Tough polyamide compositions having high melt flow for complex moldings

Claim 2

A multiphase thermoplastic blend comprising: a) 60-90 wt. % of a polyamide matrix wherein at least 50% of the polyamide matrix by weight is composed of aliphatic moieties, wherein the number average molecular weight of the polyamide(s) in the matrix is between 3,000 and 8,000, wherein the polyamide matrix is comprised of polyamide molecules having end groups selected from amine groups, carboxyl groups and capped groups, wherein the difference between the quantity of amine groups and the quantity of carboxyl groups is the imbalance, wherein the total quantity of the capped groups is the capped ends, wherein the ratio of the quantity of the amino groups to the quantity of the carboxyl groups or the ratio of the quantity of the carboxyl groups to the quantity of the amine groups, whichever is larger, is the end group ratio, and further wherein the polyamide matrix is characterized by 1) a total quantity of imbalance plus capped ends of at least 200 equivalents per 10 6 grams of polyamide, or 2) an end group ratio of at least 1.9 and a total quantity of imbalance plus capped ends of at least 100 equivalents per 10 6 grams of polyamide and b) complementally, 10-40 wt. % of at least one organic polymer toughener having a tensile modulus below 10,000 psi or for a mixture of tougheners an average modulus below 10,000, and having a number average particle size less than about 1,000 nanometers, and wherein the blend has a notched Izod of over 2 ft. lbs/inch, and a melt flow greater than 200 gm per 10 minutes, and also has a tensile strength and melt flow such that the product of notched Izod in ft. lb/inch, tensile strength in thousands of pounds/in 2 and flow in grams/10 minutes is greater than 5,000, and has 0.5-15 weight % of the polyamide matrix grafted to or entrapped in the toughener.

Claim 3

A multiphase thermoplastic blend comprising: a) 60-90 wt. % of a polyamide matrix wherein at least 50% of the polyamide matrix by weight is composed of aliphatic moieties, wherein the number average molecular weight of the polyamide(s) in the matrix is between 3,000 and 8,000 and b) complementally, 10-40 wt. % of at least one organic polymer toughener having a tensile modulus below 10,000 psi or for a mixture of tougheners an average modulus below 10,000, and having a number average particle size less than about 1,000 nanometers, and wherein the blend has a notched Izod of over 2 ft. lbs./inch, and a melt flow greater than 200 gm per 10 minutes, and also has a tensile strength and melt flow such that the product of notched Izod in ft. lb./inch, tensile strength in thousands of pounds/in2 and flow in grams/10 minutes is greater than 5,000, and has 0.5-15 weight % of the polyamide matrix grafted to or entrapped in the toughener, which blend has been made by a process comprising: 1) mixing a high molecular weight polyamide or mixture of polyamides, having a number average molecular weight over 10,000 and having an inherent viscosity greater than 0.7 deciliters/gm, with an organic polymeric toughener having a tensile modulus below 10,000 or a mixture of tougheners having an average tensile modulus below 10,000, and having graft sites selected from metal neutralized carboxyl, adjacent dicarboxyl, anhydride or epoxy groups in a melt extruder at shear forces sufficient to disperse the toughener in the polyamide at toughener maximum to number average particle size below about 1,000 nanometers measured by Transmission Electron Microscope (TEM); and 2) blending into the blend obtained in step 1), a low molecular weight polyamide which will react by transamidation having a number average molecular weight below 5,000, an having an inherent viscosity less than 0.5, said polyamide being chosen to have a sufficiently low molecular weight to result, after reaction with the polyamide in step 1), in a polyamide matrix wherein the number average molecular weight is below 8,000.

Claim 4

A multiphase thermoplastic blend comprising: a) 60-90 wt. % of a polyamide matrix wherein at least 50% of the polyamide matrix by weight is composed of aliphatic moieties, wherein the number average molecular weight of the polyamide(s) in the matrix is between 3,000 and 8,000 and b) complementally, 10-40 wt. % of at least one organic polymer toughener having a tensile modulus below 10,000 psi or for a mixture of tougheners an average modulus below 10,000, and having a number average particle size less than about 1,000 nanometers, and wherein the blend has a notched Izod of over 2 ft. lbs./inch, and a melt flow greater than 200 gm per 10 minutes, and also has a tensile strength and melt flow such that the product of notched Izod in ft. lb./inch, tensile strength in thousands of pounds/in2 and flow in grams/10 minutes is greater than 5,000, and has 0.5-15 weight % of the polyamide matrix grafted to or entrapped in the toughener, which blend has been made by a process comprising: 1) mixing a high molecular weight polyamide or mixture of polyamides, having a number average molecular weight over 10,000 and having an inherent viscosity greater than 0.7 deciliters/gm, with an organic polymeric toughener having a tensile modulus below 10,000 or a mixture of tougheners having an average tensile modulus below 10,000, and having graft sites selected from metal neutralized carboxyl, adjacent dicarboxyl, anhydride or epoxy groups in a melt extruder at shear forces sufficient to disperse the toughener in the polyamide at toughener maximum to number average particle size below about 1,000 nanometers measured by Transmission Electron Microscope (TEM); and 2) blending into the blend obtained in step 1), a low molecular weight polyamide which will react by transamidation having a number average molecular weight below 5,000, an having an inherent viscosity less than 0.5, said polyamide being chosen to have a sufficiently low molecular weight to result, after reaction with the polyamide in step 1), in a polyamide matrix wherein the number average molecular weight is below 8,000.

