Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L83/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers
  • C08L83/10—Block- or graft-copolymers containing polysiloxane sequences
• • 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
  • C08G64/20—General preparatory processes
• • 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
  • C08G64/18—Block or graft polymers
  • C08G64/186—Block or graft polymers containing polysiloxane sequences
• • 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
  • C08G64/20—General preparatory processes
  • C08G64/22—General preparatory processes using carbonyl halides
  • C08G64/24—General preparatory processes using carbonyl halides and phenols
• • 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
  • C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
  • C08G77/42—Block-or graft-polymers containing polysiloxane sequences
  • C08G77/445—Block-or graft-polymers containing polysiloxane sequences containing polyester sequences
  • C08G77/448—Block-or graft-polymers containing polysiloxane sequences containing polyester sequences containing polycarbonate sequences
• • 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

Definitions

• This application relates to polycarbonate-polysiloxane copolymers and polycarbonate-polysiloxane/ polycarbonate blends having good transparency and good heat resistance and the process for preparing the same.
• Polycarbonate is a type of plastic that is used for many applications that require both strength and clarity (e.g., eyeglass lenses, windows, etc.).
• the most widely produced polycarbonate is a homopolymer made by polymerizing Bisphenol A (“BPA").
• BPA Bisphenol A
• Tg glass transition temperature
• BPA homopolymer is too low to prevent the part from softening or melting under typical use conditions.
• Tg glass transition temperature
• BHPM menthane bisphenol
• BHPM 4,4'-[l-methyl-4-(l-methyl-ethyl)-.l,3- cyclohexandiyl]-bisphenol (1,3-bis-hydroxyphenyl menthane, hereinafter referred to as 1,3-BHPM) and 2,8-di-(4-hydroxyphenyl)menthane (referred to as 2,8-BHPM), and BPA are described in U.S. Patent 5,480,959 to GE (Schmidhauser). Unfortunately, while these materials have a high Tg, they suffer from minimal ductile impact (i.e., inferior toughness, even at room temperature.
• a transparent polycarbonate-polysiloxane copolymer with a Tg above 150°C and good impact properties would be a desirable material.
• Polycarbonate-polysiloxane copolycarbonates of bisphenol A (BPA) and siloxane comonomers are known to have excellent impact resistance properties in comparison with BPA homopolycarbonates, especially at lower temperatures. Such materials have found commercial use in articles such as helmets and automobile parts, and many other applications requiring impact resistance.
• BPA/siloxane copolymers have enhanced fiame-retardant properties in comparison with BPA polycarbonate, and have been successfully been used to replace halogenated flame retardant products for some applications requiring this performance.
• BPA/siloxane copolymers have proven difficult to manufacture at commercial scale because while BPA homopolycarbonate may be used in applications requiring clarity (e.g., eyeglass lenses and optical disks) it has proven difficult to make clear (i.e., high % transmission and low haze) BPA/siloxane copolymers. Also, the difficulty in making a transparent copolycarbonate adversely affects manufacturing change-over between products because large amounts of "off specification" products are made when changing back and forth between making clear BPA homopolycarbonate and unclear BPA/sjloxane copolymers.
• Phelps method which comprises adding phosgene to a bisphenol under interfacial reaction conditions and at a pH in the range of from about 10 to about 12 in the presence of an effective amount of phase transfer catalyst.
• the Phelps method produced a more random copolymer since no phosgene and few short BPA oligomers were present to react and form carbonates with neighboring siloxane oligomers.
• the BPA had been present simultaneously with the phosgene and siloxane, leading to formation of two separate block copolymers due to reactivity differences between the BPA and the siloxane. It was believed that reactions carried out in this manner circumvented the differences in' reactivity between the hydroxyaryl polydiorganosiloxane and BPA. These reaction mixtures were characterized by a single homogenous organic phase.
• the Phelps method produced a more random distribution of the siloxane and resulted in a more transparent product.
• BPA polycarbonate can be improved through incorporation of a high heat monomer, such as menthane bisphenol (BHPM), into the BPA polycarbonate polymer chains.
• BHPM menthane bisphenol
• BHPM 4,4'- [1 -methyl -4-(l -methyl-ethyl)- 1,3- cyclohexandiyl]-bisphenol (1,3-bis-hydroxyphenyl menthane, hereinafter referred to as 1,3-BHPM) and 2,8-di-(4-hydroxyphenyl)menthane (referred to as 2,8-BHPM), and BPA are described in U.S. Patent 5,480,959 to GE (Schmidhauser). These materials suffer from minimal ductile impact, even at room temperature. A transparent polycarbonate copolymer with a Tg above 150°C and good impact properties would be ideal.
• the present invention is based at least in part on the discovery that in order to produce a highly clear copolymer, the bischloroformate must be produced at much lower pH (e.g., 3-8) than was used in the process of Phelps. Without wishing to be bound by any theory, Applicants believe t hat the process of Phelps only produced a relatively small excess of bischloroformate groups available to react with a hydroxyaryl-terminated polydiorganosiloxane, (i.e., probably less than 4X and this was not sufficient to create a truly clear copolymer.
