix, and having a tensile modulus in the range of 1.0 to 20,000 p.s.i., the ratio of the tensile modulus of said matrix to tensile modulus of said at least one polymer being greater than 10 to 1 wherein said at least one polymer comprises at least 20 percent by weight of said at least one other phase and is represented by the formula: A.sub.(a) -B.sub.(b) -C.sub.(c) -D.sub.(d) -E.sub.(e) -F.sub.(f) -G.sub.(g) -H.sub.(h) derived in any order from monomers A to H wherein A is ethylene; B is CO; C is an unsaturated monomer taken from the class consisting of α,β-ethylenically unsaturated carboxylic acids having from 3 to 8 carbon atoms, and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms and the dicarboxylic acids and anhydrides of the dicarboxylic acids and the metal salts of the monocarboxylic, dicarboxylic acids and the monoester of the dicarboxylic acid having from 0 to 100 percent of the carboxylic acid groups ionized by neutralization with metal ions and dicarboxylic acids and monoesters of the dicarboxylic acid neutralized by amine-ended caprolactam oligomers having a DP of 6 to 24; D is an unsaturated epoxide of 4 to 11 carbon atoms; E is the residue derived by the loss of nitrogen from an aromatic sulfonyl azide substituted by carboxylic acids taken from the class consisting of monocarboxylic and dicarboxylic acids having from 7 to 12 carbon atoms and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms and the dicarboxylic acids and anhydrides of the dicarboxylic acids and the metal salts of the monocarboxylic, dicarboxylic acids and the monoester of the dicarboxylic acid having from 0 to 100 percent of the carboxylic acid groups ionized by neutralization with metal ions; F is an unsaturated monomer taken from the class consisting of acrylate esters having from 4 to 22 carbon atoms, vinyl esters of acids having from 1 to 20 carbon atoms, vinyl ethers of 3 to 20 carbon atoms, vinyl and vinylidene halides, and nitriles having from 3 to 6 carbon atoms; G is an unsaturated monomer having at least one substituent selected from the group consisting of pendant hydrocarbon chains of 1 to 12 carbon atoms and pendant aromatic groups which may have 1 to 6 substituent groups having a total of 14 carbon atoms; and H is an unsaturated monomer taken from the class consisting of branched, straight chain and cyclic compounds having from 4 to 14 carbon atoms and at least one additional unsaturated carbon-carbon bond capable of being grafted with a monomer having at least one reactive group of the type defined in C, D and E; monomers A to H being present in the following mole fraction: (a) 0 to 0.95, (b) 0 to 0.30, (c) 0 to 0.5, (d) 0 to 0.5, (e) 0 to 0.5, (f) 0 to 0.99, (g) 0 to 0.99, and (h) 0 to 0.99; said at least one polymer having present at least one of monomers B, C, D and E with the proviso that when monomer A is present, in addition to at least one of monomers B, C, D and E, at least one of monomers F, G and H is also present, and further provided that when said at least one polymer is present as part of a mixture, that the components of the mixture co-exist in the same discrete particles in the polyamide matrix.

Claim 50

A process according to claim 45 wherein the notched Izod in the dry as molded condition is at least the values represented by the formulae: B+0.2 C.sub.1 B+2.0+0.5 (C.sub.2 -10) B+12.0 where B is the notched Izod of the polyamide matrix resin, C 1 is 2 to 10 percent by weight of the at least one polymer, and C 2 is 10 to 30 percent by weight of the at least one polymer, and the notched Izod is at least B+12.0 when the concentration of the at least one polymer is between 30 and 40 percent by weight.

Claim 51

A process according to claim 45 wherein said at least one polymer consists essentially of polymerized ethylene, at least one polymerized α-olefin of 3 to 6 carbon atoms, and at least one polymerized unsaturated monomer taken from the class consisting of branched, straight chain and cyclic compounds having from 4 to 14 carbon atoms and at least one additional nonconjugated unsaturated carbon-carbon bond, and grafted thereto an unsaturated monomer taken from the class consisting of α,β-ethylenically unsaturated dicarboxylic acids having from 3 to 8 carbon atoms, and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms, anhydrides of the dicarboxylic acids, the metal salts of the dicarboxylic acids and the monoesters of said dicarboxylic acid having from 0 to 100 percent of the carboxylic groups ionized by neutralization with metal ions.

