Thermoplastic resin composition and molded article made using the same

Abstract

A thermoplastic resin composition comprises (A) a polycarbonate resin; (B) a rubber-modified aromatic vinyl copolymer that includes a rubbery polymer having an average particle size of about 0.5 to about 20 m; and (C) metal particles. A molded article can be prepared using the composition.

Claims

1. A thermoplastic resin composition comprising: (A) about 30 to about 90 weight % of a polycarbonate resin and (B) about 10 to about 70 weight % of a rubber-modified aromatic vinyl copolymer, each based on about 100 weight % of the polycarbonate resin (A) and the rubber-modified aromatic vinyl copolymer (B); and (C) about 0.1 to about 5 parts by weight of metal particles based on about 100 parts by weight of the polycarbonate resin (A) and the rubber-modified aromatic vinyl copolymer (B), wherein the rubber-modified aromatic vinyl copolymer (B) comprises about 30 to less than about 100 weight % of a first rubber-modified aromatic vinyl copolymer (B-1) comprising a rubbery polymer having an average particle size of about 0.5 to about 20 m and greater than 0 to about 70 weight % of a second rubber-modified aromatic vinyl copolymer (B-2) comprising a rubbery polymer having an average particle size of about 0.1 to less than about 0.5 m, wherein a molded article produced from the thermoplastic resin composition prepared under injection molding at a cylinder temperature set to about 250 C. and a molding temperature set to about 60 C. has a degree of gloss of 59 to about 80 GU measured at an angle of 60 by an evaluation method according to ASTM D523.

2. The thermoplastic resin composition according to claim 1, wherein the first rubber-modified aromatic vinyl copolymer (B-1) comprises about 5 to about 30 weight % of the rubbery polymer having an average particle size of about 0.5 to about 20 m based on about 100 weight % of the first rubber-modified aromatic vinyl copolymer (B-1).

3. The thermoplastic resin composition according to claim 1, wherein the second rubber-modified aromatic vinyl copolymer (B-2) comprises about 30 to about 80 weight % of the rubbery polymer having an average particle size of about 0.1 to less than about 0.5 m based on about 100 weight % of the second rubber-modified aromatic vinyl copolymer (B-2).

4. The thermoplastic resin composition according to claim 1, wherein an average particle size of the metal particles (C) is about 5 to about 100 m.

5. The thermoplastic resin composition according to claim 1, wherein the composition further comprises an aromatic vinyl copolymer (D).

6. The thermoplastic resin composition according to claim 5, comprising about 30 to about 80 weight % of the polycarbonate resin (A), about 10 to about 60 weight % of the rubber-modified aromatic vinyl copolymer (B), and about 1 to about 50 weight % of the aromatic vinyl copolymer (D), each based on about 100 weight % of the polycarbonate resin (A), the rubber-modified aromatic vinyl copolymer (B) and the aromatic vinyl copolymer (D), and about 0.1 to about 5 parts by weight of the metal particles (C) based on about 100 parts by weight of the polycarbonate resin (A), the rubber-modified aromatic vinyl copolymer (B) and the aromatic vinyl copolymer (D).

7. The thermoplastic resin composition according to claim 1, further comprising an additive (E) including a flame retardant, lubricant, plasticizer, heat stabilizer, antioxidant, light stabilizer, UV absorbent, releasing agent, colorant, or a combination thereof.

8. The thermoplastic resin composition according to claim 1, wherein a molded article produced from the thermoplastic resin composition has a E value of about 3.0 or less after exposure to 2,400 kJ/m.sup.2 as measured by an evaluation method according to FLTM BO 116-01.

9. The thermoplastic resin composition according to claim 1, wherein the rubber-modified aromatic vinyl copolymer (B) comprises: about 70 to about 95 weight % of the first rubber-modified aromatic vinyl copolymer (B-1) comprising the rubbery polymer having an average particle size of about 0.5 to about 20 m; and about 5 to about 30 weight % of the second rubber-modified aromatic vinyl copolymer (B-2) comprising the rubbery polymer having an average particle size of about 0.1 to less than about 0.5 m.

10. The thermoplastic resin composition according to claim 1, wherein a molded article produced from the thermoplastic resin composition prepared under injection molding at a cylinder temperature set to about 250 C. and a molding temperature set to about 60 C. has a degree of gloss of 62 to about 80 GU measured at an angle of 60 by an evaluation method according to ASTM D523.

11. A molded article produced from the thermoplastic resin composition according to claim 1.

12. The molded article according to claim 11, having a E value of about 3.0 or less after exposure to 2,400 kJ/m.sup.2 as measured by an evaluation method according to FLTM BO 116-01.

13. The molded article according to claim 11, having a E value of about 3.0 or less after exposure to 1,050 kJ/m.sup.2 as measured by an evaluation method according to SAE J 1885.

14. A molded article produced from the thermoplastic resin composition according to claim 5.

15. The molded article according to claim 14, having a E value of about 3.0 or less after exposure to 2,400 kJ/m.sup.2 as measured by an evaluation method according to FLTM BO 116-01.

16. The molded article according to claim 14, having a E value of about 3.0 or less after exposure to 1,050 kJ/m.sup.2 as measured by an evaluation method according to SAE J 1885.