Claim 5

The blend of claim 1 or 2 wherein the polyamide matrix is at least 75% aliphatic by weight.

Claim 6

The blend of claim 1 or 2 wherein the polyamide matrix is composed of entirely aliphatic polyamides.

Claim 7

The blend of claim 1 or 2 wherein the polyamide matrix is substantially 6 nylon.

Claim 8

The blend of claim 1 or 2 wherein the polyamide matrix is 15 to 30% 6 nylon and 85 to 70% 66 nylon.

Claim 9

The blend of claim 1 or 2 wherein the weight percent of the polyamide matrix grafted to or entrapped in the toughener is between 1 and 7 weight percent.

Claim 10

The blend of claim 1 or 2 wherein the toughener is a polymer of ethylene, at least one alpha-olefin of 3 to 6 carbon atoms, and at least one unsaturated monomer taken from the class consisting of branched, straight chain and cyclic hydrocarbon compounds having from 4 to 14 carbon atoms and said unsaturated monomer having at least one additional nonconjugated unsaturated carbon-carbon bond, in which said polymer has grafted thereto an unsaturated monomer taken from the class consisting of (a) alpha, beta-ethylenically unsaturated dicarboxylic acids having from 3 to 10 carbon atoms. (b) monoesterified esters of such acids where the alcohol moiety contains 1 to 29 carbon atoms, (c) anhydrides of dicarboxylic acids covered in (a), and (d) dicarboxylic acids and the monoesters of said dicarboxylic acid covered in (a) and (b) having at least a portion of the carboxylic groups ionized by neturalization with metal ions.

Claim 11

The blend of claim 1 or 2 where the polymer toughener is a copolymer of ethylene, propylene, and 1,4-hexadiene and, optionally, norbonadiene, monomers selected from the group consisting of i) ethylene, propylene and 1,4-hexadiene, and ii) ethylene, propylene, 1,4-hexadiene and norbornadiene; said copolymer having grafted thereto an unsaturated monomer taken from the class consisting of fumaric acid, maleic acid and maleic anhydride.

Claim 12

The blend of claim 1 or 2 wherein the toughener is a copolymer of ethylene, methyl or ethyl acrylate, and from about 0.0025-0.077 mole/100 g polymer of a mono alkyl ester of 1,4-butenedioic acid in which the alkyl group of the ester has 1 to 6 carbon atoms and having 0 to 100 percent of the esters of 1,4-butenedioic acid ionized by neutralization with metal ions selected from lithium, sodium, potassium, calcium and zinc ions.

Claim 13

The blend of claim 1 or 2 wherein the toughener is an ionic copolymer of units derived from alpha-olefin having the formula RCH═CH 2 wherein R is H or alkyl having from 1 to 8 carbon atoms and from 0.2 to 25 mole percent of units derived from an alpha,beta-ethylenically unsaturated mono- or dicarboxylic acid, at least 10% of the acid groups of said units being neutralized by metal ions having a valence of from 1 to 3, inclusive.

Claim 14

The blend of claim 1 or 2 wherein the toughener is an organic polymer which contains graft sites and sufficient alkyl acrylate, butadiene or substituted butadiene, isoprene, isobutylene, or other rubber producing monomers to achieve the desired modulus.

Claim 15

The blend of claim 1, or 2 where the product of notched Izod in ft. lb./in., tensile strength in thousands of pounds in/ 2 and flow in grams/10 minutes is greater than 10,000.

Claim 16

The blend of claim 1 or 2 wherein the number average particle size of the organic toughener is less than about 500 nanometers.

Claim 17

The blend of claim 1 or 2 wherein the tensile modulus of the toughener is below 3,000 psi.

Claim 18

The blend of claim 1 which additionally contains a reinforcing filler.

Claim 19

The blend of claim 16 where the reinforcing filler is glass fiber.

Claim 20

The blend of claim 14 which additionally contains a reinforcing filler.

Claim 21

The blend of claim 18 where the reinforcing filler is glass fiber.