WO2014031731A1 - Method of making a transparent plastic article - Google Patents
Method of making a transparent plastic article Download PDFInfo
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- WO2014031731A1 WO2014031731A1 PCT/US2013/055964 US2013055964W WO2014031731A1 WO 2014031731 A1 WO2014031731 A1 WO 2014031731A1 US 2013055964 W US2013055964 W US 2013055964W WO 2014031731 A1 WO2014031731 A1 WO 2014031731A1
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- WIPO (PCT)
- Prior art keywords
- thermoplastic composition
- formula
- polycarbonate
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- mole
- Prior art date
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 14
- 229920003023 plastic Polymers 0.000 title claims abstract description 14
- 239000000203 mixture Substances 0.000 claims abstract description 161
- 229920001169 thermoplastic Polymers 0.000 claims abstract description 125
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract description 124
- 238000000465 moulding Methods 0.000 claims abstract description 38
- 230000002411 adverse Effects 0.000 claims abstract description 31
- 238000001746 injection moulding Methods 0.000 claims abstract description 20
- 239000004033 plastic Substances 0.000 claims abstract description 12
- 229920000515 polycarbonate Polymers 0.000 claims description 106
- 239000004417 polycarbonate Substances 0.000 claims description 106
- 125000003118 aryl group Chemical group 0.000 claims description 56
- 238000000034 method Methods 0.000 claims description 55
- 238000012360 testing method Methods 0.000 claims description 45
- 125000005587 carbonate group Chemical group 0.000 claims description 39
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 claims description 38
- 239000000654 additive Substances 0.000 claims description 36
- 239000002253 acid Substances 0.000 claims description 32
- 239000001257 hydrogen Substances 0.000 claims description 20
- 229910052739 hydrogen Inorganic materials 0.000 claims description 20
- 230000000996 additive effect Effects 0.000 claims description 19
- 125000001183 hydrocarbyl group Chemical group 0.000 claims description 18
- ISIJQEHRDSCQIU-UHFFFAOYSA-N tert-butyl 2,7-diazaspiro[4.5]decane-7-carboxylate Chemical compound C1N(C(=O)OC(C)(C)C)CCCC11CNCC1 ISIJQEHRDSCQIU-UHFFFAOYSA-N 0.000 claims description 18
- 238000002834 transmittance Methods 0.000 claims description 14
- 239000003086 colorant Substances 0.000 claims description 13
- 229910052736 halogen Inorganic materials 0.000 claims description 12
- 150000002367 halogens Chemical class 0.000 claims description 12
- CHRJZRDFSQHIFI-UHFFFAOYSA-N 1,2-bis(ethenyl)benzene;styrene Chemical compound C=CC1=CC=CC=C1.C=CC1=CC=CC=C1C=C CHRJZRDFSQHIFI-UHFFFAOYSA-N 0.000 claims description 11
- 239000004593 Epoxy Substances 0.000 claims description 10
- 238000001125 extrusion Methods 0.000 claims description 10
- 238000005227 gel permeation chromatography Methods 0.000 claims description 10
- 230000032683 aging Effects 0.000 claims description 9
- 238000010438 heat treatment Methods 0.000 claims description 9
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 8
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 claims description 8
- 150000002431 hydrogen Chemical group 0.000 claims description 8
- 125000001931 aliphatic group Chemical group 0.000 claims description 7
- PXZQEOJJUGGUIB-UHFFFAOYSA-N isoindolin-1-one Chemical compound C1=CC=C2C(=O)NCC2=C1 PXZQEOJJUGGUIB-UHFFFAOYSA-N 0.000 claims description 5
- ACVYVLVWPXVTIT-UHFFFAOYSA-N phosphinic acid Chemical compound O[PH2]=O ACVYVLVWPXVTIT-UHFFFAOYSA-N 0.000 claims description 5
- 125000002723 alicyclic group Chemical group 0.000 claims description 4
- 229910000147 aluminium phosphate Inorganic materials 0.000 claims description 4
- 238000005286 illumination Methods 0.000 claims description 4
- TVDOOGATMOHWAB-UHFFFAOYSA-N carbonic acid;isoindole-1,3-dione Chemical group OC(O)=O.C1=CC=C2C(=O)NC(=O)C2=C1 TVDOOGATMOHWAB-UHFFFAOYSA-N 0.000 abstract 1
- -1 alkylidene carbon Chemical compound 0.000 description 76
- 229920000728 polyester Polymers 0.000 description 23
- 125000000217 alkyl group Chemical group 0.000 description 20
- 230000000052 comparative effect Effects 0.000 description 19
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 18
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- 238000002360 preparation method Methods 0.000 description 17
- ZYGHJZDHTFUPRJ-UHFFFAOYSA-N benzo-alpha-pyrone Natural products C1=CC=C2OC(=O)C=CC2=C1 ZYGHJZDHTFUPRJ-UHFFFAOYSA-N 0.000 description 15
- 150000001875 compounds Chemical class 0.000 description 15
- 125000004432 carbon atom Chemical group C* 0.000 description 14
- 239000003063 flame retardant Substances 0.000 description 14
- 125000002947 alkylene group Chemical group 0.000 description 13
- 239000000975 dye Substances 0.000 description 13
- 150000002148 esters Chemical group 0.000 description 13
- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 description 13
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 12
- QIGBRXMKCJKVMJ-UHFFFAOYSA-N Hydroquinone Chemical compound OC1=CC=C(O)C=C1 QIGBRXMKCJKVMJ-UHFFFAOYSA-N 0.000 description 12
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 12
- 229920001577 copolymer Polymers 0.000 description 12
- QQVIHTHCMHWDBS-UHFFFAOYSA-N perisophthalic acid Natural products OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 12
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 11
- XMBWDFGMSWQBCA-UHFFFAOYSA-N hydrogen iodide Chemical compound I XMBWDFGMSWQBCA-UHFFFAOYSA-N 0.000 description 11
- 229930185605 Bisphenol Natural products 0.000 description 9
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 9
- 239000000945 filler Substances 0.000 description 9
- 229960003742 phenol Drugs 0.000 description 9
- 229910019142 PO4 Inorganic materials 0.000 description 8
- 125000003710 aryl alkyl group Chemical group 0.000 description 8
- 125000000732 arylene group Chemical group 0.000 description 8
- 235000001671 coumarin Nutrition 0.000 description 8
- 238000005259 measurement Methods 0.000 description 8
- 239000008188 pellet Substances 0.000 description 8
- 235000021317 phosphate Nutrition 0.000 description 8
- 125000003545 alkoxy group Chemical group 0.000 description 7
- 229910052799 carbon Inorganic materials 0.000 description 7
- 229960000956 coumarin Drugs 0.000 description 7
- 238000002347 injection Methods 0.000 description 7
- 239000007924 injection Substances 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- 230000008569 process Effects 0.000 description 7
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- 239000011347 resin Substances 0.000 description 7
- 125000004400 (C1-C12) alkyl group Chemical group 0.000 description 6
- HPEUJPJOZXNMSJ-UHFFFAOYSA-N Methyl stearate Chemical compound CCCCCCCCCCCCCCCCCC(=O)OC HPEUJPJOZXNMSJ-UHFFFAOYSA-N 0.000 description 6
- 239000006096 absorbing agent Substances 0.000 description 6
- 125000004104 aryloxy group Chemical group 0.000 description 6
- 235000010290 biphenyl Nutrition 0.000 description 6
- 239000003054 catalyst Substances 0.000 description 6
- 238000006243 chemical reaction Methods 0.000 description 6
- 238000002474 experimental method Methods 0.000 description 6
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 6
- 239000004611 light stabiliser Substances 0.000 description 6
- 229910052760 oxygen Inorganic materials 0.000 description 6
- 239000001301 oxygen Chemical group 0.000 description 6
- 239000003444 phase transfer catalyst Substances 0.000 description 6
- ZUOUZKKEUPVFJK-UHFFFAOYSA-N phenylbenzene Natural products C1=CC=CC=C1C1=CC=CC=C1 ZUOUZKKEUPVFJK-UHFFFAOYSA-N 0.000 description 6
- 238000006116 polymerization reaction Methods 0.000 description 6
- GHMLBKRAJCXXBS-UHFFFAOYSA-N resorcinol Chemical compound OC1=CC=CC(O)=C1 GHMLBKRAJCXXBS-UHFFFAOYSA-N 0.000 description 6
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 5
- 125000004203 4-hydroxyphenyl group Chemical group [H]OC1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 description 5
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical group N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 5
- WKBOTKDWSSQWDR-UHFFFAOYSA-N Bromine atom Chemical compound [Br] WKBOTKDWSSQWDR-UHFFFAOYSA-N 0.000 description 5
- 238000012695 Interfacial polymerization Methods 0.000 description 5
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 5
- 125000002252 acyl group Chemical group 0.000 description 5
- 125000004429 atom Chemical group 0.000 description 5
- 239000004305 biphenyl Substances 0.000 description 5
- GDTBXPJZTBHREO-UHFFFAOYSA-N bromine Substances BrBr GDTBXPJZTBHREO-UHFFFAOYSA-N 0.000 description 5
- 229910052794 bromium Inorganic materials 0.000 description 5
- 125000004435 hydrogen atom Chemical group [H]* 0.000 description 5
- 125000002950 monocyclic group Chemical group 0.000 description 5
- 229910052698 phosphorus Chemical group 0.000 description 5
- 239000002243 precursor Substances 0.000 description 5
- 239000002904 solvent Substances 0.000 description 5
- 125000001424 substituent group Chemical group 0.000 description 5
- 238000005809 transesterification reaction Methods 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- JLZIIHMTTRXXIN-UHFFFAOYSA-N 2-(2-hydroxy-4-methoxybenzoyl)benzoic acid Chemical compound OC1=CC(OC)=CC=C1C(=O)C1=CC=CC=C1C(O)=O JLZIIHMTTRXXIN-UHFFFAOYSA-N 0.000 description 4
- VPWNQTHUCYMVMZ-UHFFFAOYSA-N 4,4'-sulfonyldiphenol Chemical class C1=CC(O)=CC=C1S(=O)(=O)C1=CC=C(O)C=C1 VPWNQTHUCYMVMZ-UHFFFAOYSA-N 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 4
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 4
- 239000005977 Ethylene Substances 0.000 description 4
- 239000004609 Impact Modifier Substances 0.000 description 4
- 150000007513 acids Chemical class 0.000 description 4
- 125000003342 alkenyl group Chemical group 0.000 description 4
- 125000002877 alkyl aryl group Chemical group 0.000 description 4
- 239000003963 antioxidant agent Substances 0.000 description 4
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical group [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 4
- 230000009286 beneficial effect Effects 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 125000001797 benzyl group Chemical group [H]C1=C([H])C([H])=C(C([H])=C1[H])C([H])([H])* 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 125000006267 biphenyl group Chemical group 0.000 description 4
- 239000006085 branching agent Substances 0.000 description 4
- 239000000460 chlorine Substances 0.000 description 4
- 229910052801 chlorine Inorganic materials 0.000 description 4
- 125000000753 cycloalkyl group Chemical group 0.000 description 4
- 125000002993 cycloalkylene group Chemical group 0.000 description 4
- 239000012760 heat stabilizer Substances 0.000 description 4
- 239000000314 lubricant Substances 0.000 description 4
- QUAMTGJKVDWJEQ-UHFFFAOYSA-N octabenzone Chemical compound OC1=CC(OCCCCCCCC)=CC=C1C(=O)C1=CC=CC=C1 QUAMTGJKVDWJEQ-UHFFFAOYSA-N 0.000 description 4
- VLTRZXGMWDSKGL-UHFFFAOYSA-M perchlorate Inorganic materials [O-]Cl(=O)(=O)=O VLTRZXGMWDSKGL-UHFFFAOYSA-M 0.000 description 4
- VLTRZXGMWDSKGL-UHFFFAOYSA-N perchloric acid Chemical compound OCl(=O)(=O)=O VLTRZXGMWDSKGL-UHFFFAOYSA-N 0.000 description 4
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 4
- 239000010452 phosphate Substances 0.000 description 4
- 239000011574 phosphorus Substances 0.000 description 4
- 229920000139 polyethylene terephthalate Polymers 0.000 description 4
- 239000005020 polyethylene terephthalate Substances 0.000 description 4
- 239000000376 reactant Substances 0.000 description 4
- 239000003381 stabilizer Substances 0.000 description 4
- KKEYFWRCBNTPAC-UHFFFAOYSA-L terephthalate(2-) Chemical compound [O-]C(=O)C1=CC=C(C([O-])=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-L 0.000 description 4
- 239000003981 vehicle Substances 0.000 description 4
- NAWXUBYGYWOOIX-SFHVURJKSA-N (2s)-2-[[4-[2-(2,4-diaminoquinazolin-6-yl)ethyl]benzoyl]amino]-4-methylidenepentanedioic acid Chemical compound C1=CC2=NC(N)=NC(N)=C2C=C1CCC1=CC=C(C(=O)N[C@@H](CC(=C)C(O)=O)C(O)=O)C=C1 NAWXUBYGYWOOIX-SFHVURJKSA-N 0.000 description 3
- 125000000008 (C1-C10) alkyl group Chemical group 0.000 description 3
- 125000001140 1,4-phenylene group Chemical group [H]C1=C([H])C([*:2])=C([H])C([H])=C1[*:1] 0.000 description 3
- VEUMBMHMMCOFAG-UHFFFAOYSA-N 2,3-dihydrooxadiazole Chemical compound N1NC=CO1 VEUMBMHMMCOFAG-UHFFFAOYSA-N 0.000 description 3
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- 239000004215 Carbon black (E152) Substances 0.000 description 3
- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 description 3
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 3
- YGYAWVDWMABLBF-UHFFFAOYSA-N Phosgene Chemical compound ClC(Cl)=O YGYAWVDWMABLBF-UHFFFAOYSA-N 0.000 description 3
- ABLZXFCXXLZCGV-UHFFFAOYSA-N Phosphorous acid Chemical compound OP(O)=O ABLZXFCXXLZCGV-UHFFFAOYSA-N 0.000 description 3
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical group [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 3
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 3
- ZMANZCXQSJIPKH-UHFFFAOYSA-N Triethylamine Chemical compound CCN(CC)CC ZMANZCXQSJIPKH-UHFFFAOYSA-N 0.000 description 3
- 150000001491 aromatic compounds Chemical class 0.000 description 3
- PASDCCFISLVPSO-UHFFFAOYSA-N benzoyl chloride Chemical compound ClC(=O)C1=CC=CC=C1 PASDCCFISLVPSO-UHFFFAOYSA-N 0.000 description 3
- 239000000298 carbocyanine Substances 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 3
- AOGYCOYQMAVAFD-UHFFFAOYSA-N chlorocarbonic acid Chemical class OC(Cl)=O AOGYCOYQMAVAFD-UHFFFAOYSA-N 0.000 description 3
- 125000004122 cyclic group Chemical group 0.000 description 3
- QYQADNCHXSEGJT-UHFFFAOYSA-N cyclohexane-1,1-dicarboxylate;hydron Chemical compound OC(=O)C1(C(O)=O)CCCCC1 QYQADNCHXSEGJT-UHFFFAOYSA-N 0.000 description 3
- CAMHHLOGFDZBBG-UHFFFAOYSA-N epoxidized methyl oleate Natural products CCCCCCCCC1OC1CCCCCCCC(=O)OC CAMHHLOGFDZBBG-UHFFFAOYSA-N 0.000 description 3
- 230000009477 glass transition Effects 0.000 description 3
- 125000005843 halogen group Chemical group 0.000 description 3
- 229930195733 hydrocarbon Natural products 0.000 description 3
- 150000002430 hydrocarbons Chemical class 0.000 description 3
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 3
- 235000019239 indanthrene blue RS Nutrition 0.000 description 3
- 239000004615 ingredient Substances 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 229910052757 nitrogen Inorganic materials 0.000 description 3
- 150000002894 organic compounds Chemical class 0.000 description 3
- 125000000962 organic group Chemical group 0.000 description 3
- KWYUFKZDYYNOTN-UHFFFAOYSA-M potassium hydroxide Inorganic materials [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 3
- 150000003839 salts Chemical class 0.000 description 3
- 229920006395 saturated elastomer Polymers 0.000 description 3
- 229910052717 sulfur Inorganic materials 0.000 description 3
- 239000011593 sulfur Chemical group 0.000 description 3
- 125000004642 (C1-C12) alkoxy group Chemical group 0.000 description 2
- 125000006681 (C2-C10) alkylene group Chemical group 0.000 description 2
- 150000005208 1,4-dihydroxybenzenes Chemical class 0.000 description 2
- YBLBHSSRHHJKEK-UHFFFAOYSA-N 3,3-bis(4-hydroxyphenyl)-2-phenylisoindol-1-one Chemical compound C1=CC(O)=CC=C1C1(C=2C=CC(O)=CC=2)C2=CC=CC=C2C(=O)N1C1=CC=CC=C1 YBLBHSSRHHJKEK-UHFFFAOYSA-N 0.000 description 2
- WPMYUUITDBHVQZ-UHFFFAOYSA-N 3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoic acid Chemical compound CC(C)(C)C1=CC(CCC(O)=O)=CC(C(C)(C)C)=C1O WPMYUUITDBHVQZ-UHFFFAOYSA-N 0.000 description 2
- HXDOZKJGKXYMEW-UHFFFAOYSA-N 4-ethylphenol Chemical compound CCC1=CC=C(O)C=C1 HXDOZKJGKXYMEW-UHFFFAOYSA-N 0.000 description 2
- YXALYBMHAYZKAP-UHFFFAOYSA-N 7-oxabicyclo[4.1.0]heptan-4-ylmethyl 7-oxabicyclo[4.1.0]heptane-4-carboxylate Chemical compound C1CC2OC2CC1C(=O)OCC1CC2OC2CC1 YXALYBMHAYZKAP-UHFFFAOYSA-N 0.000 description 2
- 125000000041 C6-C10 aryl group Chemical group 0.000 description 2
- GXGJIOMUZAGVEH-UHFFFAOYSA-N Chamazulene Chemical group CCC1=CC=C(C)C2=CC=C(C)C2=C1 GXGJIOMUZAGVEH-UHFFFAOYSA-N 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 2
- HEDRZPFGACZZDS-UHFFFAOYSA-N Chloroform Chemical compound ClC(Cl)Cl HEDRZPFGACZZDS-UHFFFAOYSA-N 0.000 description 2
- 229920001634 Copolyester Polymers 0.000 description 2
- XDTMQSROBMDMFD-UHFFFAOYSA-N Cyclohexane Chemical compound C1CCCCC1 XDTMQSROBMDMFD-UHFFFAOYSA-N 0.000 description 2
- OTMSDBZUPAUEDD-UHFFFAOYSA-N Ethane Chemical compound CC OTMSDBZUPAUEDD-UHFFFAOYSA-N 0.000 description 2
- UFWIBTONFRDIAS-UHFFFAOYSA-N Naphthalene Chemical compound C1=CC=CC2=CC=CC=C21 UFWIBTONFRDIAS-UHFFFAOYSA-N 0.000 description 2
- 239000002202 Polyethylene glycol Substances 0.000 description 2
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical group [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
- YSMRWXYRXBRSND-UHFFFAOYSA-N TOTP Chemical compound CC1=CC=CC=C1OP(=O)(OC=1C(=CC=CC=1)C)OC1=CC=CC=C1C YSMRWXYRXBRSND-UHFFFAOYSA-N 0.000 description 2
- DTQVDTLACAAQTR-UHFFFAOYSA-N Trifluoroacetic acid Chemical class OC(=O)C(F)(F)F DTQVDTLACAAQTR-UHFFFAOYSA-N 0.000 description 2
- 239000007983 Tris buffer Substances 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- 125000003302 alkenyloxy group Chemical group 0.000 description 2
- 125000005248 alkyl aryloxy group Chemical group 0.000 description 2
- 125000004414 alkyl thio group Chemical group 0.000 description 2
- 125000001118 alkylidene group Chemical group 0.000 description 2
- MWPLVEDNUUSJAV-UHFFFAOYSA-N anthracene Chemical compound C1=CC=CC2=CC3=CC=CC=C3C=C21 MWPLVEDNUUSJAV-UHFFFAOYSA-N 0.000 description 2
- 125000002102 aryl alkyloxo group Chemical group 0.000 description 2
- QMKYBPDZANOJGF-UHFFFAOYSA-N benzene-1,3,5-tricarboxylic acid Chemical compound OC(=O)C1=CC(C(O)=O)=CC(C(O)=O)=C1 QMKYBPDZANOJGF-UHFFFAOYSA-N 0.000 description 2
- IINQAVTXAIJUOI-UHFFFAOYSA-N benzene-1,3-dicarboxylic acid;benzene-1,3-diol;terephthalic acid Chemical class OC1=CC=CC(O)=C1.OC(=O)C1=CC=C(C(O)=O)C=C1.OC(=O)C1=CC=CC(C(O)=O)=C1 IINQAVTXAIJUOI-UHFFFAOYSA-N 0.000 description 2