Claim 52

A process according to claim 45 wherein said at least one polymer is a random copolymer 45 consisting essentially of polymerized ethylene, alkyl acrylate selected from methyl and ethyl acrylate, and from about 0.0025-0.077 mole/100 g. polymers of a mono alkyl ester of 1,4-butene-dioic acid in which the alkyl group of the ester has 1 to 6 carbon atoms, said copolymer having from about 0.64-0.80 mole of (--CO 2 --) units per 100 grams of copolymer, and having 0 to 100 percent of the esters of 1,4-butene-dioic acid ionized by neutralization with metal ions selected from lithium, sodium, potassium, calcium and zinc ions, said copolymer having a melt index at 190° C. and a total load of 2160 grams of about 0.3 to 100 grams/10 minutes, and when neutralized having a melt flow rate of 0.04 to 100 grams/10 minutes under condition G of ASTM D 1238.

Claim 53

Process for preparing a toughened multiphase thermoplastic composition consisting essentially of one phase containing 80 to 99 percent by weight of a polyamide matrix resin of number average molecular weight of at least 5000, and 1 to 20 percent by weight of at least one other phase containing particles of at least one polymer taken from the class consisting of branched and straight chain polymers having a particle size in the range of 0.01 to 1.0 microns and having sites which adhere to the polyamide matrix resin, and said at least one polymer having a tensile modulus in the range of about 1.0 to 20,000 p.s.i., the ratio of the tensile modulus of the polyamide matrix resin to tensile modulus of said at least one polymer being greater than 10 to 1, which comprises initially admixing said polyamide matrix resin and up to about 40 percent by weight of the said at least one polymer and additionally admixing said polyamide matrix resin until said desired concentration is achieved and wherein said at least one polymer comprises at least 20 percent by weight of said at least one other phase and is represented by the formula: A.sub.(a) -B.sub.(b) -C.sub.(c) -D.sub.(d) -E.sub.(e) -F.sub.(f) -G.sub.(g) -H.sub.(h) derived in any order from monomers A to H wherein A is ethylene; B is CO; C is an unsaturated monomer taken from the class consisting of α,β-ethylenically unsaturated carboxylic acids having from 3 to 8 carbon atoms, and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms and the dicarboxylic acids and anhydrides of the dicarboxylic acids and the metal salts of the monocarboxylic, dicarboxylic acids and the monoester of the dicarboxylic acid having from 0 to 100 percent of the carboxylic acid groups ionized by neutralization with metal ions and dicarboxylic acids and monoesters of the dicarboxylic acid neutralized by amine-ended caprolactam oligomers having a DP of 6 to 24; D is an unsaturated epoxide of 4 to 11 carbon atoms; E is the residue derived by the loss of nitrogen from an aromatic sulfonyl azide substituted by carboxylic acids taken from the class consisting of monocarboxylic and dicarboxylic acids having from 7 to 12 carbon atoms and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms and the dicarboxylic acids and anhydrides of the dicarboxylic acids and the metal salts of the monocarboxylic, dicarboxylic acids and the monoester of the dicarboxylic acid having from 0 to 100 percent of the carboxylic acid groups ionized by neutralization with metal ions; F is an unsaturated monomer taken from the class consisting of acrylate esters having from 4 to 22 carbon atoms, vinyl esters of acids having from 1 to 20 carbon atoms, vinyl ethers of 3 to 20 carbon atoms, vinyl and vinylidene halides, and nitriles having from 3 to 6 carbon atoms; G is an unsaturated monomer having at least one substituent selected from the group consisting of pendant hydrocarbon chains of 1 to 12 carbon atoms and pendant aromatic groups which may have 1 to 6 substituent groups having a total of 14 carbon atoms; and H is an unsaturated monomer taken from the class consisting of branched, straight chain and cyclic compounds having from 4 to 14 carbon atoms and at least one additional unsaturated carbon-carbon bond capable of being grafted with a monomer having at least one reactive group of the type defined in C, D and E; monomers A to H being present in the following mole fraction: (a) 0 to 0.95, (b) 0 to 0.30, (c) 0 to 0.5, (d) 0 to 0.5, (e) 0 to 0.5, (f) 0 to 0.99, (g) 0 to 0.99, and (h) 0 to 0.99; said at least one polymer having present at least one of monomers B, C, D and E with the proviso that when monomer A is present, in addition to at least one of monomers B, C, D and E, at least one of monomers F, G and H is also present, and further provided that when said at least one polymer is present as part of a mixture, that the components of the mixture co-exist in the same discrete particles in the polyamide matrix.

