TW201634577A - 聚碳酸酯組成物及包含彼之物件 - Google Patents

聚碳酸酯組成物及包含彼之物件 Download PDF

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TW201634577A
TW201634577A TW104140764A TW104140764A TW201634577A TW 201634577 A TW201634577 A TW 201634577A TW 104140764 A TW104140764 A TW 104140764A TW 104140764 A TW104140764 A TW 104140764A TW 201634577 A TW201634577 A TW 201634577A
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weight
polycarbonate
chemical formula
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alkyl
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TWI618747B (zh
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鄭允善
李武錫
李慄
安成泰
曺益煥
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Ｌｇ化學股份有限公司
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Abstract

本發明係關於一種聚碳酸酯組成物，其包括聚碳酸酯和衝擊強化劑(impact reinforcing agent)、及無機填料以改良其機械性質，且包括共聚碳酸酯以解決因為含括無機填料而造成的外觀缺陷之問題。

Description

聚碳酸酯組成物及包含彼之物件 相關申請案之交互參照
此申請案主張2014年12月4日向韓國智慧財產局提出申請的韓國專利申請案第10-2014-0173005號和2015年12月3日提出申請的韓國專利申請案第10-2015-0171781號之權利，茲將其中所揭示者全文納入參考。
本發明係關於具有極佳的機械性質和外觀之聚碳酸酯組成物及包含彼之物件。
聚碳酸酯樹脂係藉芳族二醇(如雙酚A)與碳酸酯前驅物(如光氣)之縮合-聚合反應製得並具有極佳的機械和熱性質。特別地，聚碳酸酯樹脂的室溫耐衝擊性高，並具有極佳的尺寸安定性。至今，進行藉由將各種填料加至聚碳酸酯樹脂中以實現極佳的物理性質之技術之研究。
最近，積極地進行藉由除了聚碳酸酯樹脂以外，混合以丙烯腈-丁二烯-苯乙烯(ABS)為基礎的共聚物以提高聚碳酸酯樹脂組成物之加工性的研究，其中通常將該聚碳酸酯樹脂稱為PC/ABS樹脂或PC/ABS摻混物。在PC/ABS樹脂的情況中，為了要改良機械性質，將無機填料(例如，滑石)加至PC/ABS樹脂中，以改良機械性質。但是，仍有缺點(如射出模製時的流動痕跡)存在。當發生外觀缺陷(如流動痕跡)時，須要額外的程序(如塗覆程序等)作為後處理程序，此使得產製成本提高。
同時，為了使聚碳酸酯樹脂施用於更多種領域，進行許多研究以得到所欲的物理性質，此藉由使得二或更多種具有不同結構的芳族二醇化合物共聚及將具有不同結構的單元引至聚碳酸酯主鏈中的方式進行。
在以上的情況下，本發明者致力於解決因為無機填料含括於聚碳酸酯樹脂中而引發外觀缺陷的問題，結果，發現共聚碳酸酯除了以下描述的無機填料以外，包含二或更多種不同的重複單元時，根據無機填料之添加，可以在維持改良的機械性質的同時，解決外觀缺陷問題，並完成本發明。
本發明的目的是提出聚碳酸酯組成物，其具有機械性質和外觀極佳的優點。