- OBTARUYASFQRHM-UHFFFAOYSA-N benzene-1,3-diol;diphenoxyphosphoryl diphenyl phosphate Chemical compound OC1=CC=CC(O)=C1.C=1C=CC=CC=1OP(OP(=O)(OC=1C=CC=CC=1)OC=1C=CC=CC=1)(=O)OC1=CC=CC=C1 OBTARUYASFQRHM-UHFFFAOYSA-N 0.000 description 2
- PXKLMJQFEQBVLD-UHFFFAOYSA-N bisphenol F Chemical compound C1=CC(O)=CC=C1CC1=CC=C(O)C=C1 PXKLMJQFEQBVLD-UHFFFAOYSA-N 0.000 description 2
- 238000000071 blow moulding Methods 0.000 description 2
- 150000001721 carbon Chemical group 0.000 description 2
- 150000007942 carboxylates Chemical class 0.000 description 2
- YCIMNLLNPGFGHC-UHFFFAOYSA-N catechol Chemical compound OC1=CC=CC=C1O YCIMNLLNPGFGHC-UHFFFAOYSA-N 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 239000007795 chemical reaction product Substances 0.000 description 2
- 150000001805 chlorine compounds Chemical class 0.000 description 2
- MVPPADPHJFYWMZ-UHFFFAOYSA-N chlorobenzene Chemical compound ClC1=CC=CC=C1 MVPPADPHJFYWMZ-UHFFFAOYSA-N 0.000 description 2
- 125000000068 chlorophenyl group Chemical group 0.000 description 2
- WDECIBYCCFPHNR-UHFFFAOYSA-N chrysene Chemical compound C1=CC=CC2=CC=C3C4=CC=CC=C4C=CC3=C21 WDECIBYCCFPHNR-UHFFFAOYSA-N 0.000 description 2
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- TUIHPLOAPJDCGN-UHFFFAOYSA-M rhodamine 800 Chemical compound [Cl-].C1CCN2CCCC3=C2C1=C1OC2=C(CCC4)C5=[N+]4CCCC5=CC2=C(C#N)C1=C3 TUIHPLOAPJDCGN-UHFFFAOYSA-M 0.000 description 1
- 238000001175 rotational moulding Methods 0.000 description 1
- YYMBJDOZVAITBP-UHFFFAOYSA-N rubrene Chemical compound C1=CC=CC=C1C(C1=C(C=2C=CC=CC=2)C2=CC=CC=C2C(C=2C=CC=CC=2)=C11)=C(C=CC=C2)C2=C1C1=CC=CC=C1 YYMBJDOZVAITBP-UHFFFAOYSA-N 0.000 description 1
- 239000005336 safety glass Substances 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 229920002545 silicone oil Polymers 0.000 description 1
- 229910000029 sodium carbonate Inorganic materials 0.000 description 1
- 235000011121 sodium hydroxide Nutrition 0.000 description 1
- 235000012424 soybean oil Nutrition 0.000 description 1
- 239000003549 soybean oil Substances 0.000 description 1
- 230000003595 spectral effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- BDHFUVZGWQCTTF-UHFFFAOYSA-M sulfonate Chemical compound [O-]S(=O)=O BDHFUVZGWQCTTF-UHFFFAOYSA-M 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-N sulfuric acid group Chemical class S(O)(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- LXEJRKJRKIFVNY-UHFFFAOYSA-N terephthaloyl chloride Chemical compound ClC(=O)C1=CC=C(C(Cl)=O)C=C1 LXEJRKJRKIFVNY-UHFFFAOYSA-N 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- MCZDHTKJGDCTAE-UHFFFAOYSA-M tetrabutylazanium;acetate Chemical compound CC([O-])=O.CCCC[N+](CCCC)(CCCC)CCCC MCZDHTKJGDCTAE-UHFFFAOYSA-M 0.000 description 1
- GFZMLBWMGBLIDI-UHFFFAOYSA-M tetrabutylphosphanium;acetate Chemical compound CC([O-])=O.CCCC[P+](CCCC)(CCCC)CCCC GFZMLBWMGBLIDI-UHFFFAOYSA-M 0.000 description 1
- DFQPZDGUFQJANM-UHFFFAOYSA-M tetrabutylphosphanium;hydroxide Chemical compound [OH-].CCCC[P+](CCCC)(CCCC)CCCC DFQPZDGUFQJANM-UHFFFAOYSA-M 0.000 description 1
- SFORWUUPTGSYHA-UHFFFAOYSA-M tetrabutylphosphanium;phenoxide Chemical compound [O-]C1=CC=CC=C1.CCCC[P+](CCCC)(CCCC)CCCC SFORWUUPTGSYHA-UHFFFAOYSA-M 0.000 description 1
- 125000003831 tetrazolyl group Chemical group 0.000 description 1
- 238000003856 thermoforming Methods 0.000 description 1
- KOJDPIMLHMVCDM-UHFFFAOYSA-N thianthrene-1,7-diol Chemical compound C1=CC=C2SC3=CC(O)=CC=C3SC2=C1O KOJDPIMLHMVCDM-UHFFFAOYSA-N 0.000 description 1
- 239000001017 thiazole dye Substances 0.000 description 1
- 125000004001 thioalkyl group Chemical group 0.000 description 1
- 125000005000 thioaryl group Chemical group 0.000 description 1
- 150000005075 thioxanthenes Chemical class 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 125000005407 trans-1,4-cyclohexylene group Chemical group [H]C1([H])C([H])([H])[C@]([H])([*:2])C([H])([H])C([H])([H])[C@@]1([H])[*:1] 0.000 description 1
- QVOFCQBZXGLNAA-UHFFFAOYSA-M tributyl(methyl)azanium;hydroxide Chemical compound [OH-].CCCC[N+](C)(CCCC)CCCC QVOFCQBZXGLNAA-UHFFFAOYSA-M 0.000 description 1
- YNJBWRMUSHSURL-UHFFFAOYSA-N trichloroacetic acid Chemical class OC(=O)C(Cl)(Cl)Cl YNJBWRMUSHSURL-UHFFFAOYSA-N 0.000 description 1
- MZHULIWXRDLGRR-UHFFFAOYSA-N tridecyl 3-(3-oxo-3-tridecoxypropyl)sulfanylpropanoate Chemical compound CCCCCCCCCCCCCOC(=O)CCSCCC(=O)OCCCCCCCCCCCCC MZHULIWXRDLGRR-UHFFFAOYSA-N 0.000 description 1
- SRPWOOOHEPICQU-UHFFFAOYSA-N trimellitic anhydride Chemical compound OC(=O)C1=CC=C2C(=O)OC(=O)C2=C1 SRPWOOOHEPICQU-UHFFFAOYSA-N 0.000 description 1
- WVLBCYQITXONBZ-UHFFFAOYSA-N trimethyl phosphate Chemical compound COP(=O)(OC)OC WVLBCYQITXONBZ-UHFFFAOYSA-N 0.000 description 1
- 125000003258 trimethylene group Chemical group [H]C([H])([*:2])C([H])([H])C([H])([H])[*:1] 0.000 description 1
- YJLVKRVGSARISS-UHFFFAOYSA-N tris(2,6-dimethylphenyl) phosphite Chemical compound CC1=CC=CC(C)=C1OP(OC=1C(=CC=CC=1C)C)OC1=C(C)C=CC=C1C YJLVKRVGSARISS-UHFFFAOYSA-N 0.000 description 1
- OOZBTDPWFHJVEK-UHFFFAOYSA-N tris(2-nonylphenyl) phosphate Chemical compound CCCCCCCCCC1=CC=CC=C1OP(=O)(OC=1C(=CC=CC=1)CCCCCCCCC)OC1=CC=CC=C1CCCCCCCCC OOZBTDPWFHJVEK-UHFFFAOYSA-N 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
- 239000001018 xanthene dye Substances 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0001—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor characterised by the choice of material
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/24—Acids; Salts thereof
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/32—Phosphorus-containing compounds
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2011/00—Optical elements, e.g. lenses, prisms
Definitions
- thermoplastic articles and in particular to transparent low-low color articles based on polycarbonate compositions that can withstand demanding processing conditions and perform in high-temperature environments.
- Polycarbonates are useful in the manufacture of articles and components for a wide range of applications, from automotive parts to electronic appliances. Because of their beneficial properties such as transparency and impact resistance, polycarbonates have been widely used in applications such as instrument screens, helmet face shields, eyeglass and safety glass lenses, and illumination lenses such as light fixtures, flashlight and lantern lenses, and motor vehicle headlight lenses and covers. In some applications including but not limited to motor vehicle headlight lenses and covers, other performance properties may also be desirable such as transparency, low color, ability to withstand elevated temperatures without deformation or discoloration, and/or ability to maintain these properties even when molded under adverse conditions.
- Plastic articles can be fabricated using a variety of manufacturing techniques such as extrusion, blow molding, injection molding, and others known in the art. Injection molding is typically carried out with an injection molding apparatus, which is depicted in simplified schematic fashion in FIG. 1.
- an injection molding device 10 feeds polymer thermoplastic resin granules 12 through a hopper 14 into barrel 16. Barrel 16 is heated with heater elements 18 to heat the resin to cause it to flow so that it can be injection molded.
- Screw 20 is turned to move the flowable resin from barrel 16 so that it is injected into mold 22. It is noted that details of the device such as a drive mechanism for the screw 20 or an ejection mechanism for ejecting the formed resin part from the mold 22 are not shown in this simplified schematic diagram.
- the amount of time that the thermoplastic resin spends in its flowable or molten state is referred to as the residence time, and it may be
- thermoplastic composition in the barrel divided by the mass or volume quantity of the shot of the thermoplastic
- Cycle time is defined as the time for one injection cycle, and in a continuously running injection molding process is the time it takes between the same point of adjacent injection cycles such as the time between when resin begins to flow into the mold in one injection cycle until the time when resin begins to flow into the mold in the next subsequent injection cycle.
- Many parts such as those with thin walls and/or large and/or complex surface areas, long cycle times (and thus long residence times) may be required to properly fill the mold with resin. Such long cycle and residence times can expose the polymer to high temperatures for extended periods.
- many polycarbonate compositions can provide beneficial properties in a wide variety of conditions, there remains a need for plastic articles that provide beneficial combinations of properties such as high transparency, heat deformation resistance, and stable color even when subjected to long cycle and residence times in the injection molding device.
- thermoplastic composition introducing a thermoplastic composition to the barrel of an injection molding device that comprises a barrel assembly and a mold assembly, the thermoplastic composition comprising:
- R is hydrogen, a Ci_ 2 5 hydrocarbyl group, or halogen, and R hydrogen or a C 1-2 5 hydrocarbyl group,
- thermoplastic composition in the barrel assembly to a temperature sufficient for injection molding of the thermoplastic composition and injecting a shot of the thermoplastic composition into the mold assembly under adverse molding conditions; and removing a molded article of the thermoplastic composition from the mold assembly.
- FIG. 1 depicts a typical apparatus for injection molding of thermoplastic compositions.
- a "polycarbonate” means compositions having repeating structural carbonate units of formula (1)
- each R 1 is a C 6 -3o aromatic group, that is, contains at least one aromatic moiety.
- R 1 can be derived from a dihydroxy compound of the formula HO-R ⁇ OH, in particular of formula (2)
- each R 1 can be derived from a dihydroxy aromatic compound of formula 3)
- R a and R b are each independently a halogen, C 1-12 alkoxy, or C 1-12 alkyl; and p and q are each independently integers of 0 to 4. It will be understood that R a is hydrogen when p is 0, and likewise R b is hydrogen when q is 0. Also in formula (3), X a is a bridging group connecting the two hydroxy- substituted aromatic groups, where the bridging group and the hydroxy substituent of each C 6 arylene group are disposed ortho, meta, or para (specifically para) to each other on the C 6 arylene group.
- the bridging group X a is single bond, -0-, -S-, -S(O)-, -S(0) 2 -, -C(O)-, or a C 1-18 organic group.
- the C 1-18 organic bridging group can be cyclic or acyclic, aromatic or non-aromatic, and can further comprise heteroatoms such as halogens, oxygen, nitrogen, sulfur, silicon, or phosphorous.
- the C 1-18 organic group can be disposed such that the C 6 arylene groups connected thereto are each connected to a common alkylidene carbon or to different carbons of the C 1-18 organic bridging group.
- p and q is each 1, and R a and R b are each a C 1-3 alkyl group, specifically methyl, disposed meta to the hydroxy group on each arylene group.
- hydrocarbon group groups of this type include methylene, cyclohexylmethylene, ethylidene, neopentylidene, and isopropylidene, as well as 2-[2.2.1]-bicycloheptylidene,
- X a is a C 1-18 alkylene group, a C 3 _i 8 cycloalkylene group, a fused C 6-18 cycloalkylene group, or a group of the formula -B 1 -G-B2 - wherein B 1 and B are the same or different Ci_ 6 alkylene group and G is a C 3 _i 2 cycloalkylidene group or a C 6-16 arylene group.
- X a can be a substituted C 3-18 cycloalkylidene of formula (4)
- R r , R p , R q , and R 1 are each independently hydrogen, halogen, oxygen, or C 1-12 hydrocarbon groups;
- Q is a direct bond, a carbon, or a divalent oxygen, sulfur, or -N(Z)- where Z is hydrogen, halogen, hydroxy, C 1-12 alkyl, C 1-12 alkoxy, or C 1-12 acyl;
- r is 0 to 2, t is 1 or 2, q is 0 or 1, and k is 0 to 3, with the proviso that at least two of R r , R p , R q , and R 1 taken together are a fused cycloaliphatic, aromatic, or heteroaromatic ring.
- the ring as shown in formula (4) will have an unsaturated carbon-carbon linkage where the ring is fused.
- the ring as shown in formula (4) contains 4 carbon atoms
- the ring as shown in formula (4) contains 5 carbon atoms
- the ring contains 6 carbon atoms.
- two adjacent groups e.g., R q and R 1 taken together
- R q and R 1 taken together form an aromatic group
- R r and R p taken together form a second aromatic group.
- R p can be a double-bonded oxygen atom, i.e., a ketone.
- R 2 is hydrogen, a C 1-25 hydrocarbyl group, or halogen
- R 3 is hydrogen or a C 1-25 hydrocarbyl group
- R a , R b , p, and q are as in formula (4)
- R 3 is each independently a Ci_ 6 alkyl group
- j is 0 to 4
- R 4 is a Ci_ 6 alkyl, phenyl, or phenyl substituted with up to five Ci_ 6 alkyl groups.
- R 2 can be hydrogen and R 3 can be a C 6-1 o aromatic group such as phenyl or substituted phenyl
- the phthalimidine carbonate units can be of formula (4b)
- R 5 is hydrogen or a Ci_ 6 alkyl, more specifically hydrogen.
- Such carbonate units wherein R 5 is hydrogen can be derived from 2-phenyl-3,3'-bis(4-hydroxy
- phenyl)phthalimidine also known as N-phenyl phenolphthalein bisphenol, or "PPPBP”
- PPPBP N-phenyl phenolphthalein bisphenol
- R a and R b are each independently C 1-12 alkyl, p and q are each independently 0 to 4, and R 1 is C 1-12 alkyl, phenyl, optionally substituted with 1 5 to Ci_io alkyl, or benzyl optionally substituted with 1 to 5 C 1-10 alkyl.
- R a and R b are each methyl, p and q are each independently 0 or 1, and R 1 is Ci_ 4 alkyl or phenyl.
- Examples of bisphenol carbonate units derived from bisphenols (4) wherein X a is a substituted or unsubstituted C 3-1 8 cycloalkylidene include the cyclohexylidene- bridged, alkyl-substituted bisphenol of formula (4e)
- R a and R b are disposed meta to the cyclohexylidene bridging group.
- R a and R b are each independently Ci_ 4 alkyl
- R g is Ci_ 4 alkyl
- p and q are each 0 or 1
- t is 0 to 5.
- R a , R b , and R g are each methyl
- r and s are each 0 or 1
- t is 0 or 3, specifically 0.
- Examples of other bisphenol carbonate units derived from bisphenol (4) wherein X a is a substituted or unsubstituted C 3-18 cycloalkylidene include units (4f) (also known as adamantyl units) and units (4g)
- each of R a and R b are disposed meta to the cycloalkylidene bridging group.
- R a and R b are each independently Ci_ 3 alkyl, and p and q are each 0 or 1.
- R a , R b are each methyl, p and q are each 0 or 1.
- Carbonates containing units (4) to (4g) can be used for making polycarbonates with high glass transition temperatures (Tg) and high heat distortion temperatures.
- each R h is independently a halogen atom, a Ci_io hydrocarbyl such as a Ci_io alkyl group, a halogen-substituted C 1-10 alkyl group, a C 6 -io aryl group, or a halo gen- substituted C 6 - io aryl group, and n is 0 to 4.
- the halogen is usually bromine.
- aromatic dihydroxy compounds include the following: 4,4'-dihydroxybiphenyl, 1,6-dihydroxynaphthalene, 2,6- dihydroxynaphthalene, bis(4-hydroxyphenyl)methane, bis(4- hydroxyphenyl)diphenylmethane, bis(4-hydroxyphenyl)-l-naphthylmethane, l,2-bis(4- hydroxyphenyl)ethane, l,l-bis(4-hydroxyphenyl)-l-phenylethane, 2-(4-hydroxyphenyl)-2-(3- hydroxyphenyl)propane, bis(4-hydroxyphenyl)phenylmethane, 2,2-bis(4-hydroxy-3- bromophenyl)propane, 1,1 -bis (hydroxyphenyl)cyclopentane, l,l-bis(4- hydroxyphenyl)cyclohexane, 1 , 1
- hydroquinone 2-propyl hydroquinone, 2-butyl hydroquinone, 2-t-butyl hydroquinone, 2- phenyl hydroquinone, 2-cumyl hydroquinone, 2,3,5,6-tetramethyl hydroquinone, 2,3,5,6- tetra-t-butyl hydroquinone, 2,3,5,6-tetrafluoro hydroquinone, 2,3,5, 6-tetrabromo
- hydroquinone or the like, or combinations comprising at least one of the foregoing dihydroxy compounds.
- bisphenol compounds of formula (3) include l,l-bis(4- hydroxyphenyl) methane, l,l-bis(4-hydroxyphenyl) ethane, 2,2-bis(4-hydroxyphenyl) propane (hereinafter "bisphenol A” or "BPA”), 2,2-bis(4-hydroxyphenyl) butane, 2,2-bis(4- hydroxyphenyl) octane, l,l-bis(4-hydroxyphenyl) propane, l,l-bis(4-hydroxyphenyl) n- butane, 2,2-bis(4-hydroxy-2-methylphenyl) propane, l,l-bis(4-hydroxy-t-butylphenyl) propane, 3,3-bis(4-hydroxyphenyl) phthalimidine, 2-phenyl-3,3-bis(4-hydroxyphenyl) phthalimidine (PPPBP), and l,l-bis(4-hydroxy-3-methylphenyl)cyclohexane
- BPA 2,2-
- the polycarbonate is a linear homopolymer derived from bisphenol A, in which each of A 1 and A2 is p-phenylene and Y 1 is isopropylidene in formula (3).
- the polycarbonate has flow properties for the manufacture of thin articles.
- Melt flow rate (often abbreviated MFR) measures the rate of extrusion of a thermoplastic through an orifice at a prescribed temperature and load, and can be determined according to ASTM D1238-04C.
- Polycarbonates for the formation of thin articles can have an MFR, measured at 330°C/2.16 kg, of 10 to 90 grams per 10 minutes (g/10 min), specifically 20 to 40 g/10 min. Combinations of polycarbonates of different flow properties can be used to achieve the overall desired flow property.
- Polycarbonates includes homopolycarbonates (wherein each R 1 in the polymer is the same), copolymers comprising different R 1 moieties in the carbonate
- copolycarbonates are copolymers comprising carbonate units and other types of polymer units, such as ester units, and combinations comprising at least one of homopolycarbonates and/or copolycarbonates.
- a specific type of copolymer is a polyester carbonate, also known as a polyester-polycarbonate.
- Such copolymers further contain, in addition to recurring carbonate chain units of formula (1), repeating units of formula (7)
- the molar ratio of ester units to carbonate units in the copolymers can vary broadly, for example 1:99 to 99:1, specifically 10:90 to 90:10, more specifically 25:75 to 75:25, depending on the desired properties of the final composition.
- Phosgene can also be a carbonate precursor in, an interfacial polymerization reaction to form carbonate linkages, which is referred to as a phosgenation reaction.