Claim 54

Process for preparing a toughened multiphase thermoplastic composition consisting essentially of one phase containing 80 to 99 percent by weight of a polyamide matrix resin of number average molecular weight of at least 5000, and 1 to 20 percent by weight of at least one other phase containing particles of at least one polymer taken from the class consisting of branched and straight chain polymers having a particle size in the range of 0.01 to 1.0 microns and having sites which adhere to the polyamide matrix resin, and said at least one polymer having a tensile modulus in the range of about 1.0 to 20,000 p.s.i., the ratio of the tensile modulus of the polyamide matrix resin to tensile modulus of said at least one polymer being greater than 10 to 1, which comprises initially admixing said polyamide matrix resin and up to about 40 percent by weight of the said at least one polymer and additionally admixing said polyamide matrix resin until said desired concentration is achieved and wherein said at least one polymer comprises at least 20 percent by weight of said at least one other phase and is represented by the formula: A.sub.(a) -B.sub.(b) -C.sub.(c) -D.sub.(d) -E.sub.(e) -F.sub.(f) -G.sub.(g) -H.sub.(h) derived in any order from monomers A to H wherein A is ethylene; B is CO; C is an unsaturated monomer taken from the class consisting of α,β-ethylenically unsaturated carboxylic acids having from 3 to 8 carbon atoms, and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms and the dicarboxylic acids and anhydrides of the dicarboxylic acids and the metal salts of the monocarboxylic, dicarboxylic acids and the monoester of the dicarboxylic acid having from 0 to 100 percent of the carboxylic acid groups ionized by neutralization with metal ions and dicarboxylic acids and monoesters of the dicarboxylic acid neutralized by amine-ended caprolactam oligomers having a DP of 6 to 24; D is an unsaturated epoxide of 4 to 11 carbon atoms; E is the residue derived by the loss of nitrogen from an aromatic sulfonyl azide substituted by carboxylic acids taken from the class consisting of monocarboxylic and dicarboxylic acids having from 7 to 12 carbon atoms and derivatives thereof taken from the class consisting of monoesters of alcohols of 1 to 29 carbon atoms and the dicarboxylic acids and anhydrides of the dicarboxylic acids and the metal salts of the monocarboxylic, dicarboxylic acids and the monoester of the dicarboxylic acid having from 0 to 100 percent of the carboxylic acid groups ionized by neutralization with metal ions; F is an unsaturated monomer taken from the class consisting of acrylate esters having from 4 to 22 carbon atoms, vinyl esters of acids having from 1 to 20 carbon atoms, vinyl ethers of 3 to 20 carbon atoms, vinyl and vinylidene halides, and nitriles having from 3 to 6 carbon atoms; G is an unsaturated monomer having at least one substituent selected from the group consisting of pendant hydrocarbon chains of 1 to 12 carbon atoms and pendant aromatic groups which may have 1 to 6 substituent groups having a total of 14 carbon atoms; and H is an unsaturated monomer taken from the class consisting of branched, straight chain and cyclic compounds having from 4 to 14 carbon atoms and at least one additional unsaturated carbon-carbon bond capable of being grafted with a monomer having at least one reactive group of the type defined in C, D and E; monomers A to H being present in the following mole fraction: (a) 0 to 0.95, (b) 0 to 0.30, (c) 0 to 0.5, (d) 0 to 0.5, (e) 0 to 0.5, (f) 0 to 0.99, (g) 0 to 0.99, and (h) 0 to 0.99; said at least one polymer having present at least one of monomers B, C, D and E with the proviso that when monomer A is present, in addition to at least one of monomers B, C, D and E, at least one of monomers F, G and H is also present, and further provided that when said at least one polymer is present as part of a mixture, that the components of the mixture co-exist in the same discrete particles in the polyamide matrix.