本發明的另一目的是提出包含該聚碳酸酯樹脂之物件。
欲達到這些目的，本發明提出一種聚碳酸酯組成物，其包含：聚碳酸酯，衝擊強化劑(impact reinforcing agent)，共聚碳酸酯，其包含以芳族聚碳酸酯為基礎的第一重複單元；及一或更多種具有矽氧烷鍵之以芳族聚碳酸酯為基礎的第二重複單元，以及無機填料，其中該第一重複單元係藉由下列化學式1表示，且該第二重複單元包含藉由下列化學式2表示的重複單元及藉由下列化學式3表示的重複單元：
在化學式1中，R1、R2、R3和R4各自獨立地為氫、C1-10烷基、C1-10烷氧基、或鹵素，而Z是未經取代或經苯基取代的C1-10伸烷基、未經取代或經C1-10烷基取代的C3-15伸環烷基、O、S、SO、SO2、或CO，
化學式2中，X1各自獨立地為C1-10伸烷基，R5各自獨立地為氫；未經取代或經氧(oxiranyl)取代的C1-15烷基；經氧基取代的C1-10烷氧基、或C6-20芳基；鹵素；C1-10烷氧基；烯丙基；C1-10鹵烷基；或C6-20芳基，且n是10至200的整數，
化學式3中，X2各自獨立地為C1-10伸烷基，Y1各自獨立地為氫、C1-6烷基、鹵素、羥基、C1-6烷氧基、或C6-20芳基，R6各自獨立地為氫；未經取代或經氧基取代的C1-15烷基；經氧基取代的C1-10烷氧基，或C6-20芳基；鹵素；C1-10烷氧基；烯丙基；C1-10鹵烷基；或C6-20芳基，且m是10至200的整數。
較佳地，該聚碳酸酯組成物包含1至13重量份的聚碳酸酯、1重量份的衝擊強化劑、1至6重量份的共聚碳酸酯、和0.5至4重量份的無機填料。
根據本發明之聚碳酸酯組成物包含聚碳酸酯和衝擊強化劑，以及用以改良其機械性質的無機填料。此外，為了解決因為包含無機填料而引起的外觀缺陷，該聚碳酸酯組成物包含上述共聚碳酸酯。
根據本發明之共聚碳酸酯係藉由將特定矽氧烷化合物引至聚碳酸酯主鏈中而得，其可解決外觀缺陷的問題，同時維持根據無機填料之添加而改良機械性質的效果，使得機械性質和外觀同時獲得改良。
下文中，將更詳細地描述本發明。
聚碳酸酯和衝擊強化劑
本發明所用聚碳酸酯與以下描述的共聚碳酸酯的區別在於聚矽氧烷結構未引至聚碳酸酯主鏈中。
除了聚碳酸酯以外，根據本發明之聚碳酸酯組成物進一步包含衝擊強化劑以改良耐衝擊性、耐熱性、形成性等。
可以使用以甲基丙烯酸甲酯-丁二烯-苯乙烯為基礎的共聚物、以苯乙烯-丙烯腈為基礎的共聚物、以丙烯腈-丁二烯-苯乙烯為基礎的共聚物、或其混合物作為本發明之衝擊強化劑。以上依序描述的衝擊強化劑分別被稱為MBS樹脂、SAN樹脂、和ABS樹脂。更佳地，MBS樹脂和SAN樹脂可之混合物可作為衝擊強化劑，且其重量 比可為1：10至10：1，更佳為1：5至5：1，且最佳為1：3至3：1。
相對於1重量份的衝擊強化劑，該聚碳酸酯含量較佳地為5至13重量份，且更佳地為8至100重量份。在前述範圍內，改良耐衝擊、耐熱性、形成性等的效果極佳。
該聚碳酸酯較佳地藉芳族二醇化合物與碳酸酯前驅物之反應製得，且較佳地包含藉以下的化學式4所示的重複單元：
在化學式4中，R’1、R’2、R’3和R’4各自獨立地為氫、C1-10烷基、C1-10烷氧基、或鹵素，而Z’是未經取代或經苯基取代的C1-10伸烷基、未經取代或經C1-10烷基取代的C3-15伸環烷基、O、S、SO、SO2、或CO。
此外，較佳地，該共聚碳酸酯所具有的重量平均分子量(g/mol)為1,000至100,000且更佳地為15,000至35,000。更佳地，以上重量平均分子量不低於20,000，不低於21,000，不低於22,000，不低於23,000，不低於24,000，不低於25,000，不低於26,000，不低於27,000，或不低於28,000。此外，此重量平均分子量不高 於34,000，不高於33,000，或不高於32,000。
較佳地，R’1、R’2、R’3和R’4各自獨立地為氫、甲基、氯、或溴。
