WO2016166633A1 - Procédé d'utilisation d'articles comprenant une structure micro-cellulaire et ayant une meilleure performance de vieillissement sous un éclairage à del (bleu) - Google Patents

Procédé d'utilisation d'articles comprenant une structure micro-cellulaire et ayant une meilleure performance de vieillissement sous un éclairage à del (bleu) Download PDF

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WO2016166633A1
WO2016166633A1 PCT/IB2016/051911 IB2016051911W WO2016166633A1 WO 2016166633 A1 WO2016166633 A1 WO 2016166633A1 IB 2016051911 W IB2016051911 W IB 2016051911W WO 2016166633 A1 WO2016166633 A1 WO 2016166633A1
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article
illumination
phosphor
polycarbonate
cells
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PCT/IB2016/051911
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English (en)
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Franciscus Petrus Maria Mercx
Andries Jakobus Petrus Van Zyl
Hendrikus Petrus Cornelis VAN HEERBEEK
Sascha Jan Ter Horst
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Sabic Global Technologies B.V.
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Publication of WO2016166633A1 publication Critical patent/WO2016166633A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0061—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0066—Use of inorganic compounding ingredients
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0095—Mixtures of at least two compounding ingredients belonging to different one-dot groups
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
    • C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
    • C08J9/122—Hydrogen, oxygen, CO2, nitrogen or noble gases
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V7/00—Reflectors for light sources
    • F21V7/22—Reflectors for light sources characterised by materials, surface treatments or coatings, e.g. dichroic reflectors
    • F21V7/24—Reflectors for light sources characterised by materials, surface treatments or coatings, e.g. dichroic reflectors characterised by the material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2203/00—Foams characterized by the expanding agent
    • C08J2203/06—CO2, N2 or noble gases
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2205/00—Foams characterised by their properties
    • C08J2205/04—Foams characterised by their properties characterised by the foam pores
    • C08J2205/044—Micropores, i.e. average diameter being between 0,1 micrometer and 0,1 millimeter
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2205/00—Foams characterised by their properties
    • C08J2205/04—Foams characterised by their properties characterised by the foam pores
    • C08J2205/052—Closed cells, i.e. more than 50% of the pores are closed
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2369/00—Characterised by the use of polycarbonates; Derivatives of polycarbonates
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2383/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen, or carbon only; Derivatives of such polymers
    • C08J2383/10—Block- or graft-copolymers containing polysiloxane sequences
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2469/00—Characterised by the use of polycarbonates; Derivatives of polycarbonates

Definitions

  • the present disclosure relates to the field of reflective cellular materials.
  • LED lights are replacing incandescent and halogen light sources.
  • Some LED light sources have been optimized with respect to lumen/watt output to render them as energy efficient as possible. This may be accomplished, e.g., by using a blue-emitting LED exiting green/yellow phosphors to emit "white" light.
  • Diffuse reflectors are at times combined with LED lights to get a homogenous illumination, particularly for indirect light, or to get a higher efficacy by combining them in the reflector of a spot light.
  • photo-thermal thermal degradation can result in yellowing. After yellowing occurs, the absorption of particular the blue and blue-green light increases, speeding up the degradation (auto-catalytic effect) and leading to catastrophic failure.
  • aging may be the result of exposure of the material to high-intensity blue and long wavelength UV phonons emitted by the LED/phosphor matrix.
  • incandescent or LED lamps in combination with either aluminum or anodized metal (specular) reflectors directing the light towards white plastered/painted walls/ceilings are used or ceramic-coated white reflectors are used in illumination applications.
  • white diffuse reflecting polymers is growing. Accordingly, there is a need in the art for reflective articles having improved aging performance under blue LED illumination.
  • the present disclosure first provides articles, comprising: a region having a cellular structure comprising a plurality of cells, the plurality of cells having a number-average cross-sectional dimension in the range of from about 0.3 micrometers up to about 100 micrometers, and the article having a YI of less than 15 upon exposure for 100 hours to 35 kW/m 2 .
  • the present disclosure also provides methods of modifying illumination performance, comprising in an illumination device having a surface configured to reflect illumination, replacing or covering at least some of said surface with an article according to the present disclosure.
  • FIG. 1 provides the Spectrum of the blue-LEDs used in the ETIC-082 equipment for accelerated testing of exemplary articles.
  • Ranges can be expressed herein as from one particular value, and/or to another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. For example, a range of "1 to 10" includes all intermediate values, e.g., 3, 5.56, and 7.3. Similarly, when values are expressed as
  • the terms "about” and “at or about” mean that the amount or value in question can be the value designated some other value approximately or about the same. It is generally understood, as used herein, that it is the nominal value indicated +/- 10% a variation unless otherwise indicated or inferred. For example, “about 10” encompasses the range from 9 to 11, including 10. The term is intended to convey that similar values promote equivalent results or effects recited in the claims. That is, it is understood that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but can be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art.
  • an amount, size, formulation, parameter or other quantity or characteristic is “about” or “approximate” whether or not expressly stated to be such. It is understood that where "about” is used before a quantitative value, the parameter also includes the specific quantitative value itself, unless specifically stated otherwise.
  • the terms “optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
  • the phrase “optionally substituted alkyl” means that the alkyl group can or cannot be substituted and that the description includes both substituted and unsubstituted alkyl groups.