Claim 55

A process according to claim 45 wherein said composition prepared using a polyamide matrix resin having an initial number average molecular weight of 5,000 to 15,000 is held at a temperature about 10° to 40° C. above the melting point of said polyamide matrix resin for up to one hour at a pressure of about 1 to 25 mm Hg absolute.

Claim 56

A process according to claim 45 wherein said composition prepared using a polyamide matrix resin having an initial number average molecular weight of 5,000 to 15,000 is extruded through a die into the form of beading, cut, quenched, dried and is held at an elevated temperature at least 15° C. below the melting point of said polyamide matrix resin for at least two hours in a stream of inert gas.

Claim 57

A composition according to claim 1 in the form of a film.

Claim 58

A toughened multiphase thermoplastic composition consisting essentially of one phase containing 60 to 99 percent by weight of a polyamide matrix resin of number average molecular weight of at least 5,000, and 1 to 40 percent by weight of at least one other hase containing particles of at least one polymer taken from the class consisting of branched and straight chain polymers having a particle size in the range of 0.01 to 1.0 microns and having sites which adhere to the polyamide matrix resin, and said at least one polymer having a tensile modulus in the range of about 1.0 to 20,000 psi, the ratio of the tensile modulus of the polyamide matrix resin to tensile modulus of said at least one polymer being greater than 10:1 wherein said at least one polymer comprises at least 20 percent by weight of said at least one other phase and is represented by the formula: A.sub.(a) -B.sub.(b) -C.sub.(c) -D.sub.(d) -E.sub.(e) -F.sub.(f) -G.sub.(g) -H.sub.(h) derived in any order from monomers A to H wherein A is ethylene; B is CO; C is an unsaturated monomer taken from the class consisting of methacrylic acid having from 0 to 100 percent of the carboxylic acid groups neutralized with metal ions selected from zinc and calcium; ethyl hydrogen maleate having from 0 to 100 percent of the carboxylic acid groups neutralized with metal ions selected from zinc, lithium, potassium, sodium, calcium and antimony; ethyl hydrogen maleate having from 0 to 100 percent of the carboxylic acid groups neutralized with zinc rosinate or potassium stearate; acrylic acid; maleic anhydride having from 0 to 100 percent of the carboxylic acid groups neutralized with zinc ions; fumaric acid; butyl hydrogen maleate; ethyl hydrogen fumarate; 3,6-endomethylene, 1,2,3,6-tetrahydrophthalic anhydride; D is glycidyl methacrylate; E is an azide selected from the group consisting of benzoic acid sulfonyl azide, phthalic anhydride sulfonyl azide, the monoethyl ester of phthalic anhydride sulfonyl azide and the mono-octadecylester of phthalic anhydride sulfonyl azide; F is an unsaturated monomer taken from the class consisting of isobutylacrylate, methyl acrylate, vinyl acetate, methylmethacrylate, n-butylacrylate, 2-ethyl hexyl methacrylate, methyl vinyl ether, ethyl acrylate and acrylonitrile; G is an unsaturated monomer taken from the class consisting of propylene, styrene, and isobutylene; H is an unsaturated monomer taken from the class consisting of 1,4-hexadiene, 2,5-norbornadiene, butadiene, and isoprene; monomers A through H being present in the following mole fraction: (a) 0 to 0.95, (b) 0 to 0.30, (c) 0 to 0.5, (d) 0 to 0.5, (e) 0 to 0.5, (f) 0 to 0.99, (g) 0 to 0.99, and (h) 0 to 0.99; said at least one polymer having present at least one of monomers B, C, D and E with the proviso that when monomer A is present, in addition to at least one of monomers B, C, D and E, at least one of monomers F, G and H is also present, and further provided that when said at least one polymer is present as part of a mixture, that the components of the mixture co-exist in the same discrete particles in the polyamide matrix.