此外，較佳地，Z’為未經取代或經苯基取代的直鏈或支鏈C1-10伸烷基，且更佳地為亞甲基、伸乙-1,1-二基、伸丙-2,2-二基、伸丁-2,2-二基、1-苯基乙-1,1-二基或二苯亞甲基。此外，較佳地，Z’是環己-1,1-二基、O、S、SO、SO2、或CO。
較佳地，化學式4所示的重複單元可衍生自選自由以下所組成之群組中之一或更多種芳族二醇化合物：雙(4-羥基苯基)甲烷、雙(4-羥基苯基)醚、雙(4-羥基苯基)碸、雙(4-羥基苯基)亞碸、雙(4-羥基苯基)硫醚、雙(4-羥基苯基)酮、1,1-雙(4-羥基苯基)乙烷、雙酚A、2,2-雙(4-羥基苯基)丁烷、1,1-雙(4-羥基苯基)環己烷、2,2-雙(4-羥基-3,5-二溴苯基)丙烷、2,2-雙(4-羥基-3,5-二氯苯基)丙烷、2,2-雙(4-羥基-3-溴苯基)丙烷、2,2-雙(4-羥基-3-氯苯基)丙烷、2,2-雙(4-羥基-3-甲基苯基)丙烷、2,2-雙(4-羥基-3,5-二甲基苯基)丙烷、1,1-雙(4-羥基苯基)-1-苯基乙烷、雙(4-羥基苯基)二苯基甲烷、和α,ω-雙[3-(鄰-羥基苯基)丙基]聚二甲基矽氧烷。
文中所用的'衍生自芳族二醇化合物'是指芳族二醇化合物的羥基和碳酸酯前驅物反應以形成化學式4所示的重複單元。
例如，雙酚A(其為芳族二醇化合物)和三光氣(其為碳酸酯前驅物)聚合時，化學式4所示的重複單元係藉下列化學式4-1表示：
可以使用選自由以下所組成之群組中之至少一者作為碳酸酯前驅物：碳酸二甲酯、碳酸二乙酯、碳酸二丁酯、碳酸二環己酯、碳酸二苯酯、碳酸二甲苯酯、碳酸雙(氯苯基)酯、碳酸二-間-甲苯酚酯、碳酸二萘酯、碳酸雙(二苯基)酯、光氣、三光氣、二光氣、溴光氣、和雙鹵甲酸酯。較佳地，使用三光氣或光氣。
共聚碳酸酯
本發明中所用的共聚碳酸酯是指聚矽氧烷結構引至聚碳酸酯主鏈中之聚合物。該共聚碳酸酯具有抑制因為添加無機填料而造成的外觀缺陷的效果。
以1重量份的衝擊強化劑計，該共聚碳酸酯含量較佳地為1至6重量份，且更佳地，2至5重量份。在上述範圍內，抑制外觀缺陷的效果極佳。
聚碳酸酯主鏈係藉由令芳族二醇化合物和碳酸酯前驅物反應而形成，且特定地指藉化學式1表示的重複單元。
在化學式1中，較佳地，R1、R2、R3和R4各 自獨立地為氫、甲基、氯、或溴。
此外，較佳地，Z為未經取代或經苯基取代的直鏈或支鏈C1-10伸烷基，且更佳地為亞甲基、伸乙-1,1-二基、伸丙-2,2-二基、伸丁-2,2-二基、1-苯基乙-1,1-二基或二苯基亞甲基。此外，較佳地，Z是環己-1,1-二基、O、S、SO、SO2、或CO。
較佳地，化學式1所示的重複單元可衍生自選自由以下所組成之群組中之一或更多種芳族二醇化合物：雙(4-羥基苯基)甲烷、雙(4-羥基苯基)醚、雙(4-羥基苯基)碸、雙(4-羥基苯基)亞碸、雙(4-羥基苯基)硫醚、雙(4-羥基苯基)酮、1,1-雙(4-羥基苯基)乙烷、雙酚A、2,2-雙(4-羥基苯基)丁烷、1,1-雙(4-羥基苯基)環己烷、2,2-雙(4-羥基-3,5-二溴苯基)丙烷、2,2-雙(4-羥基-3,5-二氯苯基)丙烷、2,2-雙(4-羥基-3-溴苯基)丙烷、2,2-雙(4-羥基-3-氯苯基)丙烷、2,2-雙(4-羥基-3-甲基苯基)丙烷、2,2-雙(4-羥基-3,5-二甲基苯基)丙烷、1,1-雙(4-羥基苯基)-1-苯基乙烷、雙(4-羥基苯基)二苯基甲烷、和α,ω-雙[3-(鄰-羥基苯基)丙基]聚二甲基矽氧烷。
文中所用的'衍生自芳族二醇化合物'是指芳族二醇化合物的羥基和碳酸酯前驅物反應以形成化學式1所示的重複單元。
例如，雙酚A(其為芳族二醇化合物)和三光氣(其為碳酸酯前驅物)聚合時，化學式1所示的重複 單元係藉由下列化學式1-1表示：
可以使用選自由以下所組成之群組中之至少一者作為碳酸酯前驅物：碳酸二甲酯、碳酸二乙酯、碳酸二丁酯、碳酸二環己酯、碳酸二苯酯、碳酸二甲苯酯、碳酸雙(氯苯基)酯、碳酸二-間-甲苯酚酯、碳酸二萘酯、碳酸雙(二苯基)酯、光氣、三光氣、二光氣、溴光氣、和雙鹵甲酸酯。較佳地，使用三光氣或光氣。