  • an "effective amount” of a recycled polycarbonate blend refers to an amount that is sufficient to achieve the desired improvement in the property modulated by the formulation component, e.g. splaying, under applicable test conditions and without adversely affecting other specified properties.
  • the specific level in terms of wt % in a composition required as an effective amount will depend upon a variety of factors including the amount and type of recycled polycarbonate blend, amount and type of virgin polycarbonate polymer compositions, amount and type of impact modifier compositions, including virgin and recycled impact modifiers, and end use of the article made using the composition.
  • compositions of the invention Disclosed are the components useful in preparing the compositions of the invention as well as the compositions themselves to be used within the methods disclosed herein. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these materials are disclosed that while specific reference of each various individual and collective combinations and permutation of these compounds cannot be explicitly disclosed, each is specifically contemplated and described herein. For example, if a particular compound is disclosed and discussed and a number of modifications that can be made to a number of molecules including the compounds are discussed, specifically contemplated is each and every combination and permutation of the compound and the modifications that are possible unless specifically indicated to the contrary.
  • X and Y are present at a weight ratio of 2:5, and are present in such ratio regardless of whether additional components are contained in the compound.
  • a weight percent ("wt %") of a component is based on the total weight of the formulation or composition in which the component is included. For example if a particular element or component in a composition or article is said to have 8% by weight, it is understood that this percentage is relative to a total compositional percentage of 100% by weight.
  • alkyl group is a branched or unbranched saturated hydrocarbon group of 1 to 24 carbon atoms, such as methyl, ethyl, n propyl, isopropyl, n butyl, isobutyl, t butyl, pentyl, hexyl, heptyl, octyl, decyl, tetradecyl, hexadecyl, eicosyl, tetracosyl and the like.
  • a "lower alkyl” group is an alkyl group containing from one to six carbon atoms.
  • aryl group as used herein is any carbon-based aromatic group including, but not limited to, benzene, naphthalene, etc.
  • aromatic also includes “heteroaryl group,” which is defined as an aromatic group that has at least one heteroatom incorporated within the ring of the aromatic group. Examples of heteroatoms include, but are not limited to, nitrogen, oxygen, sulfur, and phosphorus.
  • the aryl group can be substituted or unsubstituted.
  • the aryl group can be substituted with one or more groups including, but not limited to, alkyl, alkynyl, alkenyl, aryl, halide, nitro, amino, ester, ketone, aldehyde, hydroxy, carboxylic acid, or alkoxy.
  • aralkyl as used herein is an aryl group having an alkyl, alkynyl, or alkenyl group as defined above attached to the aromatic group.
  • An example of an aralkyl group is a benzyl group.
  • thermoplastic is a plastic material - suitably a polymer - that becomes pliable or moldable above a specific temperature and solidifies upon cooling.
  • carbonate group as used herein is represented by the formula OC(0)OR, where R can be hydrogen, an alkyl, alkenyl, alkynyl, aryl, aralkyl, cycloalkyl, halogenated alkyl, or heterocycloalkyl group described above.
  • organic residue defines a carbon containing residue, i.e., a residue comprising at least one carbon atom, and includes but is not limited to the carbon-containing groups, residues, or radicals defined hereinabove.
  • Organic residues can contain various heteroatoms, or be bonded to another molecule through a heteroatom, including oxygen, nitrogen, sulfur, phosphorus, or the like. Examples of organic residues include but are not limited alkyl or substituted alkyls, alkoxy or substituted alkoxy, mono or di-substituted amino, amide groups, etc.
  • Organic residues can preferably comprise 1 to 18 carbon atoms, 1 to 15, carbon atoms, 1 to 12 carbon atoms, 1 to 8 carbon atoms, 1 to 6 carbon atoms, or 1 to 4 carbon atoms.
  • an organic residue can comprise 2 to 18 carbon atoms, 2 to 15, carbon atoms, 2 to 12 carbon atoms, 2 to 8 carbon atoms, 2 to 4 carbon atoms, or 2 to 4 carbon atoms.
  • ABS Acrylonitrile-butadiene-styrene
  • ABS materials generally exhibit excellent impact resistance and toughness.
  • ABS materials combine the strength and rigidity of the acrylonitrile and styrene polymers with the toughness of the polybutadiene rubber.
  • neat acrylonitrile-butadiene-styrene is typically used for applications with less stringent mechanical properties, such as tensile, flexural, heat, and fatigue requirements.
  • Styrene acrylonitrile resin is a copolymer plastic comprising styrene and acrylonitrile.
  • the chains of the polymer comprise alternating repeat units of styrene and acrylonitrile.
  • PC Polycarbonates
  • Polymerization may be in aqueous, interfacial, or in nonaqueous solution.
  • Polycarbonates are a useful class of polymers known for optical clarity and enhanced impact strength, high heat resistance, and relative ductility at room temperature or below.
  • Polycarbonate may refer to an oligomer or polymer comprising residues of one or more dihydroxy compounds, e.g. dihydroxy aromatic compounds, joined by carbonate linkages; it also encompasses homopolycarbonates, copolycarbonates, and (co)polyester carbonates.
  • PC— PS polycarbonate -siloxane copolymer
  • poly(carbonate-siloxane) copolymer poly(carbonate-siloxane) copolymer
  • polycarbonate -poly siloxane copolymer refers to a copolymer comprising repeating carbonate and siloxane units.
