Thermoplastic composition and use for large parison blow molding applications

1 . A polymeric blend composition, comprising:

a. greater than about 50 parts by weight of a carbonate polymer component; and

b. less than about 50 parts by weight of an acrylonitrile-butadiene-styrene (ABS) component, the ABS component including:

i. a styrene acrylonitrile (SAN) phase including acrylonitrile in an amount greater than 26 percent by weight of the SAN phase; and

ii. a butadiene-based rubber particle phase, which includes butadiene grafted with SAN.

2 . The polymeric blend composition of claim 1 , wherein the polymeric blend composition includes a fluorinated olefin in an amount less than about 0.5 percent by weight of the polymeric blend composition.

3 . The polymeric blend composition of claim 2 , wherein the polymeric blend composition includes polytetrafluoroethylene (PTFE), in an amount of about 0.01 to about 0.05 percent by weight of the polymeric blend composition.

4 . The polymeric blend composition of claim 1 , wherein the carbonate polymer includes a branched polycarbonate.

5 . The polymeric blend composition of claim 4 , wherein the carbonate polymer has a weight average molecular weight (M w ) of about 28,000 to about 36,000.

6 . The polymeric blend composition of claim 5 , wherein the polymeric blend composition includes a stabilizer, a lubricant or both.

7 . The polymeric blend composition of claim 5 , wherein the blend composition includes a color concentrate.

8 . The polymeric blend composition of claim 4 , wherein the branched polycarbonate is present in an amount of about 55 to about 65 parts by weight of the blend composition.

9 . The polymeric blend composition of claim 4 , wherein the butadiene-based rubber particle is present in an amount of about 28 parts by weight to about 34 percent by weight of the ABS component, and wherein the concentration of butadiene is about 8 to about 13 percent by weight of the polymeric blend composition.

10 . The polymeric blend composition of claim 1 wherein the acrylonitrile in the SAN phase is present in an amount of about 29 percent by weight of the SAN phase.

11 . The polymeric blend composition of claim 9 wherein the acrylonitrile in the SAN phase is present in an amount of about 29 percent by weight of the SAN phase.

12 . The polymeric blend composition of claim 8 , wherein the butadiene-based rubber particle is present in an amount of about 28 parts by weight to about 34 percent by weight of the ABS component, and wherein the concentration of butadiene is about 8 to about 13 percent by weight of the polymeric blend composition.

13 . The polymeric blend composition of claim 12 , wherein the acrylonitrile in the SAN phase is present in an amount of about 29 percent by weight of the SAN phase.

14 . The polymeric blend composition of claim 1 , wherein the polymeric blend composition exhibits a value for R* of at least about 4.5.

15 . The polymeric blend composition of claim 4 , wherein the polymeric blend composition exhibits a value for R* of at least about 4.5.

16 . The polymeric blend composition of claim 9 , wherein the polymeric blend composition exhibits a value for R* of at least about 4.5.

17 . The polymeric blend composition of claim 13 , wherein the polymeric blend composition exhibits a value for R* of at least about 4.5.

18 . The polymeric blend composition of claim 1 , wherein the polymeric blend composition exhibits at least one or any combination of the following properties:

a. a critical stress to draw value of at least about 24,000 Pa;

b. a retraction amount (for 40 minute anneal) of less than about 20%; or

c. a dynamic viscosity at 100 rad/sec (at 240° C.) (per ASTM D4440-07) of between about 1500 and about 5000 Pa-s.

19 . The polymeric blend composition of claim 17 , wherein the polymeric blend composition exhibits at least one or any combination of the following properties:

a. a critical stress to draw value of at least about 24,000 Pa;

b. a retraction amount (for 40 minute anneal) of less than about 20%; or

c. a dynamic viscosity at 100 rad/sec (at 240° C.) (per ASTM D4440-07) of between about 1500 and about 5000 Pa-s.

20 . The polymeric blend composition of claim 1 , wherein the polymeric blend composition exhibits at least one or any combination of the following properties:

a. flexural modulus (tangent) per ASTM D790-07, of at least about 1800 MPa;

b. temperature of deflection under load (DTUL, flatwise) (0.45 MPa) per ASTM D-648-07 of at least about 120° C.;

c. temperature of deflection under load (DTUL, flatwise) (1.81 MPa) per ASTM D648-07 of at least about 95° C.;

d. tensile elongation per ASTM D638-03 of at least about 80%; or

e. a notched Izod impact strength per ASTM D-256-06a (at −40° C.) of at least about 450 J/m; or

f. A notched Izod impact strength per ASTM D-256-06a (at 23° C.) of at least about 450 J/m.