該聚矽氧烷結構是指藉化學式2所示的重複單元和藉化學式3所示的重複單元。
在化學式2中，較佳地，X1各自獨立地為C2-10伸烷基，更佳地為C2-4伸烷基，且最佳地為丙-1,3-二基。
此外，較佳地，Y1是氫、或C1-6烷氧基，更佳地，氫或C1-4烷氧基，且最佳地，氫或甲氧基。
此外，較佳地，R5各自獨立地為氫、甲基、乙基、丙基、3-苯基丙基、2-苯基丙基、3-(氧基甲氧基)丙基、氟、氯、溴、碘、甲氧基、乙氧基、丙氧基、烯丙基、2,2,2-三氟乙基、3,3,3-三氟丙基、苯基或萘基。此外，較佳地，各個R5獨立地為C1-10烷基，更佳為C1-6烷基，更佳為C1-3烷基，且最佳為甲基。
此外，較佳地，n是不低於10，不低於15，不低於20，不低於25，不低於30，不低於31，或不低於32；且不高於75，不高於70，不高於65，不高於60，不高於55，不高於50，不高於45，不高於40，不高於39，不高於38，或不高於37的整數。
在化學式3中，較佳地，X2各自獨立地為C2-10伸烷基，更佳地為C2-6伸烷基，且最佳地為伸異丁基。
此外，較佳地，Y2是氫。
此外，較佳地，R6各自獨立地為氫、甲基、乙基、丙基、3-苯基丙基、2-苯基丙基、3-(氧基甲氧基)丙基、氟、氯、溴、碘、甲氧基、乙氧基、丙氧基、烯丙基、2,2,2-三氟乙基、3,3,3-三氟丙基、苯基或萘基。更佳地，各個R6獨立地為C1-10烷基，更佳地為C1-6烷基，更佳地為C1-3烷基且最佳地為甲基。
此外，較佳地，m是不低於40，不低於45，不低於50，不低於55，不低於56，不低於57，或不低於58；且不高於80，不高於75，不高於70，不高於65，不高於64，不高於63，或不高於62的整數。
化學式2所示之重複單元和化學式3所示之重複單元分別衍生自以下化學式2-1所示的矽氧烷化合物及以下化學式3-1所示的矽氧烷化合物：
在化學式2-1中，X1、Y1、R5和n與先前定義者相同，
化學式3-1中，X2、Y2、R6和m與先前定義者相同。
此處所謂'衍生自矽氧烷化合物'是指各矽氧烷化合物的羥基和碳酸酯前驅物反應形成化學式2所示之重複單元和化學式3所示之重複單元。此外，可用以形成化學式2和3所示之重複單元之碳酸酯前驅物與所述之可用以形成前述化學式1所示之重複單元之碳酸酯前驅物相同。
製備化學式2-1所示之矽氧烷化合物和化學式3-1所示之矽氧烷化合物之方法分別藉以下反應流程1和2表示：
以上反應流程1中，X1'是C2-10烯基，且X1、Y1、R5和n與先前定義者相同。
反應流程2中，X2'是C2-10烯基，且X2、Y2、R6和m與先前定義者相同。
反應流程1和反應流程2中，反應較佳地在 金屬觸媒存在下進行。較佳地使用鉑(Pt)觸媒作為金屬觸媒。此處所用Pt觸媒可包括選自由以下所組成之群組中之至少一者：Ashby觸媒、Karstedt觸媒、Lamoreaux觸媒、Speier觸媒、PtCl2(COD)、PtCl2(苄腈)2和H2PtBr6。以100重量份化學式7或9所示化合物計，該金屬觸媒用量不低於0.001重量份，不低於0.005重量份，或不低於0.01重量份；且不高於1重量份，不高於0.1重量份，或不高於0.05重量份。
此外，反應溫度較佳地為80至100℃。此外，反應時間較佳地為1至5小時。
此外，化學式7或9所示化合物可藉有機二矽氧烷和有機環矽氧烷在酸觸媒存在下反應而製得，且可藉由調整所用反應物的量而調整n和m。反應溫度較佳地為50至70℃。反應時間亦較佳地為1至6小時。
可以使用選自由四甲基二矽氧烷、四苯基二矽氧烷、六甲基二矽氧烷和六苯基二矽氧烷所組成之群組中之至少一者作為有機二矽氧烷。此外，可以使用，例如，有機環四矽氧烷作為有機環矽氧烷。有機環四矽氧烷的例子可包括八甲基環四矽氧烷、八苯基環四矽氧烷等。
以100重量份的有機環矽氧烷計，以上有機二矽氧烷用量可為不低於0.1重量份，或不低於2重量份；且不高於10重量份，或不高於8重量份。
