# US 12,180,363 B2 · Thermoplastic resin composition and article produced therefrom > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,180,363 B2 - Document ID: US12180363B2 - Status: Granted - Kind: B2 - Application number: 17/280,992 - Filed: 2019-11-18 - Published: 2021-11-18 - Granted: 2024-12-31 - Earliest claimed: 2018-11-26 - Assignees: Lotte Chemical Corporation - Applicants: Lotte Chemical Corporation - Inventors: Woo Jin Lee; Hyuk Jin Jeong - Web page: https://patentgrep.com/patent/US12180363B2 ## CPC - C08L 69/00: Compositions of polycarbonates; Compositions of derivatives of polycarbonates - C08L 2201/02: Flame or fire retardant/resistant - C08L 2205/035: containing four or more polymers in a blend - C08L 2205/14: containing polymeric additives characterised by shape - C08L 2207/53: Core-shell polymer - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) ## Abstract A thermoplastic resin composition of the present invention comprises: a polycarbonate resin; a large-particle diameter rubber polymer having an average particle size of about 500-3,000 nm; an aromatic vinyl copolymer resin; a core-shell graft copolymer; and a phosphorus flame retardant, wherein the core-shell graft copolymer comprises a shell formed by graft polymerization of epoxy group-containing acrylate monomers to a silicon-based rubber polymer core having an average particle size of about 100-300 nm. The thermoplastic resin composition is excellent in hydrolysis resistance, impact resistance, flame retardancy, heat resistance, fluidity, appearance characteristics, etc. ## Claims ### Claim 1 A thermoplastic resin composition comprising: about 100 parts by weight of (A) a polycarbonate resin; a rubber-modified aromatic vinyl copolymer resin which is a mixture of (B) a large-diameter rubber polymer as a dispersed phase and having an average particle diameter of about 500 nm to about 3,000 nm and (C1) an aromatic vinyl copolymer resin as a continuous phase; (C2) a separate aromatic vinyl copolymer resin; about 1 to about 10 parts by weight of (D) a core-shell graft copolymer; and about 1 to about 20 parts by weight of (E) a phosphorus flame retardant, wherein (D) the core-shell graft copolymer is obtained through graft polymerization of an epoxy group-containing acrylate monomer for a shell to a core formed of a silicone-based rubber polymer having an average particle diameter of about 100 nm to about 300 nm, wherein (B) the large-diameter rubber polymer is present in an amount of from about 1 to about 20 parts by weight, wherein (C1) the aromatic vinyl copolymer resin and (C2) the separate aromatic vinyl copolymer resin are present in a combined amount of from about 1 to about 20 parts by weight, and wherein (B) the large-diameter rubber polymer and (D) the core-shell graft copolymer are present in a weight ratio of about 1:0.1 to about 1:3. ### Claim 2 (depends on 1) The thermoplastic resin composition according to claim 1, wherein the rubber-modified aromatic vinyl copolymer resin is prepared through continuous solution polymerization of a rubber polymer having a viscosity of about 40 cPs to about 80 cPs in a 5 wt % styrene solution, an aromatic vinyl monomer, and a monomer copolymerizable with the aromatic vinyl monomer. ### Claim 3 (depends on 1) The thermoplastic resin composition according to claim 1, wherein (C1) the aromatic vinyl copolymer resin and (C2) the separate aromatic vinyl copolymer resin are each a copolymer of an aromatic vinyl monomer and a monomer copolymerizable with the aromatic vinyl monomer. ### Claim 4 (depends on 3) The thermoplastic resin composition according to claim 3, wherein the aromatic vinyl monomer is present in an amount of about 20 wt % to about 90 wt % and the monomer copolymerizable with the aromatic vinyl monomer is present in an amount of about 10 wt % to about 80 wt %, based on 100 wt % of the aromatic vinyl monomer and the monomer copolymerizable with the aromatic vinyl. ### Claim 5 (depends on 3) The thermoplastic resin composition according to claim 3, wherein (C1) the aromatic vinyl copolymer resin and (C2) the separate aromatic vinyl copolymer resin are each a copolymer of an aromatic vinyl monomer and a vinyl cyanide monomer. ### Claim 