21 . The polymeric blend composition of claim 17 , wherein the polymeric blend composition exhibits at least one or any combination of the following properties:

a. flexural modulus (tangent) per ASTM D790-07, of at least about 1800 MPa;

b. temperature of deflection under load (DTUL, flatwise) (0.45 MPa) per ASTM D-648-07 of at least about 120° C.;

c. temperature of deflection under load (DTUL, flatwise) (1.81 MPa) per ASTM D648-07 of at least about 95° C.;

d. tensile elongation per ASTM D638-03 of at least about 80%; or

e. a notched Izod impact strength per ASTM D-256-06a (at −40° C.) of at least about 450 J/m; or

f. A notched Izod impact strength per ASTM D-256-06a (at 23° C.) of at least about 450 J/m.

22 . The polymeric blend composition of claim 1 , wherein the composition exhibits either or both of: i) heat stability is characterized by heat aging performance (as measured by ISO 188, Tensile Strength and Notched Izod (at either or both of 23° C. or −40° C.), % deterioration after aging for 1000 hours at 80° C.) of within ±25%; or hydrolytic stability performance of the polymeric blend composition (as measured by ISO 188, Notched Izod (at either or both of 23° C. or −40° C.), % deterioration after aging for 500 hours at 90° C./70% relative humidity (“RH”)) is within ±50%.

23 . The polymeric blend composition of claim 17 , wherein the composition exhibits either or both of: i) heat stability is characterized by heat aging performance (as measured by ISO 188, Tensile Strength and Notched Izod (at either or both of 23° C. or −40° C.), % deterioration after aging for 1000 hours at 80° C.) of within ±25%; or hydrolytic stability performance of the polymeric blend composition (as measured by ISO 188, Notched Izod (at either or both of 23° C. or −40° C.), % deterioration after aging for 500 hours at 90° C./70% relative humidity (“RH”)) is within ±50%.

24 . A blow molded polymeric blend article, comprising:

a. greater than about 50 parts by weight of a carbonate polymer component; and

b. less than about 50 parts by weight of an acrylonitrile-butadiene-styrene (ABS) component, the ABS component including:

i. a styrene acrylonitrile (SAN) phase including acrylonitrile; and

ii. a butadiene-based rubber particle phase, which includes butadiene grafted with SAN;

wherein the blow molded polymeric blend article:

1. weighs at least 5 kg;

2. exhibits either or both of:

i. heat aging performance (as measured by ISO 188, Tensile Strength and Notched Izod (at either or both of 23° C. or −40° C.), % deterioration after aging for 1000 hours at 80° C.) of within ±25%; or

ii. hydrolytic stability performance of the polymeric blend composition (as measured by ISO 188, Notched Izod (at either or both of 23° C. or −40° C.), % deterioration after aging for 500 hours at 90° C./70% relative humidity (“RH”)) is within ±50%; and

3. exhibits at least one or any combination of the following properties:

i. flexural modulus (tangent) per ASTM D790-07, of at least about 1800 MPa;

ii. temperature of deflection under load (DTUL, flatwise) (0.45 MPa) per ASTM D-648-07 of at least about 120° C.;

iii. temperature of deflection under load (DTUL, flatwise) (1.81 MPa) per ASTM D648-07 of at least about 95° C.;

iv. tensile elongation per ASTM D638-03 of at least about 80%;

v. notched Izod impact strength per ASTM D-256-06a (at −40° C.) of at least about 450 J/m; or

vi. notched Izod impact strength per ASTM D-256-06a (at 23° C.) of at least about 450 J/m.

25 . The polymeric blend article of claims 24 , wherein the article is a seat back.

26 . The polymeric blend article of claim 25 , wherein the seat back exhibits at least one response selected from (1) withstanding without rupture at least about 13000 Newtons in the direction in which the seat faces in a plane, parallel to the longitudinal centerline of the vehicle; (2) upon rapid acceleration up to at least about 20 to about 30 g, substantially no fragmentation of the seat back with at least a 36 kg mass placed behind the seat back; or (3) a combination of both responses (1) and (2).