可以使用選自由H2SO4、HClO4、AlCl3、SbCl5、SnCl4和酸黏土(漂白土)所組成之群組中之至少 一者作為酸觸媒。此外，以100重量份的有機環矽氧烷基計，該酸觸媒用量高於0.1重量份，不低於0.5重量份，或不低於1重量份；且不高於10重量份，不高於5重量份，或不高於3重量份。
特別地，藉由調整化學式2所示之重複單元和化學式3所示之重複單元的量，可調整共聚碳酸酯(A)的物理性質。較佳地，介於該重複單元之間的重量比可為1：99至99：1。較佳地，該重量比為3：97至97：3，5：95至95：5，10：90至90：10，或15：85至85：15，且更佳地20：80至80：20。以上重複單元的重量比對應於矽氧烷化合物(例如化學式2-1所示之矽氧烷化合物和化學式3-1所示之矽氧烷化合物)的重量比。
較佳地，化學式2所示之重複單元藉由下列化學式2-2表示：
在化學式2-2中，R5和n與先前定義者相同。較佳地，R5是甲基。
亦較佳地，化學式3所示之重複單元藉由下列化學式3-2表示：
在化學式3-2中，R6和m與先前定義相同。較佳地，R6是甲基。
此外，共聚碳酸酯(A)中包含所有化學式1-1、2-2、和3-2所示之重複單元。
此外，藉化學式1所示之重複單元的重量對藉化學式2所示之重複單元和藉化學式3所示之重複單元的重量和之重量比，即，重量比(化學式1：(化學式2+化學式3))較佳地為1：0.04至0.07。
此外，本發明提出製備共聚碳酸酯(A)之方法，其包括聚合芳族二醇化合物、碳酸酯前驅物和一或更多種矽氧烷化合物，作為製備上述共聚碳酸酯(A)之方法。
該芳族二醇化合物、碳酸酯前驅物和至少一種矽氧烷化合物與前述者相同。
聚合反應期間內，至少一種矽氧烷化合物的用量可為不低於1重量%，不低於1.1重量%，不低於1.2重量%，不低於1.3重量%，不低於1.4重量%，或不低於1.5重量%；且不高於3重量%，不高於2.9重量%，不高於2.8重量%，不高於2.7重量%，不高於2.6重量%，不高於2.5重量%，不高於2.4重量%，不高於2.3重量%,不高於2.2重量%，不高於2.1重量%、或不高於2.0重量 %，此以100重量%的芳族二醇化合物、碳酸酯前驅物和至少一種矽氧烷化合物總重計。此外，該芳族二醇化合物的用量不低於40重量%，不低於50重量%，或不低於55重量%；且不高於80重量%，不高於70重量%，或不高於65重量%，此以100重量%的芳族二醇化合物、碳酸酯前驅物和至少一種矽氧烷化合物總重計。此外，該碳酸酯前驅物的用量亦不低於10重量%，不低於20重量%，或不低於30重量%；且不高於60重量%，不高於50重量%，或不高於40重量%，此以100重量%的芳族二醇化合物、碳酸酯前驅物和至少一種矽氧烷化合物總重計。
此外，界面聚合法可作為聚合法的例子。此情況中，有著聚合反應可於低溫在大氣壓下進行的效果，且易控制分子量。以上界面聚合反應較佳地在酸黏合劑和有機溶劑存在下進行。以上界面聚合反應可包括，例如，進行預聚合反應，之後添加偶合劑及再度進行聚合反應的步驟。此情況中，可得到具有高分子量的共聚碳酸酯(A)。
未特別限制界面聚合反應所用材料，只要其可用於聚碳酸酯的聚合反應即可。可視所需地調整其用量。
該酸結合劑可包括，例如，鹼金屬氫氧化物(如氫氧化鈉、氫氧化鉀等)或胺化合物(如吡啶)等。
未特別限制有機溶劑，只要其為常用於聚碳酸酯之聚合反應的溶劑即可。例如，可以使用鹵化烴，如 二氯甲烷、氯苯等。
此外，界面聚合反應期間內，反應加速劑，例如，三級胺化合物(如三乙胺、溴化四正丁基銨和溴化四正丁基鏻之類)或四級銨化合物、四級鏻化合物之類可進一步用於加速此反應。
該界面聚合反應中，反應溫度較佳地由0至40℃，且反應時間較佳地由10分鐘至5小時。此外，在界面聚合反應期間內，pH較佳地維持於9或更高，或11或更高。
此外，該界面聚合反應可藉由進一步包括分子量修飾劑而進行。該分子量修飾劑可以在引發聚合反應之前、引發聚合反應之時或引發聚合反應之後添加。