• a method for preparing an aromatic bischloroformate mixture comprises combining one or more aromatic dihydroxy compounds, phosgene, a phase transfer catalyst, an aqueous solvent and an organic solvent under typical reaction conditions for making polycarbonates via the interfacial reaction method while maintaining the pH in a range of about 3 to about 8, preferably about 6 to about 7.
• phase transfer catalyst should be present in an amount effective to catalyze the reaction between phosgene and the aromatic dihydroxy compound(s) until about 105 to 150 mole percent of phosgene has been added based on the total moles of available hydroxyl groups of the one or more aromatic dihydroxy compounds.
• a method for making a polycarbonate-polysiloxane copolymer comprises from about 0.5% to about 80% by weight of a hydroxyaryl-terminated polydiorganosiloxane.
• the method comprises the steps of:
• step (C) adjusting the pH of the mixture forward in step (B) to a value in the range of about 10 to about 14 either before, or during after step (B);
• Another facet of the invention is copolymers prepared by the above method and blends of such copolymers with other polymers such as BPA homopolycarbonate.
• Another facet of the invention is a polycarbonate-polysiloxane copolymer comprising Bishpenol A sub units and polydiorganosiloxane sub units wlierein less than ' 0.5 mole % of the polydiorganosiloxane sub units are directly coupled to another polydiorganosiloxane sub units. Also, blends of such copolymers with other resins are included.
• Another facet of the invention is shaped articles comprising the polycarbonate-
• Another aspect of the invention is a method for making a polycarbonate- polysiloxane copolymer, which method comprises steps of:
• a method for making a transparent polycarbonate-polysiloxane copolymer by reacting, in the presence of a phase transfer catalyst and a pH of from 3-8, an amount of chloroformate oligomers formed from aromatic dihydroxy compounds together with am amount of hydroxaryl- terminated polydiorganosiloxanes.
• the ratio of mole % of chloroformate groups to mole % of phenolic endgroups from the polydiorganosiloxane is preferably at least 4X, more preferably at least 10X.
• Figure 1 is a table depicting haze measurements of molded polycarbonate- polysiloxane test parts under standard and abusive molding conditions.
• Figure 2 is a table depicting haze measurements of molded polycarbonate- polysiloxane test parts under standard and abusive molding conditions, wherein the formulations comprise phosphorous acid stabilizers.
• Figure 3 is a table depicting further' data similar to Figure 2.
• Figure 4 is a table depicting further multilot data similar to Figures 2 and 3.
• the bischlorformate oligomers are formed in the presence of a phase transfer catalyst (PTC) at a pH of about 3 to about 8, more preferably 6-7 (optimum pH depends on equipment and the exact copolymer used - best conditions for transparency may be determined by trial and error).
• PTC phase transfer catalyst
• concentration of chloroformate end groups was increased to greater than a 30 fold excess over the eugenol siloxane endgroups versus the less'smaller excess typical of the prior art.
• additional reaction time is beneficial for the process. However, the reaction time should be short enough such that undesirable hydrolysis is avoided.
• the % transmission means the ratio of transmitted light to incident light in accordance with Method E 308 (ASTM D 1003-61).
• glass transition temperature means the approximate temperature at which increased molecular mobility results in significant changes in properties of a cured resin between a viscous or rubbery condition and a hard, relatively brittle one.
• the measured value of Tg can vary, depending upon the test method.
• BPI is herein defined as 1 ,1 -bis-(4- hydroxyphenyl)-3 ,3 ,5-trimethylcyclohexane.
• Polycarbonate-polysiloxane copolymer refers to a copolycarbonate containing both carbonate and silicone structural units.
• Wt % Si (Weight percent siloxane) denotes the weight of diorganosiloxy units in a given polycarbonate-polysiloxane copolymer relative to the total weight of the polycarbonate-polysiloxane copolymer. It is obtained by multiplying the weight in grams of the siloxane used times the weight fraction of diorganosiloxy units in the aromatic dihydroxy compounds and dividing the product by the total weight in grams of all of the aromatic dihydroxy compounds used in the preparation of the polycarbonate-polysiloxane copolymer.
• a reactor was charged with a portion of an aromatic dihydroxy compound (such as BPA), water, and an organic solvent (such as a chlorinated aliphatic organic liquid, such as methylene chloride) and was phosgenated in the presence of a PTC (such as a methyltributylam onium salt) at a pH of 3-8, preferably 6-7, to form bischloroformate oligomers.
• BPA aromatic dihydroxy compound
• an organic solvent such as a chlorinated aliphatic organic liquid, such as methylene chloride
• PTC such as a methyltributylam onium salt
• a hydroxyaryl- terminated polydiorganosiloxane such as eugenol-capped siloxane, 2-allylphenol capped siloxane, isopropenylphenol capped siloxane, or 4-hyroxystyrene capped siloxane
• a pH of 10-14 preferably 10.5
• the pH should be achieved relatively quickly (approximately a minute or two). It is also possible to raise the pH during or after addition of the polydiorganosiloxane.
• the optimal time for maximum molecular weight build short of hydrolysis may be determined by trial and error. Simply varying the time versus molecular weight.
• the resulting resin was purified. For example, the resin was centrifuged to remove the brine phase, followed by two acid washes, 4 water washes and a final water strip. The chloride-free resin was then steam- precipitated and dried.
• a reactor is charged with a portion of the total high heat monomer and is phosgenated in the presence of a PTC at pH of 3-8, preferably 6-7 to form bischloroformate oligomers.