- trimellitic acid trimellitic anhydride
- trimellitic trichloride tris-p-hydroxy phenyl ethane, isatin-bis-phenol, tris-phenol TC (l,3,5-tris((p-hydroxyphenyl)isopropyl)benzene), tris-phenol PA (4(4(1, l-bis(p-hydroxyphenyl)-ethyl) alpha, alpha-dimethyl benzyl)phenol), 4-chloroformyl phthalic anhydride, trimesic acid, and benzophenone tetracarboxylic acid.
- the branching agents can be added at a level of 0.05 to 2.0 wt , based on the total weight of dihydroxy compound in the polymerization reaction mixture. Mixtures comprising linear polycarbonates and branched polycarbonates can be used.
- a chain stopper (also referred to as a capping agent) can be included during polymerization.
- the chain stopper limits molecular weight growth rate, and so controls molecular weight in the polycarbonate
- chain stoppers include certain mono-phenolic compounds, mono-carboxylic acid chlorides, and/or mono-chloroformates.
- Mono-phenolic chain stoppers are exemplified by monocyclic phenols such as phenol and Ci-C 22 alkyl- substituted phenols such as p-cumyl-phenol, resorcinol monobenzoate, and p-and tertiary- butyl phenol; and monoethers of diphenols, such as p-methoxyphenol.
- Polyesters can have repeating units of formula (7), which include poly(alkylene
- E in formula (10) is selected so as to provide a desired level of properties such as flame retardance to the thermoplastic composition.
- the value of E will therefore vary depending on the type and relative amount of each component in the thermoplastic composition. Values for E can be determined by one of ordinary skill in the art without undue experimentation using the guidelines taught herein. Generally, E has an average value of 2 to 1,000, specifically 10 to 100, more specifically 25 to 75. In an embodiment, E has an average value of 40 to 60, and in still another embodiment, E has an average value of 50. Where E is of a lower value, e.g., less than 40, it can be necessary to use a relatively larger amount of the polysiloxane-polycarbonate copolymer. Conversely, where E is of a higher value, e.g., greater than or equal to 40, it can be necessary to use a relatively smaller amount of the polysiloxane-polycarbonate copolymer.
- M is independently bromo or chloro, a Ci-C 3 alkyl group such as methyl, ethyl, or propyl, a Ci-C 3 alkoxy group such as methoxy, ethoxy, or propoxy, or a C 6 -C 7 aryl group such as phenyl, chlorophenyl, or tolyl; R is a dimethylene,
- phenyl)phosphite tris(2,4-di-t-butylphenyl)phosphite, bis(2,4-di-t- butylphenyl)pentaerythritol diphosphite, distearyl pentaerythritol diphosphite; alkylated monophenols or polyphenols; alkylated reaction products of polyphenols with dienes, such as tetrakis[methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate)] methane; butylated reaction products of para-cresol or dicyclopentadiene; alkylated hydroquinones; hydroxylated thiodiphenyl ethers; alkylidene-bisphenols; benzyl compounds; esters of beta-(3,5-di-tert- butyl-4-hydroxyphenyl)-propionic acid with monohydric or polyhydric alcohols; esters of beta
- Heat stabilizer additives include organophosphites such as triphenyl phosphite, tris-(2,6-dimethylphenyl)phosphite, tris-(mixed mono-and di-nonylphenyl)phosphite;
- Heat stabilizers are used in amounts of 0.01 to 0.1 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
- Light stabilizers including ultraviolet light (UV) absorbers, can also be used.
- Light stabilizers include benzotriazoles such as 2-(2-hydroxy-5-methylphenyl)benzotriazole and 2-(2-hydroxy-5-tert-octylphenyl)-benzotriazole, 2-hydroxy-4-n-octoxy benzophenone, or combinations comprising at least one of the foregoing light stabilizers.
- Light stabilizers are used in amounts of 0.01 to 5 parts by weight, based on 100 parts by weight of the
- UV absorbers 2.2- bis[[(2-cyano-3, 3 -diphenylacryloyl)oxy] methyl] propane (UVINUL* 3030); 2,2'-(l,4- phenylene) bis(4H-3,l-benzoxazin-4-one); l,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy] -2,2- bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane; phenol, 2-(2H-benzotriazol-2-yl)- 4,6-bis(l -methyl- 1- phenylethyl)- (TINUVIN* 234); BCAP bismalonate from Clariant; nano- size inorganic materials such as titanium oxide, cerium oxide, and zinc oxide, all with particle size less than or equal to 100 nanometers;, or combinations comprising at least one of the foregoing UV absorbers. UV absorbers are used in amounts of 0.01 to 5 parts by weight
- Plasticizers, lubricants, and/or mold release agents can also be used.
- phthalic acid esters such as dioctyl-4,5-epoxy-hexahydrophthalate; tris-(octoxycarbonylethyl)isocyanurate; tristearin; di- or polyfunctional aromatic phosphates such as resorcinol tetraphenyl diphosphate (RDP), the bis(diphenyl) phosphate of hydroquinone and the bis(diphenyl) phosphate of bisphenol A; poly-alpha-olefins; epoxidized soybean oil; silicones, including silicone oils; esters, for example, fatty acid esters such as alkyl stearyl esters, e.g., methyl stearate, stearyl stearate, pentaerythritol tetrastearate, and the like; combinations of methyl stearate
- Colorants can be added to the thermoplastic composition to achieve specifically targeted color space values within the limits specified hereinabove.
- Colorants include, for example, anthraquinones, perylenes, perinones, indanthrones, quinacridones, xanthenes, oxazines, oxazolines, thioxanthenes, indigoids, thioindigoids, naphtalimides, cyanines, xanthenes, methines, lactones, coumarins, bis-benzoxaxolylthiophenes (BBOT), napthalenetetracarboxylic derivatives, monoazo and disazo pigments, triarylmethanes, aminoketones, bis(styryl)biphenyl derivatives, and the like, as well as combinations comprising at least one of the foregoing colorants.
- BBOT bis-benzoxaxolylthiophenes
- the amount of colorant depends on the target color properties for the article, the spectral absorbance properties of the colorant(s), and the intrinsic color properties of the polycarbonate and any other materials or additives in the thermoplastic composition.
- the amount can vary, provided that it is kept below the level at which transmittance of the article would fall below the 85% level disclosed herein.
- Exemplary amounts can range from 0.00005 to 0.01 parts by weight per 100 parts by weight of polycarbonate resin and any impact modifier.
- Specific exemplary colorants include organic dyes such as coumarin 460 (blue), coumarin 6 (green), nile red or the like; lanthanide complexes; hydrocarbon and substituted hydrocarbon dyes; polycyclic aromatic hyrdocarbons; scintillation dyes
- oxazoles and oxadiazoles preferably oxazoles and oxadiazoles
- carbocyanine dyes preferably oxazoles and oxadiazoles
- phthalocyanine dyes and pigments preferably oxazine dyes
- carbostyryl dyes preferably oxazoles and oxadiazoles
- aryl- or heteroaryl-substituted poly (2-8 olefins preferably carbocyanine dyes; phthalocyanine dyes and pigments; oxazine dyes; carbostyryl dyes;
- porphyrin dyes acridine dyes; anthraquinone dyes; arylmethane dyes; azo dyes; diazonium dyes; nitro dyes; quinone imine dyes; tetrazolium dyes; thiazole dyes; perylene dyes, perinone dyes; bis-benzoxazolylthiophene (BBOT); and xanthene dyes; fluorophores such as anti- stokes shift dyes which absorb in the near infrared wavelength and emit in the visible wavelength, or the like; luminescent dyes such as 5-amino-9- diethyliminobenzo(a)phenoxazonium perchlorate; 7-amino-4-methylcarbostyryl; 7-amino-4- methylcoumarin; 7-amino-4-trifluoromethylcoumarin; 3-(2'-benzimidazolyl)-7-N,N- diethylaminocoumarin; 3-(2'
- rhodamine 800 IR 125; IR 144; IR 140; IR 132; IR 26; IR5; diphenylhexatriene;
- thermoplastic composition disclosed herein can include flame retardants in addition to the above-described perfluoroalkyl sulfonate salt and cyclic siloxane compound. Notwithstanding that, in some exemplary embodiments described herein, such additional flame retardants are not needed. Therefore, in an exemplary embodiment the flame retardant additives used in the thermoplastic composition consist essentially of the perfluoroalkyl sulfonate salt and cyclic siloxane compound. In another exemplary embodiment, the flame retardant additives used in the thermoplastic composition consist of the perfluoroalkyl sulfonate salt and cyclic siloxane compound. If additional flame retardants are used, possible candidates include organic compounds that include phosphorus, bromine, and/or chlorine. Non-brominated and non-chlorinated phosphorus-containing flame retardants can be preferred in certain applications for regulatory reasons, for example organic phosphates and organic compounds containing phosphorus-nitrogen bonds.
- Flame retardant aromatic phosphates include triphenyl phosphate, tricresyl phosphate, isopropylated triphenyl phosphate, phenyl bis(dodecyl) phosphate, phenyl bis(neopentyl) phosphate, phenyl bis(3,5,5'-trimethylhexyl) phosphate, ethyl diphenyl phosphate, 2-ethylhexyl di(p-tolyl) phosphate, bis(2-ethylhexyl) p-tolyl phosphate, tritolyl phosphate, bis (2-ethylhexyl) phenyl phosphate, tri(nonylphenyl) phosphate, bis(dodecyl) p- tolyl phosphate, dibutyl phenyl phosphate, 2-chloroethyl diphenyl phosphate, p-tolyl bis(2,
- flame retardants include di- or polyfunctional aromatic phosphorus-containing compounds, for example resorcinol tetraphenyl diphosphate (RDP), the bis(diphenyl) phosphate of hydroquinone and the bis(diphenyl) phosphate of bisphenol A, respectively, and their oligomeric and polymeric counterparts.
- Flame retardant compounds containing phosphorus- nitrogen bonds include phosphonitrilic chloride, phosphorus ester amides, phosphoric acid amides, phosphonic acid amides, phosphinic acid amides, and tris(aziridinyl) phosphine oxide.
- phosphorus-containing flame retardants are present in amounts of 0.1 to 30 parts by weight, more specifically 1 to 20 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
- Halogenated materials can also be used as flame retardants, for example bisphenols of which the following are representative: 2,2-bis-(3,5-dichlorophenyl)-propane; bis-(2-chlorophenyl)-methane; bis(2,6-dibromophenyl)-methane; l,l-bis-(4-iodophenyl)- ethane; l,2-bis-(2,6-dichlorophenyl)-ethane; l,l-bis-(2-chloro-4-iodophenyl)ethane; 1,1-bis- (2-chloro-4-methylphenyl)-ethane; l,l-bis-(3,5-dichlorophenyl)-ethane; 2,2-bis-(3-phenyl-4- bromophenyl) -ethane; 2,6-bis-(4,6-dichloronaphthyl)-propane; and
- halogenated materials include 1,3-dichlorobenzene, 1,4-dibromobenzene, l,3-dichloro-4-hydroxybenzene, and biphenyls such as 2,2'-dichlorobiphenyl, polybrominated 1,4-diphenoxybenzene, 2,4'- dibromobiphenyl, and 2,4'-dichlorobiphenyl as well as decabromo diphenyl oxide, as well as oligomeric and polymeric halogenated aromatic compounds, such as a copolycarbonate of bisphenol A and tetrabromobisphenol A and a carbonate precursor, e.g., phosgene.
- biphenyls such as 2,2'-dichlorobiphenyl, polybrominated 1,4-diphenoxybenzene, 2,4'- dibromobiphenyl, and 2,4'-dichlorobiphenyl as well as decabromo diphenyl oxide, as well as oligo
- Metal synergists e.g., antimony oxide
- halogen containing flame retardants are present in amounts of 1 to 25 parts by weight, more specifically 2 to 20 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
- the thermoplastic composition can be essentially free of chlorine and bromine.
- "Essentially free of chlorine and bromine” is defined as having a bromine and/or chlorine content of less than or equal to 100 parts per million by weight (ppm), less than or equal to 75 ppm, or less than or equal to 50 ppm, based on the total parts by weight of the composition, excluding any filler.
- Salt-based flame retardants in addition to the perfluoroalkyl sulfonate salt can also be used, for example salts of C 1-16 alkyl sulfonate salts such as potassium
- diphenylsulfone sulfonate such as Na 2 C0 3 , K 2 C0 3 , MgC0 3 , CaC0 3 , and BaC0 3 , or fluoro-anion complexes such as Li 3 AlF 6 , BaSiF 6 , KBF 4 , K 3 A1F 6 , KalF 4 , K 2 SiF 6 , and/or Na 3 AlF 6 .
- flame retardant salts are present in amounts of 0.01 to 10 parts by weight, more specifically 0.02 to 1 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
- the thermoplastic composition comprises 1-50 mole % of carbonate units according to formula (I) and 50-99 mole of carbonate units according to formula (II), based on the total number of carbonate units in the thermoplastic composition.
- the thermoplastic composition comprises 10-50 mole % of carbonate units according to formula (I) and 50-90 mole of carbonate units according to formula (II), and even more specifically 20-45 mole % of carbonate units according to formula (I) and 55-80 mole of carbonate units according to formula (II).
- the specified carbonate unit content for the thermoplastic composition can be provided by any combination of homopolycarbonate(s) based on units of formula (I), co-polycarbonates containing units of formula (I) and carbonate units of formula (II), co-polymers containing units of formula (I) and other copolymerizable units such as ester units, and/or homopolycarbonates, co- polycarbonates or other co-polymers containing carbonate units of formula (II) but not formula (I).
- thermoplastic composition's specified carbonate content of formula (I) and formula (II) carbonate units can be provided by a single co-polycarbonate containing units of formulas (I) and (II), blends of polycarbonates are often used to achieve desired performance properties such as MFR, glass transition temperature, etc.
- the specified carbonate unit content is provided by a blend of a first polycarbonate comprising units of formula (I) (which can also contain carbonate units of formula (II)) and a second polycarbonate comprising units of formula (II).
- the first and second polycarbonates can be blended by melt blending techniques well-known in the art.
- the first polycarbonate comprises 10-70 mole % of units of formula (I), more specifically from 20-45 mole % of units of formula (I), based on the total number of carbonate units in the first polymer, with the balance of carbonate units in the first polycarbonate chosen according to formula (II).
- the first polycarbonate can be present in the thermoplastic composition in amounts of 5 wt.% to 95 wt.%, more specifically from 10 wt.% to 50 wt.%, and even more specifically from 20 wt.% to 45 wt.%, based on the total weight of polycarbonate in the thermoplastic composition.
- the second polycarbonate can be present in the thermoplastic composition in amounts of 95 wt.% to 5 wt.%, more specifically from 50 wt.% to 90 wt.%, and even more specifically from 55 wt.% to 80 wt.%, based on the total weight of polycarbonate in the thermoplastic composition.
- the first and second polymers can have an intrinsic viscosity, as determined in chloroform at 25 °C, of 0.3 to 1.5 deciliters (dl) per gram (g), specifically 0.45 to 1.0 dl/g.
- the first and second polymers can have a molecular weight of 10,000 to 200,000 Daltons, specifically 20,000 to 100,000 Daltons.
- the first polycarbonate can have a weight average molecular weight of 10,000 to 35,000, more specifically 20,000 to 30,000
- the second polycarbonate can have a weight average molecular weight of 18,000 to 32,000, more specifically 18,000 to 20,000, as determined by gel permeation
- the thermoplastic composition comprises an acid additive in an amount of 0.1 to 10 ppm by weight, specifically from 1 to 6 ppm by weight, and more specifically 3 to 5 ppm by weight.
- the acid additive can be any Arrhenius acid (i.e., protic acid), more specifically any acid with a pKa of less than or equal to about 5 (measured in water).
- the acid is a stronger acid, i.e., an acid having a pKa (measured in water) of less or equal to about 2, specifically about 2 to about -1.
- a weaker acid i.e., having a pKa (measured in water) of greater than about 2, specifically greater than about 2 to about 4.5, has a stronger effect on both molding and heat aging. If a stronger acid is used, a lower amount may be used compared to if a weaker acid is used. In one
- a stronger acid having a pKa of less than 2 is used; in other embodiments, a weaker acid having a pKa of greater than 2 is used. In some embodiments, an acid having a pKa of less than 4.5 is used.
- Acid stabilizers can include phosphoric acid, phosphorous acid, hypophosphorous acid, C 6 -3o aryl, C 7 _3o aralkyl or Ci_3o phosphonic acids, sulfurous acids, C 6- 30 aryl, C 7 _3o aralkyl or Ci_3o alkyl sulfonic acids, ammonium salts of sulfuric acids, halogenated carboxylic acids such as, for example, trifluoroacetic acid, trichloroacetic acid, and the like.
- a weaker acid is phosphorous acid
- a stronger acid is p-toluenesulfonic acid.
- the acid additive is a phosphorous- containing additive, more specifically phosphorous acid, hypophosphorous acid, or phosphoric acid, even more specifically phosphorous acid.
- Epoxy additives such as epoxy- modified acrylic oligomers or polymers can also be included as is known in the art; however, it has been discovered that for the thermoplastic compositions described herein, epoxy additives surprisingly can have a detrimental effect on molecular weight retention.
- thermoplastic composition is free of epoxy additive.
- thermoplastic compositions can be manufactured by various methods. For example, powdered polycarbonate and phosphorous acid modifier, along with any impact modifier and/or other optional components are first blended, optionally with fillers in a HENSCHEL-Mixer high speed mixer. Other low shear processes, including but not limited to hand mixing, can also accomplish this blending. The blend is then fed into the throat of a twin-screw extruder via a hopper. Alternatively, at least one of the components can be incorporated into the composition by feeding directly into the extruder at the throat and/or downstream through a sidestuffer. Additives can also be compounded into a masterbatch with a desired polymeric resin and fed into the extruder.
- the extruder is generally operated at a temperature higher than that necessary to cause the composition to flow.
- the extrudate is immediately quenched in a water batch and pelletized.
- the pellets, so prepared, when cutting the extrudate can be one-fourth inch long or less as desired. Such pellets can be used for subsequent molding, shaping, or forming.
- Transparent compositions can be produced by manipulation of the process used to manufacture the polycarbonate composition.
- One example of such a process to produce transparent polycarbonate compositions is described in U.S. Patent Application No. 2003/0032725.
- the thermoplastic composition can have flow properties for the manufacture of thin articles.
- Melt flow rate (often abbreviated MFR) measures the rate of extrusion of a thermoplastic through an orifice at a prescribed temperature and load.
- Thermoplastic compositions for the formation of thin articles can have an MFR, measured at 330°C/2.16 kg, of at least 12 grams per 10 minutes (g/10 min). In another exemplary embodiment, the MFR ranges from 10 to 20 g/10 min. Combinations of polycarbonates of different flow properties can be used to achieve the overall desired flow property.
- thermoplastic composition used to form the plastic article described herein has a heat deflection temperature (HDT) of at least 160°C, more specifically from 160°C to 165°C, measured under a load of 0.45 MPa according to ASTM D648-06, with a test sample having a thickness of 3.2 mm.
- HDT heat deflection temperature
- thermoplastic composition used to form the plastic article described herein can also have a Notched Izod Impact (Nil) of at least 50 (Joules per meter) J/m, more specifically 50 J/m to 150 J/m, even more specifically from 80 J/m to 150 J/m, and even more specifically from 90 J/m to 120 J/m, determined according to ASTM D256-05 at 23°C using a 2.27 kg weight with a test sample having a thickness of 3.2 mm.
- Notched Izod Impact Nail
- thermoplastic composition used to form the plastic article described herein has a light transmittance of at least 85%, more specifically at least 86%, and can be as high as 90%, when tested in the form of a 3.2 mm thick test sample molded at 580°F (304°C) with a 1.7 minute residence time according to ASTM D 1003-00 using procedure A and CIE illuminant C.
- Transparency can be characterized by transmittance and/or by haze levels, so the article can also have a haze of less than 4%, more specifically less than 2%, i.e., from 0% to 2%, wherein haze is measured on a CE7000A in accordance with ASTM D-1003-97, with a 3.2 mm thick test sample molded at 580°F (304°C) (barrel temperature) with a 1.7 minute residence time.
- the thermoplastic composition used to form the plastic article described herein has CIE 1976 L*, a*, b* values determined according to ASTM E308-08.
- the CIE 1976 L* value is greater than 92, more specifically greater than 94, and can range as high as 98.
- the CIE 1976 a* value is between -1.5 and +1.5, more specifically between -0.72 and -0.12, and even more specifically between -0.70 and -0.20.
- the CIE 1976 b* value is between -2.0 and 3.0, more specifically between 0.2 and 1.3, and even move specifically between 0.3 and 1.2, when tested in the form of a 3.2 mm thick test sample molded at 580°F (304°C) with a 1.7 minute residence time, using CIE illuminant C and 2 degree observer.