  • the terms are inclusive of block copolymers having poly siloxane and polycarbonate blocks.
  • ABS acrylonitrile-butadiene-styrene copolymer
  • ABS acrylonitrile-butadiene-styrene copolymer
  • acrylonitrile-butadiene-styrene polymer which can be an acrylonitrile-butadiene-styrene terpolymer or a blend of styrene- butadiene rubber and styrene-acrylonitrile copolymer.
  • an impact modifier refers to a component of the disclosed impact modified polycarbonate blend compositions wherein the impact modifier is a polymeric material effective in improving the impact properties of the disclosed impact modified polycarbonate blend compositions, e.g. the notched Izod impact strength of the composition.
  • an impact modifier can be a one or more polymers such as acrylonitrile butadiene styrene copolymer (ABS), methacrylate butadiene styrene copolymer (MBS), bulk polymerized ABS (BABS), and/or silicon-graft copolymers.
  • PET refers to poly(ethylene terephthalate).
  • PET poly(ethylene terephthalate)
  • PET include PET homopolymers PET copolymers and PETG.
  • PET copolymer refers to PET that has been modified by up to 10 mole percent with one or more added comonomers.
  • PET copolymer includes PET modified with up to 10 mole percent isophthalic acid on a 100 mole percent carboxylic acid basis.
  • PET copolymer includes PET modified with up to 10 mole percent 1,4 cyclohexane dimethanol (CHDM) on a 100 mole percent diol basis.
  • PETG refers to PET modified with 10 to 50 percent CHDM on a 100 mole percent diol basis.
  • the terms "ITR-PC,” and (isophthalic acid-terephthalic acid- resorcinol)-bisphenol A copolyestercarbonate refer to copolyestercarbonates comprising a polycarbonate unit and a polyester unit, the polyester unit derived from the reaction of isophthalic acid, terephthalic acid, and a resorcinol moiety.
  • talc is used herein to mean a mineral composed of hydrated magnesium silicate.
  • surface treated talc (or “surface modified talc” or “coated talc”) is used herein to mean particles of talc, whose surface has been fully or partially, physically or chemically, modified using a surface treating agent.
  • agents can be of organic or inorganic nature. These agents can include fatty acids, fatty acid esters, silicones, Teflon, silanes, silane coupling agents, metal salts of fatty acid, or polyethylene glycol.
  • weight percent As used herein the terms "weight percent,” “wt %,” “wt %,” and “wt. %,” which can be used interchangeably, indicate the percent by weight of a given component based on the total weight of the composition, unless otherwise specified. That is, unless otherwise specified, all weight percent values are based on the total weight of the composition. It should be understood that the sum of weight percent values for all components in a disclosed composition or formulation are equal to 100.
  • compositions disclosed herein have certain functions. Disclosed herein are certain structural requirements for performing the disclosed functions, and it is understood that there are a variety of structures that can perform the same function that are related to the disclosed structures, and that these structures will typically achieve the same result.
  • Polycarbonates As described herein, the disclosed articles may comprise a polycarbonate. Polycarbonates are known in the art, and are described in, e.g., PCT/US2013/035456,
  • Polycarbonates include aromatic carbonate chain units include compositions having structural units of the formula (II):
  • R 1 groups are aromatic, aliphatic or alicyclic radicals.
  • R 1 is an aromatic organic radical and, more preferably, a radical of the formula (III):
  • each of Al and A2 is a monocyclic divalent aryl radical and Yl is a bridging radical having zero, one, or two atoms which separate Al from A2. In an exemplary embodiment, one or more atoms separate Al from A2.
  • Polycarbonates can be produced by the Schotten-Bauman interfacial reaction of the carbonate precursor with dihydroxy compounds.
  • Polycarbonates can be produced by the interfacial reaction polymer precursors such as dihydroxy compounds.
  • Typical carbonate precursors include the carbonyl halides, for example carbonyl chloride (phosgene), and carbonyl bromide; the bis-haloformates, for example, the bis- haloformates of dihydric phenols such as bisphenol A, hydroquinone, or the like, and the bis- haloformates of glycols such as ethylene glycol and neopentyl glycol; and the diaryl carbonates, such as diphenyl carbonate, di(tolyl)carbonate, and di(naphthyl)carbonate.
  • the preferred carbonate precursor for the interfacial reaction is carbonyl chloride.
  • polycarbonates resulting from the polymerization of two or more different dihydric phenols or a copolymer of a dihydric phenol with a glycol or with a hydroxy- or acid-terminated polyester or with a dibasic acid or with a hydroxy acid or with an aliphatic diacid in the event a carbonate copolymer rather than a homopolymer is desired for use.
  • useful aliphatic diacids have about 2 to about 40 carbons.
  • a preferred aliphatic diacid is dodecanedioic acid.
  • Branched polycarbonates as well as blends of linear polycarbonate and a branched polycarbonate can also be used.
  • the branched polycarbonates can be prepared by adding a branching agent during polymerization.
  • Polycarbonate can be produced by a melt polycondensation reaction between a dihydroxy compound and a carbonic acid diester.
