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Low gloss thermoplastic articlesRelated Patent Categories: Synthetic Resins Or Natural Rubbers -- Part Of The Class 520 Series, Natural Rubber Compositions Having Nonreactive Materials (dnrm) Other Than: Carbon, Silicon Dioxide, Glass Titanium Dioxide, Water, Hydrocarbon, Halohydrocarbon, Ethylenically Unsaturated Reactant Admixed With A Preformed Reaction Product Derived From: (a) At Least One Polycarboxylic Acid, Ester, Or Anhydride; (b) At Least One Polyhydroxy Compound; And (c) At Least One Fatty Acid Glycerol Ester, Or A Fatty Acid Or Salt Derived From A Naturally Occurring Glyceride, Tall Oil, Or A Tall Oil Fatty Acid, Solid Polymer Derived From O-c(=o)-o- Or Hal-c(=o)-containing Reactant, Solid Polymer Derived From O-c(=o)-o- Or Hal-c(=o)-containing Reactant And Polyhydroxy Reactant, Mixed With Polycarboxylic Acid Or Derivative And Polyhydroxy Reactants Or Polymer Thereof; Or Di- Or Higher Ester Of Polycarboxylic Acid As Sole Reactant Or Polymer TherefromLow gloss thermoplastic articles description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070173619, Low gloss thermoplastic articles. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application is a Continuation In Part of and claims priority to U.S. Provisional Application Ser. No. 60/683826 filed on May 23, 2005, and U.S. Original application Ser. No. 11/316227 filed on Dec. 22, 2005, both which are incorporated herein by reference in their entirety. BACKGROUND OF THE INVENTION [0002] Plastics have been replacing metals and other material products in industry for many years. This is particularly true with respect to automotive parts. The lighter weight of plastics and their flexibility in structural design provide significant motivation to designers and engineers to use plastics. One of the areas in which plastics are contemplated being employed is where paint elimination in a molded part is desirable. However, the look of paint, that is the exterior surface being of low gloss, is also desired. Most plastic materials produce high gloss surfaces when molded. Achieving that low gloss while maintaining the required structural, mechanical, dimensional, chemical resistance, and the like characteristics of the molded part, is difficult to achieve. Of course such desired molded parts are not restricted to automotive use but can be employed in machine housings, appliances, consumer or electronic devices, and outdoor vehicles and devices and any other part needing good mechanical strength and low gloss. [0003] We have succeeded in designing a material that produces a low gloss molded part that satisfies the requirements of its intended use. The look of paint is matched but the advantages of plastic are achieved particularly with respect to performance in higher-heat environments and good mechanical properties. Certain multiple component plastic compositions can be used. Certain additives also enhance the reduction of gloss. Molding conditions can also result in gloss reduction. We have also succeeded in reducing the gloss of an article molded from certain compositions by heating the article under certain conditions. These significant gloss reductions can be achieved even when molding against a polished tool. Substantially uniform low gloss to totally uniform low gloss can be achieved over the molded part surface. The composition can also be readily molded, the viscosity varying according to the requirements of the part to be molded. For example, viscosities below about 500 Pa-s at 271.degree. C. as measured by capillary rheometry following the ISO 11443 standard can be achieved, particularly when large and/or intricate parts are desired. SUMMARY OF THE INVENTION [0004] The invention relates to a composition of matter comprising an article derived from a composition containing: [0005] 1) from about 30 to 80 wt. % of a polycarbonate component, [0006] 2) from about 5 to about 50 wt. % of a polyester component, wherein when polybutylene terephthalate is present in the composition, the polybutylene terephthalate is present in conjunction with at least one other polyester that is not polybutylene terephthalate; [0007] 3) from about 2 to about 25 wt. % of an impact modifier; and [0008] 4) from a gloss reducing effective amount of a multifunctional additive comprising at least one epoxy group. [0009] In one embodiment, the invention relates to a process for making an article by injection molding comprising: [0010] (a) heating a composition to a temperature that is at least the melting point of the composition to a viscous liquid [0011] (b) injecting the viscous liquid under pressure into a mold cavity dimensioned to the length, width, and height of a the article, and [0012] (c) allowing the injection molded article to cool and solidify into the article, [0013] (d) removing the article from the mold cavity; wherein composition comprises: [0014] 1) from about 30 to 80 wt. % of a polycarbonate component, [0015] 2) from about 5 to about 50 wt. % of a polyester component, wherein when polybutylene terephthalate is present in the composition, the polybutylene terephthalate is present in conjunction with at least one other polyester that is not polybutylene terephthalate; [0016] 3) from about 2 to about 25 wt. % of an impact modifier; and [0017] 4) a gloss reducing effective amount of a multifunctional additive comprising at least one epoxy group. [0018] And in another embodiment, the invention relates to a thermo-forming process for making an article comprising: [0019] (a) extruding a sheet having at least one layer from a composition comprising: [0020] (1) from about 30 to 80 wt. % of a polycarbonate component, [0021] (2) from about 5 to about 50 wt. % of a polyester component, wherein when polybutylene terephthalate is present in the composition, the polybutylene terephthalate is present in conjunction with at least one other polyester that is not polybutylene terephthalate; [0022] (3) about 2 to about 25 wt. % of an impact modifier; and [0023] (4) a gloss reducing effective amount of a multifunctional additive comprising at least one epoxy group. [0024] (b) heating the sheet to a temperature sufficient to soften the sheet, [0025] (c) applying the sheet over a mold dimensioned to the length, width, and height of the article, and [0026] (d) cooling and removing the article from the mold. [0027] Molding conditions can also bring about a reduction in gloss. Good color and low gloss uniformity are hard to obtain at the same time. The compositions accomplish these goals, while maintaining good dimensional stability at high temperature and good mechanical properties. A relatively low viscosity can be achieved which is particularly desirable when molding large or intricate parts, such as those found in automotive applications. [0028] Additionally there is a method for reducing the gloss of an article molded from a composition having at least one aromatic polycarbonate and at least one polyester comprising adding to said composition a gloss reducing effective amount of a multifunctional additive comprising at least one epoxy group, e.g., an epoxy silane or a glycidyl methacrylate modified polyolefin. [0029] Still further, gloss is reduced by lowering the quantity of polybutylene terephthalate (PBT) in a composition. [0030] Additionally, gloss is reduced by increasing the quantity of polyethylene terephthalate (PET) in a composition. [0031] Still further is a composition of a, b, c, and d where at least 5 wt % of the multifunctional additive has reacted with a component of the composition. [0032] Still further, there is a process wherein a, b, c, and d are combined under reactive conditions. DETAILED DESCRIPTION OF THE INVENTION [0033] The invention is based on the remarkable discovery that it is now possible to produce a molding composition containing polycarbonate and polyester having unexpected low gloss. Articles made from these compositions can also exhibit unexpectedly reduced gloss. Articles made from these compositions can also exhibit highly useful physical and thermal properties. The term article(s) and part(s) are used interchangeably in this application. [0034] The singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. "Optional" or "optionally" as used herein means that the subsequently described event may or may not occur, and that the description includes instances where the event occurs and the instances where it does not occur. [0035] A "multifunctional additive comprising at least one epoxy group" refers to a compound having at least three reactive sites, e.g., epoxy functional groups, a silane having a reactive site. Continue reading about Low gloss thermoplastic articles... Full patent description for Low gloss thermoplastic articles Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Low gloss thermoplastic articles patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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