Description

DETAILED DESCRIPTION

(1) The present invention now will be described more fully hereinafter in the following detailed description of the invention, in which some, but not all embodiments of the invention are described. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

(2) The following detailed description is provided to assist the reader in gaining a comprehensive understanding of the methods, apparatuses, and/or systems described herein. Accordingly, various changes, modifications, and equivalents of the systems, apparatuses and/or methods described herein will be suggested to those of ordinary skill in the art. Also, descriptions of well-known functions and constructions may be omitted for increased clarity and conciseness.

(3) Furthermore, a singular form may include a plural from as long as it is not specifically mentioned in a sentence. Furthermore, include/comprise or including/comprising used in the specification represents that one or more components, steps, operations, and elements exist or are added.

(4) Furthermore, unless defined otherwise, all the terms used in this specification including technical and scientific terms have the same meanings as would be generally understood by those skilled in the related art. The terms defined in generally used dictionaries should be construed as having the same meanings as would be construed in the context of the related art, and unless clearly defined otherwise in this specification, should not be construed as having idealistic or overly formal meanings.

(5) Hereinbelow, explanation will be made on a thermoplastic resin composition according to the present disclosure and a molded article using the same.

(6) The present invention relates to a thermoplastic resin composition that can have excellent appearance properties and a molded article manufactured by the same.

(7) First, the thermoplastic resin composition according to the present disclosure may comprise a polycarbonate resin (A), rubber-modified aromatic vinyl copolymer (B), and metal particles (C). In exemplary embodiments, the thermoplastic resin composition of the present disclosure may comprise a polycarbonate resin (A), rubber-modified aromatic vinyl copolymer (B), metal particles (C), and aromatic vinyl copolymer (D). These components can provide excellent metal particle shielding property, impact resistance, light stability and the like. Each of these components will be explained in detail hereinbelow.

(8) The thermoplastic resin composition of the present disclosure may comprise about 30 to about 90 weight % of the polycarbonate resin (A), about 10 to about 70 weight % of the rubber-modified aromatic vinyl copolymer (B), each based on about 100 weight % of the polycarbonate resin (A) and the rubber-modified aromatic vinyl copolymer (B), and about 0.1 to about 5 parts by weight of the metal particles (C) based on about 100 parts by weight of the polycarbonate resin (A) and the rubber-modified aromatic vinyl copolymer (B).

(9) In exemplary embodiments, the thermoplastic resin composition of the present disclosure may comprise about 50 to about 90 weight % of the polycarbonate resin (A), about 10 to about 50 weight % of the rubber-modified aromatic vinyl copolymer (B), each based on about 100 weight % of the polycarbonate resin (A) and the rubber-modified aromatic vinyl copolymer (B), and about 0.1 to about 2 parts by weight of the metal particles (C) based on about 100 parts by weight of the polycarbonate resin (A) and the rubber-modified aromatic vinyl copolymer (B). The appearance properties, impact resistance, light stability, and the like may be maximized in the above-described amount ratios.

(10) Furthermore, the thermoplastic resin composition of the present disclosure may further comprise the aromatic vinyl copolymer (D). In exemplary embodiments, the thermoplastic resin composition of the present disclosure may comprise about 30 to about 80 weight % of the polycarbonate resin (A), about 10 to about 60 weight % of the rubber-modified aromatic vinyl copolymer (B), and about 1 to about 50 weight % of the aromatic vinyl copolymer (D), each based on about 100 weight % of the polycarbonate resin (A), the rubber-modified aromatic vinyl copolymer (B) and the aromatic vinyl copolymer (D), and about 0.1 to about 5 parts by weight of the metal particles (C) based on about 100 parts by weight of the polycarbonate resin (A), the rubber-modified aromatic vinyl copolymer (B) and the aromatic vinyl copolymer (D).

(11) In exemplary embodiments, the thermoplastic resin composition of the present disclosure may comprise about 50 to about 80 weight % of the polycarbonate resin (A), about 10 to about 40 weight % of the rubber-modified aromatic vinyl copolymer (B), and about 1 to about 30 weight % of the aromatic vinyl copolymer (D), each based on about 100 weight % of the polycarbonate resin (A), the rubber-modified aromatic vinyl copolymer (B) and the aromatic vinyl copolymer (D), and about 0.1 to about 2 parts by weight of the metal particles (C) based on about 100 parts by weight of the polycarbonate resin (A), the rubber-modified aromatic vinyl copolymer (B) and the aromatic vinyl copolymer (D).

(12) In some embodiments, the thermoplastic resin composition may comprise the polycarbonate resin (A) in an amount of about 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, or 90 weight %, based on about 100 weight % of the polycarbonate resin (A) and the rubber-modified aromatic vinyl copolymer (B). Further, according to some embodiments of the present invention, the amount of polycarbonate resin (A) can be in a range from about any of the foregoing amounts to about any other of the foregoing amounts.

(13) In some embodiments, the thermoplastic resin composition may comprise the rubber-modified aromatic vinyl copolymer (B) in an amount of about 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, or 70 weight %, based on about 100 weight % of the polycarbonate resin (A) and the rubber-modified aromatic vinyl copolymer (B). Further, according to some embodiments of the present invention, the amount of rubber-modified aromatic vinyl copolymer (B) can be in a range from about any of the foregoing amounts to about any other of the foregoing amounts.