  • the number average molecular weight of the polycarbonate is about 3,000 to about 1,000,000 grams/mole (g/mole). Within this range, it is desirable to have a number average molecular weight of greater than or equal to about 10,000, preferably greater than or equal to about 20,000, and more preferably greater than or equal to about 25,000 g/mole. Also desirable is a number average molecular weight of less than or equal to about 100,000, preferably less than or equal to about 75,000, more preferably less than or equal to about 50,000, and most preferably less than or equal to about 35, 000 g/mole.
  • the disclosed thermoplastic compositions may comprise a polycarbonate - polysiloxane block copolymer component.
  • polycarbonate-polysiloxane copolymer is equivalent to polysiloxane-polycarbonate copolymer, polycarbonate-polysiloxane polymer, or polysiloxane-polycarbonate polymer.
  • a non-limiting example of a polycarbonate-siloxane copolymer includes transparent EXL, available from SABIC Innovative Plastics.
  • the transparent EXL from SABIC is a polycarbonate-polysiloxane (9030T) copolymer, having been tested commercially and found to have about 6 mole % siloxane, a Mw of about 23,000 Daltons (polystyrene basis).
  • Another non-limiting example of a polycarbonate-siloxane copolymer includes opaque EXL, available from SABIC Innovative Plastics.
  • the opaque EXL from SABIC is a polycarbonate-polysiloxane (9030P) copolymer, having been tested commercially and found to have about 20 mole % siloxane, a Mw of about 29,900 Daltons (polystyrene basis).
  • the polysiloxane polycarbonate copolymer component can be present in the thermoplastic composition in any desired amount.
  • the polysiloxane polycarbonate copolymer is present in an amount of about 0 wt % to about 30 wt % of a polycarbonate-polysiloxane copolymer component relative to the total weight of the thermoplastic composition.
  • the polysiloxane polycarbonate copolymer is present in an amount of at least about 1 wt % relative to the total weight of the thermoplastic composition.
  • the polycarbonate-polysiloxane copolymer can be present in an amount in the range of from l wt % to 30 wt % relative to the total weight of the thermoplastic composition, including exemplary amounts of 0.1 wt %, 0.25 wt %, 0.5 wt %, 1.0 wt %, 1.5 wt
  • the polysiloxane polycarbonate copolymer can be present within any range of amounts derived from any two of the above stated values.
  • the polysiloxane polycarbonate copolymer can be present in an amount in the range of from about 1 to about 5 wt %, or in an amount in the range of from about 1 wt % to about 10 wt %.
  • the polycarbonate-polysiloxane copolymer component is a polycarbonate-polydimethylsiloxane copolymer.
  • the polycarbonate portion of the polycarbonate-polysiloxane copolymer comprises residues derived from BPA.
  • the polycarbonate portion of the polycarbonate-polysiloxane copolymer comprising residues derived from BPA is a homopolymer.
  • the polycarbonate- polysiloxane copolymer component comprises a polycarbonate-polysiloxane block copolymer.
  • the polycarbonate-polysiloxane block copolymer comprises a polycarbonate-polydimethylsiloxane block copolymer.
  • the polycarbonate block comprises residues derived from BPA.
  • the polycarbonate block comprising residues derived from BPA is a homopolymer.
  • the polycarbonate-polysiloxane block copolymer comprises from about 3 wt % to about 10 wt % siloxane. In another aspect, the polycarbonate-polysiloxane block copolymer comprises from about 4 wt % to about 8 wt % siloxane. In still another aspect, the polycarbonate-polysiloxane block copolymer comprises about 5 wt % siloxane. In still another aspect, the polycarbonate-polysiloxane block copolymer comprises about 6 wt % siloxane.
  • the polycarbonate-polysiloxane block copolymer comprises about 7 wt % siloxane. In still another aspect, the polycarbonate-polysiloxane block copolymer comprises about 8 wt % siloxane.
  • the PC-Si copolymer has a weight average molecular weight from about 20,000 to about 26,000 Daltons (polystyrene basis). In another aspect, the PC-Si block copolymer has a weight average molecular weight from about 21,000 to about 25,000 Daltons. In still another aspect, the PC-Si block copolymer has a weight average molecular weight from about 22,000 to about 24,000 Daltons (polystyrene basis). In still another aspect, the PC-Si block copolymer has a weight average molecular weight of about 22,000 Daltons (polystyrene basis).
  • the PC-Si block copolymer has a weight average molecular weight of about 23,000 Daltons (polystyrene basis). In still another aspect, the PC-Si block copolymer has a weight average molecular weight of about 24,000 Daltons (polystyrene basis). In still another aspect, the PC-Si block copolymer has a weight average molecular weight of about 25,000 Daltons (polystyrene basis).
  • the polycarbonate-polysiloxane block copolymer comprises from about 1 wt % to about 25 wt % siloxane. In another aspect, the polycarbonate-polysiloxane block copolymer comprises from about 11 wt % to about 23 wt % siloxane. In still another aspect, the polycarbonate-polysiloxane block copolymer comprises from about 18 wt % to about 22 wt % siloxane. In still another aspect, the polycarbonate-polysiloxane block copolymer comprises from about 19 wt % to about 21 wt % siloxane.
  • the polycarbonate-polysiloxane block copolymer comprises about 18 wt % siloxane. In still another aspect, the polycarbonate- polysiloxane block copolymer comprises about 19 wt % siloxane. In still another aspect, the polycarbonate-polysiloxane block copolymer comprises about 20 wt % siloxane. In still another aspect, the polycarbonate-polysiloxane block copolymer comprises about 21 wt % siloxane. In still another aspect, the polycarbonate-polysiloxane block copolymer comprises about 22 wt % siloxane.