可以使用單-烷基酚作為該分子量修飾劑。例如，單-烷基酚係選自由對-三級丁基酚、對-異丙苯基酚、癸基酚、十二基酚、十四基酚、十六基酚、十八基酚、二十基酚、二十二基酚和三十基酚所組成之群組中之至少一者。較佳地，該單-烷基酚為對-三級丁基酚，此情況中，調整分子量控制的效果大。
該以100重量份的芳族二醇化合物計，該分子量修飾劑含量不低於0.01重量份，不低於0.1重量份，或不低於1重量份；且不高於10重量份，不高於6重量份，或不高於5重量份。在此範圍內，可得到所欲分子量。
較佳地，該共聚碳酸酯組成物具有1,000至 100,000，更佳地為15,000至35,000的重量平均分子量(g/mol)。更佳地，該重量平均分子量不低於20,000，不低於21,000，不低於22,000，不低於23,000，不低於24,000，不低於25,000，不低於26,000，不低於27,000，或不低於28,000。此外，該重量平均分子量不高於34,000，不高於33,000，或不高於32,000。
無機填料
本發明中使用的無機填料係用以改良聚碳酸酯的物理性質。
通常，含括無機填料時，物理性質獲得改良，但在進行程序(如射出模製)的同時會造成外觀缺陷的問題(如流動痕跡)。但是，藉由包含上述共聚碳酸酯，本發明可抑制外觀缺陷之產生。
以1重量份的衝擊強化劑計，該無機填料含量可以較佳地為0.5至4重量份，更佳地為0.5至3重量份，且最佳地為0.5至2重量份。在上述範圍內，改良物理性質的效果極佳。
可以使用滑石、矽灰石、雲母、或其混合物作為無機填料。
聚碳酸酯組成物
本發明之聚碳酸酯樹脂組成物包含前述的聚碳酸酯、衝擊強化劑、共聚碳酸酯、和無機填料。
此外，必要時，該聚碳酸酯樹脂組成物可以進一步包含至少一種添加劑，其選自由以下所組成之群組 中之一或多者：阻燃劑、抗氧化劑、熱安定劑、光安定劑、塑化劑、抗靜電劑、成核劑、潤滑劑、衝擊強化劑、螢光亮光劑、紫外光吸收劑、顏料和染料。
特別地，該阻燃劑可為以磷為基礎的阻燃劑。未特別限制該以磷為基礎的阻燃劑，只要其為此技術中慣用者即可，且例如，可以使用雙酚-A雙(二苯基磷酸酯)(bis(diphenyl phosphate))。以1重量份的衝擊強化劑計，該阻燃劑的含量可為0.5至4重量份。在上述範圍內，改良阻燃性的效果極佳。
此外，本發明提出包含聚碳酸酯組成物之物件。較佳地，該物件是射出模製物件。如前述者，根據本發明之聚碳酸酯組成物可包含聚碳酸酯和衝擊強化劑，且可包含無機填料以改良其機械性質，且可包含共聚碳酸酯以解決因為含括無機填料而引發的外觀缺陷之問題。
用於製造該模製物件之方法可包含使用混合機混合根據本發明之聚碳酸酯組成物和必要的添加劑，以壓出機壓出模塑該混合物以製造粒，乾燥該粒及之後以射出模塑機射出經乾燥的粒。
如前述者，根據本發明之聚碳酸酯組成物可包含聚碳酸酯和衝擊強化劑，且可包含無機填料以改良其機械性質，且可包含共聚碳酸酯以解決因為含括無機填料而造成的外觀缺陷之問題。
下文中，將提出較佳具體實施例以有助於瞭解本揭示。但這些實例僅用於說明本發明，且不應將本發明限制於這些實例。
製備例1：AP-PDMS(n=34)
47.60g(160mmol)的八甲基環四矽氧烷與2.40g(17.8mmol)的四甲基二矽氧烷混合，此混合物與相對於100重量份的八甲基環四矽氧烷為1重量份的酸黏土(DC-A3)一起置於3L瓶中並於60℃反應4小時。反應中止之後，反應產物以乙酸乙酯稀釋並使用矽藻土(celite)迅速過濾。經由1H NMR證實藉此製得之終端未經修飾的聚有機矽氧烷的重複單元(n)是34。
在所得之終端未經修飾的聚有機矽氧烷中添加4.81g(35.9mmol)的2-烯丙基酚和0.01g(50ppm)的Karstedt's鉑觸媒並於90℃反應3小時。反應中止之後，在120℃和1torr條件下蒸發以移除未反應的聚有機矽氧烷。將前述製得之終端經修飾的聚有機矽氧烷稱為AP-PDMS(n=34)。AP-PDMS為淡黃色油質，使用Varian 500MHz經由1H NMR證實其重複單元(n)是34，且不需進一步純化。