(14) In some embodiments, the thermoplastic resin composition may comprise the metal particles (C) in an amount of about 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, or 5 parts by weight. Further, according to some embodiments of the present invention, the amount of metal particles (C) can be in a range from about any of the foregoing amounts to about any other of the foregoing amounts.

(15) (A) Polycarbonate Resin

(16) The polycarbonate resin used in the present disclosure may be an aromatic polycarbonate resin produced by reacting a diphenol represented by the following Chemical Formula with phosgene, halogen formate, and/or carbonic acid diester.

(17) ##STR00001##

(18) wherein, A.sub.1 is a single bond, substituted or unsubstituted C.sub.1 to C.sub.5 alkylene, substituted or unsubstituted C.sub.1 to C.sub.5 alkylidene, substituted or unsubstituted C.sub.3 to C.sub.6 cycloalkylene, substituted or unsubstituted C.sub.5 to C.sub.6 cycloalkylidene, CO, S, or SO.sub.2; each of R.sub.1 and R.sub.2 is the same or different and each is independently substituted or unsubstituted C.sub.1 to C.sub.30 alkyl or substituted or unsubstituted C.sub.6 to C.sub.30 aryl; and each of n.sub.1 and n.sub.2 is the same or different and each is independently an integer of 0 to 4.

(19) As used herein, unless otherwise defined, the term substituted means that a hydrogen atom has been substituted by a halogen radical, C.sub.1 to C.sub.30 alkyl, C.sub.1 to C.sub.30 haloalkyl, C.sub.6 to C.sub.30 aryl, C.sub.2 to C.sub.30 heteroaryl, C.sub.1 to C.sub.20 alkoxy, or a combination thereof. Also as used herein, unless otherwise defined, the term hetero refers to a nitrogen, sulfur, oxygen, and/or phosphorus atom in place of a carbon atom.

(20) Examples of the diphenol may include without limitation hydroquinone, resorcinol, 4,4-dihydroxydiphenyl, 2,2-bis-(4-hydroxyphenyl)-propane, 2,4-bis-(4-hydroxyphenyl)-2-methylbutane, 1,1-bis-(4-hydroxyphenyl)-cyclohexane, 2,2-bis-(3-chloro-4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dichloro-4-hydroxyphenyl)-propane, 2,2-bis-(3-methyl-4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dimethyl-4-hydroxyphenyl)-propane, and the like, and mixtures thereof. In exemplary embodiments, 2,2-bis-(4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dichloro-4-hydroxyphenyl)-propane, 2,2-bis-(3-methyl-4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dimethyl-4-hydroxyphenyl)-propane and/or 1,1-bis-(4-hydroxyphenyl)-cyclohexane may be used. For example, 2,2-bis-(4-hydroxyphenyl)-propane (also called bisphenol-A) may be used.

(21) The polycarbonate resin used in the present disclosure may have a weight average molecular weight (Mw) measured by Gel Permeation Chromatography (GPC) using polystyrene as a standard sample of about 10,000 to about 50,000 g/mol, for example, a weight average molecular weight (Mw) of about 15,000 to about 40,000 g/mol, but the present invention is not limited thereto.

(22) The polycarbonate resin may be a polycarbonate resin having a branched-chain. For example, the polycarbonate resin may be produced by adding a tri- or higher multifunctional compound, for example, a compound with trivalent or more phenol radicals, in an amount of about 0.05 to about 2 mol % based on the total mol % of diphenols used in the polymerization of polycarbonate resin.

(23) The polycarbonate resin used in the present disclosure may include a homopolycarbonate resin and/or a copolycarbonate resin. Also, a blend of one or more copolycarbonate resins and/or one or more homopolycarbonate resins may be used.

(24) Some or an entirety of the aforementioned polycarbonate resin of the present disclosure may be replaced by an aromatic polyester-carbonate resin obtained through a polymerization reaction in the presence of an ester precursor, for example, a difunctional carboxylic acid.

(25) (B) Rubber-Modified Aromatic Vinyl Copolymer

(26) The rubber-modified aromatic vinyl copolymer used in the present disclosure may be a resin polymer in which a grafted rubbery polymer exists as dispersed particles in a matrix (continuous phase) including a copolymer of an aromatic vinyl compound and a vinyl compound that may be copolymerized with the aromatic vinyl compound. In addition, such a rubber-modified aromatic vinyl copolymer may be a grafted copolymer produced by adding an aromatic vinyl compound and a vinyl compound that may be copolymerized with the aromatic vinyl compound in the presence of a rubbery polymer, and graft-copolymerizing the same, and may include the grafted rubbery polymer. Such a rubber-modified aromatic vinyl copolymer may be produced by known polymerization methods such as emulsion polymerization, solution polymerization, suspension polymerization, and mass polymerization.

(27) In general, the rubber-modified aromatic vinyl copolymer including the grafted rubbery polymer being dispersed in the form of particles may be produced by producing a grafted rubbery polymer with a high content of a rubbery polymer and an aromatic vinyl copolymer with no rubbery polymer separately, and then melting/mixing them in a suitable manner according to the purpose of use. However, when using the mass polymerization method, the rubber-modified aromatic vinyl copolymer including the grafted rubbery polymer being dispersed in the form of particles may be produced through a continuous reaction process at one time without producing the grafted rubbery polymer and the aromatic vinyl copolymer separately and melting/mixing them.