• a PTC pH of 3-8, preferably 6-7 to form bischloroformate oligomers.
• a PTC pH of 3-8, preferably 6-7 to form bischloroformate oligomers.
• the remaining portion of high heat monomer is then added and the disappearance of chloroformates was monitored by phosgene paper. When all the chloroformates completely disappear, the chainstopper and TEA are added, and the reaction is phosgenated to completion typically at pH 10-11.
• the resulting resin is then purified by centrifuging to remove the brine phase followed by two acid washes, 4 water washes and a final water strip.
• the chloride free resin is then steam . precipitated and dried.
• Hydroxyaryl-terminated polydiorganosiloxanes may be prepared in the manner described in US Patent No. 5,530,083.
• Some non-limiting examples of the aliphatically unsaturated monohydric phenols which can be used to make the hydroxyaryl-terminated polydiorganosiloxanes are: 2-methoxy-4-alkylphenol (also known as eugenol), 2-allylphenol 2-alkylphenol, 4-allyl-2-methylphenol, 4-allyl-2- phenylphenol, 4-allyl-2-bromophenol, 4-allyl-2-t-butoxyphenol, 4-phenyl-2- phenylphenol, 2-methyl-4-propargylphenol, 2-allyl-4,6-dimethylphenol, 2-allyl-4- bromo-6-methylphenol, 2-allyl-6-methoxy-4-methylphenol and 2-allyl-4,6- dimethyl phenol.
• hydroxyaryl-terminated polydiorganosiloxanes used in this invention are phenol-siloxanes included within the formula:
• each R may be the same or different and is selected from the group of radicals consisting of hydrogen, halogen, C ( i -8) alkoxy, C(i -8) alkyl and C( 6- j 3) aryl
• R 1 is a C (2-8) divalent aliphatic radical
• R is selected from the same or different C (1-13) monovalent organic radicals
• n is an integer greater than or equal to 1, preferably greater than or equal to 6, more prefereablyl 0, more preferably greater than or equal to 25, and most preferably greater than or equal to 40. It is also preferred to have n be an integer less than or equal to 1000, preferably less than or equal to 100, more preferably less than or equal to 75, and most preferably less than or equal to 60.
• n is less than or equal to 50. In another embodiment, n is an integer from 30 to 60.
• diorganosiloxy units are defined as the portion -[R -SiO-R ]- of the formula shown above.
• Preferred hydroxyaryl-terminated polydiorganosiloxanes are those where R 2 is methyl and R is hydrogen or methoxy and is located in the ortho position to the phenolic substituent and R 1 is propyl and is located ortho or para to the phenolic substituent.
• Typical chainstoppers may be used, such as p-cumylphenol.
• Some non- limiting examples of chainstoppers include phenol, p-tert-butylphenol, p- cumylphenol, cardinol, octylphenol, nonylphenol and other endcapping agents that are well-known in the art or any combination of these.
• Suitable organic solvents which can be used are, for example, chlorinated aliphatic hydrocarbons, such as methylene chloride, chloroform, carbon tetrachloride, dichloroethane, trichloroethane, tetrachloroethane, dichloropropane and 1 ,2- dichloroethylene; substituted aromatic hydrocarbons such as, chlorobenzene, o- dichlorobenzene, and the various chlorotoluenes.
• chlorinated aliphatic hydrocarbons especially methylene chloride, are preferred.
• Aqueous alkali, or alkaline earth metal hydroxide addition can be used to maintain the pH of the phosgenation mixture near the pH set point.
• alkali metal or alkaline earth metal hydroxides which can be employed are sodium hydroxide, potassium hydroxide, and calcium hydroxide.
• Sodium and potassium hydroxides, and particularly sodium hydroxide are preferred.
• the pH can be regulated by recirculating the reaction mixture past a pH electrode which regulates the rate of addition of the aqueous alkali metal or alkaline earth metal hydroxide.
• Some non-limiting examples of the methods which can be used to eliminate any excess chloroformate groups from the reaction mixture after the addition of the hydroxyaryl-terminated polydiorganosiloxane and increase in pH are adding a calculated amount of a tertiary amine, such as triethylamine, or addition of a measured amount of a bisphenol.
• Some non-limiting examples of the preferred phase transfer catalysts which can be utilized in the practice of the present invention are:
• R is a member selected from the same or different, C ( i -10) alkyl groups, Q is nitrogen or phosphorus, and X is a halogen or an —OR 4 group, where R 4 is hydrogen, a C(i_g) alkyl group or a C( 6-18) aryl group.
• PTC phase transfer catalysts
• X is selected from CI “ , Br “ or -OR 4 , where R 4 is hydrogen, a C( 1-8) alkyl group or a C( 6 -i8) aryl group.
• An effective amount of a PTC is 0.1% to 4 mol%, and' preferably 0.25% to 2 mol% relative to the aromatic dihydroxy compound in the phosgenation mixture.
• a preferred PTC is methyl tributyl ammonium chloride salt (MTBA).