- Test samples can be molded from pellets that have been cooled and stored, followed by drying at an elevated temperature (e.g., 8 hours at 140°C). For testing during commercial scale production, test samples can be molded from still-hot pellets taken directly from an extruder.
- thermoplastic composition can have a yellowness index (YI), measure in accordance with ASTM D1925- 95, of less than 6 when tested with a 3.2 mm thick test sample molded at 580°F (304°C) with a 1.7 minute residence time.
- YI yellowness index
- the thermoplastic composition used to form the plastic article described herein provides color properties that are surprisingly tolerant of adverse molding conditions such as longer mold retention times.
- the b* value differs by less than 0.7, more specifically less than 0.5, if the molding residence time is changed from 1.7 minutes to 6.8 minutes.
- Adverse molding conditions includes subjecting the thermoplastic composition to high residence times, high temperatures, or both high residence times and high temperatures.
- Residence time is the average amount of time a thermoplastic composition spends in molten form in the heated barrel of an injection molding machine before entering a mold.
- Residence time can be mathematically characterized by a formula where residence time equals the cycle time used multiplied the mass or volume capacity of the barrel divided by the mass or volume capacity of the mold cavity.
- adverse molding conditions can include residence times of at least 4 minutes, more specifically at least 5 minutes, more specifically at least 6 minutes, more specifically at least 7 minutes, more specifically at least 8 minutes, more specifically at least 9 minutes, and more specifically at least 10 minutes.
- the temperature to which the thermoplastic composition is heated in the barrel of the injection molding device can be at least 600°F (316°C), more specifically at least 610°F (321°C), and even more specifically at least 620°F (327°C)°C.
- the above conditions are characterized as average residence time and average barrel temperature; however, adverse molding conditions can also involve exposing only portions of the thermoplastic composition to such high residence times and/or high temperatures, such as when the design of the injection molding device leads to areas of the barrel where the thermoplastic composition gets held up and thus exposed to a longer residence time even if the average residence time may not be elevated.
- the hot spots in the barrel can create adverse molding conditions by exposing a portion of the thermoplastic composition to an elevated temperature even if the average temperature is not elevated.
- the plastic article can be molded into useful shapes by a variety of means such as injection molding, extrusion, rotational molding, blow molding and thermoforming to form articles having a thickness of 0.5 mm to 5 mm, more specifically from 2 mm to 4 mm.
- Examples of articles include illumination lenses or covers for light fixtures, motor vehicle headlights, flashlights, image projector lamp lenses, as well as numerous other components for high-temperature applications.
- Examples of such other components include, but are not limited to windows, viewing portals, electronic device display screens and/or housings, and lenses for various applications such as image or data recording.
- a method of making a plastic article comprises:
- thermoplastic composition introducing a thermoplastic composition to the barrel of an injection molding device that comprises a barrel assembly and a mold assembly, the thermoplastic composition comprising:
- R is hydrogen, a C 1-25 hydrocarbyl group, or halogen, and R hydrogen or a Ci-25 hydrocarbyl group,
- thermoplastic composition from 0.1 to 10 ppm by weight of phosphorous acid; heating the thermoplastic composition in the barrel assembly to a temperature sufficient for injection molding of the thermoplastic composition and injecting a shot of the thermoplastic composition into the mold assembly under adverse molding conditions; and removing a molded article of the thermoplastic composition from the mold assembly.
- the adverse molding conditions include subjecting the thermoplastic composition to a residence time in the barrel assembly of at least
- the adverse molding conditions include subjecting the thermoplastic composition to a residence time in the barrel assembly of at least 7 minutes; and/or (iii) the adverse molding conditions include subjecting the thermoplastic composition to a residence time in the barrel assembly of at least 10 minutes; and/or the (iv) the residence time is the mass or volume quantity of thermoplastic composition in the barrel divided by the mass or volume quantity, respectively, of the shot of the thermoplastic composition, multiplied by the cycle time; and/or (v) the adverse molding conditions include heating the thermoplastic composition in the barrel to a temperature of at least 600°F (316°C); and/or (vi) the adverse molding conditions include heating the thermoplastic composition in the barrel to a temperature of at least 610°F (321°C); and/or (vii) the adverse molding conditions include heating the thermoplastic composition in the barrel to a temperature of at least 620°F
- thermoplastic composition has a heat deflection temperature of at least 145°C when tested in the form of a 3.2 mm thick test sample according to ASTM D648-
- thermoplastic composition comprises a blend of a first polycarbonate consisting of units of formula (I) and units of formula (II) and a second polycarbonate consisting of units of formula (II); and/or (xv) the thermoplastic composition comprises a blend of a first polycarbonate comprising units of formula (I) and a second polycarbonate comprising units of formula (II); and/or (xvi) the first polycarbonate comprises units of formula (I) and units of formula (II); and/or (xvii) the first polycarbonate comprises from 10 mole % to 70 mole % of units of formula (I) and from 30 mole % to 90 mole % of units of formula (II), based on the total number of carbonate units in the first polymer; and/or (xviii) the second polycarbonate comprises 100 mole % of units of formula (II), based on
- thermoplastic compositions are further illustrated by the following non- limiting examples.
- thermoplastic compositions except where indicated were compounded on a single screw laboratory scale extruder. All ingredients were tumble-blended prior to compound using a single feeder to the extruder. The typical sample size of the extruder is 3 kg. Compositions were compounded and extruded at a temperature of 285 to 330°C and allowed to cool. Test samples were prepared from polymer pellets that had been subject to drying for 8 hours at 140°C. Test measurements were made using the tests and test methods described above.
- thermoplastic composition having an MFR of 30-40 g/10 min at 330°C/2.16 kg and a weight average MW of 22,000 determined by gel permeation chromatography, using a crosslinked styrene-divinylbenzene column and calibrated to polycarbonate references:
- thermoplastic composition having an MFR of 30-40 g/10 min at 330°C/2.16kg and a weight average MW of 22,000 determined by gel permeation chromatography, using a crosslinked styrene-divinylbenzene column and calibrated to polycarbonate references:
- Comparative Examples 4-6 were prepared from the formulation of Preparation 1, but replacing the phosphorous acid with 3 ppm by weight of the following comparison additives: trisnonylphenylphosphite (TNPP) (Comparative Example 4), diphenyl phosphite (Comparative Example 5), diphenyldecyl(isodecyl)phosphite (DPDP) (Comparative Example 6).
- TNPP trisnonylphenylphosphite
- DPDP diphenyldecyl(isodecyl)phosphite
- the samples, along with a second sample of Example 3 were placed in a 140°C oven for 900 hours. Color measurements were taken of the samples at the times set forth in Table 3, using the ASTM methods described above. The results, set forth in Table 3, show that initial YI values increased at an unacceptable level over the aging period.
- Example 1 and test samples of Comparative Example 3 were injection molded with a flat-profile barrel temperature of 580°F.
- the mold temperature was 230 °F. Molding was performed with cycle times of 30 seconds up to 120 seconds to model an increase in mold residence time from 1.7 minutes to 6.8 minutes.
- Example 1 and Comparative Example 3 were prepared by injection molding with a flat-profile barrel temperature of 620°F.
- the mold temperature was 230 °F.
- Molding was performed with cycle times of 30 seconds up to 120 seconds to model an increase in mold residence time from 1.7 minutes to 6.8 minutes.
- Transmittance and color measurements were taken of the samples ASTM methods described above. The results, set forth in Table 5, show from the delta values between the 30 second and 120 second cycle times, that the Example 1 provided a significant advantage in tolerance of adverse molding conditions.
- Preparation 2 was prepared in the same fashion as Preparation 1, except that it utilized 5 ppm by weight of phosphorous acid.
- Preparation 3 was prepared in the same fashion as Preparation 2, with the addition of 300 ppm by weight of a commercially available epoxy additive ERL-4221.
- Comparative Preparation 4 was prepared in the same fashion as Comparative Preparation 3, with the addition of 300 ppm by weight of a commercially available epoxy additive ERL-4221. The materials were tested for molecular weight change observed from before extrusion to after extrusion at 600°F.
- cycloalkyl refers to a non-aromatic monovalent monocyclic or multicylic hydrocarbon group having at least three carbon atoms
- cycloalkenyl refers to a non-aromatic cyclic divalent hydrocarbon group having at least three carbon atoms, with at least one degree of unsaturation
- aryl refers to an aromatic monovalent group containing only carbon in the aromatic ring or rings
- arylene refers to an aromatic divalent group containing only carbon in the aromatic ring or rings
- alkylaryl refers to an aryl group that has been substituted with an alkyl group as defined above, with 4-methylphenyl being an exemplary alkylaryl group
- arylalkyl refers to an alkyl group that has been substituted with an aryl group as defined above, with benzyl being an exemplary arylalkyl group
- acyl refers to an alkyl group as defined above with the indicated number of carbon atoms attached through a carbonyl carbon
- Exemplary groups that can be present on a "substituted" position include, but are not limited to, cyano; hydroxyl; nitro; azido; alkanoyl (such as a C2-6 alkanoyl group such as acyl); carboxamido; Cl-6 or Cl-3 alkyl, cycloalkyl, alkenyl, and alkynyl (including groups having at least one unsaturated linkages and from 2 to 8, or 2 to 6 carbon atoms); Cl-6 or Cl-3 alkoxy groups; C6-10 aryloxy such as phenoxy; Cl-6 alkylthio; Cl-6 or Cl-3 alkylsulfinyl; Cl-6 or Cl-3 alkylsulfonyl; aminodi(Cl-6 or Cl-3)alkyl; C6-12 aryl having at least one aromatic rings (e.g., phenyl, biphenyl, naphthyl, or the like, each ring either substituted or unsubstituted aromatic);
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Abstract
A method of making plastic article is disclosed in which a thermoplastic composition including phthalimide carbonate units is introduced to the barrel of an injection molding device that comprises a barrel assembly and a mold assembly, the thermoplastic composition is heated in the barrel assembly to a temperature sufficient for injection molding of the thermoplastic composition and then a shot of the thermoplastic composition is injected into the mold assembly under adverse molding conditions, followed by removing the molded article of the thermoplastic composition from the mold assembly.
Description
METHOD OF MAKING A TRANSPARENT PLASTIC ARTICLE
BACKGROUND OF THE INVENTION
[0001] This disclosure relates to thermoplastic articles, and in particular to transparent low-low color articles based on polycarbonate compositions that can withstand demanding processing conditions and perform in high-temperature environments.
[0002] Polycarbonates are useful in the manufacture of articles and components for a wide range of applications, from automotive parts to electronic appliances. Because of their beneficial properties such as transparency and impact resistance, polycarbonates have been widely used in applications such as instrument screens, helmet face shields, eyeglass and safety glass lenses, and illumination lenses such as light fixtures, flashlight and lantern lenses, and motor vehicle headlight lenses and covers. In some applications including but not limited to motor vehicle headlight lenses and covers, other performance properties may also be desirable such as transparency, low color, ability to withstand elevated temperatures without deformation or discoloration, and/or ability to maintain these properties even when molded under adverse conditions.
[0003] Plastic articles can be fabricated using a variety of manufacturing techniques such as extrusion, blow molding, injection molding, and others known in the art. Injection molding is typically carried out with an injection molding apparatus, which is depicted in simplified schematic fashion in FIG. 1. As shown in FIG. 1, an injection molding device 10 feeds polymer thermoplastic resin granules 12 through a hopper 14 into barrel 16. Barrel 16 is heated with heater elements 18 to heat the resin to cause it to flow so that it can be injection molded. Screw 20 is turned to move the flowable resin from barrel 16 so that it is injected into mold 22. It is noted that details of the device such as a drive mechanism for the screw 20 or an ejection mechanism for ejecting the formed resin part from the mold 22 are not shown in this simplified schematic diagram. The amount of time that the thermoplastic resin spends in its flowable or molten state is referred to as the residence time, and it may be
mathematically represented as the mass or volume quantity of thermoplastic composition in the barrel divided by the mass or volume quantity of the shot of the thermoplastic
composition, multiplied by the cycle time. Cycle time is defined as the time for one injection cycle, and in a continuously running injection molding process is the time it takes between the same point of adjacent injection cycles such as the time between when resin begins to flow into the mold in one injection cycle until the time when resin begins to flow into the
mold in the next subsequent injection cycle. Many parts such as those with thin walls and/or large and/or complex surface areas, long cycle times (and thus long residence times) may be required to properly fill the mold with resin. Such long cycle and residence times can expose the polymer to high temperatures for extended periods. Although many polycarbonate compositions can provide beneficial properties in a wide variety of conditions, there remains a need for plastic articles that provide beneficial combinations of properties such as high transparency, heat deformation resistance, and stable color even when subjected to long cycle and residence times in the injection molding device.
SUMMARY OF THE INVENTION
[0004] In an embodiment, the above-described and other deficiencies of the art are addressed by a method of making a plastic article, comprising:
introducing a thermoplastic composition to the barrel of an injection molding device that comprises a barrel assembly and a mold assembly, the thermoplastic composition comprising:
1 mole % to 50 mole % of carbonate units represented by the formula (I)
2 3 wherein R is hydrogen, a Ci_25 hydrocarbyl group, or halogen, and R hydrogen or a C1-25 hydrocarbyl group,
50 mole % to 99 mole % of carbonate units represented by the formula (II)
O
R1— O C O
in which at least 60 percent of the total number of R1 groups contain aromatic moieties and the balance thereof are aliphatic, alicyclic, or aromatic moieties, with the proviso that the carbonate units of formula (II) are not within the scope of formula (I), the mole percentages of formulas (I) and (II) based on the total number of carbonate units in the thermoplastic composition, and
from 0.1 to 10 ppm by weight of phosphorous acid;
heating the thermoplastic composition in the barrel assembly to a temperature sufficient for injection molding of the thermoplastic composition and injecting a shot of the thermoplastic composition into the mold assembly under adverse molding conditions; and removing a molded article of the thermoplastic composition from the mold assembly.
DESCRIPTION OF THE FIGURES
[0001] Referring now to the figures, which are exemplary embodiments and wherein like elements are numbered alike:
[0002] FIG. 1 depicts a typical apparatus for injection molding of thermoplastic compositions.
DETAILED DESCRIPTION OF THE INVENTION
[0005] Surprisingly, it has been discovered that the above-described method of making an article can provide beneficial stable properties such as high light transmittance, targeted color balance even with extended cycle times and residence times, and impact strength.
[0006] As used herein, a "polycarbonate" means compositions having repeating structural carbonate units of formula (1)
O R1— O C O (1)
in which at least 60 percent of the total number of R1 groups contain aromatic moieties and the balance thereof are aliphatic, alicyclic, or aromatic. Also, carbonate units of formula (II) described above are carbonate units according to formula (1), subject to the proviso that the carbonate units of formula (II) are not within the scope of formula (I). With respect to formula (1), in an embodiment, each R1 is a C6-3o aromatic group, that is, contains at least one aromatic moiety. R1 can be derived from a dihydroxy compound of the formula HO-R^OH, in particular of formula (2)
HO-A -Y -A^OH (2)
1 2 1 wherein each of A and A is a monocyclic divalent aromatic group and Y is a single bond or
1 2
a bridging group having one or more atoms that separate A from A . In an embodiment, one
atom separates A 1 from A2. Specifically, each R 1 can be derived from a dihydroxy aromatic compound of formula 3)
wherein Ra and Rb are each independently a halogen, C1-12 alkoxy, or C1-12 alkyl; and p and q are each independently integers of 0 to 4. It will be understood that Ra is hydrogen when p is 0, and likewise Rb is hydrogen when q is 0. Also in formula (3), Xa is a bridging group connecting the two hydroxy- substituted aromatic groups, where the bridging group and the hydroxy substituent of each C6 arylene group are disposed ortho, meta, or para (specifically para) to each other on the C6 arylene group. In an embodiment, the bridging group Xa is single bond, -0-, -S-, -S(O)-, -S(0)2-, -C(O)-, or a C1-18 organic group. The C1-18 organic bridging group can be cyclic or acyclic, aromatic or non-aromatic, and can further comprise heteroatoms such as halogens, oxygen, nitrogen, sulfur, silicon, or phosphorous. The C1-18 organic group can be disposed such that the C6 arylene groups connected thereto are each connected to a common alkylidene carbon or to different carbons of the C1-18 organic bridging group. In an embodiment, p and q is each 1, and Ra and Rb are each a C1-3 alkyl group, specifically methyl, disposed meta to the hydroxy group on each arylene group.
[0007] In an embodiment, Xa is a substituted or unsubstituted C3_i8 cycloalkylidene, a C1-25 alkylidene of formula -C(Rc)(Rd) - wherein Rc and Rd are each independently hydrogen, C1-12 alkyl, C1-12 cycloalkyl, C7-12 arylalkyl, C1-12 heteroalkyl, or cyclic C7-12 heteroarylalkyl, or a group of the formula -C(=R6)- wherein Re is a divalent C1-12
hydrocarbon group, groups of this type include methylene, cyclohexylmethylene, ethylidene, neopentylidene, and isopropylidene, as well as 2-[2.2.1]-bicycloheptylidene,
cyclohexylidene, cyclopentylidene, cyclododecylidene, and adamantylidene.
[0008] In another embodiment, Xa is a C1-18 alkylene group, a C3_i8 cycloalkylene group, a fused C6-18 cycloalkylene group, or a group of the formula -B 1 -G-B2 - wherein B 1 and B are the same or different Ci_6 alkylene group and G is a C3_i2 cycloalkylidene group or a C6-16 arylene group. For example, Xa can be a substituted C3-18 cycloalkylidene of formula (4)
wherein Rr, Rp, Rq, and R1 are each independently hydrogen, halogen, oxygen, or C1-12 hydrocarbon groups; Q is a direct bond, a carbon, or a divalent oxygen, sulfur, or -N(Z)- where Z is hydrogen, halogen, hydroxy, C1-12 alkyl, C1-12 alkoxy, or C1-12 acyl; r is 0 to 2, t is 1 or 2, q is 0 or 1, and k is 0 to 3, with the proviso that at least two of Rr, Rp, Rq, and R1 taken together are a fused cycloaliphatic, aromatic, or heteroaromatic ring. It will be understood that where the fused ring is aromatic, the ring as shown in formula (4) will have an unsaturated carbon-carbon linkage where the ring is fused. When k is one and i is 0, the ring as shown in formula (4) contains 4 carbon atoms, when k is 2, the ring as shown in formula (4) contains 5 carbon atoms, and when k is 3, the ring contains 6 carbon atoms. In an embodiment, two adjacent groups (e.g., Rq and R1 taken together) form an aromatic group, and in another embodiment, Rq and R1 taken together form one aromatic group and Rr and Rp taken together form a second aromatic group. When Rq and R1 taken together form an aromatic group, Rp can be a double-bonded oxygen atom, i.e., a ketone.
[0009] Bisphenols where Xa is of formula (4) can be used in the manufacture of polycarbonates containing phthalimidine carbonate units of formula (II)
wherein R 2 is hydrogen, a C1-25 hydrocarbyl group, or halogen, and R 3 is hydrogen or a C1-25 hydrocarbyl group Ra, Rb, p, and q are as in formula (4), R3 is each independently a Ci_6 alkyl group, j is 0 to 4, and R4 is a Ci_6 alkyl, phenyl, or phenyl substituted with up to five Ci_6 alkyl groups. More specifically, R 2 can be hydrogen and R 3 can be a C6-1o aromatic group such as phenyl or substituted phenyl, In some embodiments, the phthalimidine carbonate units can be of formula (4b)
wherein R5 is hydrogen or a Ci_6 alkyl, more specifically hydrogen. Such carbonate units wherein R5 is hydrogen can be derived from 2-phenyl-3,3'-bis(4-hydroxy
phenyl)phthalimidine (also known as N-phenyl phenolphthalein bisphenol, or "PPPBP") (also known as 3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-l-one).
[0010] Other bisphenol carbonate repeating units where Xa is according to formula (4) are the
wherein Ra and Rb are each independently C1-12 alkyl, p and q are each independently 0 to 4, and R1 is C1-12 alkyl, phenyl, optionally substituted with 1 5 to Ci_io alkyl, or benzyl optionally substituted with 1 to 5 C1-10 alkyl. In an embodiment, Ra and Rb are each methyl, p and q are each independently 0 or 1, and R1 is Ci_4 alkyl or phenyl.
[0011] Examples of bisphenol carbonate units derived from bisphenols (4) wherein Xa is a substituted or unsubstituted C3-18 cycloalkylidene include the cyclohexylidene- bridged, alkyl-substituted bisphenol of formula (4e)
wherei
is C1-12 alkyl, p and q are each independently 0 to 4, and t is 0 to 10. In a specific embodiment, at least one of each of Ra and Rb are disposed meta to the cyclohexylidene bridging group. In an embodiment, Ra and Rb are each independently Ci_4 alkyl, Rg is Ci_4 alkyl, p and q are each 0 or 1, and t is 0 to 5.