(28) Examples of the rubber-modified aromatic vinyl copolymer used in the present disclosure may include without limitation an acrylonitrile-butadiene-styrene copolymer (ABS), acrylonitrile-styrene-acrylate copolymer (ASA), acrylonitrile-ethylene propylene rubber-styrene copolymer (AES), methyl methacrylate-butadiene-styrene copolymer (MBS), and the like, and mixtures thereof.

(29) Examples of the rubbery polymer that may be used in the rubber-modified aromatic vinyl copolymer may include without limitation diene rubbery polymers such as polybutadiene, styrene-butadiene copolymer, acrylonitrile-butadiene copolymer and the like; saturated rubbery polymers which are hydrogenated diene rubber polymers; isoprene rubbery polymers; acrylic-based rubbery polymers such as butyl acrylate and the like; ethylene/propylene/diene monomer ternary copolymers (EPDM) and the like, and mixtures thereof. In exemplary embodiments, the rubbery polymer may include polybutadiene which is a diene rubber polymer.

(30) The rubber-modified aromatic vinyl copolymer may include a rubbery polymer having the average particle size of about 0.5 to about 20 m, for example, about 0.5 to about 15 m, and as another example about 0.7 to about 10 m. The above-described particle size is an optimized particle size to improve a degree of gloss and a shielding effect of a thermoplastic resin composition comprising the rubber-modified aromatic vinyl copolymer. The thermoplastic resin composition including the same can thus exhibit excellent impact resistance and light stability, and also can exhibit excellent appearance by minimizing the appearance problems caused by the orientation and/or non-uniformity of metal particles in a molded article made from the resin composition.

(31) Herein, the particle size may be expressed by an average size of a group, the average size being digitized by a measurement method, but there are also a mode diameter that represents a maximum value of a distribution, a median diameter that corresponds to a median value of an integral calculus distribution curve, and various average diameters (number average, length average, area average, mass average, volume average and the like) that are more commonly used. In the present disclosure, however, an average particle size refers to a number average diameter that is a measurement of D50 (a particle size of the point where the distribution rate is 50%) unless expressed otherwise.

(32) Examples of the aromatic vinyl compound that may be graft-copolymerized with the rubber polymer may include without limitation styrene, -methylstyrene, -methylstyrene, p-methylstyrene, p-t-butylstyrene, ethylstyrene, vinylxylene, monochlorostyrene, dichlorostyrene, dibromostyrene, vinylnaphthalene, and the like, and combinations thereof. In exemplary embodiments, the aromatic vinyl compound may include styrene.

(33) Examples of the vinyl compound that may be copolymerized with the aromatic vinyl compound may include without limitation acrylonitrile, methacrylonitrile, fumaronitrile, methacrylic acid alkyl esters, acrylic acid alkyl esters, maleic anhydride, alkyl and/or phenyl nucleus-substituted maleimide, and the like, and combinations thereof. Here, the term alkyl means C.sub.1 to C.sub.8 alkyl. In exemplary embodiments, the vinyl compound may include acrylonitrile.

(34) Furthermore, the rubber-modified aromatic vinyl copolymer (B) may include a first rubber-modified aromatic vinyl copolymer (B-1) and a second rubber-modified aromatic vinyl copolymer (B-2).

(35) The rubber-modified aromatic vinyl copolymer (B) may include about 30 to about 100 weight % of the first rubber-modified aromatic vinyl copolymer (B-1) and 0 to about 70 weight % of the second rubber-modified aromatic vinyl copolymer (B-2).

(36) In exemplary embodiments, the rubber-modified aromatic vinyl copolymer (B) may include about 50 to about 99 weight % of the first rubber-modified aromatic vinyl copolymer (B-1) and about 1 to about 50 weight % of the second rubber-modified aromatic vinyl copolymer (B-2). For example, the rubber-modified aromatic vinyl copolymer (B) may include about 70 to about 95 weight % of the first rubber-modified aromatic vinyl copolymer (B-1) and about 5 to about 30 weight % of the second rubber-modified aromatic vinyl copolymer (B-2).

(37) Within the above range, it is possible to implement excellent appearance and physical properties of the molded article made from the thermoplastic resin composition.

(38) In some embodiments, the rubber-modified aromatic vinyl copolymer (B) may include about 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99 or 100 weight % of the first rubber-modified aromatic vinyl copolymer (B-1). Further, according to some embodiments of the present invention, the amount of first rubber-modified aromatic vinyl copolymer (B-1) can be in a range from about any of the foregoing amounts to about any other of the foregoing amounts.

(39) In some embodiments, the rubber-modified aromatic vinyl copolymer (B) may include the second rubber-modified aromatic vinyl copolymer (B-2) in an amount of 0 (the second rubber-modified aromatic vinyl copolymer (B-2) is not present), about 0 (the second rubber-modified aromatic vinyl copolymer (B-2) is present), 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, or 70 weight %. Further, according to some embodiments of the present invention, the amount of second rubber-modified aromatic vinyl copolymer (B-2) can be in a range from about any of the foregoing amounts to about any other of the foregoing amounts.