  • the polysiloxane block has a weight average molecular weight from about 25,000 to about 32,000 Daltons (polystyrene basis). In another aspect, the polysiloxane block has a weight average molecular weight from about 26,000 to about 31,000 Daltons (polystyrene basis). In still another aspect, the polysiloxane block has a weight average molecular weight from about 27,000 to about 30,000 Daltons (polystyrene basis). In still another aspect, the polysiloxane block has a weight average molecular weight from about 28,000 to about 30,000 Daltons (polystyrene basis).
  • the polysiloxane block has a weight average molecular weight of about 27,000 Daltons (polystyrene basis). In still another aspect, the polysiloxane block has a weight average molecular weight of about 28,000 Daltons. In still another aspect, the polysiloxane block has a weight average molecular weight of about 29,000 Daltons (polystyrene basis). In still another aspect, the polysiloxane block has a weight average molecular weight of about 30,000 Daltons (polystyrene basis). In still another aspect, the polysiloxane block has a weight average molecular weight of about 31,000 Daltons (polystyrene basis).
  • Cycloaliphatic polyesters can also be used and are generally prepared by reaction of organic polymer precursors such as a diol with a dibasic acid or derivative.
  • the diols useful in the preparation of the cycloaliphatic polyester polymers are straight chain, branched, or cycloaliphatic, preferably straight chain or branched alkane diols, and can contain from 2 to 12 carbon atoms.
  • One or more fillers may be used, e.g., graphite, Ti02, ZnS, or BN. producers provide expanded/exfoliated graphite, like Timcal TIMREX C-THERMTM, SGL Carbon Ecophit GTM, which can show higher thermal conductivity performance compared to conventional flake like graphite. A challenge with these materials, however, is compounding, as the
  • expanded/exfoliated graphite is difficult to feed into extruders due to the material's low bulk density (e.g., 0.14 ⁇ 0.15 g/cc) compared to conventional graphite density of over 0.5 g/cc.
  • the compositions of the present invention can include various additives ordinarily incorporated in resin compositions of this type. Mixtures of additives can be used. Such additives can be mixed at a suitable time during the mixing of the components for forming the composition.
  • the one or more additives are included in the thermoplastic compositions to impart one or more selected characteristics to the thermoplastic compositions and any molded article made therefrom.
  • additives examples include, but are not limited to, heat stabilizers, process stabilizers, antioxidants, light stabilizers, plasticizers, antistatic agents, mold releasing agents, UV absorbers, lubricants, pigments, dyes, colorants, flow promoters, flame retardants, or a combination of one or more of the foregoing additives.
  • Suitable heat stabilizers include, for example, organo phosphites such as triphenyl phosphite, tris-(2,6-dimethylphenyl)phosphite, tris-(mixed mono-and di- nonylphenyl)phosphite or the like; phosphonates such as dimethylbenzene phosphonate or the like, phosphates such as trimethyl phosphate, or the like, or combinations including at least one of the foregoing heat stabilizers.
  • Heat stabilizers are generally used in amounts of from 0.01 to 0.5 parts by weight based on 100 parts by weight of the total composition, excluding any filler.
  • Suitable antioxidants include, for example, 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 or the like; alkylated monophenols or polyphenols; alkylated reaction products of polyphenols with dienes, such as
  • 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 or the like; amides of beta-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid or the like, or combinations including at least one of the foregoing antioxidants.
  • Antioxidants are generally used in amounts of from 0.01
  • Suitable light stabilizers include, for example, benzotriazoles such as 2-(2- hydroxy-5-methylphenyl)benzotriazole, 2-(2-hydroxy-5-tert-octylphenyl)-benzotriazole and 2- hydroxy-4-n-octoxy benzophenone or the like or combinations including at least one of the foregoing light stabilizers.
  • Light stabilizers are generally used in amounts of from 0.1 to 1.0 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
  • Suitable plasticizers include, for example, phthalic acid esters such as dioctyl- 4,5-epoxy-hexahydrophthalate, tris-(octoxycarbonylethyl)isocyanurate, tristearin, epoxidized soybean oil or the like, or combinations including at least one of the foregoing plasticizers.
  • Plasticizers are generally used in amounts of from 0.5 to 3.0 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
  • Suitable antistatic agents include, for example, glycerol monostearate, sodium stearyl sulfonate, sodium dodecylbenzenesulfonate, polyether block amides, which are commercially available from, for example, BASF under the Tradename Irgastat; from Arkema under the Tradename PEBAX; and from Sanyo Chemical industries under the tradename Pelestat, or combinations of the foregoing antistatic agents.
  • carbon fibers, carbon nanofibers, carbon nanotubes, carbon black, or any combination of the foregoing can be used in a polymeric resin containing chemical antistatic agents to render the composition electrostatically dissipative.
  • Suitable mold releasing agents include for example, metal stearate, stearyl stearate, pentaerythritol tetrastearate, beeswax, montan wax, paraffin wax, or the like, or combinations including at least one of the foregoing mold release agents. Mold releasing agents are generally used in amounts of from 0.1 to 1.0 parts by weight, (e.g., 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or even 0.9 parts by weight) based on 100 parts by weight of the total composition, excluding any filler.