Claim 59

A toughened multiphase thermoplastic composition consisting essentially of one phase containing 60 to 99 percent by weight of a polyamide matrix resin of number average molecular weight of at least 5,000, and 1 to 40 percent by weight of at least one other hase containing particles of at least one polymer taken from the class consisting of branched and straight chain polymers having a particle size in the range of 0.01 to 1.0 microns and having sites which adhere to the polyamide matrix resin, and said at least one polymer having a tensile modulus in the range of about 1.0 to 20,000 psi, the ratio of the tensile modulus of the polyamide matrix resin to tensile modulus of said at least one polymer being greater than 10:1 wherein said at least one polymer comprises at least 20 percent by weight of said at least one other phase and is represented by the formula: A.sub.(a) -B.sub.(b) -C.sub.(c) -D.sub.(d) -E.sub.(e) -F.sub.(f) -G.sub.(g) -H.sub.(h) derived in any order from monomers A to H wherein A is ethylene; B is CO; C is an unsaturated monomer taken from the class consisting of methacrylic acid having from 0 to 100 percent of the carboxylic acid groups neutralized with metal ions selected from zinc and calcium; ethyl hydrogen maleate having from 0 to 100 percent of the carboxylic acid groups neutralized with metal ions selected from zinc, lithium, potassium, sodium, calcium and antimony; ethyl hydrogen maleate having from 0 to 100 percent of the carboxylic acid groups neutralized with zinc rosinate or potassium stearate; acrylic acid; maleic anhydride having from 0 to 100 percent of the carboxylic acid groups neutralized with zinc ions; fumaric acid; butyl hydrogen maleate; ethyl hydrogen fumarate; 3,6-endomethylene, 1,2,3,6-tetrahydrophthalic anhydride; D is glycidyl methacrylate; E is an azide selected from the group consisting of benzoic acid sulfonyl azide, phthalic anhydride sulfonyl azide, the monoethyl ester of phthalic anhydride sulfonyl azide and the mono-octadecylester of phthalic anhydride sulfonyl azide; F is an unsaturated monomer taken from the class consisting of isobutylacrylate, methyl acrylate, vinyl acetate, methylmethacrylate, n-butylacrylate, 2-ethyl hexyl methacrylate, methyl vinyl ether, ethyl acrylate and acrylonitrile; G is an unsaturated monomer taken from the class consisting of propylene, styrene, and isobutylene; H is an unsaturated monomer taken from the class consisting of 1,4-hexadiene, 2,5-norbornadiene, butadiene, and isoprene; monomers A through H being present in the following mole fraction: (a) 0 to 0.95, (b) 0 to 0.30, (c) 0 to 0.5, (d) 0 to 0.5, (e) 0 to 0.5, (f) 0 to 0.99, (g) 0 to 0.99, and (h) 0 to 0.99; said at least one polymer having present at least one of monomers B, C, D and E with the proviso that when monomer A is present, in addition to at least one of monomers B, C, D and E, at least one of monomers F, G and H is also present, and further provided that when said at least one polymer is present as part of a mixture, that the components of the mixture co-exist in the same discrete particles in the polyamide matrix.