• aromatic dihydroxy compounds include menthane bisphenols (BHPM), such as 4,4'- [1 -methyl -4-(l -methyl-ethyl)- 1,3- cyclohexandiylj-bisphenol (1,3-bis-hydroxyphenyl menthane, referred to as 1,3- BHPM) and 2,8-di-(4-hydroxyphenyl)menthane (referred to as 2,8-BHPM); bis(hydroxyaryl)alkanes, such as bis(4-hydroxyphenyl)methane; l,l-bis(4- hydroxyphenyl)ethane; 2,2-bis(4-hydroxyphenyl)propane (also known as Bisphenol A); 2,2-bis(4-hydroxyphenyl)butane; 2,2-bis(4-hydroxyphenyl)octane; bis(4- hydroxyphenyl)phenylmethane; 2,2-bis(4-hydroxy-methylphenyl)propane; 1,
• the aromatic dihydroxy compound used is Bisphenol A (BPA).
• the aromatic dihydroxy compound used is a menthane bisphenol.
• the aromatic dihydroxy compound used is 2,8-BHPM.
• the aromatic dihydroxy compound used is 1 ,3 -BHPM.
• the polycarbonate-polysiloxane copolymer can be made in a wide variety of either semi-batch or continuous flow reactors.
• Such reactors are, for example, stirred tank reactors, which may be either semi-batch or continuous flow. Additional reactors which are included are agitated column and recirculating loop continuous reactors.
• the volume ratio of aqueous to organic phase during and at the termination of the phosgenation reaction can be in the range of about 0.2-1 :1.
• Reaction temperatures can be in the range of between about 15-50°C.
• the reaction may be conducted at reflux which can be 35-42°C.
• the reaction can be conducted at atmospheric pressures, although sub- or super-atmospheric pressures . maybe employed if desired. '
• the mixture is preferably agitated, such as, by using a stirrer or other conventional equipment.
• the phosgenation rate can be varied depending on other reaction conditions.
• aqueous solvent such as de-ionized water
• Recovery of the polycarbonate-polysiloxane copolymer can be achieved by conventional means, such by the use of an anti-solvent, or steam precipitation or gel- crush methods.
• the resin is centrifuged to remove the brine phase, followed by acid washes and water washes and a final water strip. Even more preferably, the resin is centrifuged to remove the brine phase, followed by two acid washes, 4 water washes and a final water strip.
• the chloride-free resin is then steam-precipitated and dried.
• Mw stands for weight- averaged molecular weight determined using polycarbonate or polystyrene standards (unless otherwise noted).
• Mn refers to number-averaged molecular weight
• MWD refers to molecular weight distribution
• disp refers to polydispersity.
• the yellowness index was determined in accordance with ASTM D 1925.
• Blends may be prepared according to mixing techniques well known in the art.
• the different components of the blend are dry mixed mechanically (blenders/high speed mixers), fed to an extruder where the different resins are melted, and the different phases of the blend will get dispersed.
• the polycarbonates which can be blended with the polycarbonate- polysiloxane copolymer are those formed by phosgenating bisphenol as previously . described and preferably bisphenol A (BPA).
• BPA bisphenol A
• Additional procedures which can be used to make polycarbonates useful in blending with polycarbonate-polysiloxane copolymer include polycarbonate made by ester interchange under melt polymerization conditions.
• the polycarbonate- polysiloxane copolymer can be blended with other polymers such as polycarbonates, BHPM homopolymer, copolycarbonates, copolyestercarbonates and polyesters which are illustrated by but not limited to the following: bisphenol A polycarbonate, BCC polycarbonate, BPZ (l,l,-bis(4-hydroxyphenyl)cyclohexane ("cycoloyhexanone bisphenol”)) polycarbonate, copolycarbonates of BPA and BPI, BPA-dodecanedioic acid copolyestercarbonate, polyethylene terephthalate, SBI (6,6'-dihydroxy-3,3,3'3'- tetramethylsprio(bis)indane (“spirobiindane bisphenol”)), CD-I (3-(4- hydroxyphenyl)-l , 1 ,3-trimethyl-indan-5-0l)), TMBPA (2,2-bis(3,5-di
• the polycarbonate-polysiloxane copolymers or blends of the polycarbonate-polysiloxane copolymer obtained by the methods as described above can be used to form shaped articles and optical articles. They can be, used in blow molding processes like extrusion blow molding or injection stretch blow molding for the production of hollow products like bottles. Also, they can be used in extrusion processes for the production of profiles, solid sheets, multi -wall sheets and corrugated sheets. Polycarbonate-polysiloxane copolymers according to the inention are particularly suitable to commercial applications for plastics that require good impact resistance, particularly at lower temperature and good flame resistant performance without making use of halogenated compounds.
• Polycarbonate-polysiloxane copolymers are also particularly suitable for applications where a higher flow resin is required, meaning that the molten resin is less viscous.
• High flow resins are important for injection molding plastic parts that require filling of a thin mold, or for applications where cycle time is particularly important.
• a lower molecular weight (and hence higher flow) resin can be used in the same application while still maintaining the same strength as BPA polycarbonate homopolymer.
• Blow molded and extruded articles can be prepared using various weight percentages of the polycarbonate-polysiloxane copolymer or the blends of the polycarbonate-polysiloxane copolymer.
