Impact modified carbonnate polymer composition having improved resistance to degradation and improved thermal stability

An impact resistant carbonate polymer composition having improved thermal stability and improved resistance to polymer degradation comprising in admixture an aromatic polycarbonate and an impact modifier prepared by an emulsion polymerization process wherein the impact modifier is essentially free of basic compounds from the emulsion polymerization that catalytically degrade the aromatic polycarbonate, wherein the impact modifier has a shell-core structure, said impact modifier being prepared employing a surfactant selected from the group consisting of alkyl sulfonates, alkylaryl sulfonates, alkyl sulfates, alkylaryl sulfates, alkyl phosphates and alkylarylphosphates, and mixtures thereof and wherein the core consists essentially of a diene rubber polymer selected from the group consisting of conjugated dienes, copolymers containing at least about 50 weight % of a conjugated diene, an olefin rubber, a silicone rubber, an alkyl arylate of C1 to C8 carbon atoms in the alkyl group, copolymers of alkyl acrylates with a styrene or butadiene, and mixtures thereof, and the shell is a thermoplastic polymer.

An impact resistant carbonate polymer composition having improved thermal stability and improved resistance to polymer degradation comprising in admixture an aromatic polycarbonate, a polyester, and an impact modifier prepared by an emulsion polymerization process wherein the impact modifier is essentially free of basic compounds from the emulsion polymerization that catalytically degrade the aromatic polycarbonate.

A shell-core impact modifier prepared by an emulsion polymerization process comprising a rubbery core and a thermoplastic polymer shell, said shell-core impact modifier being essentially free of residual emulsion polymerization emulsifiers which catalytically degrade an aromatic polycarbonate.

A method for preparing an impact modified aromatic carbonate polymer composition, comprising the steps of:

• (a) preparing an impact modifier using a method comprising an emulsion polymerization process, wherein the method results in an impact modifier that is essentially free of residual basic compounds from the emulsion polymerization that catalytically degrade aromatic polycarbonates;
• and
• (b) combining the impact modifier prepared in step (a) with an aromatic polycarbonate polymer in an amount effective to increase the impact resistance of the aromatic polycarbonate polymer to form an impact-modified aromatic polycarbonate polymer, wherein the impact-modified aromatic polycarbonate polymer has a greater thermal stability than an impact-modified polymer formed from the same aromatic polycarbonate polymer and the same impact modifier, but including residual polymerization aids.