In another specific embodiment, Ra, Rb, and Rg are each methyl, r and s are each 0 or 1, and t is 0 or 3, specifically 0. For example,
[0012] Examples of other bisphenol carbonate units derived from bisphenol (4) wherein Xa is a substituted or unsubstituted C3-18 cycloalkylidene include units (4f) (also known as adamantyl units) and units (4g)
4. In a specific embodiment, at least one of each of Ra and Rb are disposed meta to the cycloalkylidene bridging group. In an embodiment, Ra and Rb are each independently Ci_3 alkyl, and p and q are each 0 or 1. In another specific embodiment, Ra, Rb are each methyl, p and q are each 0 or 1. Carbonates containing units (4) to (4g) can be used for making polycarbonates with high glass transition temperatures (Tg) and high heat distortion temperatures.
[0013] Other aromatic dihydroxy compounds of the formula HO-R^OH include compounds of formula (6)
(6)
wherein each Rh is independently a halogen atom, a Ci_io hydrocarbyl such as a Ci_io alkyl group, a halogen-substituted C1-10 alkyl group, a C6-io aryl group, or a halo gen- substituted C6- io aryl group, and n is 0 to 4. The halogen is usually bromine.
[0014] Some illustrative examples of specific aromatic dihydroxy compounds include the following: 4,4'-dihydroxybiphenyl, 1,6-dihydroxynaphthalene, 2,6- dihydroxynaphthalene, bis(4-hydroxyphenyl)methane, bis(4- hydroxyphenyl)diphenylmethane, bis(4-hydroxyphenyl)-l-naphthylmethane, l,2-bis(4- hydroxyphenyl)ethane, l,l-bis(4-hydroxyphenyl)-l-phenylethane, 2-(4-hydroxyphenyl)-2-(3- hydroxyphenyl)propane, bis(4-hydroxyphenyl)phenylmethane, 2,2-bis(4-hydroxy-3- bromophenyl)propane, 1,1 -bis (hydroxyphenyl)cyclopentane, l,l-bis(4- hydroxyphenyl)cyclohexane, 1 , 1 -bis(4-hydroxyphenyl)isobutene, 1 , 1 -bis(4- hydroxyphenyl)cyclododecane, trans-2,3-bis(4-hydroxyphenyl)-2-butene, 2,2-bis(4-
hydroxyphenyl)adamantane, alpha, alpha'-bis(4-hydroxyphenyl)toluene, bis(4- hydroxyphenyl)acetonitrile, 2,2-bis(3-methyl-4-hydroxyphenyl)propane, 2,2-bis(3-ethyl-4- hydroxyphenyl)propane, 2,2-bis(3-n-propyl-4-hydroxyphenyl)propane, 2,2-bis(3-isopropyl-4- hydroxyphenyl)propane, 2,2-bis(3-sec-butyl-4-hydroxyphenyl)propane, 2,2-bis(3-t-butyl-4- hydroxyphenyl)propane, 2,2-bis(3-cyclohexyl-4-hydroxyphenyl)propane, 2,2-bis(3-allyl-4- hydroxyphenyl)propane, 2,2-bis(3-methoxy-4-hydroxyphenyl)propane, 2,2-bis(4- hydroxyphenyl)hexaf uoropropane, 1 , 1 -dichloro-2,2-bis (4-hydroxyphenyl)ethylene, 1,1- dibromo-2,2-bis(4-hydroxyphenyl)ethylene, l,l-dichloro-2,2-bis(5-phenoxy-4- hydroxyphenyl)ethylene, 4,4'-dihydroxybenzophenone, 3,3-bis(4-hydroxyphenyl)-2- butanone, l,6-bis(4-hydroxyphenyl)-l,6-hexanedione, ethylene glycol bis(4- hydroxyphenyl)ether, bis(4-hydroxyphenyl)ether, bis(4-hydroxyphenyl)sulfide, bis(4- hydroxyphenyl) sulfoxide, bis(4-hydroxyphenyl)sulfone, 9,9-bis(4-hydroxyphenyl)fluorine, 2,7-dihydroxypyrene, 6,6'-dihydroxy-3,3,3',3'- tetramethylspiro(bis)indane ("spirobiindane bisphenol"), 3,3-bis(4-hydroxyphenyl)phthalimide, 2,6-dihydroxydibenzo-p-dioxin, 2,6- dihydroxythianthrene, 2,7-dihydroxyphenoxathin, 2,7-dihydroxy-9, 10-dimethylphenazine, 3,6-dihydroxydibenzofuran, 3,6-dihydroxydibenzothiophene, and 2,7-dihydroxycarbazole, resorcinol, substituted resorcinol compounds such as 5-methyl resorcinol, 5-ethyl resorcinol, 5-propyl resorcinol, 5-butyl resorcinol, 5-t-butyl resorcinol, 5-phenyl resorcinol, 5-cumyl resorcinol, 2,4,5, 6-tetrafluoro resorcinol, 2,4,5, 6-tetrabromo resorcinol, or the like; catechol; hydroquinone; substituted hydroquinones such as 2-methyl hydroquinone, 2-ethyl
hydroquinone, 2-propyl hydroquinone, 2-butyl hydroquinone, 2-t-butyl hydroquinone, 2- phenyl hydroquinone, 2-cumyl hydroquinone, 2,3,5,6-tetramethyl hydroquinone, 2,3,5,6- tetra-t-butyl hydroquinone, 2,3,5,6-tetrafluoro hydroquinone, 2,3,5, 6-tetrabromo
hydroquinone, or the like, or combinations comprising at least one of the foregoing dihydroxy compounds.
[0015] Specific examples of bisphenol compounds of formula (3) include l,l-bis(4- hydroxyphenyl) methane, l,l-bis(4-hydroxyphenyl) ethane, 2,2-bis(4-hydroxyphenyl) propane (hereinafter "bisphenol A" or "BPA"), 2,2-bis(4-hydroxyphenyl) butane, 2,2-bis(4- hydroxyphenyl) octane, l,l-bis(4-hydroxyphenyl) propane, l,l-bis(4-hydroxyphenyl) n- butane, 2,2-bis(4-hydroxy-2-methylphenyl) propane, l,l-bis(4-hydroxy-t-butylphenyl) propane, 3,3-bis(4-hydroxyphenyl) phthalimidine, 2-phenyl-3,3-bis(4-hydroxyphenyl) phthalimidine (PPPBP), and l,l-bis(4-hydroxy-3-methylphenyl)cyclohexane (DMBPC). Combinations comprising at least one of the foregoing dihydroxy compounds can also be
used. In one specific embodiment, the polycarbonate is a linear homopolymer derived from bisphenol A, in which each of A 1 and A2 is p-phenylene and Y 1 is isopropylidene in formula (3).
[0016] In an embodiment, the polycarbonate has flow properties for the manufacture of thin articles. Melt flow rate (often abbreviated MFR) measures the rate of extrusion of a thermoplastic through an orifice at a prescribed temperature and load, and can be determined according to ASTM D1238-04C. Polycarbonates for the formation of thin articles can have an MFR, measured at 330°C/2.16 kg, of 10 to 90 grams per 10 minutes (g/10 min), specifically 20 to 40 g/10 min. Combinations of polycarbonates of different flow properties can be used to achieve the overall desired flow property.
[0017] "Polycarbonates" includes homopolycarbonates (wherein each R1 in the polymer is the same), copolymers comprising different R1 moieties in the carbonate
("copolycarbonates"), copolymers comprising carbonate units and other types of polymer units, such as ester units, and combinations comprising at least one of homopolycarbonates and/or copolycarbonates.
[0018] A specific type of copolymer is a polyester carbonate, also known as a polyester-polycarbonate. Such copolymers further contain, in addition to recurring carbonate chain units of formula (1), repeating units of formula (7)
O O
II II
— c— T— c— o— J— o— 7)
wherein J is a divalent group derived from a dihydroxy compound, and can be, for example, a C2-10 alkylene, a C6-2o cycloalkylene a C6-2o arylene, or a polyoxyalkylene group in which the alkylene groups contain 2 to 6 carbon atoms, specifically 2, 3, or 4 carbon atoms; and T is a divalent group derived from a dicarboxylic acid, and can be, for example, a C2-10 alkylene, a C6-2o cycloalkylene, or a C6-2o arylene. Copolyesters containing a combination of different T and/or J groups can be used. The polyesters can be branched or linear. In another embodiment, J is a C2-30 alkylene group having a straight chain, branched chain, or cyclic (including polycyclic) structure. J can be derived from an aromatic dihydroxy compound of formula (3) above, or from an aromatic dihydroxy compound of formula (4) above, or from an aromatic dihydroxy compound of formula (6) above.
[0019] Aromatic dicarboxylic acids that can be used to prepare the polyester units include isophthalic or terephthalic acid, l,2-di(p-carboxyphenyl)ethane, 4,4'-
dicarboxydiphenyl ether, 4,4'-bisbenzoic acid, or a combination comprising at least one of the foregoing acids. Acids containing fused rings can also be present, such as in 1,4-, 1,5-, or 2,6-naphthalenedicarboxylic acids. Specific dicarboxylic acids include terephthalic acid, isophthalic acid, naphthalene dicarboxylic acid, cyclohexane dicarboxylic acid, or a combination comprising at least one of the foregoing acids. A specific dicarboxylic acid comprises a combination of isophthalic acid and terephthalic acid wherein the weight ratio of isophthalic acid to terephthalic acid is 91:9 to 2:98. In another specific embodiment, J is a C2-6 alkylene group and T is p-phenylene, m-phenylene, naphthalene, a divalent
cycloaliphatic group, or a combination thereof. This class of polyester includes the poly(alkylene terephthalates).
[0020] The molar ratio of ester units to carbonate units in the copolymers can vary broadly, for example 1:99 to 99:1, specifically 10:90 to 90:10, more specifically 25:75 to 75:25, depending on the desired properties of the final composition.
[0021] In an embodiment, the polyester unit of a polyester-polycarbonate is derived from the reaction of a combination of isophthalic and terephthalic diacids (or derivatives thereof) with resorcinol. In another embodiment, the polyester unit of a polyester- polycarbonate is derived from the reaction of a combination of isophthalic acid and terephthalic acid with bisphenol A. In anotherc embodiment, the polycarbonate units are derived from bisphenol A. In another embodiment, the polycarbonate units are derived from resorcinol and bisphenol A in a molar ratio of resorcinol carbonate units to bisphenol A carbonate units of 1:99 to 99:1.
[0022] Polycarbonates can be manufactured by processes such as interfacial polymerization and melt polymerization. Although the reaction conditions for interfacial polymerization can vary, an process generally involves dissolving or dispersing a dihydric phenol reactant in aqueous caustic soda or potash, adding the resulting mixture to a water- immiscible solvent medium, and contacting the reactants with a carbonate precursor in the presence of a catalyst such as triethylamine and/or a phase transfer catalyst, under controlled pH conditions, e.g., 8 to 12. The most commonly used water immiscible solvents include methylene chloride, 1,2-dichloroethane, chlorobenzene, toluene, and the like.
[0023] Carbonate precursors include a carbonyl halide such as carbonyl bromide or carbonyl chloride, or a haloformate such as a bishaloformates of a dihydric phenol (e.g., the bischloroformates of bisphenol A, hydroquinone, or the like) or a glycol (e.g., the
bishaloformate of ethylene glycol, neopentyl glycol, polyethylene glycol, or the like).
Combinations comprising at least one of the foregoing types of carbonate precursors can also be used. Phosgene can also be a carbonate precursor in, an interfacial polymerization reaction to form carbonate linkages, which is referred to as a phosgenation reaction.
[0024] Among the phase transfer catalysts that can be used are catalysts of the formula (R 3 )4Q X, wherein each R 3 is the same or different, and is a C1-10 alkyl group; Q is a nitrogen or phosphorus atom; and X is a halogen atom or a Ci_8 alkoxy group or C6-18 aryloxy group, phase transfer catalysts include, for example, [CH3(CH2)3]4NX, [CH3(CH2)3]4PX, [CH3(CH2)5]4NX, [CH3(CH2)6]4NX, [CH3(CH2)4]4NX, CH3[CH3(CH2)3]3NX, and
CH3[CH3(CH2)2]3NX, wherein X is CI", Br", a Ci_8 alkoxy group or a C6-i8 aryloxy group. A phase transfer catalyst can be used in an amount of 0.1 to 10 wt , more specifically from 0.5 to 2 wt , based on the weight of bisphenol in the phosgenation mixture.
[0025] All types of polycarbonate end groups are contemplated for the polycarbonate composition, provided that such end groups do not significantly adversely affect desired properties of the compositions.
[0026] Branched polycarbonate blocks can be prepared by adding a branching agent during polymerization. These branching agents include polyfunctional organic compounds containing at least three functional groups selected from hydroxyl, carboxyl, carboxylic anhydride, haloformyl, and mixtures of the foregoing functional groups. Specific examples include trimellitic acid, trimellitic anhydride, trimellitic trichloride, tris-p-hydroxy phenyl ethane, isatin-bis-phenol, tris-phenol TC (l,3,5-tris((p-hydroxyphenyl)isopropyl)benzene), tris-phenol PA (4(4(1, l-bis(p-hydroxyphenyl)-ethyl) alpha, alpha-dimethyl benzyl)phenol), 4-chloroformyl phthalic anhydride, trimesic acid, and benzophenone tetracarboxylic acid. The branching agents can be added at a level of 0.05 to 2.0 wt , based on the total weight of dihydroxy compound in the polymerization reaction mixture. Mixtures comprising linear polycarbonates and branched polycarbonates can be used.
[0027] A chain stopper (also referred to as a capping agent) can be included during polymerization. The chain stopper limits molecular weight growth rate, and so controls molecular weight in the polycarbonate, chain stoppers include certain mono-phenolic compounds, mono-carboxylic acid chlorides, and/or mono-chloroformates. Mono-phenolic chain stoppers are exemplified by monocyclic phenols such as phenol and Ci-C22 alkyl- substituted phenols such as p-cumyl-phenol, resorcinol monobenzoate, and p-and tertiary- butyl phenol; and monoethers of diphenols, such as p-methoxyphenol. Alkyl-substituted phenols with branched chain alkyl substituents having 8 to 9 carbon atom can be specifically
mentioned. Certain mono-phenolic UV absorbers can also be used as a capping agent, for example 4-substituted-2-hydroxybenzophenones and their derivatives, aryl salicylates, monoesters of diphenols such as resorcinol monobenzoate, 2-(2-hydroxyaryl)-benzotriazoles and their derivatives, 2-(2-hydroxyaryl)-l,3,5-triazines and their derivatives, and the like.
[0028] Mono-carboxylic acid chlorides can also be used as chain stoppers. These include monocyclic, mono-carboxylic acid chlorides such as benzoyl chloride, C1-C22 alkyl- substituted benzoyl chloride, toluoyl chloride, halogen-substituted benzoyl chloride, bromobenzoyl chloride, cinnamoyl chloride, 4-nadimidobenzoyl chloride, and combinations thereof; polycyclic, mono-carboxylic acid chlorides such as trimellitic anhydride chloride, and naphthoyl chloride; and combinations of monocyclic and polycyclic mono-carboxylic acid chlorides. Chlorides of aliphatic monocarboxylic acids with less than or equal to 22 carbon atoms are exemplary. Other examples include functionalized chlorides of aliphatic monocarboxylic acids, such as acryloyl chloride and methacryoyl chloride, mono- chloroformates including monocyclic, mono-chloroformates, such as phenyl chloroformate, alkyl-substituted phenyl chloroformate, p-cumyl phenyl chloroformate, toluene
chloroformate, and combinations thereof.
[0029] Alternatively, melt processes can be used to make the polycarbonates.
Generally, in the melt polymerization process, polycarbonates can be prepared by co- reacting, in a molten state, the dihydroxy reactant(s) and a diaryl carbonate ester, such as diphenyl carbonate, in the presence of a transesterification catalyst in a Banbury* mixer, twin screw extruder, or the like to form a uniform dispersion. Volatile monohydric phenol is removed from the molten reactants by distillation and the polymer is isolated as a molten residue. A specific melt process for making polycarbonates uses a diaryl carbonate ester having electron- withdrawing substituents on the aryls. Examples of specific diaryl carbonate esters with electron withdrawing substituents include bis(4-nitrophenyl)carbonate, bis(2- chlorophenyl)carbonate, bis(4-chlorophenyl)carbonate, bis(methyl salicyl)carbonate, bis(4- methylcarboxylphenyl) carbonate, bis(2-acetylphenyl) carboxylate, bis(4-acetylphenyl) carboxylate, or a combination comprising at least one of the foregoing esters. In addition, transesterification catalysts can include phase transfer catalysts of formula (R3)4Q+X, wherein each R , Q, and X are as defined above, transesterification catalysts include
tetrabutylammonium hydroxide, methyltributylammonium hydroxide, tetrabutylammonium acetate, tetrabutylphosphonium hydroxide, tetrabutylphosphonium acetate,
tetrabutylphosphonium phenolate, or a combination comprising at least one of the foregoing.
[0030] The polyester-polycarbonates can also be prepared by interfacial polymerization. Rather than utilizing the dicarboxylic acid or diol per se, the reactive derivatives of the acid or diol, such as the corresponding acid halides, in particular the acid dichlorides and the acid dibromides can be used. Thus, for example instead of using isophthalic acid, terephthalic acid, or a combination comprising at least one of the foregoing acids, isophthaloyl dichloride, terephthaloyl dichloride, or a combination comprising at least one of the foregoing dichlorides can be used.
[0031] In addition to the polycarbonates described above, combinations of the polycarbonate with other thermoplastic polymers, for example combinations of
homopolycarbonates and/or polycarbonate copolymers with polyesters, can be used.
Polyesters can have repeating units of formula (7), which include poly(alkylene
dicarboxylates), liquid crystalline polyesters, and polyester copolymers. The polyesters described herein are generally completely miscible with the polycarbonates when blended.
[0032] Polyesters can be obtained by interfacial polymerization or melt-process condensation as described above, by solution phase condensation, or by transesterification polymerization wherein, for example, a dialkyl ester such as dimethyl terephthalate can be transesterified with ethylene glycol using acid catalysis, to generate poly(ethylene
terephthalate). A branched polyester, in which a branching agent, for example, a glycol having three or more hydroxyl groups or a trifunctional or multifunctional carboxylic acid has been incorporated, can be used. Furthermore, it can be desirable to have various concentrations of acid and hydroxyl end groups on the polyester, depending on the ultimate end use of the composition.
[0033] Polyesters can include aromatic polyesters, poly(alkylene esters) including poly(alkylene arylates), and poly(cycloalkylene diesters). Aromatic polyesters can have a polyester structure according to formula (7), wherein J and T are each aromatic groups as described hereinabove. Aromatic polyesters can include, for example, poly(isophthalate- terephthalate-resorcinol) esters, poly(isophthalate-terephthalate-bisphenol A) esters, poly[(isophthalate-terephthalate-resorcinol) ester-co-(isophthalate-terephthalate-bisphenol A)] ester, or a combination comprising at least one of these. Also contemplated are aromatic polyesters with a minor amount, e.g., 0.5 to 10 weight percent, based on the total weight of the polyester, of units derived from an aliphatic diacid and/or an aliphatic polyol to make copolyesters. Poly(alkylene arylates) can have a polyester structure according to formula (7), wherein T comprises groups derived from aromatic dicarboxylates, cycloaliphatic
dicarboxylic acids, or derivatives thereof. Examples of T groups include 1,2-, 1,3-, and 1,4- phenylene; 1,4- and 1,5- naphthylenes; cis- or trans- 1,4-cyclohexylene; and the like.
Specifically, where T is 1,4-phenylene, the poly(alkylene arylate) is a poly(alkylene terephthalate). In addition, for poly(alkylene arylate), specific alkylene groups J include, for example, ethylene, 1,4-butylene, and bis-(alkylene-disubstituted cyclohexane) including cis- and/or trans-l,4-(cyclohexylene)dimethylene. Examples of poly(alkylene terephthalates) include poly(ethylene terephthalate) (PET), poly( 1,4-butylene terephthalate) (PBT), and poly(propylene terephthalate) (PPT). Other examples include poly(alkylene naphthoates), such as poly(ethylene naphthanoate) (PEN), and poly(butylene naphthanoate) (PBN). A specifical poly(cycloalkylene diester) is poly(cyclohexanedimethylene terephthalate) (PCT). Combinations comprising at least one of the foregoing polyesters are also contemplated.
[0034] Copolymers comprising alkylene terephthalate repeating ester units with other ester groups can also be used. Specific ester units can include different alkylene terephthalate units, which can be present in the polymer chain as individual units, or as blocks of poly(alkylene terephthalates). copolymers of this type include poly(cyclohexanedimethylene terephthalate)-co-poly(ethylene terephthalate), abbreviated as PETG where the polymer comprises greater than or equal to 50 mol of poly(ethylene terephthalate), and abbreviated as PCTG where the polymer comprises greater than 50 mol of poly(l,4- cyclohexanedimethylene terephthalate) .
