Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L69/00—Compositions of polycarbonates; Compositions of derivatives of polycarbonates
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
  • C08G64/04—Aromatic polycarbonates

Definitions

• thermoplastic compositions and more particularly to polycarbonate compositions having high impact strength at low temperatures.
• thermoplastic molding composition suitable for making articles having good combination of properties is disclosed.
• the composition contains 80 to 60 percent of (A) a copolycarbonate wherein 65 to 75 mole percent of its structural units are derived from compounds of formula (I)
• R 1 to R 4 independently of one another represent H, C- ⁇ -C 4 - alkyl, phenyl, substituted phenyl or halogen, and wherein 25 to 35 mole percent of its structural units are derived from compounds of formula (II)
• R 5 to R 8 independently of the others denote H, CH 3 , Cl or Br and X is C ⁇ -C 5 -alkylene, C 2 -C 5 -alkylidene, Cs-C ⁇ -cycloalkylene, C 5 -C 10 - cycloalkylidene, and 20 to 40 percent of (B) a homopolycarbonate of bisphenol A having a melt flow rate, determined in accordance with ASTM D-1238 under 1.2 kg loading, at 300°C of 3 to 12 gm/10 minutes, the percents in both occurrences being relative to the weight of the composition.
• Copolycarbonates based on 4,4'-dihydroxydiphenyl (herein "DOD") and 2,2-bis(4-hydroxyphenyl)propane are already known from JP5117382, EP 544 407 and U.S. Patents 5,470,938; 5,532,324 and 5,401 ,826 These are disclosed as being resistant to chemicals and heat and are flame retardant, while having the same mechanical properties and transparency as commercially available homopolycarbonate of bisphenol A.
• DOD 4,4'-dihydroxydiphenyl
• 2,2-bis(4-hydroxyphenyl)propane are already known from JP5117382, EP 544 407 and U.S. Patents 5,470,938; 5,532,324 and 5,401 ,826 These are disclosed as being resistant to chemicals and heat and are flame retardant, while having the same mechanical properties and transparency as commercially available homopolycarbonate of bisphenol A.
• a presently pending patent application (Attorney docket number Mo-7146) disclosed blends containing copolycarbonates of DOD and homopolycarbonate of bisphenol A that exhibit highly desirable properties.
• the impact strength is that which is determined as notched Izod and as multiaxial impact strength. It has now been found that the art has not recognized the critical dependence of the multi-axial impact strength at low temperatures on the melt flow rate of the homopolycarbonate component. It has also been found that not all the blends thus disclosed are the equivalents to one another and that compositions within a narrowly defined range exhibit surprising and unexpected properties.
• thermoplastic molding composition containing 80 to 60, preferably 65 to 75, percent of (A) a copolycarbonate wherein 65 to 75, preferably 68 to 73, mole percent of its structural units are derived from compounds of formula (I)
• R 1 , R 2 , R 3 and R 4 independently of one another represents
• H, CrC 4 -alkyl, phenyl, substituted phenyl or halogen preferably H, C 1 -C 4 - alkyl or halogen, and particularly preferably all represent the same radical, especially H or tert-butyl, and 25 to 35, preferably 27 to 32, mole percent of its structural units are derived from compounds of formula (II)
• R 5 , R 6 , R 7 and R 8 independently one of the others denote H, CH 3 , Cl or Br and X is CrC 5 -alkylene, C 2 -C 5 -alkylidene, C 5 -C 6 - cycloalkylene, Cs-C-io-cycloalkylidene, and 20 to 40, preferably 25 to 35, percent of (B) a homopolycarbonate of bisphenol A, having a melt flow rate, determined in accordance with ASTM D-1238 under 1.2 kg loading, at 300°C (herein "MFR") of 3 to 12 gm/10 minutes, the percents, both occurrences being relative to the weight of the composition.
• MFR melt flow rate
• the polycarbonate blends according to the invention have good low-temperature properties including notched Izod and multi-axial impact strength.