  • Suitable UV absorbers include for example, hydroxybenzophenones
  • UVINULTM 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-diphenyl- acryloyl)oxy]methyl]propane; nano-size inorganic materials such as titanium oxide, cerium oxide, and zinc oxide, all with particle size less than 100 nanometers; or the like, or
  • UV absorbers are generally used in amounts of from 0.01 to 3.0 parts by weight, based on 100 parts by weight based on 100 parts by weight of the total composition, excluding any filler.
  • Suitable lubricants include for example, fatty acid esters such as alkyl stearyl esters, e.g., methyl stearate or the like; mixtures of methyl stearate and hydrophilic and hydrophobic surfactants including polyethylene glycol polymers, polypropylene glycol polymers, and copolymers thereof e.g., methyl stearate and polyethylene-polypropylene glycol copolymers in a suitable solvent; or combinations including at least one of the foregoing lubricants.
  • Lubricants are generally used in amounts of from 0.1 to 5 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
  • Suitable pigments include for example, inorganic pigments such as metal oxides and mixed metal oxides such as zinc oxide, titanium dioxides, iron oxides or the like; sulfides such as zinc sulfides, or the like; aluminates; sodium sulfo-silicates; sulfates and chromates; zinc ferrites; ultramarine blue; Pigment Brown 24; Pigment Red 101; Pigment Yellow 119; organic pigments such as azos, di-azos, quinacridones, perylenes, naphthalene tetracarboxylic acids, flavanthrones, isoindolinones, tetrachloroisoindolinones, anthraquinones, anthanthrones, dioxazines, phthalocyanines, and azo lakes; Pigment Blue 60, Pigment Red 122, Pigment Red 149, Pigment Red 177, Pigment Red 179, Pigment Red 202, Pigment Violet 29, Pigment Blue
  • Suitable dyes include, for example, organic dyes such as coumarin 460 (blue), coumarin 6 (green), nile red or the like; lanthanide complexes; hydrocarbon and substituted hydrocarbon dyes; polycyclic aromatic hydrocarbons; 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; 3-(2'-benzimidazolyl)-7-N,N- diethy
  • naphthalene naphthalene; anthracene; 9, 10-diphenylanthracene; pyrene; chrysene; rubrene; coronene;
  • Dyes are generally used in amounts of from 0.1 to 5 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
  • Suitable colorants include, for example titanium dioxide, anthraquinones, perylenes, perinones, indanthrones, quinacridones, xanthenes, oxazines, oxazolines,
  • Colorants are generally used in amounts of from 0.1 to 5 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
  • Suitable blowing agents include for example, low boiling halohydrocarbons and those that generate carbon dioxide; blowing agents that are solid at room temperature and when heated to temperatures higher than their decomposition temperature, generate gases such as nitrogen, carbon dioxide, ammonia gas, such as azodicarbonamide, metal salts of
  • Blowing agents are generally used in amounts of from 1 to 20 parts by weight, based on 100 parts by weight of the total composition, excluding any filler.
  • materials to improve flow and other properties can be added to the composition, such as low molecular weight hydrocarbon resins or dendritic polyols (such as
  • olefins e.g. pentenes, hexenes, heptenes and the like
  • diolefins e.g. pentadienes, hexadienes and the like
  • cyclic olefins and diolefins e.g.
  • cyclopentene cyclopentadiene, cyclohexene, cyclohexadiene, methyl cyclopentadiene and the like
  • cyclic diolefin dienes e.g., dicyclopentadiene, methylcyclopentadiene dimer and the like
  • aromatic hydrocarbons e.g. vinyltoluenes, indenes, methylindenes and the like.
  • the resins can additionally be partially or fully hydrogenated.
  • flame retardants include, but are not limited to, halogenated flame retardants, like tretabromo bisphenol A oligomers such as BC58 and BC52, brominated polystyrene or poly(dibromo-styrene), brominated epoxies, decabromodiphenyleneoxide, pentabrombenzyl acrylate monomer, pentabromobenzyl acrylate polymer, ethylene- bis(tetrabromophthalimide, bis(pentabromobenzyl)ethane, metal hydroxides like Mg(OH) 2 and Al(OH) 3 , melamine cyanurate, phosphor based FR systems like red phosphorus, melamine polyphosphate, phosphate esters, metal phosphinates, ammonium polyphosphates, expandable graphites, sodium or potassium perfluorobutane sulfate, sodium or potassium perfluorooctane sulfate, sodium or
  • Foamed micro-cellular polycarbonate and polyesters materials are known and marketed as sheet materials by Furukawa and Toray. Although these materials will probably also have a good white/blue-LED aging performance, so far this aspect has to my knowledge not been reported in patent or open literature.
  • sheets are of interest, most of our reflective materials are used for injection molding, allowing more design freedom in the final part than using a foamed sheet and laminating it to a load-bearing structure.
  • MuCell Technology to create the micro-cellular structure in the injection molded process, resulting in injection molded products showing the improved aging performance under blue/white LED exposure.
  • Foamed, micro-cellular structures can improve the reflectivity significantly.
  • Cell-size is important and in general the smaller the cell size, the higher the reflectivity.