[0035] Poly(cycloalkylene diester)s can also include poly(alkylene
cyclohexanedicarboxylate)s. Of these, a specific example is poly(l,4-cyclohexane- dimeth aving recurring units of formula (9)
(9)
wherein, as described using formula (7), J is a 1,4-cyclohexanedimethylene group derived from 1,4-cyclohexanedimethanol, and T is a cyclohexane ring derived from
cyclohexanedicarboxylate or a chemical equivalent thereof, and can comprise the cis-isomer, the trans-isomer, or a combination comprising at least one of the foregoing isomers.
[0036] Another type of polycarbonate copolymer is a polysiloxane-polycarbonate copolymer having polydiorganosiloxane blocks comprise repeating structural units of formula (9):
wherein each R is same or different, and is a C1-13 monovalent organic group. For example, R can be a CrC13 alkyl group, CrC13 alkoxy group, C2-Ci3 alkenyl group, C2-Ci3 alkenyloxy group, C3-C6 cycloalkyl group, C3-C6 cycloalkoxy group, C6-C10 aryl group, C6-C10 aryloxy group, C7-Ci3 aralkyl group, C7-Ci3 aralkoxy group, C7-Ci3 alkylaryl group, or C7-Ci3 alkylaryloxy group. Combinations of the foregoing R groups can be used in the same copolymer. R in formula (10) is a divalent Q-Cg aliphatic group. Each M in formula (10) can be the same or different, and can be a halogen, cyano, nitro, Q-Cg alkylthio, Q-Cg alkyl, Ci-Cg alkoxy, C2-Cg alkenyl, C2-Cg alkenyloxy group, C3-Cg cycloalkyl, C3-Cg cycloalkoxy, C6-C10 aryl, C6-C10 aryloxy, C7-Ci2 aralkyl, C7-Ci2 aralkoxy, C7-Ci2 alkylaryl, or C7-Ci2 alkylaryloxy, wherein each n is independently 0, 1, 2, 3, or 4. Although a polysiloxane- polycarbonate copolymer can be included in the composition in some embodiments, it should be noted that inclusion of a polysiloxane-polycarbonate copolymer can have an adverse impact on the transparency of the article, and therefore the thermoplastic composition can be free of polysiloxane-polycarbonate copolymer.
[0037] E in formula (10) is selected so as to provide a desired level of properties such as flame retardance to the thermoplastic composition. The value of E will therefore vary depending on the type and relative amount of each component in the thermoplastic composition. Values for E can be determined by one of ordinary skill in the art without undue experimentation using the guidelines taught herein. Generally, E has an average value of 2 to 1,000, specifically 10 to 100, more specifically 25 to 75. In an embodiment, E has an average value of 40 to 60, and in still another embodiment, E has an average value of 50. Where E is of a lower value, e.g., less than 40, it can be necessary to use a relatively larger amount of the polysiloxane-polycarbonate copolymer. Conversely, where E is of a higher value, e.g., greater than or equal to 40, it can be necessary to use a relatively smaller amount of the polysiloxane-polycarbonate copolymer.
[0038] In an embodiment, M is independently bromo or chloro, a Ci-C3 alkyl group such as methyl, ethyl, or propyl, a Ci-C3 alkoxy group such as methoxy, ethoxy, or propoxy, or a C6-C7 aryl group such as phenyl, chlorophenyl, or tolyl; R is a dimethylene,
trimethylene or tetramethylene group; and R is a C1-8 alkyl, haloalkyl such as trifluoropropyl,
cyanoalkyl, or aryl such as phenyl, chlorophenyl or tolyl. In another embodiment, R is methyl, or a combination of methyl and trifluoropropyl, or a combination of methyl and phenyl. In still another embodiment, M is methoxy, n is one, R is a divalent C1-C3 aliphatic group, and R is methyl.
[0039] The polysiloxane-polycarbonate copolymer can be manufactured by reaction of the corresponding dihydroxy polysiloxane with a carbonate source and a dihydroxy aromatic compound of formula (3), optionally in the presence of a phase transfer catalyst as described above. Conditions are similar to those used in forming polycarbonates.
Alternatively, the polysiloxane-polycarbonate copolymers can be prepared by co-reacting in a molten state, the dihydroxy monomers and a diaryl carbonate ester, such as diphenyl carbonate, in the presence of a transesterification catalyst as described above. Generally, the amount of dihydroxy polydiorganosiloxane is selected so as to produce a copolymer comprising 1 to 60 mole percent of polydiorganosiloxane blocks, and more generally, 3 to 50 mole percent of polydiorganosiloxane blocks. When present, the polysiloxane-polycarbonate copolymer can be used in amounts of 5 to 50 parts by weight (pbw), more specifically 10 to 40 parts by weight, based on 100 parts by weight of the total parts of resin and impact modifier in the thermoplastic composition.
[0040] In addition to the above-described components, the thermoplastic composition can include various additives ordinarily incorporated into polymer compositions of this type, with the proviso that the additive(s) are selected so as to not significantly adversely affect the desired properties of the thermoplastic composition, in particular the above-described light transmittance, color properties, HDT, and impact resistance properties. Such additives can be mixed at an appropriate time during the mixing of the components for forming the composition. Additives include impact modifiers, reinforcing agents, antioxidants, heat stabilizers, light stabilizers (including ultraviolet (UV) light stabilizers), plasticizers, lubricants, mold release agents, antistatic agents, colorants such as such as titanium dioxide, carbon black, and organic dyes, surface effect additives, radiation stabilizers, flame retardants, and anti-drip agents. A combination of additives can be used, as is known in the art. In general, the additives are used in the amounts generally known to be effective. The total amount of additives is generally 0.01 to 5 weight percent (wt.%), based on the total weight of the composition.
[0041] Antioxidant additives include organophosphites such as tris(nonyl
phenyl)phosphite, tris(2,4-di-t-butylphenyl)phosphite, bis(2,4-di-t-
butylphenyl)pentaerythritol diphosphite, distearyl pentaerythritol diphosphite; alkylated monophenols or polyphenols; alkylated reaction products of polyphenols with dienes, such as tetrakis[methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate)] methane; butylated reaction products of para-cresol or dicyclopentadiene; alkylated hydroquinones; hydroxylated thiodiphenyl ethers; alkylidene-bisphenols; benzyl compounds; esters of beta-(3,5-di-tert- butyl-4-hydroxyphenyl)-propionic acid with monohydric or polyhydric alcohols; esters of beta-(5-tert-butyl-4-hydroxy-3-methylphenyl)-propionic acid with monohydric or polyhydric alcohols; esters of thioalkyl or thioaryl compounds such as distearylthiopropionate, dilaurylthiopropionate, ditridecylthiodipropionate, octadecyl-3-(3,5-di-tert-butyl-4- hydroxyphenyl)propionate, pentaerythrityl-tetrakis[3-(3,5-di-tert-butyl-4- hydroxyphenyl)propionate; amides of beta-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid, or combinations comprising at least one of the foregoing antioxidants. Antioxidants are used in amounts of 0.01 to 0.1 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
[0042] Heat stabilizer additives include organophosphites such as triphenyl phosphite, tris-(2,6-dimethylphenyl)phosphite, tris-(mixed mono-and di-nonylphenyl)phosphite;
phosphonates such as dimethylbenzene phosphonate, phosphates such as trimethyl phosphate, or combinations comprising at least one of the foregoing heat stabilizers. Heat stabilizers are used in amounts of 0.01 to 0.1 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
[0043] Light stabilizers, including ultraviolet light (UV) absorbers, can also be used. Light stabilizers include benzotriazoles such as 2-(2-hydroxy-5-methylphenyl)benzotriazole and 2-(2-hydroxy-5-tert-octylphenyl)-benzotriazole, 2-hydroxy-4-n-octoxy benzophenone, or combinations comprising at least one of the foregoing light stabilizers. Light stabilizers are used in amounts of 0.01 to 5 parts by weight, based on 100 parts by weight of the
thermoplastic composition, excluding any filler.
[0044] UV absorbing additives include hydroxybenzophenones;
hydroxybenzotriazoles; hydroxybenzotriazines; cyanoacrylates; oxanilides; benzoxazinones; 2- (2H-benzotriazol-2-yl)-4-(l,l,3,3-tetramethylbutyl)-phenol (CYASORB* 5411); 2- hydroxy-4-n-octyloxybenzophenone (CYASORB* 531); 2-[4,6-bis(2,4-dimethylphenyl)- l,3,5-triazin-2-yl]- 5-(octyloxy)-phenol (CYASORB* 1164); 2,2' -(1,4- phenylene)bis(4H-
3.1- benzoxazin-4-one) (CYASORB* UV-3638); l,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-
2.2- bis[[(2-cyano-3, 3 -diphenylacryloyl)oxy] methyl] propane (UVINUL* 3030); 2,2'-(l,4-
phenylene) bis(4H-3,l-benzoxazin-4-one); l,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy] -2,2- bis[[(2-cyano-3,3-diphenylacryloyl)oxy]methyl]propane; phenol, 2-(2H-benzotriazol-2-yl)- 4,6-bis(l -methyl- 1- phenylethyl)- (TINUVIN* 234); BCAP bismalonate from Clariant; nano- size inorganic materials such as titanium oxide, cerium oxide, and zinc oxide, all with particle size less than or equal to 100 nanometers;, or combinations comprising at least one of the foregoing UV absorbers. UV absorbers are used in amounts of 0.01 to 5 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
[0045] Plasticizers, lubricants, and/or mold release agents can also be used. There is considerable overlap among these types of materials, which include phthalic acid esters such as dioctyl-4,5-epoxy-hexahydrophthalate; tris-(octoxycarbonylethyl)isocyanurate; tristearin; di- or polyfunctional aromatic phosphates such as resorcinol tetraphenyl diphosphate (RDP), the bis(diphenyl) phosphate of hydroquinone and the bis(diphenyl) phosphate of bisphenol A; poly-alpha-olefins; epoxidized soybean oil; silicones, including silicone oils; esters, for example, fatty acid esters such as alkyl stearyl esters, e.g., methyl stearate, stearyl stearate, pentaerythritol tetrastearate, and the like; combinations of methyl stearate and hydrophilic and hydrophobic nonionic surfactants comprising polyethylene glycol polymers,
polypropylene glycol polymers, poly(ethylene glycol-co-propylene glycol) copolymers, or a combination comprising at least one of the foregoing glycol polymers, e.g., methyl stearate and polyethylene-polypropylene glycol copolymer in a solvent; waxes such as beeswax, montan wax, and paraffin wax. Such materials are used in amounts of 0.1 to 1 parts by weight, based on 100 parts by weight of the total composition.
[0046] Colorants can be added to the thermoplastic composition to achieve specifically targeted color space values within the limits specified hereinabove. Colorants include, for example, anthraquinones, perylenes, perinones, indanthrones, quinacridones, xanthenes, oxazines, oxazolines, thioxanthenes, indigoids, thioindigoids, naphtalimides, cyanines, xanthenes, methines, lactones, coumarins, bis-benzoxaxolylthiophenes (BBOT), napthalenetetracarboxylic derivatives, monoazo and disazo pigments, triarylmethanes, aminoketones, bis(styryl)biphenyl derivatives, and the like, as well as combinations comprising at least one of the foregoing colorants. The amount of colorant depends on the target color properties for the article, the spectral absorbance properties of the colorant(s), and the intrinsic color properties of the polycarbonate and any other materials or additives in the thermoplastic composition. The amount can vary, provided that it is kept below the level at which transmittance of the article would fall below the 85% level disclosed herein.
Exemplary amounts can range from 0.00005 to 0.01 parts by weight per 100 parts by weight of polycarbonate resin and any impact modifier.
[0047] Specific exemplary colorants include organic dyes such as coumarin 460 (blue), coumarin 6 (green), nile red or the like; lanthanide complexes; hydrocarbon and substituted hydrocarbon dyes; polycyclic aromatic hyrdocarbons; scintillation dyes
(preferably oxazoles and oxadiazoles); aryl- or heteroaryl-substituted poly (2-8 olefins); carbocyanine dyes; phthalocyanine dyes and pigments; oxazine dyes; carbostyryl dyes;
porphyrin dyes; acridine dyes; anthraquinone dyes; arylmethane dyes; azo dyes; diazonium dyes; nitro dyes; quinone imine dyes; tetrazolium dyes; thiazole dyes; perylene dyes, perinone dyes; bis-benzoxazolylthiophene (BBOT); and xanthene dyes; fluorophores such as anti- stokes shift dyes which absorb in the near infrared wavelength and emit in the visible wavelength, or the like; luminescent dyes such as 5-amino-9- diethyliminobenzo(a)phenoxazonium perchlorate; 7-amino-4-methylcarbostyryl; 7-amino-4- methylcoumarin; 7-amino-4-trifluoromethylcoumarin; 3-(2'-benzimidazolyl)-7-N,N- diethylaminocoumarin; 3-(2'-benzothiazolyl)-7-diethylaminocoumarin; 2-(4-biphenylyl)-5- (4-t-butylphenyl)-l,3,4-oxadiazole; 2-(4-biphenylyl)-5-phenyl-l,3,4-oxadiazole; 2-(4- biphenyl)-6-phenylbenzoxazole-l,3; 2,5-Bis-(4-biphenylyl)-l,3,4-oxadiazole; 2,5-bis-(4- biphenylyl)-oxazole; 4,4'-bis-(2-butyloctyloxy)-p-quaterphenyl; p-bis(o-methylstyryl)- benzene; 5,9-diaminobenzo(a)phenoxazonium perchlorate; 4-dicyanomethylene-2-methyl-6- (p-dimethylaminostyryl)-4H-pyran; l,l'-diethyl-2,2'-carbocyanine iodide; l,l'-diethyl-4,4'- carbocyanine iodide; 3,3'-diethyl-4,4',5,5'-dibenzothiatricarbocyanine iodide; l,l'-diethyl- 4,4'-dicarbocyanine iodide; l,l'-diethyl-2,2'-dicarbocyanine iodide; 3,3'-diethyl-9,l l - neopentylenethiatricarbocyanine iodide; l,3'-diethyl-4,2'-quinolyloxacarbocyanine iodide; 1 ,3'-diethyl-4,2'-quinolylthiacarbocyanine iodide; 3-diethylamino-7- diethyliminophenoxazonium perchlorate; 7-diethylamino-4-methylcoumarin; 7-diethylamino- 4-trifluoromethylcoumarin; 7-diethylaminocoumarin; 3,3'-diethyloxadicarbocyanine iodide; 3,3'-diethylthiacarbocyanine iodide; 3,3'-diethylthiadicarbocyanine iodide; 3,3'- diethylthiatricarbocyanine iodide; 4,6-dimethyl-7-ethylaminocoumarin; 2,2'-dimethyl-p- quaterphenyl; 2,2-dimethyl-p-terphenyl; 7-dimethylamino-l -methyl-4-methoxy-8- azaquinolone-2; 7-dimethylamino-4-methylquinolone-2; 7-dimethylamino-4- trifluoromethylcoumarin ; 2- (4- (4-dimethylaminophenyl) -1,3 -butadienyl)- 3 - ethylbenzothiazolium perchlorate; 2-(6-(p-dimethylaminophenyl)-2,4-neopentylene-l,3,5- hexatrienyl)-3- methylbenzothiazolium perchlorate; 2-(4-(p-dimethylaminophenyl)-l,3-
butadienyl)- 1 ,3,3-trimethyl-3H-indolium perchlorate; 3,3'-dimethyloxatricarbocyanine iodide; 2,5-diphenylfuran; 2,5-diphenyloxazole; 4,4'-diphenylstilbene; l-ethyl-4-(4-(p- dimethylaminophenyl)-l,3-butadienyl)-pyridinium perchlorate; l-ethyl-2-(4-(p- dimethylaminophenyl)-l,3-butadienyl)-pyridinium perchlorate; l-Ethyl-4-(4-(p- dimethylaminophenyl)- 1 ,3-butadienyl)-quinolium perchlorate; 3-ethylamino-7-ethylimino- 2,8-dimethylphenoxazin-5-ium perchlorate; 9-ethylamino-5-ethylamino-10-methyl-5H- benzo(a) phenoxazonium perchlorate; 7-ethylamino-6-methyl-4-trifluoromethylcoumarin; 7- ethylamino-4-trifluoromethylcoumarin; l, ,3,3,3',3'-hexamethyl-4,4',5,5'-dibenzo-2,2'- indotricarboccyanine iodide; l, ,3,3,3',3'-hexamethylindodicarbocyanine iodide;
l, ,3,3,3',3'-hexamethylindotricarbocyanine iodide; 2-methyl-5-t-butyl-p-quaterphenyl; N- methyl-4-trifluoromethylpiperidino-<3,2-g>coumarin; 3-(2'-N-methylbenzimidazolyl)-7- Ν,Ν-diethylaminocoumarin; 2-(l -naphthyl)-5-phenyloxazole; 2,2'-p-phenylen-bis(5- phenyloxazole); 3,5,3"",5""-tetra-t-butyl-p-sexiphenyl; 3,5,3"",5""-tetra-t-butyl-p- quinquephenyl; 2,3,5,6- lH,4H-tetrahydro-9-acetylquinolizino-<9,9a,l-gh>coumarin; 2,3,5,6- lH,4H-tetrahydro-9-carboethoxyquinolizino-<9,9a,l-gh> coumarin; 2,3,5,6-lH,4H- tetrahydro-8-methylquinolizino-<9,9a, l-gh> coumarin; 2,3,5, 6-lH,4H-tetrahydro-9-(3- pyridyl)-quinolizino-<9,9a,l-gh> coumarin; 2,3,5,6- lH,4H-tetrahydro-8- trifluoromethylquinolizino-<9,9a,l-gh> coumarin; 2,3,5,6- lH,4H-tetrahydroquinolizino- <9,9a,l-gh>coumarin; 3,3',2",3"'-tetramethyl-p-quaterphenyl; 2,5,2"",5"'-tetramethyl-p- quinquephenyl; P-terphenyl; P-quaterphenyl; nile red; rhodamine 700; oxazine 750;
rhodamine 800; IR 125; IR 144; IR 140; IR 132; IR 26; IR5; diphenylhexatriene;
diphenylbutadiene; tetraphenylbutadiene; naphthalene; anthracene; 9,10-diphenylanthracene; pyrene; chrysene; rubrene; coronene; phenanthrene or the like, 3-hydroxyflavones such as disclosed in US 2009/0054586 Al, or combinations comprising at least one of the foregoing dyes.
[0048] The thermoplastic composition disclosed herein can include flame retardants in addition to the above-described perfluoroalkyl sulfonate salt and cyclic siloxane compound. Notwithstanding that, in some exemplary embodiments described herein, such additional flame retardants are not needed. Therefore, in an exemplary embodiment the flame retardant additives used in the thermoplastic composition consist essentially of the perfluoroalkyl sulfonate salt and cyclic siloxane compound. In another exemplary embodiment, the flame retardant additives used in the thermoplastic composition consist of the perfluoroalkyl sulfonate salt and cyclic siloxane compound. If additional flame retardants
are used, possible candidates include organic compounds that include phosphorus, bromine, and/or chlorine. Non-brominated and non-chlorinated phosphorus-containing flame retardants can be preferred in certain applications for regulatory reasons, for example organic phosphates and organic compounds containing phosphorus-nitrogen bonds.