• a blow molded or extruded article comprising about 0.1 to 99.9 % by weight of the polycarbonate-polysiloxane copolymer or the blends of the polycarbonate-polysiloxane copolymer may be prepared;
• a blow molded or extruded article comprising about 10 to 75 % by weight of the polycarbonate-polysiloxane copolymer or the blends of the polycarbonate- polysiloxane copolymer may also be prepared; and a blow molded or extruded article comprising about 20 to 60 % by weight of the polycarbonate-polysiloxane copolymer or the blends of the polycarbonate-polysiloxane copolymer may be prepared.
• the desired optical article may be obtained by molding the substantially single phase copolycarbonate or alternatively molding a blend of the substantially single phase copolycarbonate with a polycarbonate, a copolycarbonate, a copolyestercarbonate or a polyester by injection molding, compression molding, extrusion methods and solution casting methods. Injection molding is the more preferred method of forming the article.
• the final resin may further contain any, none, or all of the following: heat stabilizers, light stabilizers, ultraviolet absorbents, mold releasing agents, fire retardants, colorants, pigments, dyes, anti-static agents, lubricants, anti-fogging agents, natural oils, synthetic oils, waxes, organic fillers and inorganic fillers, which are generally described in the prior art.
• One embodiment of the invention is a polycarbonate-polysiloxane copolymer resin prepared using BPA and from about 1 to about 10% hydroxyaryl-terminated polydiorganosiloxane, using the eugenol-capped polydiorganosiloxane having the following structure:
• the resin has a Mw of from about 18,000 to 28,000.
• D-50 n in the tables means that n is an average of 48, or the total diorganosiloxane content is on average about 50.
• the n number can be determined by NMR methods.
• the transparent resin will be 5% siloxane and have a Mw of about 21,000 to 25,000.
• a class of additive stabilizers which suppress this haze formation a method for suppressing haze formation by addition of acid stabilizers.
• useful acid additive stabilizer compounds include but are not limited to: phosphoric acid, phosphorous acid, hypophosphorous, pyrophosphoric acid, polyphosphoric acid, boric acid, hydrochloric acid, hydrobromic acid, sulfuric acid, sulfurous acid, benzenesulfinic acid, toluenesulfinic acid, benzenesulfonic acid, p-toluenesulfonic acid, trifluoromethane sulfonic acid, naphthalene sulfonic acid, sulfonated polystyrene and copolymers.
• I transparent polycarbonate-siloxane copolymers to prevent haze formation under abusive molding conditions (i.e., molding at a higher temperature and longer time than is necessary).
• US 5,608,027 discloses the combination of either H3PO3 or H3PO4 + phosphite esters in a wide range of PC resin compositions (blends and copolymers) as a color stabilizer, there is reference to PC siloxane (even specifically resins with eugenol siloxane blocks) in the description of the invention, and example #76 is a blend of such a PC siloxane with PC homopolymer and the stabilizer combination, but the PC-siloxane composition is an opaque resin and the benefit reported is improved color.
• US 5,608,027 cites a large number of earlier patents that primarily relate to stabilization of polycarbonate resin with similar stabilizers.
• Example 1 BPA/D-50 Eugenolsiloxane copolycarbonate (BCF-PTC Method - Using Pre-formed BCF
• the pH was adjusted to 10.5 with 50 wt% NaOH, and the reaction mixture was stirred for 10 minutes.
• BPA (1254 g, 5500 mmol) was added, and the reaction . mixture was stirred until the chloroformates were gone.
• a 150L stirred-reactor was charged with 15L of methylene chloride, 15L of de-ionized (Dl) water, 1585g (6.94 mol) of BPA, and 100ml of MTBA.
• the mixture was phosgenated at a rate of between 40 and 140g/min until 1050g of phosgene was delivered. (The delivered amount was determined by a totalizer connected to a mass flowmeter).
• the phosgenation target rate was 140 g/min; however, it was necessary to deviate from this rate due to heavy foaming in the reactor.
• the pH was held between 6 and 7 by the continuous addition of sodium hydroxide (50wt%).
• reaction sample was taken and analyzed for chloroformates and phenolic groups.
• the reaction mixture was then transferred to the centrifuge feed tank and purified in a series of 7 centrifugations to separate the resin from the brine.
• the resin was then washed by two HCl acid washes and 4 DI water washes.
• the purified resin solution was then steam-precipitated and dried.
• the dried powder was analyzed for TEA (0.35ppm), ionic chloride (Oppm), and Molecular weight (Mw 25599, Mn 10052, and MWD 2.54).
• the powder was then hot-pressed and found to form a transparent film. A 15wt% solution of the dried powder was also found to be transparent.
• a 150L stirred-reactor was charged with 15L of methylene chloride, 15L of DI water, 5000g (21.9 mol) of BPA, and 100ml of MTBA.
• the mixture was phosgenated at a rate between 40 and 140g/min until 3360g of phosgene was delivered. (The delivered amount was determined by a totalizer connected to a mass flowmeter).
• the phosgenation target rate was 140 g/min; however, it was necessary to deviate from this rate due to heavy foaming in the reactor.
• the pH was held between 6 and 7 by the continuous addition of sodium hydroxide (50 wt%). Once the addition of phosgene was complete the reactor was sparged with nitrogen to remove excess phosgene.
• a reactor sample was then taken, tested for phosgene using phosgene paper, and analyzed for chloroformate.
• the chloroformate concentration was found to be 0.39 moles/liter.