(40) (B-1) First Rubber-Modified Aromatic Vinyl Copolymer

(41) The first rubber-modified aromatic vinyl copolymer (B-1) may include a rubbery polymer having an average particle size of about 0.5 to about 20 m. The first rubber-modified aromatic vinyl copolymer includes a rubbery polymer having a relatively larger particle size, and thereby may control a degree of gloss of a thermoplastic composition comprising the same, and improve the shielding property of metal particles (C) and the appearance properties of a molded article made from the thermoplastic composition without use of an additional matting agent and/or change of the metal particles.

(42) The average particle size of the rubbery polymer may be about 0.5 to about 20 m, for example about 0.5 to about 15 m, and as another example about 0.7 to about 10 m. In some embodiments, the average particle size of the rubbery polymer may be about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 m.

(43) When the average particle size of the rubbery polymer is less than about 0.5 m, the shielding property of metal particles and the effect of controlling the degree of gloss of the thermoplastic resin composition can be significantly deteriorated. When the average particle size of the rubbery polymer exceeds about 20 m, a metallic appearance of the molded article can be deteriorated.

(44) The first rubber-modified aromatic vinyl copolymer (B-1) may include about 5 to about 30 weight % of the rubbery polymer based on about 100 weight % of the first rubber-modified aromatic vinyl copolymer (B-1). In exemplary embodiments, the first rubber-modified aromatic vinyl copolymer (B-1) may include about 5 to about 20 weight %, for example about 7 to about 20 weight %, of the rubbery polymer based on about 100 weight % of the first rubber-modified aromatic vinyl copolymer (B-1). When the amount of the rubbery polymer is less than about 5 weight %, the effect for improving an impact resistance can be deteriorated. When the amount of the rubbery polymer exceeds about 30 weight %, mechanical physical properties and molding processability of the thermoplastic composition can be deteriorated.

(45) In some embodiments, the first rubber-modified aromatic vinyl copolymer (B-1) may include about 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 weight % of the rubbery polymer based on about 100 weight % of the first rubber-modified aromatic vinyl copolymer (B-1). Further, according to some embodiments of the present invention, the amount of rubbery polymer can be in a range from about any of the foregoing amounts to about any other of the foregoing amounts.

(46) Further, the first rubber-modified aromatic vinyl copolymer (B-1) may be used as a combination of two or more types having the different average particle sizes and amounts of the rubbery polymer.

(47) (B-2) Second Rubber-Modified Aromatic Vinyl Copolymer

(48) The second rubber-modified aromatic vinyl copolymer (B-2) may include a rubbery polymer having an average particle size of about 0.1 to less than about 0.5 m. The second rubber-modified aromatic vinyl copolymer (B-2) may play a role of improving appearance and/or physical properties such as impact resistance like the first rubber-modified aromatic vinyl copolymer (B-1).

(49) The average particle size of the rubbery polymer may be about 0.1 to less than about 0.5 m, for example about 0.1 to about 0.4 m. In some embodiments, the average particle size of the rubbery polymer may be about 0.1, 0.2, 0.3, or 0.4 m.

(50) When the average particle size of the rubbery polymer is less than about 0.1 m, or is or exceeds about 0.5 m, the improvement efficiency of impact resistance can be significantly deteriorated.

(51) The second rubber-modified aromatic vinyl copolymer (B-2) may include about 30 to about 80 weight % of the rubbery polymer based on about 100 weight % of the second rubber-modified aromatic vinyl copolymer (B-2). In exemplary embodiments, the second rubber-modified aromatic vinyl copolymer (B-2) may include about 40 to about 70 weight % of the rubbery polymer based on about 100 weight % of the second rubber-modified aromatic vinyl copolymer (B-2). When the amount of the rubbery polymer is less than about 30 weight %, the effect for improving an impact resistance can be insufficient. When the amount of the rubbery polymer exceeds about 80 weight %, mechanical physical properties and molding processability of the thermoplastic composition can be deteriorated.

(52) In some embodiments, the second rubber-modified aromatic vinyl copolymer (B-2) may include about 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, or 80 weight % of the rubbery polymer based on about 100 weight % of the second rubber-modified aromatic vinyl copolymer (B-2). Further, according to some embodiments of the present invention, the amount of rubbery polymer can be in a range from about any of the foregoing amounts to about any other of the foregoing amounts.

(53) Further, the second rubber-modified aromatic vinyl copolymer (B-2) may be used as a combination of two or more types having the different average particle sizes and amounts of the rubbery polymer.

(54) (C) Metal Particles

(55) The metal particles used in the present disclosure may be used singly or in combination of two or more types. The material for the metal particles may be any kinds of metals and/or alloys, for example aluminum. In addition, the surface of the metal particles may be coated and/or surface-treated.

(56) The metal particles (C) may be included in an amount of about 0.1 to about 5 parts by weight, for example about 0.1 to about 2 parts by weight, based on about 100 parts by weight of the polycarbonate resin (A) and the rubber-modified aromatic vinyl copolymer (B), or about 100 parts by weight of the polycarbonate resin (A), the rubber-modified aromatic vinyl copolymer (B), and the aromatic vinyl copolymer (D).

(57) When the amount of the metal particles is less than about 0.1 part by weight, it can be difficult to realize a metallic appearance of the thermoplastic composition. When the amount of the metal particles exceeds about 5 parts by weight, mechanical physical properties and/or molding processability of the thermoplastic composition can be significantly deteriorated.