[0049] Flame retardant aromatic phosphates include triphenyl phosphate, tricresyl phosphate, isopropylated triphenyl phosphate, phenyl bis(dodecyl) phosphate, phenyl bis(neopentyl) phosphate, phenyl bis(3,5,5'-trimethylhexyl) phosphate, ethyl diphenyl phosphate, 2-ethylhexyl di(p-tolyl) phosphate, bis(2-ethylhexyl) p-tolyl phosphate, tritolyl phosphate, bis (2-ethylhexyl) phenyl phosphate, tri(nonylphenyl) phosphate, bis(dodecyl) p- tolyl phosphate, dibutyl phenyl phosphate, 2-chloroethyl diphenyl phosphate, p-tolyl bis(2,5,5'-trimethylhexyl) phosphate, and 2-ethylhexyl diphenyl phosphate. Other flame retardants include di- or polyfunctional aromatic phosphorus-containing compounds, for example resorcinol tetraphenyl diphosphate (RDP), the bis(diphenyl) phosphate of hydroquinone and the bis(diphenyl) phosphate of bisphenol A, respectively, and their oligomeric and polymeric counterparts. Flame retardant compounds containing phosphorus- nitrogen bonds include phosphonitrilic chloride, phosphorus ester amides, phosphoric acid amides, phosphonic acid amides, phosphinic acid amides, and tris(aziridinyl) phosphine oxide. When used, phosphorus-containing flame retardants are present in amounts of 0.1 to 30 parts by weight, more specifically 1 to 20 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
[0050] Halogenated materials can also be used as flame retardants, for example bisphenols of which the following are representative: 2,2-bis-(3,5-dichlorophenyl)-propane; bis-(2-chlorophenyl)-methane; bis(2,6-dibromophenyl)-methane; l,l-bis-(4-iodophenyl)- ethane; l,2-bis-(2,6-dichlorophenyl)-ethane; l,l-bis-(2-chloro-4-iodophenyl)ethane; 1,1-bis- (2-chloro-4-methylphenyl)-ethane; l,l-bis-(3,5-dichlorophenyl)-ethane; 2,2-bis-(3-phenyl-4- bromophenyl) -ethane; 2,6-bis-(4,6-dichloronaphthyl)-propane; and 2,2-bis-(3,5-dichloro-4- hydroxyphenyl)-propane 2,2 bis-(3-bromo-4-hydroxyphenyl)-propane. Other halogenated materials include 1,3-dichlorobenzene, 1,4-dibromobenzene, l,3-dichloro-4-hydroxybenzene, and biphenyls such as 2,2'-dichlorobiphenyl, polybrominated 1,4-diphenoxybenzene, 2,4'- dibromobiphenyl, and 2,4'-dichlorobiphenyl as well as decabromo diphenyl oxide, as well as oligomeric and polymeric halogenated aromatic compounds, such as a copolycarbonate of bisphenol A and tetrabromobisphenol A and a carbonate precursor, e.g., phosgene. Metal synergists, e.g., antimony oxide, can also be used with the flame retardant. When present,
halogen containing flame retardants are present in amounts of 1 to 25 parts by weight, more specifically 2 to 20 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
[0051] Alternatively, the thermoplastic composition can be essentially free of chlorine and bromine. "Essentially free of chlorine and bromine" is defined as having a bromine and/or chlorine content of less than or equal to 100 parts per million by weight (ppm), less than or equal to 75 ppm, or less than or equal to 50 ppm, based on the total parts by weight of the composition, excluding any filler.
[0052] Salt-based flame retardants in addition to the perfluoroalkyl sulfonate salt can also be used, for example salts of C1-16 alkyl sulfonate salts such as potassium
diphenylsulfone sulfonate; salts such as Na2C03, K2C03, MgC03, CaC03, and BaC03, or fluoro-anion complexes such as Li3AlF6, BaSiF6, KBF4, K3A1F6, KalF4, K2SiF6, and/or Na3AlF6. When present, flame retardant salts are present in amounts of 0.01 to 10 parts by weight, more specifically 0.02 to 1 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
[0053] As described above, the thermoplastic composition comprises 1-50 mole % of carbonate units according to formula (I) and 50-99 mole of carbonate units according to formula (II), based on the total number of carbonate units in the thermoplastic composition. In more specific embodiments, the thermoplastic composition comprises 10-50 mole % of carbonate units according to formula (I) and 50-90 mole of carbonate units according to formula (II), and even more specifically 20-45 mole % of carbonate units according to formula (I) and 55-80 mole of carbonate units according to formula (II). The specified carbonate unit content for the thermoplastic composition can be provided by any combination of homopolycarbonate(s) based on units of formula (I), co-polycarbonates containing units of formula (I) and carbonate units of formula (II), co-polymers containing units of formula (I) and other copolymerizable units such as ester units, and/or homopolycarbonates, co- polycarbonates or other co-polymers containing carbonate units of formula (II) but not formula (I). Although the thermoplastic composition's specified carbonate content of formula (I) and formula (II) carbonate units can be provided by a single co-polycarbonate containing units of formulas (I) and (II), blends of polycarbonates are often used to achieve desired performance properties such as MFR, glass transition temperature, etc. Accordingly, in some embodiments, the specified carbonate unit content is provided by a blend of a first polycarbonate comprising units of formula (I) (which can also contain carbonate units of
formula (II)) and a second polycarbonate comprising units of formula (II). The first and second polycarbonates can be blended by melt blending techniques well-known in the art. In some embodiments, the first polycarbonate comprises 10-70 mole % of units of formula (I), more specifically from 20-45 mole % of units of formula (I), based on the total number of carbonate units in the first polymer, with the balance of carbonate units in the first polycarbonate chosen according to formula (II). The first polycarbonate can be present in the thermoplastic composition in amounts of 5 wt.% to 95 wt.%, more specifically from 10 wt.% to 50 wt.%, and even more specifically from 20 wt.% to 45 wt.%, based on the total weight of polycarbonate in the thermoplastic composition. The second polycarbonate can be present in the thermoplastic composition in amounts of 95 wt.% to 5 wt.%, more specifically from 50 wt.% to 90 wt.%, and even more specifically from 55 wt.% to 80 wt.%, based on the total weight of polycarbonate in the thermoplastic composition.
[0054] The first and second polymers can have an intrinsic viscosity, as determined in chloroform at 25 °C, of 0.3 to 1.5 deciliters (dl) per gram (g), specifically 0.45 to 1.0 dl/g. The first and second polymers can have a molecular weight of 10,000 to 200,000 Daltons, specifically 20,000 to 100,000 Daltons. In some embodiments, the first polycarbonate can have a weight average molecular weight of 10,000 to 35,000, more specifically 20,000 to 30,000, and the second polycarbonate can have a weight average molecular weight of 18,000 to 32,000, more specifically 18,000 to 20,000, as determined by gel permeation
chromatography using a crosslinked styrene-divinylbenzene column and calibrated to polycarbonate references.
[0055] The thermoplastic composition comprises an acid additive in an amount of 0.1 to 10 ppm by weight, specifically from 1 to 6 ppm by weight, and more specifically 3 to 5 ppm by weight. The acid additive can be any Arrhenius acid (i.e., protic acid), more specifically any acid with a pKa of less than or equal to about 5 (measured in water). In some embodiments, the acid is a stronger acid, i.e., an acid having a pKa (measured in water) of less or equal to about 2, specifically about 2 to about -1. In some embodiments, a weaker acid, i.e., having a pKa (measured in water) of greater than about 2, specifically greater than about 2 to about 4.5, has a stronger effect on both molding and heat aging. If a stronger acid is used, a lower amount may be used compared to if a weaker acid is used. In one
embodiment, a stronger acid having a pKa of less than 2 is used; in other embodiments, a weaker acid having a pKa of greater than 2 is used. In some embodiments, an acid having a pKa of less than 4.5 is used. Acid stabilizers can include phosphoric acid, phosphorous acid,
hypophosphorous acid, C6-3o aryl, C7_3o aralkyl or Ci_3o phosphonic acids, sulfurous acids, C6- 30 aryl, C7_3o aralkyl or Ci_3o alkyl sulfonic acids, ammonium salts of sulfuric acids, halogenated carboxylic acids such as, for example, trifluoroacetic acid, trichloroacetic acid, and the like. In an exemplary embodiment, a weaker acid is phosphorous acid, and a stronger acid is p-toluenesulfonic acid. In some embodiments, the acid additive is a phosphorous- containing additive, more specifically phosphorous acid, hypophosphorous acid, or phosphoric acid, even more specifically phosphorous acid. Epoxy additives such as epoxy- modified acrylic oligomers or polymers can also be included as is known in the art; however, it has been discovered that for the thermoplastic compositions described herein, epoxy additives surprisingly can have a detrimental effect on molecular weight retention.
Accordingly, in some embodiments the thermoplastic composition is free of epoxy additive.
[0056] The thermoplastic compositions can be manufactured by various methods. For example, powdered polycarbonate and phosphorous acid modifier, along with any impact modifier and/or other optional components are first blended, optionally with fillers in a HENSCHEL-Mixer high speed mixer. Other low shear processes, including but not limited to hand mixing, can also accomplish this blending. The blend is then fed into the throat of a twin-screw extruder via a hopper. Alternatively, at least one of the components can be incorporated into the composition by feeding directly into the extruder at the throat and/or downstream through a sidestuffer. Additives can also be compounded into a masterbatch with a desired polymeric resin and fed into the extruder. The extruder is generally operated at a temperature higher than that necessary to cause the composition to flow. The extrudate is immediately quenched in a water batch and pelletized. The pellets, so prepared, when cutting the extrudate can be one-fourth inch long or less as desired. Such pellets can be used for subsequent molding, shaping, or forming.
[0057] Transparent compositions can be produced by manipulation of the process used to manufacture the polycarbonate composition. One example of such a process to produce transparent polycarbonate compositions is described in U.S. Patent Application No. 2003/0032725.
[0058] The thermoplastic composition can have flow properties for the manufacture of thin articles. Melt flow rate (often abbreviated MFR) measures the rate of extrusion of a thermoplastic through an orifice at a prescribed temperature and load. Thermoplastic compositions for the formation of thin articles can have an MFR, measured at 330°C/2.16 kg, of at least 12 grams per 10 minutes (g/10 min). In another exemplary embodiment, the MFR
ranges from 10 to 20 g/10 min. Combinations of polycarbonates of different flow properties can be used to achieve the overall desired flow property.
[0059] The thermoplastic composition used to form the plastic article described herein has a heat deflection temperature (HDT) of at least 160°C, more specifically from 160°C to 165°C, measured under a load of 0.45 MPa according to ASTM D648-06, with a test sample having a thickness of 3.2 mm.
[0060] The thermoplastic composition used to form the plastic article described herein can also have a Notched Izod Impact (Nil) of at least 50 (Joules per meter) J/m, more specifically 50 J/m to 150 J/m, even more specifically from 80 J/m to 150 J/m, and even more specifically from 90 J/m to 120 J/m, determined according to ASTM D256-05 at 23°C using a 2.27 kg weight with a test sample having a thickness of 3.2 mm.
[0061] The thermoplastic composition used to form the plastic article described herein has a light transmittance of at least 85%, more specifically at least 86%, and can be as high as 90%, when tested in the form of a 3.2 mm thick test sample molded at 580°F (304°C) with a 1.7 minute residence time according to ASTM D 1003-00 using procedure A and CIE illuminant C.
[0062] Transparency can be characterized by transmittance and/or by haze levels, so the article can also have a haze of less than 4%, more specifically less than 2%, i.e., from 0% to 2%, wherein haze is measured on a CE7000A in accordance with ASTM D-1003-97, with a 3.2 mm thick test sample molded at 580°F (304°C) (barrel temperature) with a 1.7 minute residence time.
[0063] The thermoplastic composition used to form the plastic article described herein has CIE 1976 L*, a*, b* values determined according to ASTM E308-08. The CIE 1976 L* value is greater than 92, more specifically greater than 94, and can range as high as 98. The CIE 1976 a* value is between -1.5 and +1.5, more specifically between -0.72 and -0.12, and even more specifically between -0.70 and -0.20. The CIE 1976 b* value is between -2.0 and 3.0, more specifically between 0.2 and 1.3, and even move specifically between 0.3 and 1.2, when tested in the form of a 3.2 mm thick test sample molded at 580°F (304°C) with a 1.7 minute residence time, using CIE illuminant C and 2 degree observer. Test samples can be molded from pellets that have been cooled and stored, followed by drying at an elevated temperature (e.g., 8 hours at 140°C). For testing during commercial scale production, test samples can be molded from still-hot pellets taken directly from an extruder. In some cases, there may be some color variance between test samples molded
from fresh hot pellets versus stored pellets that have been heat-dried; however, it is within the skill of the art to make adjustments to the formulation (e.g., by modifying the tinting colorants) to produce a target color produced by stored pellets. The thermoplastic composition can have a yellowness index (YI), measure in accordance with ASTM D1925- 95, of less than 6 when tested with a 3.2 mm thick test sample molded at 580°F (304°C) with a 1.7 minute residence time. The thermoplastic composition used to form the plastic article described herein provides color properties that are surprisingly tolerant of adverse molding conditions such as longer mold retention times. In some embodiments, the b* value differs by less than 0.7, more specifically less than 0.5, if the molding residence time is changed from 1.7 minutes to 6.8 minutes.
[0064] Adverse molding conditions, as the term is used herein, includes subjecting the thermoplastic composition to high residence times, high temperatures, or both high residence times and high temperatures. Residence time, as used herein, is the average amount of time a thermoplastic composition spends in molten form in the heated barrel of an injection molding machine before entering a mold. Residence time can be mathematically characterized by a formula where residence time equals the cycle time used multiplied the mass or volume capacity of the barrel divided by the mass or volume capacity of the mold cavity. In some embodiments, adverse molding conditions can include residence times of at least 4 minutes, more specifically at least 5 minutes, more specifically at least 6 minutes, more specifically at least 7 minutes, more specifically at least 8 minutes, more specifically at least 9 minutes, and more specifically at least 10 minutes. In some embodimentsThe temperature to which the thermoplastic composition is heated in the barrel of the injection molding device can be at least 600°F (316°C), more specifically at least 610°F (321°C), and even more specifically at least 620°F (327°C)°C. The above conditions are characterized as average residence time and average barrel temperature; however, adverse molding conditions can also involve exposing only portions of the thermoplastic composition to such high residence times and/or high temperatures, such as when the design of the injection molding device leads to areas of the barrel where the thermoplastic composition gets held up and thus exposed to a longer residence time even if the average residence time may not be elevated. Similarly, the hot spots in the barrel can create adverse molding conditions by exposing a portion of the thermoplastic composition to an elevated temperature even if the average temperature is not elevated.
[0065] The plastic article can be molded into useful shapes by a variety of means such as injection molding, extrusion, rotational molding, blow molding and thermoforming to form articles having a thickness of 0.5 mm to 5 mm, more specifically from 2 mm to 4 mm.
Examples of articles include illumination lenses or covers for light fixtures, motor vehicle headlights, flashlights, image projector lamp lenses, as well as numerous other components for high-temperature applications. Examples of such other components include, but are not limited to windows, viewing portals, electronic device display screens and/or housings, and lenses for various applications such as image or data recording.
Examples of Embodiments
[0066] In an embodiment, a method of making a plastic article comprises:
introducing a thermoplastic composition to the barrel of an injection molding device that comprises a barrel assembly and a mold assembly, the thermoplastic composition comprising:
1 mole % to 50 mole % of carbonate units represented by the formula (I)
2 3 wherein R is hydrogen, a C1-25 hydrocarbyl group, or halogen, and R hydrogen or a Ci-25 hydrocarbyl group,
50 mole % to 99 mole % of carbonate units represented by the formula (II)
O
R1— O C O
in which at least 60 percent of the total number of R1 groups contain aromatic moieties and the balance thereof are aliphatic, alicyclic, or aromatic moieties, with the proviso that the carbonate units of formula (II) are not within the scope of formula (I), the mole percentages of formulas (I) and (II) based on the total number of carbonate units in the thermoplastic composition, and
from 0.1 to 10 ppm by weight of phosphorous acid;
heating the thermoplastic composition in the barrel assembly to a temperature sufficient for injection molding of the thermoplastic composition and injecting a shot of the thermoplastic composition into the mold assembly under adverse molding conditions; and removing a molded article of the thermoplastic composition from the mold assembly.
[0067] In the various embodiments, (i) the adverse molding conditions include subjecting the thermoplastic composition to a residence time in the barrel assembly of at least
5 minutes; and/or (ii) the adverse molding conditions include subjecting the thermoplastic composition to a residence time in the barrel assembly of at least 7 minutes; and/or (iii) the adverse molding conditions include subjecting the thermoplastic composition to a residence time in the barrel assembly of at least 10 minutes; and/or the (iv) the residence time is the mass or volume quantity of thermoplastic composition in the barrel divided by the mass or volume quantity, respectively, of the shot of the thermoplastic composition, multiplied by the cycle time; and/or (v) the adverse molding conditions include heating the thermoplastic composition in the barrel to a temperature of at least 600°F (316°C); and/or (vi) the adverse molding conditions include heating the thermoplastic composition in the barrel to a temperature of at least 610°F (321°C); and/or (vii) the adverse molding conditions include heating the thermoplastic composition in the barrel to a temperature of at least 620°F
(327°C); and/or (viii) the thermoplastic composition has a heat deflection temperature of at least 145°C when tested in the form of a 3.2 mm thick test sample according to ASTM D648-
06 under a load of 0.45 MPa, a light transmittance of at least 85% when tested in the form of a 3.2 mm thick test sample according to ASTM D 1003-00 using procedure A and CIE illuminant C and 2 degree observer on a Macbeth 7000A using an integrating sphere with 8 diffuse geometry, specular component included, UV included, large lens, and large area view, with the percent transmittance value reported as Y (luminous transmittance) taken from the CIE 1931 tristimulus values XYZ, and CIE1976 L*, a*, b* values determined according to ASTM E308-08 of L* greater than 92, a* between -1.5 and 1.5, and b* between -2.0 and 3.0, when tested in the form of a 3.2 mm thick test sample molded at 580°F (304°C) with a 1.7 minute residence time, using CIE illuminant C and 2 degree observer; and/or (ix) the b* value of the thermoplastic composition differs by less than 0.7 when the molding residence time of the test sample is changed from 1.7 minutes to 6.8 minute; and/or (x) the b* value of the thermoplastic composition differs by less than 0.5 when the molding cycle time of the test sample is changed from 1.7 minutes to 6.8 minutes; and/or (xi) R is a C6-io aromatic group;
and/or (xii) R is hydrogen; and/or (iv) the units of formula (II) are derived from bisphenol A; and/or (xiii) the units of formula (I) are derived from 2-phenyl-3,3'-bis(4-hydroxy
phenyl)phthalimidine, and the units of formula (II) are derived from bisphenol A; and/or (xiv) the thermoplastic composition comprises a blend of a first polycarbonate consisting of units of formula (I) and units of formula (II) and a second polycarbonate consisting of units of formula (II); and/or (xv) the thermoplastic composition comprises a blend of a first polycarbonate comprising units of formula (I) and a second polycarbonate comprising units of formula (II); and/or (xvi) the first polycarbonate comprises units of formula (I) and units of formula (II); and/or (xvii) the first polycarbonate comprises from 10 mole % to 70 mole % of units of formula (I) and from 30 mole % to 90 mole % of units of formula (II), based on the total number of carbonate units in the first polymer; and/or (xviii) the second polycarbonate comprises 100 mole % of units of formula (II), based on the total number of carbonate units in the second polycarbonate; and/or (xix) the second polycarbonate has a weight average molecular weight of 18,000 to 32,000, as determined by gel permeation chromatography, using a crosslinked styrene-divinylbenzene column and calibrated to polycarbonate references; and/or (xx) the second polycarbonate has a weight average molecular weight of 18,000 to 20,000, as determined by gel permeation chromatography, using a crosslinked styrene-divinylbenzene column and calibrated to polycarbonate references; and/or (xxi) the thermoplastic composition comprises from 5 wt.% to 95 wt.% of the first polycarbonate and from 95 wt.% to 5 wt.% of the second polycarbonate, based on the total weight of weight of polycarbonate in the thermoplastic composition; and/or (xxii) the thermoplastic composition comprises from 3 to 5 ppm by weight of the acid additive; and/or (xxiii) the acid additive is phosphorous acid, hypophosphorous acid, phosphoric acid, or combinations comprising at least one of the foregoing; and/or (xxiv) the acid additive is phosphorous acid; and/or (xxv) the thermoplastic composition is free of epoxy additive; and/or (xxvi) the weight average molecular weight of the polycarbonate in the thermoplastic composition, as determined by gel permeation chromatography, using a crosslinked styrene-divinylbenzene column and calibrated to polycarbonate references, changes by less than 1500 Daltons from before extrusion to after extrusion at 600°F (316°C); and/or (xxvii) the thermoplastic composition has a yellowness index of less than 6 determined according to ASTM D1925-95 when tested in the form of a 3.2 mm thick test sample molded at 580°F (304°C) with a 1.7 minute residence time; and/or (xxviii) the yellowness index of the test sample changes by less than 4 when the test sample is subjected to aging at 140°C for 1000 hours; and/or (xxix) the
thermoplastic composition has a haze of less than 2% when tested in the form of a 3.2 mm thick test sample molded at 580°F (304°C) with a 1.7 minute residence time according to ASTM D1003-97 using CIE illuminant C; and/or (xxx) the thermoplastic composition has a notched Izod impact strength of at least 50 J/m when tested in the form of a 3.2 mm thick test sample according to ASTM D256-05 at 23°C using a 2.27 kg weight; and/or (xxxii) the thermoplastic composition has CIE 1976 L*, a*, b* values determined according to ASTM E308-08 are L* greater than 94, a* between -0.72 and -0.12, and b* between 0.3 and 1.3, when tested in the form of a 3.2 mm thick test sample molded at 580°F (304°C) with a 1.7 minute residence time, using CIE illuminant C and 2 degree observer; and/or (xxxiii) the thermoplastic composition further comprises from 0.00005 wt.% to 0.01 wt.% of a colorant, based on the weight of the thermoplastic composition; and/or (xxxiv) the article has a thickness of 2 mm to 4 mm; and/or (xxxv) the article is an illumination device lens; and/or (xxxv) the article is a motor vehicle headlight lens or cover.