製備例2：MBHB-PDMS(m=58)
47.60g(160mmol)的八甲基環四矽氧烷與1.5g(11mmol)的四甲基二矽氧烷混合，此混合物與相對於100重量份的八甲基環四矽氧烷為1重量份的酸黏土(DC-A3)一起置於3L瓶中並於60℃反應4小時。反應中止之後，反應產物以乙酸乙酯稀釋並使用矽藻土迅速過濾。經由1H NMR證實前述製得之終端經修飾的聚有機矽氧烷的重複單元(m)是58。
在所得之終端未經修飾的聚有機矽氧烷中添加6.13g(29.7mmol)的4-羥基苯甲酸3-甲基丁-3-烯基酯和0.01g(50ppm)的Karstedt's鉑觸媒並於90℃反應3小時。反應中止之後，在120℃和1torr條件下蒸發以移除未反應的矽氧烷。將前述製得之終端經修飾的聚有機矽氧烷稱為MBHB-PDMS(m=58)。MBHB-PDMS為淡黃色油質，使用Varian 500MHz經由1H NMR證實其重複單元(m)是58，且不需進一步純化。
製備例3：Si-PC
1784g的水、385g的NaOH和232g的BPA(雙酚A)加至聚合反應器，在N2氣氛下混合溶化。4.3g的對-三級丁基酚(PTBP)與5.91g製備例1中製得的AP-PDMS(n=34)和0.66g製備例2中製得的MBHB-PDMS(m=58)之混合物(重量比90：10)溶於二氯甲烷 (MC)中並加至混合物中。之後，128g的TPG(三光氣)溶於MC中且溶解的TPG溶液加至其中並在TPG溶液的pH維持於11或更高的同時，反應1小時。10分鐘之後，46g的TEA(三乙胺)加至其中以進行偶合反應。1小時20分鐘的總反應時間之後，pH降至4以移除TEA，藉由以蒸餾水清洗三次，將所製得之聚合物的pH調整至6至7的中性pH。藉此得到的聚合物在甲醇和己烷的混合溶液中再沉澱，之後於120℃乾燥以得到最終的共聚碳酸酯(Mw=31,500)，將其稱為Si-PC。
製備例4：PC
1784g的水、385g的NaOH和232g的雙酚A(BPA)加至聚合反應器，在N2氣氛下混合溶化。4.7g的對-三級丁基酚(PTBP)溶於二氯甲烷(MC)中並加至混合物中。之後，128g的TPG(三光氣)溶於MC中且溶解的TPG溶液加至其中並在TPG溶液的pH維持於11或更高的同時，反應1小時。10分鐘之後，46g的TEA(三乙胺)加至其中以進行偶合反應。1小時20分鐘的總反應時間之後，pH降至4以移除TEA，藉由以蒸餾水清洗三次，將所製得之聚合物的pH調整至6至7的中性pH。藉此得到的聚合物在甲醇和己烷的混合溶液中再沉澱，之後於120℃乾燥以得到最終的共聚碳酸酯(Mw=29,000)，將其稱為PC。
實例和比較例
藉由以下列表1中所示的重量比混合製備例3 製得的Si-PC、製備例4製得的PC、衝擊強化劑、以磷為基礎的阻燃劑(BDP)、滑石和其他添加劑(Irganox 1076 0.1重量%，Irgafos 0.2重量%)，製得各個聚碳酸酯樹脂組成物。
實驗例
實例和比較例中製得的各種共聚碳酸酯組成物以配備抽氣設備的Φ30mm雙螺桿壓出機加以粒化，並使用N-20C射出模塑機(JSW,LTD.製造)，於300℃的筒身溫度和80℃的模具溫度射出模塑，製得模塑試樣。以上試樣的物理性質之測定如下。
1)撓曲強度(kg/cm2)：以1/8吋試樣根據ASTM D638測定。
2)IZOD衝擊強度(kg.cm/cm)：以1/8吋試樣根據ASTM D256測定。
3)阻燃性：根據UL 94評估。
特定言之，製得五個阻燃性試驗所需的具有1.0mm厚度的試樣，並進行以下評估。
首先，高度20mm的火燄與各試樣接觸10秒，之後測定試樣的燃燒時間(t1)，並記錄燃燒情況。之後，在主要的火燄接觸之後，中止燃燒，火燄再與各試樣接觸10秒(第二次燃燒接觸)。之後，測定試樣的燃燒時間(t2)和成長時間(t3)，並記錄燃燒情況。上述阻燃試驗同樣地用於五個試樣，試樣之評估示於以下的表2。