• the inventive composition is useful in making molded articles wherever the properties profile of conventional polycarbonate and copolycarbonate is insufficient. Particular applicability of the composition is indicated in the electrical and construction sectors, including glazing, especially in the automotive sector as well as in making films, sheets, fittings or housing parts where dimensional stability under heat, chemical resistance and good low-temperature properties are required.
• low temperatures are to be understood as being temperatures below 0°C, particularly preferably below -10°C, most particularly preferably below -30°C.
• Suitable compounds of formula (I) include 4,4'-dihydroxydiphenyl (DOD) and 4,4 , -dihydroxy-3,3',5,5 , -tetra(tert-butyl)diphenyl, 4,4'-dihydroxy- 3,3',5,5'-tetra(n-butyl)diphenyl and 4,4 , -dihydroxy-3,3 , ,5,5 , -tetra(methyl)- diphenyl. 4,4'-dihydroxydiphenyl is particularly preferred.
• Suitable compounds of formula (II) are 2,2-bis(4-hydroxyphenyl)- propane, 1 ,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane and 1 ,3- bis[2-(4-hydroxyphenyl)-2-propyl]benzene, 1 ,1-bis(4-hydroxyphenyl)-1- phenylethane, 1 ,1-bis(4-hydroxyphenyl)-cyclohexane, especially 2,2-bis(4- hydroxyphenyl)propane (bisphenol A) and 1 ,1-bis(4-hydroxyphenyl)-3,3,5- trimethylcyclohexane (bisphenol TMC). Particularly preferred is 2,2-bis(4- hydroxyphenyl)propane (bisphenol A).
• the copolycarbonate (A) may be derived from one or more compounds of formula (I) and one or more compounds of formula (II).
• the preparation of (co)polycarbonates is known.
• the preparation of polycarbonates by the interfacial process or by the melt transesterification process is known. Reference is made in this connection to "Schnell", Chemistry and Physics of Polycarbonates, Polymer Reviews, Vol. 9, Interscience Publishers, New York, London, Sydney, 1964, p. 33 ff and to Polymer Reviews, Volume 10, "Condensation Polymers by Interfacial and Solution Methods", Paul W. Morgan, Interscience Publishers, New York 1965, Chap. VIII, p. 325, incorporated herein by reference.
• copolycarbonates involving compounds of formula (I) takes place preferably in solution, namely by the interfacial process or the process in homogeneous phase.
• Preparation by the melt transesterification process is also possible, which process is described, for example, in DE-A 19 64 6401 or in DE-A 1 42 38 123.
• the polycarbonate and copolycarbonate according to the invention preferably contain structural units derived from any of a variety of chain terminators.
• Suitable chain terminators include ones conforming to formula (III)
• R, R' and R" each independently of the others represent H, optionally branched CrC 34 -alkyl or cycloalkyl, C 7 -C 34 -alkaryl or C 6 -C 34 - aryl.
• the preferred chain terminators include butylphenol, tritylphenol, cumylphenol, phenol and octylphenol. The most preferred are butylphenol and phenol.
• the chain terminators used in the making of copolycarbonate (A) may be either the same as or are different from the ones used in the preparation of polycarbonate (B).
• the individual components (A) and (B) may, independently of each other, contain small amounts of from 0.02 to 3.6 mol% (based on the dihydroxy compound) of branching agents.
• Suitable branching agents are compounds having three or more functional groups, preferably those having three or more phenolic OH groups, for example, 1 ,1 ,1-tri-(4- hydroxyphenyl)ethane and isatin biscresol.
• additives, fillers and/or reinforcing agents may be incorporated.
• additives, fillers and/or reinforcing agents include thermal stabilizers, UV stabilizers, flow modifiers, mold-release agents, flame retardants, pigments, finely divided minerals, fibrous substances, flame retardant agents, such as alkyl and aryl phosphites, phosphates, phosphanes, low molecular weight carboxylic acid esters, halogenated compounds, salts, chalk, quartz powder, glass fibers and carbon fibers, pigments and combinations thereof.
• flame retardant agents such as alkyl and aryl phosphites, phosphates, phosphanes, low molecular weight carboxylic acid esters, halogenated compounds, salts, chalk, quartz powder, glass fibers and carbon fibers, pigments and combinations thereof.
• polystyrene for example polyolefins, polyurethanes, polyesters, acrylonitrile-butadiene-styrene and polystyrene, may also be blended with the components of the inventive composition.