[0068] The thermoplastic compositions are further illustrated by the following non- limiting examples.
EXAMPLES
[0069] All thermoplastic compositions except where indicated were compounded on a single screw laboratory scale extruder. All ingredients were tumble-blended prior to compound using a single feeder to the extruder. The typical sample size of the extruder is 3 kg. Compositions were compounded and extruded at a temperature of 285 to 330°C and allowed to cool. Test samples were prepared from polymer pellets that had been subject to drying for 8 hours at 140°C. Test measurements were made using the tests and test methods described above.
Preparation 1
[0070] The following ingredients were dry blended and tumbled before being extruded as a thermoplastic composition having an MFR of 30-40 g/10 min at 330°C/2.16 kg and a weight average MW of 22,000 determined by gel permeation chromatography, using a crosslinked styrene-divinylbenzene column and calibrated to polycarbonate references:
• 63.58 wt.% of a co-polycarbonate containing 33 mole % PPPBP and 67 mole % BPA
• 35.56 wt.% of a blend of BPA homopolycarbonates
• 0.27 wt.% UV absorber
• 0.12 oxidative stabilizers
• 0.27 wt.% lubricant
• 0.20 wt.% of a 0.15% solution of phosphorous acid (3 ppm)
• 0.00011 wt.% Solvent Violet 36
• 0.000095 wt.% Pigment Blue 60
Comparative Preparation 2
[0071] A comparison material of BPA polycarbonate homopolymer having an MFR of 7-15 g/10 min at 300°C/1.2kg] and a weight average molecular weight of 27,000 determined by gel permeation chromatography, using a crosslinked styrene-divinylbenzene column and calibrated to polycarbonate references, was used to form comparison articles. Comparative Preparation 3
[0072] The following ingredients, representing Preparation 1 without the phosphorous acid, were dry blended and tumbled before being extruded as a thermoplastic composition having an MFR of 30-40 g/10 min at 330°C/2.16kg and a weight average MW of 22,000 determined by gel permeation chromatography, using a crosslinked styrene-divinylbenzene column and calibrated to polycarbonate references:
• 63.58 wt.% of a co-polycarbonate containing 33 mole % PPPBP and 67 mole % BPA
• 35.76 wt.% of a blend of BPA homopolycarbonates
• 0.27 wt.% UV absorber
• 0.12 oxidative stabilizers
• 0.27 wt.% lubricant
• 0.00011 wt.% Solvent Violet 36
• 0.000095 wt.% Pigment Blue 60
Example 1
[0073] 3.2 mm thick test samples made from Preparation 1 were molded for testing as further described below. Comparison Examples 1 and 2 were prepared by molding 3.2 mm thick test samples from Comparative Preparations 1 and 2 for testing as further described below.
Experiment 1 - Heat Capability Data
[0074] Test samples were measured for glass transition temperature (Tg) and heat deformation temperature (HDT) according to ASTM D648-06 under a load of 0.45 MPa. The results, set forth in Table 1, indicate a significant advantage provided by Example 1.
Table 1
[0075] 3.2 mm test samples were placed in a 140 °C oven for 900 hours. Color measurements were taken of the samples at the times set forth in Table 2, using the ASTM methods described above. The results, set forth in Table 2, show that initial YI values were lower Example 1 than with the comparative examples, and remained lower throughout heat aging. Additionally, the level of increase in YI from aging (ΔΥ) was lower at each sampling stage, meaning that not only did Example start with a lower yellowing index than
Comparative Example 3, but the amount by which it was lower increased with aging, meaning that it was more resistant to yellowing caused by the aging process.
Table 2
Experiment 3 - Color Stability After Oven Aging
[0076] Comparative Examples 4-6 were prepared from the formulation of Preparation 1, but replacing the phosphorous acid with 3 ppm by weight of the following comparison additives: trisnonylphenylphosphite (TNPP) (Comparative Example 4), diphenyl phosphite (Comparative Example 5), diphenyldecyl(isodecyl)phosphite (DPDP) (Comparative Example 6). The samples, along with a second sample of Example 3, were placed in a 140°C oven for 900 hours. Color measurements were taken of the samples at the times set forth in Table 3,
using the ASTM methods described above. The results, set forth in Table 3, show that initial YI values increased at an unacceptable level over the aging period.
Table 3
Experiment 4 - Varying Cycle Time
[0077] 3.2 mm test samples of Example 1 and test samples of Comparative Example 3 were injection molded with a flat-profile barrel temperature of 580°F. The mold temperature was 230 °F. Molding was performed with cycle times of 30 seconds up to 120 seconds to model an increase in mold residence time from 1.7 minutes to 6.8 minutes.
Transmittance and color measurements were taken of the samples using the methods described above. The results, set forth in Table 4, show from the delta values between the 30 second and 120 second cycle times, that the Example 1 provided a significant advantage in tolerance of adverse molding conditions. Specifically, b* increased by 0.16 and YI increased by 0.27 for Comparative Example 3, compared to a b* decrease of 0.01 and a YI decrease of 0.03 for Example 1, showing much greater color stability across a wide range of molding severity for Example 1.
Table 4
Experiment 5 - Varying Cycle Time
[0078] 3.2 mm test samples of Example 1 and Comparative Example 3 were injection molded with a flat-profile barrel temperature of 600°F. The mold temperature was 230°F. Molding was performed with cycle times of 30 seconds up to 120 seconds, resulting in an increase in mold residence time from 1.7 minutes to 6.8 minutes. Transmittance and color measurements were taken of the samples ASTM methods described above. The results, set forth in Table 5, show from the delta values between the 30 second and 120 second cycle times, that the Example 1 provided a significant advantage in tolerance of adverse molding conditions. Specifically, b* increased by 0.32 and YI increased by 0.55 for Comparative Example 3, compared to a b* increase of only 0.14 and a YI increase of only 0.24 for Example 1, showing much greater color stability across a wide range of molding severity for Example 1.
Table 5
Experiment 6 - Varying Cycle Time
[0079] 3.2 mm test samples of Example 1 and Comparative Example 3 were prepared by injection molding with a flat-profile barrel temperature of 620°F. The mold temperature was 230 °F. Molding was performed with cycle times of 30 seconds up to 120 seconds to model an increase in mold residence time from 1.7 minutes to 6.8 minutes. Transmittance and color measurements were taken of the samples ASTM methods described above. The results, set forth in Table 5, show from the delta values between the 30 second and 120 second cycle times, that the Example 1 provided a significant advantage in tolerance of adverse molding conditions. Specifically, b* increased by 0.73 and YI increased by 1.24 for Comparative Example 3, compared to a b* increase of only 0.56 and a YI increase of only 0.94 for Example 1, showing much greater color stability across a wide range of molding severity for Example 1.
Table 6
Experiment 7 - Molecular Weight Change
[0080] Preparation 2 was prepared in the same fashion as Preparation 1, except that it utilized 5 ppm by weight of phosphorous acid. Preparation 3 was prepared in the same fashion as Preparation 2, with the addition of 300 ppm by weight of a commercially available epoxy additive ERL-4221. Comparative Preparation 4 was prepared in the same fashion as Comparative Preparation 3, with the addition of 300 ppm by weight of a commercially available epoxy additive ERL-4221. The materials were tested for molecular weight change observed from before extrusion to after extrusion at 600°F. Samples were screened having no additive (Comparative Preparation 3), phosphorous acid only (Preparation 2), epoxy additive only (Comparative Preparation 4), and phosphorous acid and epoxy additives Preparation 3), with molecular weight being determined as weight average molecular weight as determined by gel permeation chromatography, using a crosslinked styrene-divinylbenzene column and calibrated to polycarbonate references. The results, set forth in Table 7, surprisingly show that the epoxy additive had an adverse impact on molecular weight stability.
Table 7
[0081] The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. "Or" means "and/or". The modifier "about" used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., includes the degree of error associated with measurement of the particular quantity). The notation "+ 10%" means that the indicated measurement can be from an amount that is minus 10% to an amount that is plus 10% of the stated value. The endpoints of all ranges directed to the same component or property are inclusive and independently combinable (e.g., ranges of "less than or equal to 25 wt%, or 5 wt% to 20 wt%," is inclusive of the endpoints and all intermediate values of the ranges of "5 wt% to 25 wt%," etc.). The suffix "(s)" is intended to include both the singular and the plural of the term that it modifies, thereby including at least one of that term (e.g., "the colorant(s)" includes at least one colorant and also more than one colorant). "Optional" or "optionally" means that the subsequently described event or circumstance can or can not occur, and that the description includes instances where the event occurs and instances where it does not.
[0082] As used herein, the term "hydrocarbyl" and "hydrocarbon" refers broadly to a substituent comprising carbon and hydrogen, optionally with 1 to 3 heteroatoms, for example, oxygen, nitrogen, halogen, silicon, sulfur, or a combination thereof; "alkyl" refers to a straight or branched chain, saturated monovalent hydrocarbon group; "alkylene" refers to a straight or branched chain, saturated, divalent hydrocarbon group; "alkylidene" refers to a straight or branched chain, saturated divalent hydrocarbon group, with both valences on a single common carbon atom; "alkenyl" refers to a straight or branched chain monovalent hydrocarbon group having at least two carbons joined by a carbon-carbon double bond;
"cycloalkyl" refers to a non-aromatic monovalent monocyclic or multicylic hydrocarbon
group having at least three carbon atoms, "cycloalkenyl" refers to a non-aromatic cyclic divalent hydrocarbon group having at least three carbon atoms, with at least one degree of unsaturation; "aryl" refers to an aromatic monovalent group containing only carbon in the aromatic ring or rings; "arylene" refers to an aromatic divalent group containing only carbon in the aromatic ring or rings; "alkylaryl" refers to an aryl group that has been substituted with an alkyl group as defined above, with 4-methylphenyl being an exemplary alkylaryl group; "arylalkyl" refers to an alkyl group that has been substituted with an aryl group as defined above, with benzyl being an exemplary arylalkyl group; "acyl" refers to an alkyl group as defined above with the indicated number of carbon atoms attached through a carbonyl carbon bridge (-C(=0)-); "alkoxy" refers to an alkyl group as defined above with the indicated number of carbon atoms attached through an oxygen bridge (-0-); and "aryloxy" refers to an aryl group as defined above with the indicated number of carbon atoms attached through an oxygen bridge (-0-).
[0083] Unless otherwise indicated, each of the foregoing groups can be unsubstituted or substituted, provided that the substitution does not significantly adversely affect synthesis, stability, or use of the compound. The term "substituted" as used herein means that at least one hydrogen on the designated atom or group is replaced with another group, provided that the designated atom's normal valence is not exceeded. When the substituent is oxo (i.e., =0), then two hydrogens on the atom are replaced. Combinations of substituents and/or variables are permissible provided that the substitutions do not significantly adversely affect synthesis or use of the compound. Exemplary groups that can be present on a "substituted" position include, but are not limited to, cyano; hydroxyl; nitro; azido; alkanoyl (such as a C2-6 alkanoyl group such as acyl); carboxamido; Cl-6 or Cl-3 alkyl, cycloalkyl, alkenyl, and alkynyl (including groups having at least one unsaturated linkages and from 2 to 8, or 2 to 6 carbon atoms); Cl-6 or Cl-3 alkoxy groups; C6-10 aryloxy such as phenoxy; Cl-6 alkylthio; Cl-6 or Cl-3 alkylsulfinyl; Cl-6 or Cl-3 alkylsulfonyl; aminodi(Cl-6 or Cl-3)alkyl; C6-12 aryl having at least one aromatic rings (e.g., phenyl, biphenyl, naphthyl, or the like, each ring either substituted or unsubstituted aromatic); C7-19 alkylenearyl having 1 to 3 separate or fused rings and from 6 to 18 ring carbon atoms, with benzyl being an exemplary arylalkyl group; or arylalkoxy having 1 to 3 separate or fused rings and from 6 to 18 ring carbon atoms, with benzyloxy being an exemplary arylalkoxy group.
[0084] All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts
or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.
[0085] While typical embodiments have been set forth for the purpose of illustration, the foregoing descriptions should not be deemed to be a limitation on the scope herein. Accordingly, various modifications, adaptations, and alternatives can occur to one skilled in the art without departing from the spirit and scope herein.
Claims
1. A method of manufacturing a plastic article, comprising:
introducing a thermoplastic composition to the barrel of an injection molding device that comprises a barrel assembly and a mold assembly, the thermoplastic composition comprising:
1 mole % to 50 mole % of carbonate units represented by the formula (I)
2 3 wherein R is hydrogen, a C1-25 hydrocarbyl group, or halogen, and R hydrogen or a C1-25 hydrocarbyl group,
50 mole % to 99 mole % of carbonate units represented by the formula (II)
O
R1— O C O
in which at least 60 percent of the total number of R1 groups contain aromatic moieties and the balance thereof are aliphatic, alicyclic, or aromatic moieties, with the proviso that the carbonate units of formula (II) are not within the scope of formula (I), the mole percentages of formulas (I) and (II) based on the total number of carbonate units in the thermoplastic composition, and
from 0.1 to 10 ppm by weight of phosphorous acid;
heating the thermoplastic composition in the barrel assembly to a temperature sufficient for injection molding of the thermoplastic composition and injecting a shot of the thermoplastic composition into the mold assembly under adverse molding conditions; and
removing a molded article of the thermoplastic composition from the mold assembly.
2. The method of claim 1, wherein the adverse molding conditions include subjecting the thermoplastic composition to a residence time in the barrel assembly of at least 5 minutes.
3. The method of claim 2, wherein the adverse molding conditions include subjecting the thermoplastic composition to a residence time in the barrel assembly of at least 7 minutes.
4. The method of claim 2, wherein the adverse molding conditions include subjecting the thermoplastic composition to a residence time in the barrel assembly of at least 10 minutes.
5. The method of any of claims 2-4, wherein the residence time is the mass or volume quantity of thermoplastic composition in the barrel divided by the mass or volume quantity, respectively, of the shot of the thermoplastic composition, multiplied by the cycle time.
6. The method of any of claims 1-5, wherein the adverse molding conditions include heating the thermoplastic composition in the barrel to a temperature of at least 600°F (316°C).
7. The method of any of claims 1-6, wherein the adverse molding conditions include heating the thermoplastic composition in the barrel to a temperature of at least 610°C (321°C).
8. The method of any of claims 1-7, wherein the adverse molding conditions include heating the thermoplastic composition in the barrel to a temperature of at least 620°C (327°C).
9. The method of any of claims 1-8, wherein the thermoplastic composition has:
a heat deflection temperature of at least 145°C when tested in the form of a 3.2 mm thick test sample according to ASTM D648-06 under a load of 0.45 MPa;
a light transmittance of at least 85% when tested in the form of a 3.2 mm thick test sample according to ASTM D 1003-00 using procedure A and CIE illuminant C and 2 degree observer on a Macbeth 7000A using an integrating sphere with
8 diffuse geometry, specular component included, UV included, large lens, and large area view, with the percent transmittance value reported as Y (luminous
transmittance) taken from the CIE 1931 tristimulus values XYZ; and
CIE1976 L*, a*, b* values determined according to ASTM E308-08 of L* greater than 92, a* between -1.5 and 1.5, and b* between -2.0 and 3.0, when tested in the form of a 3.2 mm thick test sample molded at 580°F (304°C) with a 1.7 minute residence time, using CIE illuminant C and 2 degree observer.
10. The method of 9, wherein the b* value of the thermoplastic
composition differs by less than 0.7 when the molding residence time of the test sample is changed from 1.7 minutes to 6.8 minutes.
11. The method of claim 10, wherein the b* value of the thermoplastic composition differs by less than 0.5 when the molding cycle time of the test sample is changed from 1.7 minutes to 6.8 minutes.
The method of any of claims 1-11, wherein R3 is a C6-io aromatic group.
The method of any of claims 1-12, wherein R is hydi
14. The method of any of claims 1-13, wherein the units of formula (II) are derived from bisphenol A.
15. The method of any of claims 1-13, wherein the units of formula (I) are derived from 2-phenyl-3,3'-bis(4-hydroxy phenyl)phthalimidine, and the units of formula (II) are derived from bisphenol A.
16. The method of claim 15, wherein the thermoplastic composition comprises a blend of a first polycarbonate consisting of units of formula (I) and units of formula (II), and a second polycarbonate consisting of units of formula (II)
17. The method of any of claims 1-14, wherein the thermoplastic composition comprises a blend of a first polycarbonate comprising units of formula (I) and a second polycarbonate comprising units of formula (II).
18. The method of claim 17, wherein the first polycarbonate comprises units of formula (I) and units of formula (II).
19. The method of claim 18, wherein the first polycarbonate comprises from 10 mole % to 70 mole % of units of formula (I), and from 30 mole % to 90 mole % of units of formula (II), based on the total number of carbonate units in the first polycarbonate.
20. The method of any of claims 17-19, wherein the second polycarbonate comprises 100 mole % of units of formula (II), based on the total number of carbonate units in the second polycarbonate
21. The method of any of claims 16-20, wherein the second polycarbonate has a weight average molecular weight of 18,000 to 32,000, as determined by gel permeation chromatography, using a crosslinked styrene-divinylbenzene column and calibrated to polycarbonate references.
22. The method of claim 21, wherein the second polycarbonate has a weight average molecular weight of 18,000 to 20,000, as determined by gel permeation chromatography, using a crosslinked styrene-divinylbenzene column and calibrated to polycarbonate references.
23. The method of any of claims 16-22, wherein the thermoplastic composition comprises from 5 wt.% to 95 wt.% of the first polycarbonate and from 95 wt.% to 5 wt.% of the second polycarbonate, based on the total weight of weight of polycarbonate in the thermoplastic composition.
24. The method of any of claims 1-23, wherein the thermoplastic composition comprises from 3 to 5 ppm by weight of the acid additive.
25. The method of any of claims 1-24, wherein the acid additive is phosphorous acid, hypophosphorous acid, phosphoric acid, or a combination of any of the foregoing.
26. The method of claim 25, wherein the acid additive is phosphorous acid.
27. The method of any of claims 1-26, wherein the thermoplastic composition is free of epoxy additive.
28. The method of any of claims 1-27, wherein the weight average molecular weight of the polycarbonate in the thermoplastic composition, as determined by gel permeation chromatography, using a crosslinked styrene- divinylbenzene column and calibrated to polycarbonate references, changes by less than 1500 Daltons from before extrusion to after extrusion at 600°F (316°C).
29. The method of any of claims 1-28, wherein the thermoplastic composition has a yellowness index of less than 6 determined according to ASTM D1925-95 when tested in the form of a 3.2 mm thick test sample molded at 580°F (304°C) with a 1.7 minute residence time.
30. The method of claim 29, wherein the yellowness index of the test sample changes by less than 4 when the test sample is subjected to aging at 140°C for 1000 hours.
31. The method of any of claims 1-30, wherein the thermoplastic composition has a haze of less than 2% when tested in the form of a 3.2 mm thick test sample molded at 580°F (304°C) with a 1.7 minute residence time according to ASTM D1003-97 using CIE illuminant C.
32. The method of any of claims 1-31, wherein the thermoplastic composition has a notched Izod impact strength of at least 50 J/m when tested in the form of a 3.2 mm thick test sample according to ASTM D256-05 at 23°C using a 2.27 kg weight.
33. The method of any of claims 1-32, wherein the thermoplastic composition has CIE 1976 L*, a*, b* values determined according to ASTM E308-08 are L* greater than 94, a* between -0.72 and -0.12, and b* between 0.3 and 1.3, when tested in the form of a 3.2 mm thick test sample molded at 580°F (304°C) with a 1.7 minute residence time, using CIE illuminant C and 2 degree observer.
34. The method of any of claims 1-33, wherein the thermoplastic composition further comprises from 0.00005 wt.% to 0.01 wt.% of a colorant, based on the weight of the thermoplastic composition.
35. The method of any of claims 1-34, having a thickness of 2 mm to 4 mm.
36. The method of any of claims 1-35, wherein the article is an
illumination device lens.
37. The method of claim 28, wherein the article is a motor vehicle headlight lens or cover.
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US201261691589P | 2012-08-21 | 2012-08-21 | |
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WO2009045791A1 (en) * | 2007-09-28 | 2009-04-09 | Sabic Innovative Plastics I.P. B.V. | High heat polycarbonates, methods of making, and articles formed therefrom |
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WO2009045791A1 (en) * | 2007-09-28 | 2009-04-09 | Sabic Innovative Plastics I.P. B.V. | High heat polycarbonates, methods of making, and articles formed therefrom |
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