(58) The average particle size of the metal particles may be about 5 to about 100 m, for example about 10 to about 60 m. In some embodiments, the average particle size of the metal particles may be about 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100 m.

(59) When the average particle size of the metal particles is less than about 5 m or exceeds about 100 m, it can be difficult to realize a metallic appearance of the thermoplastic composition, and realization of excellent appearance properties can be limited because the orientation and/or non-uniformity of the metal particles can be significant.

(60) Further, the metal particles (C) may be used as a combination of two or more types having the different average particle sizes. The type of metal particles may be changed according to the desired metallic appearance.

(61) (D) Aromatic Vinyl Copolymer

(62) The aromatic vinyl copolymer (D) used in the present disclosure is an unmodified aromatic vinyl copolymer. The aromatic vinyl copolymer (D) is prepared by copolymerizing an aromatic vinyl compound and a vinyl compound that may be copolymerized with an aromatic vinyl compound.

(63) Examples of the aromatic vinyl compound may include without limitation styrene, -methylstyrene, -methylstyrene, p-methylstyrene, p-t-butylstyrene, ethylstyrene, vinylxylene, monochlorostyrene, dichlorostyrene, dibromostyrene, vinylnaphthalene, and the like, and mixtures thereof.

(64) Examples of the vinyl compound that may be copolymerized with the aromatic vinyl compound may include without limitation acrylonitrile, methacrylonitrile, fumaronitrile, methacrylic acid alkyl esters, acrylic acid alkyl esters, maleic anhydride, alkyl and/or phenyl nucleus-substituted maleimide, and the like, and mixtures thereof. Herein, the term alkyl means C.sub.1 to C.sub.8 alkyl.

(65) The aromatic vinyl copolymer (D) may be copolymerized from a mixture including about 60 to about 80 weight % of the aromatic vinyl compound and about 20 to about 40 weight % of the vinyl compound that may be copolymerized with the aromatic vinyl compound. In exemplary embodiments, the aromatic vinyl copolymer (D) may be copolymerized from a mixture including about 70 to about 80 weight % of the aromatic vinyl compound and about 20 to about 30 weight % of the vinyl compound that may be copolymerized with the aromatic vinyl compound. For example, the aromatic vinyl copolymer (D) may be copolymerized from a mixture including about 72 to about 80 weight % of the aromatic vinyl compound and about 20 to about 27 weight % of the vinyl compound that may be copolymerized with the aromatic vinyl compound.

(66) In some embodiments, the mixture for preparing the aromatic vinyl copolymer (D) may include about 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, or 80 weight % of the aromatic vinyl compound. Further, according to some embodiments of the present invention, the amount of aromatic vinyl compound can be in a range from about any of the foregoing amounts to about any other of the foregoing amounts.

(67) In some embodiments, the mixture for preparing the aromatic vinyl copolymer (D) may include about 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40 weight % of the vinyl compound that may be copolymerized with the aromatic vinyl compound. Further, according to some embodiments of the present invention, the amount of vinyl compound can be in a range from about any of the foregoing amounts to about any other of the foregoing amounts.

(68) The aromatic vinyl copolymer (D) may have a weight average molecular weight measured by Gel Permeation Chromatography (GPC) using polystyrene as a standard sample of about 50,000 to about 400,000 g/mol, for example about 50,000 to about 200,000 g/mol.

(69) The aromatic vinyl copolymer (D) may include styrene-acrylonitrile copolymer (SAN).

(70) The styrene-acrylonitrile copolymer (SAN) may be prepared by copolymerizing about 60 to about 85 weight % of styrene and about 15 to about 40 weight % of acrylonitrile, for example may be prepared by copolymerizing about 65 to about 80 weight % of styrene and about 20 to about 35 weight % of acrylonitrile.

(71) The aromatic vinyl copolymer (D) may be included in the amount of about 1 to about 50 weight %, based on about 100 weight % of the polycarbonate resin (A), the rubber-modified aromatic vinyl copolymer (B), and the aromatic vinyl copolymer (D).

(72) In some embodiments, the aromatic vinyl copolymer (D) may be included in the amount of about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50 weight %, based on about 100 weight % of the polycarbonate resin (A), the rubber-modified aromatic vinyl copolymer (B), and the aromatic vinyl copolymer (D). Further, according to some embodiments of the present invention, the amount of aromatic vinyl copolymer (D) can be in a range from about any of the foregoing amounts to about any other of the foregoing amounts.

(73) When the amount of the aromatic vinyl copolymer (D) is within the above range, it can be effective to secure a balance of physical properties such as flowability, impact resistance and the like.

(74) (E) Additives

(75) Besides the aforementioned, the thermoplastic resin composition of the present disclosure may optionally include one or more additives (E) depending on the application thereof. Examples of the additives (E) may include, but not limited to, flame retardant, lubricant, plasticizer, heat stabilizer, antioxidant, light stabilizer, UV absorbent, releasing agent, colorant, and the like, and combinations thereof.

(76) A flame retardant is a material that reduces combustibility. Examples of the flame retardant may include without limitation phosphate compounds, phosphite compounds, phosphonate compounds, polysiloxanes, phosphazene compounds, phosphinate compounds, melamine compounds, and the like, and combinations thereof.