• a charge of eugenol capped siloxane 906 g (0.23 mol) dissolved in 1 liter of methylene chloride was then added to the reactor over a period of approximately 1 minute.
• the siloxane addition tube was then rinsed with an additional 1 liter of methylene chloride to insure that all of siloxane monomer had been transferred to the reactor.
• the pH was then raised to between 10.5-11.5 and the siloxane allowed to react with the bischloroformate BPA oligomers for a period of 10 minutes.
• the reaction mixture was then transferred to the centrifuge feed tank and purified in a series of 7 centrifugations to separate the resin from the brine.
• the resin was then washed by two HCl acid washes and 4 DI water washes.
• the purified resin solution was then steam-precipitated and dried.
• the dried powder was analyzed for TEA (0 ppm), ionic chloride (Oppm), and molecular weight (Mw 30,832, Mn 12,077, and MWD 2.55).
• the powder was then hot-pressed to form a transparent film. A 15wt% solution of the dried powder was also found to be transparent.
• a 150L stirred reactor was charged with 15L of methylene chloride, 15L of DI water, 5000g (21.9 mol) of BPA, and 100ml of MTBA.
• the mixture was phosgenated at a rate between 40 and 140g/min until 3360g of phosgene was delivered. (The delivered amount was determined by a totalizer connected to a mass flowmeter).
• the phosgenation target rate was 140 g/min; however, it was necessary to deviate from this rate due to heavy foaming in the reactor.
• the pH was held between 6 and 7 by the continuous addition of sodium hydroxide (50 wt%). Once the addition of phosgene was complete, the reactor was sparged with nitrogen to remove excess phosgene.
• a reactor sample was then taken, tested for phosgene using phosgene paper, and analyzed for chloroformate.
• the chloroformate concentration was found to be 0.18 moles/liter.
• a charge of eugenol capped siloxane 1240 g (0.31. mol) dissolved in 1 liter of methylene chloride was then added to the reactor over a period of approximately 1 minute.
• the siloxane addition tube was then rinsed with an additional 1 liter of methylene chloride to insure that all of siloxane monomer had been transferred to the reactor.
• the pH was then raised to between 10.5-11.5 and the siloxane allowed to react with the bischloroformate BPA oligomers for a period of 10 minutes.
• the reaction mixture was then transferred to the centrifuge feed tank and purified in a series of 7 centrifugations to separate the resin from the brine.
• the resin was then washed by two HCl acid washes and 4 DI water washes.
• the purified resin solution was then steam-precipitated and dried.
• the dried powder was analyzed for TEA (0.26 ppm), ionic chloride (0.62 ppm), and Molecular weight (Mw 31,430, Mn 12,154, and MWD 2.59).
• the powder was. then hot-pressed to form a transparent film. A 15 wt% solution of the dried powder was also found to be transparent.
• a 150L stirred reactor was charged with 15L of methylene chloride, 15L of DI water, 5000g (21.9 mol) of BPA, and 100ml of MTBA.
• the mixture was phosgenated at a rate between 40 and 140g/min until 3360g of phosgene was delivered. (The delivered amount was determined by a totalizer connected to a mass flowmeter).
• the phosgenation target rate was 140 g/min; however, it was necessary to deviate from this rate due to heavy reactor foaming.
• the pH was held between 6 and 7 by the continuous addition of sodium hydroxide (50 wt%). Once the addition of phosgene was complete, the reactor was sparged with nitrogen to remove excess phosgene.
• a reactor sample was then taken, tested for phosgene using phosgene paper, and analyzed for chloroformate.
• the chloroformate concentration was found to be 0.27 moles/liter.
• a charge of eugenol capped siloxane 1965 g (0.49 mol) dissolved in 1 liter of methylene chloride was then added to the reactor over a period of approximately 1 minute.
• the siloxane addition tube was then rinsed with an additional 1 liter of methylene chloride to insure that all of siloxane monomer had been transferred to the reactor.
• the pH was then raised to between 10.5-11.5 and the siloxane allowed to react with the bischloroformate BPA oligomers for a period of 10 minutes.
• the reaction mixture was then transferred to the centrifuge feed tank and purified in a series of 7 centrifugations to separate the resin from the brine.
• the resin was then washed by two HCl acid washes and 4 DI water washes.
• the purified resin solution was then steam-precipitated and dried.
• the dried powder was analyzed for TEA (0.0 ppm), ionic chloride (O.Oppm), and Molecular weight (Mw 34,194, Mn 13,509, and MWD 2.53).
• the powder was then hot-pressed and found to form a transparent film. A 15wt% solution of the dried powder was also found to be transparent.
• TINUVIN 234 (2-benzotriazol-2-yl-4,6-bis-(l-methyl-l-phenyl-ethyl)- phenol);
• IRGAPHOS 168 tris-(2,4-di-t-butylphenyl)phosphate.
• Table 1 shows the transmission and haze results for the above formulations.
• Example 6 BPI/BPA/D-50Eugenolsiloxane teroolvcarbonate fBCF-PTC Method).
• the polymer solution was separated from the brine and washed one time with IN HCl and two times with distilled water.
• the polymer solution was precipitated into boiling water (750 mL) in a blender, washed with water (500 mL) and dried overnight at 110 °C . under vacuum.