27 . A method for blow molding an article comprising the steps of:

a. providing a polymeric blend composition including greater than about 50 parts by weight of a branched polycarbonate component; and less than about 50 parts by weight of an acrylonitrile-butadiene-styrene (ABS) component, the ABS component including:

i. a styrene acrylonitrile (SAN) phase including acrylonitrile in an amount greater than 26 percent by weight of the SAN phase; and

ii. a butadiene-based rubber particle phase;

b. introducing the polymeric blend composition into an extruder;

c. advancing the polymeric blend composition at least partially along the length of the extruder;

d. extruding a parison having a mass of at least about 5 kg;

e. shaping the parison to form an article;

f. repeating steps (d) and (e) within less than about 140 seconds; and

g. maintaining the polymeric blend composition at a temperature no greater than about 240° C. through the steps (a) through (e).

28 . The method of claim 27 , wherein the polymeric blend composition exhibits either or both of:

a. heat aging performance (as measured by ISO 188, Tensile Strength and Notched Izod (at either or both of 23° C. or −40° C.), % deterioration after aging for 1000 hours at 80° C.) of within ±25%; or

b. hydrolytic stability performance of the polymeric blend composition (as measured by ISO 188, Notched Izod (at either or both of 23° C. or −40° C.), % deterioration after aging for 500 hours at 90° C./70% relative humidity (“RH”)) is within ±50%.

29 . A method for blow molding a seat back comprising the steps of:

a. providing a polymeric blend composition including greater than about 50 parts by weight of a branched polycarbonate component having a weight average molecular weight (M w ) of about 28,000 to about 36,000.; and less than about 50 parts by weight of an acrylonitrile-butadiene-styrene (ABS) component, the ABS component including:

i. a styrene acrylonitrile (SAN) phase including acrylonitrile in an amount of about 29 percent by weight of the SAN phase; and

ii. a butadiene-based rubber particle phase; and

iii. a stabilizer, a lubricant or both;

b. introducing the polymeric blend composition into an extruder;

c. advancing the polymeric blend composition at least partially along the length of the extruder;

d. extruding a parison having a mass of at least about 5 kg;

e. shaping the parison to form an seat back;

f. repeating steps (d) and (e) within less than about 140 seconds; and

g. maintaining the polymeric blend composition at a temperature no greater than about 240° C. through the steps (a) through (e);

wherein the blow molded polymeric blend article:

1. weighs at least 5 kg;

2. exhibits both:

i. heat aging performance (as measured by ISO 188, Tensile Strength and Notched Izod (at either or both of 23° C. or −40° C.), % deterioration after aging for 1000 hours at 80° C.) of within ±25%; or

ii. hydrolytic stability performance of the polymeric blend composition (as measured by ISO 188, Notched Izod (at either or both of 23° C. or −40° C.), % deterioration after aging for 500 hours at 90° C./70% relative humidity (“RH”)) is within ±50%. and

3. exhibits at least one or any combination of the following properties:

i. flexural modulus (tangent) per ASTM D790-07, of at least about 1800 MPa;

ii. temperature of deflection under load (DTUL, flatwise) (0.45 MPa) per ASTM D-648-07 of at least about 120° C.;

iii. temperature of deflection under load (DTUL, flatwise) (1.81 MPa) per ASTM D648-07 of at least about 95° C.;

iv. tensile elongation per ASTM D638-03 of at least about 80%;

v. notched Izod impact strength per ASTM D-256-06a (at −40° C.) of at least about 450 J/m; or

vi. notched Izod impact strength per ASTM D-256-06a (at 23° C.) of at least about 450 J/m; and

wherein the resulting seat back exhibits at least one response selected from (1) withstanding without rupture at least about 13000 Newtons in the direction in which the seat faces in a plane, parallel to the longitudinal centerline of the vehicle; (2) upon rapid acceleration up to at least about 20 to about 30 g, substantially no fragmentation of the seat back with at least a 36 kg mass placed behind the seat back; or (3) a combination of both responses (1) and (2).

30 . The polymeric blend composition of claim 29 , wherein the butadiene-based rubber particle is present in an amount of about 28 parts by weight to about 34 percent by weight of the ABS component, and wherein the concentration of butadiene is about 8 to about 13 percent by weight of the polymeric blend composition.