6 (depends on 5) The thermoplastic resin composition according to claim 5, wherein (C1) the aromatic vinyl copolymer resin and (C2) the separate aromatic vinyl copolymer resin are each a styrene-acrylonitrile copolymer resin. ### Claim 7 (depends on 1) The thermoplastic resin composition according to claim 1, wherein (E) the phosphorus flame retardant comprises a phosphate compound, a phosphonate compound, a phosphinate compound, a phosphine oxide compound, and/or a phosphazene compound. ### Claim 8 (depends on 1) The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has a notched Izod impact strength of about 50 kgf cm/cm to about 80 kgf cm/cm, as measured on a ⅛″ thick specimen in accordance with ASTM D256. ### Claim 9 (depends on 1) The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has a flame retardancy of V-0 or higher, as measured on a 1.5 mm thick specimen by a UL-94 vertical test method. ### Claim 10 (depends on 1) The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has a Vicat softening temperature of about 90° C. to about 120°° C., as measured under conditions of a load of 5 kg and 50° C./hr in accordance with ISO R306. ### Claim 11 (depends on 1) The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has a spiral flow length of about 300 mm to about 500 mm, as measured after injection molding in a spiral-shaped 2 mm thick mold under conditions of a molding temperature of 260° C., a mold temperature of 60° C., an injection pressure of 1,500 kgf/cm2, and an injection rate of 120 mm/s. ### Claim 12 (depends on 1) The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has a flame retardancy of V-0 or higher, as measured on a 1.5 mm thick specimen by a UL-94 vertical test method after the specimen is left under conditions of 80° C. and 90% RH for 48 hours. ### Claim 13 (depends on 1) The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has a melt-flow index increase rate of about 300% or less, as calculated according to Equation 1: Melt-flow index increase rate (%)=((MI1−MI0)/MI0)×100 [Equation 1] where MI0 indicates a melt-flow index of a specimen, as measured under conditions of 230° C. and 3.8 kgf in accordance with ASTM D1238, and MI1 indicates a melt-flow index of the specimen, as measured under conditions of 230° C. and 3.8 kgf in accordance with ASTM D1238 after the specimen is left under conditions of 95° C. and 95% RH for 168 hours. ### Claim 14 (depends on 1) The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has: a notched Izod impact strength of about 50 kgf-cm/cm to about 80 kgf-cm/cm, as measured on a ⅛″ thick specimen in accordance with ASTM D256; a flame retardancy of V-0 or higher, as measured on a 1.5 mm thick specimen by a UL-94 vertical test method; a Vicat softening temperature of about 90° C. to about 120° C., as measured under conditions of a load of 5 kg and 50° C./hr in accordance with ISO R306; a spiral flow length of about 300 mm to about 500 mm, as measured after injection molding in a spiral-shaped 2 mm thick mold under conditions of a molding temperature of 260° C., a mold temperature of 60° C., an injection pressure of 1,500 kgf/cm2 and an injection rate of 120 mm/s; a flame retardancy of V-0 or higher, as measured on a 1.5 mm thick specimen by a UL-94 vertical test method after the specimen is left under conditions of 80° C. and 90% RH for 48 hours; and a melt-flow index increase rate of about 300% or less, as calculated according to Equation 1: Melt-flow index increase rate (%)=((MI1−MI0)/MI0)×100 [Equation 1] where MI0 indicates a melt-flow index of a specimen, as measured under conditions of 230° C. and 3.8 kgf in accordance with ASTM D1238, and MI1 indicates a melt-flow index of the specimen, as measured under conditions of 230° C. and 3.8 kgf in accordance with ASTM D1238 after the specimen is left under conditions of 95° C. and 95% RH for 168 hours. ### Claim 15 (depends on 1) The thermoplastic resin composition according to claim 1, wherein (B) the large-diameter rubber polymer and (D) the core-shell graft copolymer are present in a weight ratio of about 1:0.1 to about 1:2. ### Claim 16 (depends on 1) A molded article formed of the thermoplastic resin composition according to claim 1.