• the polymer analyzed by 1-H NMR, showed complete incorporation of the eugenolsiloxane.
• a 15wt% solution of the polymer in methylene chloride was transparent as was a compression molded film.
• the Tg was 188 °C and the Mw was 36,700 (polystyrene standards).
• Example 7 BPA/BHPM copolycarbonate (01-MX-208).
• a 150L stirred-reactor was charged with 56L of methylene chloride, 38L of DI water, 12000g of BHPM, and 77ml of TEA. Then 314 g. of p-cumylphenol was added as the chainstopper. The mixture was phosgenated at pH 10-11 at rate of 130 g/min until 5226 grams of phosgene was delivered. (The delivered amount was determined by a totalizer connected to a mass flowmeter.) Once the desired amount of phosgene was added, a reaction sample was taken and analyzed for phenolic groups. After determining the batch was finished, the reaction mixture was transferred to the centrifuge feed tank and purified on a series of 7 centrifuges.
• the centrifuges were configured to split the resin from the brine followed by two HCl acid washes and 4 DI water washes.
• the purified resin solution was then steam precipitated and dried.
• the powder was then hot pressed and found to form a transparent film. A 15wt% solution of the dried powder was also found to be transparent.
• Example 8 BPA/BHPM D-50 Eugenolsiloxane copolycarbonate (5% D-50 copolymer 01 -MX-210).
• a 150L stirred-reactor was charged with 15L of methylene chloride, 15L of DI water, 2500 g of BHPM, and 75mL of MTBA.
• the mixture was phosgenated at a rate between 40 and 140 g/min until 1200 grams of phosgene was delivered. (The delivered amount was determined by a totalizer connected to a mass flowmeter.)
• the phosgenation target rate was 140 g/min; however, it was necessary to deviate from this rate due to heavy reactor foaming.
• the pH was held between 6 'and 7 by the continuous addition of sodium hydroxide (50wt%). Once the addition of phosgene was complete, the reactor was sparged with nitrogen to remove excess phosgene. A reactor sample was then taken, tested for phosgene using phosgene paper, and analyzed for chloroformate.
• reaction mixture was then allowed to stir until all the residual chloroformates had disappeared. Then 78.5 grams (0.38 mol) of p-cumylphenol and 32mL of triethylamine (TEA) were charged to the reactor. The reaction mixture was then phosgenated (1200g) to completion at a pH between 10.5 and 11.5. Once the desired amount of phosgene was added, a reaction sample was taken and analyzed for phenolic groups. After determining the batch was finished, the reaction mixture was transferred to the centrifuge feed tank and purified on a series of 7 centrifuges. The centrifuges were configured to split the resin from the brine followed by two HCl acid washes and 4 DI water washes. The purified resin solution was then steam precipitated and dried. The powder was then hot pressed and found to form a transparent film. A 15wt% solution of the dried powder was also found to be transparent.
• TAA triethylamine
• the following data describes results of testing the addition of phosphate stabilizers to eugenosiloxane copolycarbonates.
• the stabilizers were added to powdered resin prior to extrusion pelltization, and test parts were subsequently molded by conventional injection molding methods.
• Figure 1 the table shows the problem to be solved is demonstrated.
• Five different typical lots of PC siloxane copolymer were molded at a relatively high molding temperature of 620°F.
• the molding machine is operated continuously with a part ejected every approximately 36 seconds, the haze levels are normal for this material.
• the molding cycle in interrupted and the resin held in the barrel of the molding machine for either 5 or 10 minutes, (5 or 10 min dwell) the haze level in the parts initially ejected after the dwell are unacceptably high.
• a thermoplastic composition comprises a first polycarbonate/poly(diorganosiloxane) copolymer having a first light transmittance of about 0% to about 55% and a first haze of about 45 and about 104 and a second polycarbonate/poly(diorganosiloxane) copolymer having a second light transmittance of about 55 to about 100% and a second haze of 0 to about 45 wherein the first haze does not equal the second haze.
• a thermoplastic composition comprises a first polycarbonate/poly(diorganosiloxane) copolymer having a first light transmittance of about 0% to about 55% and a first haze of about 45 and about 104 and a second polycarbonate/poly(diorganosiloxane) copolymer having a second light transmittance of about 55 to about 100% and a second haze of 0 to about 45 wherein the first light transmittance does not equal the second light transmittance.
• Translucency is herein defined as having a light transmission of about 25 to about 95% and haze less than about 104. All light transmission and haze values referred to herein are measured by ASTM D1003 at a thickness of 4.0 millimeters (Note: 40 mm was an error in the provisional, the atual measurement was conducted at 3.2mm).
• the second polycarbonate/poly(diorganosiloxane) copolymer has a light transmission greater than or equal to about 55%, preferably greater than or equal to about 60% and more preferably greater than or equal to about 70%.
• the second copolymer has a haze less than or equal to about 45, preferably less than or equal to about ,25, and most preferably less than or equal to about 10.
• the second polycarbonate/poly(diorganosiloxane) copolymer is produced by phosgenating an aromatic dihydroxy compound in the presence of a phase transfer catalyst at a pH of about 5 to about 8 to form bischloroformate oligomers.
• a phase transfer catalyst at a pH of about 5 to about 8 to form bischloroformate oligomers.