  • the foamed/micro-cellular structures were obtained by injection molding PC on an injection molding machine equipped with MuCell technology and heat-and-cool technology. Nitrogen was used as "foaming" gas.
  • the Mucell unit inject at high pressure (350 bar), nitrogen into the molten PC which is injected into a heated mold. During the filling of the mold, a gas counter pressure might be used to prevent desaturation of nitrogen in the PC-melt. Typically, after a certain hold time, the mold is allowed to expand to a certain thickness and allowed to cool down before being ejected.
  • the cell size can be influenced with mold temperature, holding time and whether or not gas counter pressure is used.
  • Use of gas counter pressure (GCP) gives in general smaller cell size as without GCP.
  • Increasing the holding time results in a better homogeneous material temperature and a more homogeneous cell size.
  • mold temperature there is an optimum depending on the material and viscosity of the material used. Without being bound to any particular theory, for high-MW PC a mold temperature of 165°C gives optimum results, with the higher temperatures resulting in larger cells sizes and hence lower reflectivity.
  • Reflectivity was measured on an XRite Color 17TM with Color IQC9TM software and a 6 mm aperture.
  • ETIC-082TM Elevated Temperature Irradiance Chamber
  • Orb Optronix CSA equipped with Blue LEDs emitting the spectrum as displayed in FIG. 1.
  • the ETIC was coupled to a Thermoflex Cool unit (Neslab Thermoflex 3500TM) from Fisher Scientific. This set-up allowed study of the combined effects of high intensity blue LED radiation and heat.
  • each apparatus there were 8 stations/sample holders, each with its own Blue LED, which can independently be operated.
  • the samples were exposed to the following conditions over a series of (unequal) intervals until failure: Irradiance: 35 kW/m 2 , Temperature: 90 °C.
  • a sample was designated as being failed if visually a yellowing or charring is observed. For the majority of the tests, the failed samples remained in their station in the oven but were no longer irradiated. At the end of each interval, the samples were allowed to cool and visually inspected. If yellowing and/or charring was observed, the sample was designated as being failed and the corresponding real irradiation time was monitored. In addition, the degree of Yellowness index (YI), was then measured using a spectrophotometer for the non-failed samples.
  • YI Yellowness index
  • Table 1 gives an overview of the composition of the starting materials being used. It has been mentioned in literature that addition of so-called nucleants can improve the homogeneity of the cell structures being formed.
  • PC2 contains fumed silica, a so-called heterogeneous nucleant. The compounding conditions used to produce the PC 1 and PC2 materials are listed in Table 2.
  • PCI and PC2 materials were converted into injection molded foamed- microcellular structures using the set-up (an injection molding machine with Mucell and heat- and-cool technology) as described above and under the conditions presented in Table 3.
  • the molding conditions for the LexanTM LUX comparative materials are listed in Table 4).
  • Table 3 shows that the materials tested all have well to excellent reflectivity in the visible range (400-700nm). SEM investigations confirmed the micro-cellular structures in the PCI and PC2 materials, with cell sizes typically less than about 20 micron.
  • foamed, micro-cellular structures exhibit improved reflectivity in certain wavelengths, e.g., the 315-400 nm range.
  • wavelengths e.g., the 315-400 nm range.
  • Exemplary foamed/micro-cellular structures may be obtained by injection molding PC on an injection molding machine equipped with a cell-forming technology (e.g., MuCellTM technology) and heat and cool capability.
  • a cell-forming technology e.g., MuCellTM technology
  • heat and cool capability e.g., heat and cool capability.
  • nitrogen was be used as "foaming" gas, although other gases will be known to those of skill in the art.
  • a MuCell unit injected nitrogen at high pressure (350 bar) into molten polycarbonate (PC) (having a weight-average molecular weight, on a polystyrene basis, of about 70 kDaltons) that was injected into a heated mold.
  • PC molten polycarbonate
  • gas counter pressure may be used to prevent desaturation of nitrogen in the PC-melt.
  • cell size may be influenced with mold temperature, holding time and by whether or not gas counter pressure is used.
  • GCP gas counter pressure
  • PC 2 and PC3 contain a so-called heterogeneous nucleant (talc and silica, in this case) whereas in PC4 uses a siloxane block in the PC-siloxane copolymer as a homogeneous nucleant.
  • An article comprising: a region having a cellular structure comprising a plurality of cells, the plurality of cells having a number-average cross-sectional dimension in the range of from about 0.3 micrometers up to about 100 micrometers (e.g, from about 0.5 to about 95, from about 1 to about 90, from about 2 to about 85, from about 3 to about 80, from about 4 to about 75, from about 5 to about 70, from about 6 to about 65, from about 7 to about 60, from about 8 to about 55, from about 9 to about 50, from about 10 to about 45, from about 11 to about 40, from about 12 to about 35, from about 13 to about 30, from about 14 to about 25, from about 15 to about 20, or even about 17 micrometers), and the article having a YI of less than 15 (e.g., a YI about 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, or even about 1) upon exposure for 100 hours to 35 kW/m 2 illumination having a peak centered at about 450 n
  • the plurality of cells may have a number-average cross-sectional dimension in the range of from about 1 micrometer up to about 80 micrometers, or from about 5 micrometers up to about 40 micrometers, or even from about 10 micrometers up to about 15 micrometers.