4)白化(外觀之評估，黃色指數(YI))：射出模製盤試樣(1.5mm)，藉由使用色差計測定L值，以肉眼進一步確認外觀。
其結果示於下列表3。
如表3中所示者，可證實實例所展現的撓曲強度和IZOD衝擊強度明顯高於比較例，且亦展現明顯較 佳的外觀。
因此，可證實如本發明中所述者，當無機填料和共聚碳酸酯同時含括於PC樹脂中時，可以在改良機械性質的同時，抑制外觀缺陷。

Claims (12)

  1. 一種聚碳酸酯組成物，其包含：聚碳酸酯，衝擊強化劑(impact reinforcing agent)，共聚碳酸酯，其包含以芳族聚碳酸酯為基礎的第一重複單元；及一或更多種具有矽氧烷鍵之以芳族聚碳酸酯為基礎的第二重複單元，以及無機填料，其中該第一重複單元係藉由下列化學式1表示，且該第二重複單元包含藉由下列化學式2表示的重複單元及藉由下列化學式3表示的重複單元： 在化學式1中，R1、R2、R3和R4各自獨立地為氫、C1-10烷基、C1-10烷氧基、或鹵素，而Z是未經取代或經苯基取代的C1-10伸烷基、未經取代或經C1-10烷基取代的C3-15伸環烷基、O、S、SO、SO2、或CO， 化學式2中，X1各自獨立地為C1-10伸烷基，R5各自獨立地為氫；未經取代或經氧(oxiranyl)取代的C1-15烷基；經氧基取代的C1-10烷氧基、或C6-20芳基；鹵素；C1-10烷氧基；烯丙基；C1-10鹵烷基；或C6-20芳基，且n是10至200的整數， 化學式3中，X2各自獨立地為C1-10伸烷基，Y1各自獨立地為氫、C1-6烷基、鹵素、羥基、C1-6烷氧基、或C6-20芳基，R6各自獨立地為氫；未經取代或經氧基取代的C1-15烷基；經氧基取代的C1-10烷氧基，或C6-20芳基；鹵素；C1-10烷氧基；烯丙基；C1-10鹵烷基；或C6-20芳基，且m是10至200的整數。
  2. 如申請專利範圍第1項之聚碳酸酯組成物，其中：該聚碳酸酯組成物包含1至13重量份的聚碳酸酯，1重量份的衝擊強化劑，1至6重量份的共聚碳酸酯，以及0.5至4重量份的無機填料。
  3. 如申請專利範圍第1項之聚碳酸酯組成物，其中：該聚碳酸酯包含下列化學式4所示的重複單元： 在化學式4中，R’1、R’2、R’3和R’4各自獨立地為氫、C1-10烷基、C1-10烷氧基、或鹵素，而Z’是未經取代或經苯基取代的C1-10伸烷基、未經取代或經C1-10烷基取代的C3-15伸環烷基、O、S、SO、SO2、或CO。
  4. 如申請專利範圍第1項之聚碳酸酯組成物，其中：該衝擊強化劑是以甲基丙烯酸甲酯-丁二烯-苯乙烯為基礎的共聚物、以苯乙烯-丙烯腈為基礎的共聚物、以丙烯腈-丁二烯-苯乙烯為基礎的共聚物、或其混合物。
  5. 如申請專利範圍第1項之聚碳酸酯組成物，其中：該聚碳酸酯組成物包含5至13重量份的聚碳酸酯。
  6. 如申請專利範圍第1項之聚碳酸酯組成物，其中：該聚碳酸酯具有1,000至100,000的重量平均分子量。
  7. 如申請專利範圍第1項之聚碳酸酯組成物，其中：該共聚碳酸酯具有1,000至100,000的重量平均分子量。
  8. 如申請專利範圍第1項之聚碳酸酯組成物，其另包含：0.5至4重量份的阻燃劑。
  9. 如申請專利範圍第8項之聚碳酸酯組成物，其中：該阻燃劑是以磷為基礎的阻燃劑。
  10. 如申請專利範圍第9項之聚碳酸酯組成物，其中：該以磷為基礎的阻燃劑是雙酚-A雙(二苯基磷酸酯)(bis(diphenyl phosphate))。
  11. 如申請專利範圍第1項之聚碳酸酯組成物，其中：該無機填料是滑石、矽灰石、雲母、或其混合物。
  12. 一種物件，其藉由申請專利範圍第1至11項中任一項之聚碳酸酯組成物製得。
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