• a hydroxyaryl -terminated poly(diorganosiloxane) which is allowed to react at a pH of about 9 to about 12 for a period of time sufficient to effect the reaction between the bischloroformate oligomers and the hydroxyalryl- terminated poly(diorganosiloxane), typically a time period of about 10 to about 45 minutes.
• chloroformate groups there is a large molar excess of chloroformate groups relative to hydroxyaryl groups.
• the remaining aromatic dihydroxy compound is then added, and the disappearance of chloroformates is monitored, usually by phosgene paper.
• an end-capping agent and optionally a a trialkylamine are added and the reaction phosgenated to completion at a pH of 9-12.
• the composition additionally contain the following additives: 0.15 wt% of a mold release agent, pentaerythritol tetrastearate, commercially available as PETS G from Faci (>90 percent esterified); 0.1 wt% of a phosphite stabilizer, tris(2,4-di-tert- butylphenylphosphite), commercially available as IRGAFOS® 168 from Ciba; 0.1 wt% of a hindered phenol stabilizer, octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate, commercially available as IRGANOX® 1076 from Ciba; Flame retarded compositions additionally include a flame retardant available under the tradename NcendX P-30 (bisphenol A bis( diphenylphosphate), or BPADP) commercially available from Albemarle and T-SAN, a drip retardant encapsulated poly(tetraflu
• PC/PDMS 2 was made by combining 15 liters of methylene chloride, 15 liters of deionized water, 1585 grams (6.94 mol) of bisphenol A and 100 milliliters of methyltributyl ammonium chloride in a stirred reactor.
• the mixture was phosgenated at a rate of about 40 to about 140 grams per minute until 1050 grams of phosgene was delivered as determined by a totalizer connected to a mass flowmeter.
• the pH was held between 6 and 7 by the continuous addition of a 50 weight percent aqueous solution of sodium hydroxide. Once the addition of phosgene was complete, the reactor was sparged with nitrogen to remove excess phosgene. A sample was then feasted for phosgene using phosgene paper and tested for chloroformate.
• I chloroformate concentration was found to be 0.24 moles per liter. 450 grams (0.11 mole) of eugenol capped siloxane was dissolved in 1 liter of methylene chloride and added to the reactor over a period of approximately 1 minute. The siloxane addition tube was rinsed with an addition liter of methylene chloride to ensure that all of the siloxane was transferred to the reactor. The pH was then raised to between 10.5 and 11.5 and the siloxane was allowed to react with the bischloroformate oligomers for a period of 10 minutes. At this point another sample was taken and checked for the presence of chloroformates.
• the reactor was then charged with 6350 grams (27 moles) of bisphenol A, 20 liters of methylene chloride and 20 liters of deionized water. The reaction mixture was allowed to stir until all of the residual chloroformates had disappeared. 283 grams (1.33 moles) ofpara-cumylphenol (PCP) and 75milliliters of tri ethyl amine were added to the reactor. The reaction mixture was then phosgenated (3225 grams of phosgene) to completion at a pH of 10.5 to 11.5. Once the desired amount of phosgene had been added a sample was taken and analyzed for chloroformates and phenolic groups.
• PCP para-cumylphenol
• the reaction mixture was then transferred to a centrifuge feed tank and purified in a series of 7 centrifugations to separate the resin from the brine.
• the resin was then washed by two HCl washes and four deionized water washes. The resin solution was then steam precipitated and dried.
• composition of the examples is shown in Table 2-P. All amounts in . Table 2-P are shown in weight percent based on the total weight of the composition. All samples are compounded on a Werner & Pfleiderer co-rotating twin screw extruder (25 millimeter screw) and subsequently molded according to ISO294 on a ENGEL injection molding machine.
• thermoplastic compositions containing flame retardant were tested according to UL 94 at 1.2 millimeters for V0 and 2.0 millimeters for 5VB.
• the impact behavior of the thermoplastic compositions in general reveals a non-linear behavior when tested as function of temperature. This is caused by a change in failure mode, from Ductile to Brittle.
• the Izod notched impact is tested from Room temperature (23 degrees Celsius) till -40 degrees Celsius at 10 degrees Celsius intervals.
• the lowest temperature at which the sample still reveals ductile deformation is indicated as the Ductile to Brittle transition temperature (D/B temperature).
• Results are shown in Table 3-P. Temperatures for notched Izod, Vicat B120 and D/B temperatures are shown in °C. Values for the notched Izod are in kilojoules per square meter. Examples marked with an asterisk are comparative examples. Table 2-P
• Samples 10 to 14 have a similar blend series as samples 6 to 9, varying by the inclusion of fire retardant. Samples 15-17 further comprise an anti-drip agent. Again the remarkable variation in translucency is observed. Particularly in . the compositions containing an anti drip agent, the samples show that by mixing the first and second PC/PDMS copolymers, compositions with an excellent balance of translucency, impact and flammability are obtained.
• Examples 18 and 19 were formed using the compositions shown in Table 6. The examples were tested as discussed above and results are shown in Table 7.
• Samples 18 compared to 17 and sample 19 compared to 8 demonstrate that by mixing first and second PC/PDMS copolymers not only the transmission and haze can be varied at constant siloxane content but additionally the total amount of siloxane can be increased while maintaining similar levels of transmission and haze.

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