Claim 60

A process for the preparation of a toughened multiphase thermoplastic composition which comprises, in a closed system, (a) admixing (1) 60 to 99 percent by weight of a polyamide matrix resin of number average molecular weight of at least 5000, and (2) 1 to 40 percent by weight of at least one polymer at a temperature in the range of about 5° to 100° C. above the melting point of said polyamide matrix resin and (b) shearing to disperse said at least one polymer in said matrix to contain particles in the range of 0.01 to 1.0 microns, said at least one polymer having sites which adhere to said matrix, and having a tensile modulus in the range of 1.0 to 20,000 p.s.i., the ratio of the tensile modulus of said matrix to tensile modulus of said at least one polymer being greater than 10 to 1 wherein said at least one polymer comprises at least 20 percent by weight of said at least one other phase and is represented by the formula: A.sub.(a) -B.sub.(b) -C.sub.(c) -D.sub.(d) -E.sub.(e) -F.sub.(f) -G.sub.(g) -H.sub.(h) derived in any order from monomers A to H wherein A is ethylene; B is CO; C is an unsaturated monomer taken from the class consisting of methacrylic acid having from 0 to 100 percent of the carboxylic acid groups neutralized wiith metal ions selected from zinc and calcium; ethyl hydrogen maleate having from 0 to 100 percent of the carboxylic acid groups. neutralized with metal ions selected from zinc, lithium, potassium, sodium, calcium and antimony; ethyl hydrogen maleate having from 0 to 100 percent of the carboxylic acid groups neutralized with zinc rosinate or potassium stearate; acrylic cid; maleic anhydride having from 0 to 100 percent of the carboxylic acid groups neutralized wih zinc ions; fumaric acid; butyl hydrogen maleate; ethyl hydrogen fumarate; 3,6-endomethylene,, 1,2,3,6-tetrahydrophthalic anhydride; D is glycidyl methacrylate; E is an azide selected from the group consisting of benzoic acid sulfonyl azide, phthalic anhydride sulfonyl azide, the monoethyl ester of phthalic anhydride sulfonyl azide and the mono-octadecylester of phthalic anhydride sulfonyl azide; F is an unsaturated monomer taken from the class consisting of isobutylacrylate, methyl acrylate, vinyl acetate, methylmethacrylate, n-butylacrylate, 2-ethyl hexyl methacrylate, methyl vinyl ether, ethyl acrylate and acrylonitrile; G is an unsaturated monomer taken from the class consisting of propylene, styrene, and isobutylene; H is an unsaturated monomer taken from the class consisting of 1,5-hexadiene, 2,5-norbornadiene, butadiene and isoprene; monomers A to H being present in the following mole fraction: (a) 0 to 0.95, (b) 0 to 0.30, (c) 0 to 0.5, (d) 0 to 0.5, (e) 0 to 0.5, (f) 0 to 0.99, (g) 0 to 0.99, and (h) 0 to 0.99; said at least one polymer having present at least one of monomers B, C, D and E with the proviso that when monomer A is present, in addition to at least one of monomers B, C, D and E, at least one of monomers F, G and H is also present, and further provided that when said at least one polymer is present as part of a mixture, that the components of the mixture co-exist in the same discrete particles in the polyamide matrix.

Claim 61

A process for the preparation of a toughened multiphase thermoplastic composition which comprises, in a closed system, (a) admixing (1) 60 to 99 percent by weight of a polyamide matrix resin of number average molecular weight of at least 5000, and (2) 1 to 40 percent by weight of at least one polymer at a temperature in the range of about 5° to 100° C. above the melting point of said polyamide matrix resin and (b) shearing to disperse said at least one polymer in said matrix to contain particles in the range of 0.01 to 1.0 microns, said at least one polymer having sites which adhere to said matrix, and having a tensile modulus in the range of 1.0 to 20,000 p.s.i., the ratio of the tensile modulus of said matrix to tensile modulus of said at least one polymer being greater than 10 to 1 wherein said at least one polymer comprises at least 20 percent by weight of said at least one other phase and is represented by the formula: A.sub.(a) -B.sub.(b) -C.sub.(c) -D.sub.(d) -E.sub.(e) -F.sub.(f) -G.sub.(g) -H.sub.(h) derived in any order from monomers A to H wherein A is ethylene; B is CO; C is an unsaturated monomer taken from the class consisting of methacrylic acid having from 0 to 100 percent of the carboxylic acid groups neutralized wiith metal ions selected from zinc and calcium; ethyl hydrogen maleate having from 0 to 100 percent of the carboxylic acid groups. neutralized with metal ions selected from zinc, lithium, potassium, sodium, calcium and antimony; ethyl hydrogen maleate having from 0 to 100 percent of the carboxylic acid groups neutralized with zinc rosinate or potassium stearate; acrylic cid; maleic anhydride having from 0 to 100 percent of the carboxylic acid groups neutralized wih zinc ions; fumaric acid; butyl hydrogen maleate; ethyl hydrogen fumarate; 3,6-endomethylene,, 1,2,3,6-tetrahydrophthalic anhydride; D is glycidyl methacrylate; E is an azide selected from the group consisting of benzoic acid sulfonyl azide, phthalic anhydride sulfonyl azide, the monoethyl ester of phthalic anhydride sulfonyl azide and the mono-octadecylester of phthalic anhydride sulfonyl azide; F is an unsaturated monomer taken from the class consisting of isobutylacrylate, methyl acrylate, vinyl acetate, methylmethacrylate, n-butylacrylate, 2-ethyl hexyl methacrylate, methyl vinyl ether, ethyl acrylate and acrylonitrile; G is an unsaturated monomer taken from the class consisting of propylene, styrene, and isobutylene; H is an unsaturated monomer taken from the class consisting of 1,5-hexadiene, 2,5-norbornadiene, butadiene and isoprene; monomers A to H being present in the following mole fraction: (a) 0 to 0.95, (b) 0 to 0.30, (c) 0 to 0.5, (d) 0 to 0.5, (e) 0 to 0.5, (f) 0 to 0.99, (g) 0 to 0.99, and (h) 0 to 0.99; said at least one polymer having present at least one of monomers B, C, D and E with the proviso that when monomer A is present, in addition to at least one of monomers B, C, D and E, at least one of monomers F, G and H is also present, and further provided that when said at least one polymer is present as part of a mixture, that the components of the mixture co-exist in the same discrete particles in the polyamide matrix.

