Compatibilized blends of crystalline propylene polymers and styrenic copolymers

Claim 2

A thermoplastic resin composition comprising: A. from about 25 to 75 weight percent of a crystalline propylene polymer; B. from about 5 to 40 weight percent of a random styrenic copolymer of i. from about 50 to 99 weight percent of a vinyl aromatic monomer; ii. from about 1 to 30 weight percent of an unsaturated dicarboxylic acid derivative; and iii. optionally, up to about 40 weight percent of a copolymerizable ethylenically unsaturated monomer selected from the group consisting of unsaturated nitriles, unsaturated carboxylic acids, unsaturated carboxylic acid esters, and mixtures thereof; C. from about 2 to 40 weight percent of an elastomeric olefin polymer selected from the group consisting of ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, blends of ethylene-propylene copolymers with ethylene homopolymers, blends of ethylene-propylene-diene terpolymers with ethylene homopolymers mono-vinyl aromatic monomer/conjugated diene block copolymers, and hydrogenated mono-vinyl aromatic monomer/conjugated diene block copolymers; and D. from about 0.05 to 15 weight percent of an epoxy group-containing olefinic copolymer of i. from about 0.1 to 25 weight percent of an unsaturated epoxy monomer; ii. from about 50 to 99 weight percent of an α-olefin; and iii. optionally, up to about 50 weight percent of an ethylenically unsaturated ester.

Claim 3

The thermoplastic resin composition of claim 1 wherein the crystalline propylene polymer is selected from the group consisting of crystalline propylene homopolymers, crystalline propylene-ethylene copolymers, and mixtures thereof.

Claim 4

The thermoplastic resin composition of claim 1 wherein the vinyl aromatic monomer in the random styrenic copolymer is styrene.

Claim 5

The thermoplastic resin composition of claim 1 wherein the unsaturated dicarboxylic acid derivative in the random styrenic copolymer is an unsaturated dicarboxylic acid anhydride.

Claim 6

The thermoplastic resin composition of claim 1 wherein the random styrenic copolymer is a random copolymer of styrene and maleic anhydride.

Claim 7

The thermoplastic resin composition of claim 1 wherein the elastomeric olefin polymer is a blend of an ethylene-propylene-diene terpolymer and an ethylene homopolymer.

Claim 8

The thermoplastic resin composition of claim 1 wherein the unsaturated epoxy monomer is selected from the group consisting of unsaturated glycidyl esters, glycidyl vinyl aromatic monomers, unsaturated glycidyl ethers and epoxy alkenes.

Claim 9

The thermoplastic resin composition of claim 1 wherein the α-olefin is ethylene.

Claim 10

The thermoplastic resin composition of claim 1 wherein the epoxy group-containing olefinic copolymer is selected from the group consisting of copolymers of ethylene and glycidyl methacrylate and terpolymers of ethylene, glycidyl methacrylate, and vinyl acetate.

Claim 11

A thermoplastic resin composition comprising: A. from about 40 to 60 weight percent of a crystalline propylene polymer selected from the group consisting of crystalline propylene homopolymers and crystalline propylene-ethylene copolymers; B. from about 15 to 30 weight percent of a random copolymer of from about 70 to 95 weight percent styrene and from about 5 to 30 weight percent maleic anhydride; C. from about 15 to 35 weight percent of an elastomeric olefin polymer selected from the group consisting of ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, blends of ethylene-propylene copolymers with ethylene homopolymers, and blends of ethylene-propylene-diene terpolymers with ethylene homopolymers; and D. from about 0.25 to 5 weight percent of an epoxy group-containing olefinic copolymer selected from the group consisting of copolymers of ethylene and glycidyl methacrylate and terpolymers of ethylene, glycidyl methacrylate, and vinyl acetate.

Claim 12

A thermoplastic resin composition comprising: A. from about 40 to 60 weight percent of a crystalline propylene polymer selected from the group consisting of crystalline propylene homopolymers and crystalline propylene-ethylene copolymers; B. from about 15 to 30 weight percent of a random copolymer of from about 70 to 95 weight percent styrene and from about 5 to 30 weight percent maleic anhydride; C. from about 15 to 35 weight percent of an elastomeric olefin polymer selected from the group consisting of ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, blends of ethylene-propylene copolymers with ethylene homopolymers, and blends of ethylene-propylene-diene terpolymers with ethylene homopolymers; and D. from about 0.25 to 5 weight percent of an epoxy group-containing olefinic copolymer selected from the group consisting of copolymers of ethylene and glycidyl methacrylate and terpolymers of ethylene, glycidyl methacrylate, and vinyl acetate.