(77) A lubricant is a material for lubricating the interface of the thermoplastic resin composition between a metal surface that contacts the resin composition during processing, molding, and extruding, thereby helping the flow or movement of the resin composition. Herein, a generally used lubricant may be used.

(78) A plasticizer is a material for improving the flexibility, processibility, and expansibility of the thermoplastic resin composition. Herein, a generally used plasticizer may be used.

(79) A heat stabilizer is a material for minimizing or preventing thermal decomposition of the thermoplastic resin composition when being mixed and molded at high temperatures. A generally used material may be used as heat stabilizer.

(80) An antioxidant is a material for minimizing or preventing chemical reaction of the thermoplastic resin composition with oxygen, thus preventing the resin composition from being decomposed and losing its intrinsic properties. Examples of the antioxidant may include without limitation phenolic type antioxidants, phosphate type antioxidants, thioether type antioxidants, amine type antioxidant, and the like, and combinations thereof.

(81) A light stabilizer is a material for minimizing or preventing the thermoplastic resin composition from being color-changed or losing its mechanical properties due to decomposition by ultraviolet rays. Examples of the light stabilizer may include without limitation benzophenone type light stabilizer, benzothiazole type light stabilizer, amine type light stabilizer, and the like, and combinations thereof.

(82) Examples of the UV absorbent may include without limitation titanium dioxide, carbon black, and the like, and combinations thereof.

(83) Examples of the releasing agent may include without limitation fluorine-containing polymers, silicone oils, metal salts of stearic acid, metal salts of montanic acid, montanic ester waxes, polyethylene waxes, and the like, and combinations thereof.

(84) Examples of the colorant may include without limitation pigments, dyes, and combinations thereof.

(85) The thermoplastic resin composition may include one or more additives in an amount of about 0.1 to about 15 parts by weight, based on about 100 parts by weight of the polycarbonate resin (A) and the rubber-modified aromatic vinyl copolymer (B), or about 100 parts by weight of the polycarbonate resin (A), the rubber-modified aromatic vinyl copolymer (B) and the aromatic vinyl copolymer (D). For example, the additives may be included in an amount of about 0.1 to about 8 parts by weight. When the amount of the additives (E) is within the above range, the functions of the additives can be realized with minimal or no deterioration of appearance properties, physical properties and the like of the thermoplastic composition.

(86) In some embodiments, the thermoplastic composition of the present disclosure may include about 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 or 15 parts by weight of the additives (E) based on about 100 parts by weight of the polycarbonate resin (A), the rubber-modified aromatic vinyl copolymer (B) and/or the aromatic vinyl copolymer (D). Further, according to some embodiments of the present invention, the amount of additives can be in a range from about any of the foregoing amounts to about any other of the foregoing amounts.

(87) Exemplary embodiments also provide a molded article including the thermoplastic resin composition that can have excellent appearance properties. In some embodiments, the thermoplastic resin composition of the present disclosure may be used, without limitation, for various industrial fields, such as various electric electronic products, automobile components, miscellaneous goods, and the like. For example, the thermoplastic resin composition of the present disclosure may be used to prepare a molded article for automobile interior materials such as center fascia, control panel, console box, and the like.

(88) The gloss of the molded article measured at an angle of 60 according to ASTM D523 may be about 20 to about 80 GU, for example about 30 to about 80 GU, and as another example about 40 to about 80 GU.

(89) The molded article may have a E value of about 3.0 or less, for example about 2.0 to about 2.8, and as another example about 2.3 to about 2.7, after exposure to 2,400 kJ/m.sup.2 measured by the evaluation method according to FLTM BO 116-01.

(90) Furthermore, the molded article may have a E value of about 3.0 or less, for example about 2.0 to about 2.8, and as another example about 2.3 to about 2.7, after exposure to 1,050 kJ/m.sup.2 measured by the evaluation method according to SAE J 1885.

(91) It was confirmed through numerous tests that the thermoplastic resin composition of the present disclosure belonging to the relevant range can realize excellent physical properties as well as excellent appearance properties.

EXAMPLES

(92) Herein below are examples that include test results to prove the excellent effects of the thermoplastic resin composition of the present disclosure.

(93) The specifications of the polycarbonate resin (A), rubber-modified aromatic vinyl copolymer (B), metal particles (C), and aromatic vinyl copolymer (D) used in Examples and Comparative Examples of the present disclosure are as follows.

(94) (A) Polycarbonate Resin

(95) In the Examples and Comparative Examples of the present disclosure, a bisphenol-A type linear polycarbonate resin with the weight-average molecular weight of 25,000 g/mol is used.

(96) (B) Rubber-Modified Aromatic Vinyl Copolymer

(97) The rubber-modified aromatic vinyl copolymers (B) used in the Examples and Comparative Examples of the present disclosure are the following first rubber-modified aromatic vinyl copolymer (B-1-1), the following first rubber-modified aromatic vinyl copolymer (B-1-2), and the following second rubber-modified aromatic vinyl copolymer (B-2).

(98) (B-1-1) First Rubber-Modified Aromatic Vinyl Copolymer

(99) As the first rubber-modified aromatic vinyl copolymer (B-1-1), a copolymer including a rubber polymer having an average particle size of about 7.5 m and a particle size distribution of about 5 to about 10 m, which is prepared by a general mass polymerization process after mixing about 65 weight % of styrene and about 20 weight % of acrylonitrile with about 15 weight % of a polybutadiene rubbery polymer, is used.