Claim 62

A process for preparing a toughened multiphase thermoplastic composition consisting essentially of one phase containing 80 to 99 percent by weight of a polyamide matrix resin of number average molecular weight of at least 5,000, and 1 to 20 percent by weight of at least one other phase containing particles of at least one polymer taken from the class consisting of branched and straight chain polymers having a particle size in the range of 0.01 to 1.0 microns and having sites which adhere to the polyamide matrix resin, and said at least one polymer having a tensile modulus in the range of about 1.0 to 20,000 psi, the ratio of the tensile modulus of the polyamide matrix resin to tensile modulus of said at least one polymer being greater than 10 to 1, which comprises admixing said polyamide matrix resin and up to about 40 percent by weight of the said at least one polymer and additionally admixing said polyamide matrix resin until the desired concentration of 80 to 99 percent by weight is achieved and wherein said at least one polymer comprises at least 20 percent by weight of said at least one other phase and is represented by the formula: A.sub.(a) -B.sub.(b) -C.sub.(c) -D.sub.(d) -E.sub.(e) -F.sub.(f) -G.sub.(g) -H.sub.(h) derived in any order from monomers A to H wherein A is ethylene; B is CO; C is an unsaturated monomer taken from the class consisting of methacrylic acid having from 0 to 100 percent of the carboxylic acid groups neutralized with metal ions selected from zinc and calcium; ethyl hydrogen maleate having from 0 to 100 percent of the carboxylic acid groups neutralized with metal ions selected from zinc, lithium, potassium, sodium, calcium and antimony; ethyl hydrogen maleate having from 0 to 100 percent of the carboxylic acid groups neutralized with zinc rosinate or potassium stearate; acrylic acid; maleic anhydride having from 0 to 100 percent of the carboxylic acid groups neutralized with zinc ions; fumaric acid; butyl hydrogen maleate; ethyl hydrogen fumarate; 3,6-endomethylene, 1,2,3,6-tetrahydrophthalic anhydride; D is glycidyl methacrylate; E is an azide selected from the group consisting of benzoic acid sulfonyl azide, phthalic anhydride sulfonyl azide, the monoethyl ester of phthalic anhydride sulfonyl azide and the mono-octadecylester of phthalic anhydride sulfonyl azide; F is an unsaturated monomer taken from the class consisting of isobutylacrylate, methyl acrylate, vinyl acetate, methylmethacrylate, n-butylacrylate, 2-ethyl hexyl methacrylate, methyl vinyl ether, ethyl acrylate and acrylonitrile; G is an unsaturated monomer taken from the class consisting of propylene, styrene, and isobutylene; H is an unsaturated monomer taken from the class consisting of 1,5-hexadiene, 2,5-norbornadiene, butadiene and isoprene; monomers A to H being present in the following mole fraction: (a) 0 to 0.95, (b) 0 to 0.30, (c) 0 to 0.5, (d) 0 to 0.5, (e) 0 to 0.5, (f) 0 to 0.99, (g) 0 to 0.99, and (h) 0 to 0.99; said at least one polymer having present at least one of monomers B, C, D and E with the proviso that when monomer A is present, in addition to at least one of monomers B, C, D and E, at least one of monomers F, G and H is also present, and further provided that when said at least one polymer is present as part of a mixture, that the components of the mixture co-exist in the same discrete particles in the polyamide matrix.