Claim 13

The thermoplastic resin composition of claim 10 wherein the random copolymer of styrene and maleic anhydride is rubber-modified with from about 1 to 25 weight percent of a grafted conjugated diene elastomer.

Claim 14

The thermoplastic resin composition of claim 11 wherein the grafted conjugated diene elastomer is selected from the group consisting of styrene-butadiene block copolymers, styrene-butadiene random copolymers, butadiene homopolymers, and mixtures thereof.

Claim 15

The thermoplastic resin composition of claim 10 wherein the elastomeric olefin polymer is a blend of an ethylene-propylene-diene terpolymer with a high density polyethylene.

Claim 16

The thermoplastic resin composition of claim 10 wherein the epoxy group-containing olefinic copolymer is a copolymer of from about 80 to 99 weight percent ethylene and from about 1 to 20 weight percent glycidyl methacrylate.

Claim 17

The thermoplastic resin composition of claim 10 wherein the epoxy group-containing olefinic copolymer is a terpolymer of from about 60 to 99 weight percent ethylene, from about 1 to 20 weight percent glycidyl methacrylate, and from about 1 to 20 weight percent vinyl acetate.

Claim 18

A process for producing a compatibilized thermoplastic resin composition having improved heat distortion and impact properties comprising the steps of: I. melt blending A. a random styrenic copolymer of i. from about 50 to 99 weight percent of a vinyl aromatic monomer; ii. from about 1 to 30 weight percent of an unsaturated dicarboxylic acid anhydride; and iii. optionally, up to about 40 weight percent of a copolymerizable ethylenically unsaturated monomer selected from the group consisting of unsaturated nitriles, unsaturated carboxylic acids, and unsaturated carboxylic acid esters; B. a first portion of an elastomeric olefin polymer selected from the group consisting of ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, blends of ethylene-propylene copolymers with ethylene homopolymers, blends of ethylene-propylene-diene terpolymers with ethylene homopolymers mono-vinyl aromatic monomer/conjugated diene block copolymers, and hydrogenated mono-vinyl aromatic monomer/conjugated diene block copolymers; and C. an epoxy group-containing olefinic copolymer of i. from about 0.1 to 25 weight percent of an unsaturated epoxy monomer; ii. from about 50 to 99 weight percent of an α-olefin; and iii. optionally, up to about 50 weight percent of an ethylenically unsaturated ester; to obtain a first polyblend; and II. melt-blending the first polyblend with A. a crystalline propylene polymer; and B. a second portion of the elastomeric olefin polymer; to form the compatibilized thermoplastic resin composition, wherein the crystalline propylene polymer is from about 25 to 75 weight percent of the resin composition, the random styrenic copolymer is from about 5 to 40 weight percent of the resin composition, the elastomeric olefin polymer is from about 2 to 40 weight percent of the resin composition, the epoxy group-containing olefinic copolymer is from about 0.05 to 15 weight percent of the resin composition, and the first portion of the elastomeric olefin polymer is at least about 1 percent of the total amount of the elastomeric olefin polymer.

Claim 19

A process for producing a compatibilized thermoplastic resin composition having improved heat distortion and impact properties comprising the steps of: I. melt blending A. a random styrenic copolymer of i. from about 50 to 99 weight percent of a vinyl aromatic monomer; ii. from about 1 to 30 weight percent of an unsaturated dicarboxylic acid anhydride; and iii. optionally, up to about 40 weight percent of a copolymerizable ethylenically unsaturated monomer selected from the group consisting of unsaturated nitriles, unsaturated carboxylic acids, and unsaturated carboxylic acid esters; B. a first portion of an elastomeric olefin polymer selected from the group consisting of ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, blends of ethylene-propylene copolymers with ethylene homopolymers, blends of ethylene-propylene-diene terpolymers with ethylene homopolymers mono-vinyl aromatic monomer/conjugated diene block copolymers, and hydrogenated mono-vinyl aromatic monomer/conjugated diene block copolymers; and C. an epoxy group-containing olefinic copolymer of i. from about 0.1 to 25 weight percent of an unsaturated epoxy monomer; ii. from about 50 to 99 weight percent of an α-olefin; and iii. optionally, up to about 50 weight percent of an ethylenically unsaturated ester; to obtain a first polyblend; and II. melt-blending the first polyblend with A. a crystalline propylene polymer; and B. a second portion of the elastomeric olefin polymer; to form the compatibilized thermoplastic resin composition, wherein the crystalline propylene polymer is from about 25 to 75 weight percent of the resin composition, the random styrenic copolymer is from about 5 to 40 weight percent of the resin composition, the elastomeric olefin polymer is from about 2 to 40 weight percent of the resin composition, the epoxy group-containing olefinic copolymer is from about 0.05 to 15 weight percent of the resin composition, and the first portion of the elastomeric olefin polymer is at least about 1 percent of the total amount of the elastomeric olefin polymer.