(100) (B-1-2) First Rubber-Modified Aromatic Vinyl Copolymer

(101) As the first rubber-modified aromatic vinyl copolymer (B-1-2), a copolymer including a rubber polymer having an average particle size of about 1.0 m and a particle size distribution of about 0.5 to about 1.5 m, which is prepared by a general mass polymerization process after mixing about 65 weight % of styrene and about 20 weight % of acrylonitrile with about 15 weight % of a polybutadiene rubbery polymer, is used.

(102) (B-2) Second Rubber-Modified Aromatic Vinyl Copolymer

(103) As the second rubber-modified aromatic vinyl copolymer (B-2), a grafted copolymer including a rubber polymer having an average particle size of 0.3 m and a particle size distribution of about 0.2 to about 0.4 m, which is prepared by graft-copolymerizing through an emulsion polymerization process after mixing about 32 weight % of styrene and about 10 weight % of acrylonitrile with about 58 weight % of a polybutadiene rubbery polymer, is used.

(104) (C) Metal Particles

(105) In the Examples and Comparative Examples of the present disclosure, aluminum metal particles having an average particle size of about 30 m and a particle size distribution of about 15 to about 60 m, available from Yamoto Metal Company, are used.

(106) (D) Aromatic Vinyl Copolymer

(107) As the aromatic vinyl copolymer used in the Examples and Comparative Examples of the present disclosure, a styrene-acrylonitrile copolymer having a weight average molecular weight of about 100,000 g/mol prepared by a general suspension polymerization method using a monomer mixture including about 76 weight % of styrene and about 24 weight % of acrylonitrile is used.

(108) Each of components according to the amount ratios shown in the following Table 1 and each of additives such as antioxidant, light stabilizer and the like in the same amount are added and melt-processed to produce a thermoplastic resin composition in the type of pellets. The extrusion is performed using a twin screw extruder with LID=29 and diameter of about 45 mm, and the barrel temperature is set to be about 250 C. The prepared pellets are dried at 80 C. for 2 hours. Then, using a 60 oz injection molder, the cylinder temperature and the molding temperature are set to be about 250 C. and about 60 C., respectively, and then, specimens for evaluating physical properties, such as the specimens for evaluating the degree of gloss and appearance, having a size of 90 mm50 mm2.0 mm are manufactured.

(109) TABLE-US-00001 TABLE 1 Examples Comparative Examples 1 2 3 4 5 6 7 8 1 2 3 4 5 6 Polycarbonate resin 65 65 65 65 65 65 75 75 65 65 65 65 75 90 (A) (wt %) Vinyl- (B-1-1) 35 30 25 20 25 20 5 modified graft copolymer (B) (wt %) (B-1-2) 35 25 5 (B-2) 5 5 5 10 20 15 15 10 10 Metal particles (C) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 (parts by weight) Aromatic vinyl 10 10 10 25 15 15 15 15 copolymer (D) (wt %)

(110) The specimens obtained by the compositions of the aforementioned Table 1 are evaluated for the degree of gloss, impact resistance, flowability, weather resistance, and appearance as follows, and the results thereof are listed in the following Table 2.

(111) Physical Property Evaluation Method

(112) (1) Degree of gloss (Gloss, GU): The degree of gloss is measured at an angle of 60 by an evaluation method according to ASTM D523 using a BYK-Gardner Gloss Meter produced by BYK.

(113) (2) Impact resistance (kgf.Math.cm/cm): For a specimen having a thickness of for measurement of Izod impact strength, the notched Izod impact strength is measured by an evaluation method according to ASTM D256.

(114) (3) Flowability (g/10 min): For resin composition pellets, the melt-flow index is measured under the conditions of 250 C. and 10 kg by an evaluation method according to ASTM D1238.

(115) (4) Light stability: The color difference change (E) value is measured after exposure of 2,400 kJ/m.sup.2 by an evaluation method according to FLTM B0116-01 by Ford.

(116) (5) Appearance: For the specimen for evaluating appearance, the degree of flow-mark and the non-uniformity and orientation of the metal particles are evaluated with a naked eye, and then the values are classified into 1 to 5 points (1: bad to 5: good).

(117) TABLE-US-00002 TABLE 2 Physical Examples Comparative Examples properties 1 2 3 4 5 6 7 8 1 2 3 4 5 6 Degree of 59 74 62 67 78 72 65 71 90 89 86 90 92 92 gloss Izod impact 39 49 51 37 44 45 45 50 42 62 55 57 58 60 strength Melt index 37 45 35 44 49 41 31 29 51 37 45 47 22 15 Color 1.4 1.5 1.9 1.1 1.3 1.5 1.0 1.4 3.7 4.9 4.3 4.4 3.5 3.1 difference change Appearance 5 4 5 5 3 4 5 4 1 1 2 1 1 1

(118) The aforementioned tests prove that the aforementioned combination of components and amount ratios of the components according to the present disclosure can provide a composition with excellent mechanical properties such as impact resistance and the like, light stability and appearance characteristics.

(119) While this invention has been described in connection with what is presently considered to be practical embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. Therefore, the aforementioned embodiments should be understood to be exemplary but not limiting the present invention in any way.