Claim 63

A process for preparing a toughened multiphase thermoplastic composition consisting essentially of one phase containing 80 to 99 percent by weight of a polyamide matrix resin of number average molecular weight of at least 5,000, and 1 to 20 percent by weight of at least one other phase containing particles of at least one polymer taken from the class consisting of branched and straight chain polymers having a particle size in the range of 0.01 to 1.0 microns and having sites which adhere to the polyamide matrix resin, and said at least one polymer having a tensile modulus in the range of about 1.0 to 20,000 psi, the ratio of the tensile modulus of the polyamide matrix resin to tensile modulus of said at least one polymer being greater than 10 to 1, which comprises admixing said polyamide matrix resin and up to about 40 percent by weight of the said at least one polymer and additionally admixing said polyamide matrix resin until the desired concentration of 80 to 99 percent by weight is achieved and wherein said at least one polymer comprises at least 20 percent by weight of said at least one other phase and is represented by the formula: A.sub.(a) -B.sub.(b) -C.sub.(c) -D.sub.(d) -E.sub.(e) -F.sub.(f) -G.sub.(g) -H.sub.(h) derived in any order from monomers A to H wherein A is ethylene; B is CO; C is an unsaturated monomer taken from the class consisting of methacrylic acid having from 0 to 100 percent of the carboxylic acid groups neutralized with metal ions selected from zinc and calcium; ethyl hydrogen maleate having from 0 to 100 percent of the carboxylic acid groups neutralized with metal ions selected from zinc, lithium, potassium, sodium, calcium and antimony; ethyl hydrogen maleate having from 0 to 100 percent of the carboxylic acid groups neutralized with zinc rosinate or potassium stearate; acrylic acid; maleic anhydride having from 0 to 100 percent of the carboxylic acid groups neutralized with zinc ions; fumaric acid; butyl hydrogen maleate; ethyl hydrogen fumarate; 3,6-endomethylene, 1,2,3,6-tetrahydrophthalic anhydride; D is glycidyl methacrylate; E is an azide selected from the group consisting of benzoic acid sulfonyl azide, phthalic anhydride sulfonyl azide, the monoethyl ester of phthalic anhydride sulfonyl azide and the mono-octadecylester of phthalic anhydride sulfonyl azide; F is an unsaturated monomer taken from the class consisting of isobutylacrylate, methyl acrylate, vinyl acetate, methylmethacrylate, n-butylacrylate, 2-ethyl hexyl methacrylate, methyl vinyl ether, ethyl acrylate and acrylonitrile; G is an unsaturated monomer taken from the class consisting of propylene, styrene, and isobutylene; H is an unsaturated monomer taken from the class consisting of 1,5-hexadiene, 2,5-norbornadiene, butadiene and isoprene; monomers A to H being present in the following mole fraction: (a) 0 to 0.95, (b) 0 to 0.30, (c) 0 to 0.5, (d) 0 to 0.5, (e) 0 to 0.5, (f) 0 to 0.99, (g) 0 to 0.99, and (h) 0 to 0.99; said at least one polymer having present at least one of monomers B, C, D and E with the proviso that when monomer A is present, in addition to at least one of monomers B, C, D and E, at least one of monomers F, G and H is also present, and further provided that when said at least one polymer is present as part of a mixture, that the components of the mixture co-exist in the same discrete particles in the polyamide matrix.