Claim 20

The process of claim 16 wherein melt-blending steps I and II are performed at a temperature of from about 190° C. to 330° C.

Claim 21

The process of claim 16 wherein the random styrenic copolymer is a random copolymer of styrene and maleic anhydride.

Claim 22

The process of claim 16 wherein the unsaturated epoxy monomer is selected from the group consisting of unsaturated glycidyl esters, unsaturated glycidyl ethers, glycidyl vinyl aromatic monomers, and epoxy alkenes.

Claim 23

A process for producing a compatibilized thermoplastic resin composition having improved heat distortion and impact properties comprising the steps of: I. melt-blending at a temperature of from about 190° C. to 330° C. A. a random copolymer of from about 70 to 95 weight percent styrene and from about 5 to 30 weight percent maleic anhydride; B. a first portion of an elastomeric olefin polymer selected from the group consisting of ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, blends of ethylene-propylene copolymers with ethylene homopolymers, and blends of ethylene-propylene-diene terpolymers with ethylene homopolymers; and C. an epoxy group-containing olefinic copolymer selected from the group consisting of copolymers of ethylene and glycidyl methacrylate and terpolymers of ethylene, glycidyl methacrylate, and vinyl acetate; to form a first polyblend; and II. melt-blending at a temperature of from about 190° C. to 330° C. A. the first polyblend; and B. a crystalline propylene polymer selected from the group consisting of crystalline propylene homopolymers, and crystalline propylene-ethylene copolymers; to form the compatibilized thermoplastic resin composition, wherein the crystalline propylene polymer is from about 40 to 60 weight percent of the resin composition, the random styrenic copolymer is from about 15 to 30 weight percent of the resin composition, the elastomeric olefin polymer is from about 15 to 35 weight percent of the resin composition, the epoxy group-containing olefinic copolymer is from about 0.25 to 5 weight percent of the resin composition, and the first portion of the elastomeric olefin polymer is at least about 5 percent of the total amount of the elastomeric olefin polymer.

Claim 24

A process for producing a compatibilized thermoplastic resin composition having improved heat distortion and impact properties comprising the steps of: I. melt-blending at a temperature of from about 190° C. to 330° C. A. a random copolymer of from about 70 to 95 weight percent styrene and from about 5 to 30 weight percent maleic anhydride; B. a first portion of an elastomeric olefin polymer selected from the group consisting of ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, blends of ethylene-propylene copolymers with ethylene homopolymers, and blends of ethylene-propylene-diene terpolymers with ethylene homopolymers; and C. an epoxy group-containing olefinic copolymer selected from the group consisting of copolymers of ethylene and glycidyl methacrylate and terpolymers of ethylene, glycidyl methacrylate, and vinyl acetate; to form a first polyblend; and II. melt-blending at a temperature of from about 190° C. to 330° C. A. the first polyblend; and B. a crystalline propylene polymer selected from the group consisting of crystalline propylene homopolymers, and crystalline propylene-ethylene copolymers; to form the compatibilized thermoplastic resin composition, wherein the crystalline propylene polymer is from about 40 to 60 weight percent of the resin composition, the random styrenic copolymer is from about 15 to 30 weight percent of the resin composition, the elastomeric olefin polymer is from about 15 to 35 weight percent of the resin composition, the epoxy group-containing olefinic copolymer is from about 0.25 to 5 weight percent of the resin composition, and the first portion of the elastomeric olefin polymer is at least about 5 percent of the total amount of the elastomeric olefin polymer.