• Such substances may be added to the inventive composition by conventional means and following conventional procedures.
• the components (A) and (B) have weight-average molecular weights of 10,000 to 60,000, preferably 20,000 to 55,000, as determined at room temperature by relative solution viscosity (solution of 0.5% by weight) in dichloromethane or in mixtures of equal amounts by weight of phenol/o-dichlorobenzene, calibrated by light scattering.
• the polycarbonate blends according to the invention are thermoplastically processable conventionally at temperatures of 240°C to 380°C, preferably 260°C to 360°C. Molded articles and films of any kind may be produced in a known manner by means of injection molding or by extrusion. The present application relates also to molded articles and extrudates produced from the inventive composition.
• inventive composition is readily soluble in solvents such as chlorinated hydrocarbons, for example, methylene chloride, and may thus be processed, for example, in a known manner to cast films.
• solvents such as chlorinated hydrocarbons, for example, methylene chloride
• component (A) was prepared containing 30 mol% dihydroxydiphenyl (DOD) and 70 mol% bisphenol A. Tert- butylphenol was used as chain terminator. The granules have a relative solution viscosity of 1.30.
• a homopolycarbonate based on bisphenol A having the indicated melt flow rate (MFR) was used as component (B) and in the comparative examples.
• the exemplified compositions contained conventional flame retardant, UV stabilizer and pigments none believed to have criticality to the present findings.
• the impact performance at -30°C and at -40°C was determined as notched Izod impact strength and instrumented (multi-axial) impact strength both at 1/8" thickness.
• the multi-axial impact test was carried out on test specimens in the form of discs of 4" diameter at a speed of 15 mph using 3 in. window and a dart Vi- in radius.
• component A was a copolycarbonate of 30 mole % DOD and 70 mole % bisphenol A (BPA).
• BPA bisphenol A
• the indicated “homopolycarbonate” was a BPA-based homopolycarbonate.
• the melt flow rate, MFR, is indicated in gm/10 minutes determined in accordance with ASTM D-1238 under 1.2 kg loading at 300°C. The amounts of the components are in percent by weight, relative to the composition.
• compositions further contained a conventional flame retarding agent, a UV stabilizer and pigments having no relevance to the findings of the present invention.
• Notched Izod (ft-lbs./in): at -30°C 6.2 7.3 8.7 5.4 at -40°C 5.7 4.2 3.7 4.8
• Multi-axial Impact Strength (ft-lb.): at -30°C 37.4 36.2 40.3 42.8 at ⁇ 0°C 41 42.2 45.4 39.8
• Example D showed an undesirable failure mode at the low temperature of testing.
• compositions contained "component A” as above and as “component B”, a homopolycarbonate of BPA having MFR of 4.7.
• component B a homopolycarbonate of BPA having MFR of 4.7.
• the results are shown in Table 2.
• the compositions further contained white pigment having no criticality to the findings of the present invention.

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• Chemical & Material Sciences (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Polyesters Or Polycarbonates (AREA)

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• 2002
  • 2002-07-09 US US10/191,583 patent/US6730748B2/en not_active Expired - Fee Related
• 2003
  • 2003-07-03 CA CA002434856A patent/CA2434856A1/en not_active Abandoned
  • 2003-07-07 EP EP03763116A patent/EP1521806B1/en not_active Expired - Lifetime
  • 2003-07-07 DE DE60318578T patent/DE60318578T2/de not_active Expired - Fee Related
  • 2003-07-07 JP JP2004519778A patent/JP2005532453A/ja active Pending
  • 2003-07-07 CN CNB038161621A patent/CN1325562C/zh not_active Expired - Fee Related
  • 2003-07-07 AU AU2003251761A patent/AU2003251761A1/en not_active Abandoned
  • 2003-07-07 ES ES03763116T patent/ES2298576T3/es not_active Expired - Lifetime
  • 2003-07-07 WO PCT/US2003/020850 patent/WO2004005401A1/en not_active Ceased
  • 2003-07-07 MX MXPA03006103A patent/MXPA03006103A/es active IP Right Grant

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