  • Cells having a number-average cross-sectional dimension in the range of less than 40 micrometers are especially suitable, in particular cells having a number-average cross-sectional dimension of less than 10 micrometers, e.g. from about 1 to about 10 micrometers.
  • YI is determined according to ASTM D1925- 95 CIE illuminant C and 2 degree observer on a X-Rite i7TM spectrophotometer using an integrating sphere with 87diffuse geometry, specular component included, UV included, a 6 mm small area view lens, and a 25 mm large area view transmission port.
  • Aspect 2 The article of aspect 1, wherein the article has a YI according of less than 15 (e.g., 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1) upon exposure for 200 hours to 35 kW/m 2 illumination having a peak centered at about 450 nm.
  • Aspect 3 The article of aspect 2, wherein the article has a YI according of less than 15 (e.g., 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1) upon exposure for 300 hours to 35 kW/m 2 illumination having a peak centered at about 450 nm.
  • Aspect 4 The article of aspect 3, wherein the article has a YI of less than 15 (e.g., 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1) upon exposure for 400 hours to 35 kW/m 2 illumination having a peak centered at about 450 nm.
  • Aspect 5 The article of any of aspects 1-4, wherein the region has a reflectivity of at least about 80% (e.g., about 80%, 85%, 90%, 95%, or greater) for illumination in the range of from about 380 nm to about 420 nm and of at least about 80% (e.g., about 80%, 85%, 90%, 95%, or greater) for illumination in the range of from about 400 to about 700 nm,
  • Aspect 6 The article of any of aspects 1-5, wherein the article is characterized as injection-molded.
  • Aspect 7 The article of any of aspects 1-6, wherein the region comprises an amount of phosphor.
  • phosphor species may be incorporated into substrates (e.g., plastic substrates) to fluorescence (emit white light) when irradiated with blue light emitting LEDs thus providing white light.
  • Exemplary phosphor species include, e.g., strontium based, ZnS based, calcium based, barium based, YAG, pigment based, aluminate based (GAL), europium based, silicate based, nitride based, luminova, sulphate based, TAG, vanadates, oxazole based, silicates, NYAG (Garnet) phosphors, red nitride phosphors, and any combination thereof.
  • Aspect 8 The article of aspect 7, wherein at least some of the phosphor resides on a surface of the article.
  • Aspect 9 The article of any of aspects 1-8, wherein the region comprises plastic, metal, glass, carbon, or any combination thereof.
  • thermoplastics include, e.g., polycarbonate, polyester, or any combination thereof.
  • polycarbonate is an especially suitable thermoplastic
  • other thermoplastics polyyesters, PET, polyamides, PBT
  • one of ordinary skill in the art will encounter no difficulty in identifying thermoplastics.
  • Mixtures of two, three, or more thermoplastics are considered suitable.
  • the thermoplastic comprises a polycarbonate having a weight-average molecular weight (polystyrene basis) of from about 10 to about 100 (e.g., 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or even 95) kDaltons (polystyrene basis). Suitable weight-average molecular weights may also be from about 15 to about 95, from about 20 to about 90, from about 25 to about 85, from about 25 to about 80, from about 30 to about 70, from about 40 to about 50, or even about 50 kDaltons (polystyrene basis).
  • the thermoplastic may comprise a polycarbonate having a weight-average molecular weight (polystyrene basis) of from about 40 to about 50 kDaltons (polystyrene basis).
  • Aspect 12 The article of aspect 1, wherein the region comprises a nucleant.
  • Aspect 13 The article of aspect 12, wherein the nucleant comprises talc, silica, siloxane, clay, or any combination thereof.
  • Aspect 14 The article of aspect 13, wherein the nucleant comprises siloxane.
  • Aspect 15 The article of aspect 14, wherein the siloxane is included in a copolymer.
  • PC-Polysiloxane polymers are described elsewhere herein, and include block, branched, and all other forms of copolymers.
  • Aspect 16 The article of aspect 14, wherein the siloxane is admixed with a plastic.
  • the siloxane may have an average block length of from about 20 to about 100.
  • Aspect 17 The article of any of aspects 1-16, wherein the plurality of cells has a spatial density in the range of from 10 3 cells/cm 3 to 10 15 cells/cm 3 , e.g., from about 10 6 to about 10 9 cells/cm 3 .
  • Aspect 18 The article of any of aspects 1-16, wherein the plurality of cells represents from about 5 to about 70 vol% of the region.
  • cells are sized and dispersed such that they reduce the density of the matrix (as compared to a cell-free matrix) by from 10% to 90%, and all intermediate values. Reducing the density by 60% is considered especially suitable.
  • the microcellular materials may have a density of from about 5% to about 99% of the base thermoplastic (uncelled) material, e.g., 40% of the uncelled material.
  • Aspect 19 The article of any of aspects 1-18, wherein at least 50% of the plurality of cells, by number, are characterized as closed cells. Pluralities of cells that are from 70-95% (by number) closed cells are considered especially suitable.
  • cells in foam are bubbles that have been frozen in size and shape after solidification of a polymer melt.
  • Two types of cells are open and closed cells.
  • each cell is an independent, closed entity.
  • the walls of gas bubbles have no holes in them.
  • the cell will contain gas if the polymer is impermeable to gas used for foaming.
  • Aspect 20 The article of any of aspects 1-19, wherein at least 20% of the plurality of cells, by number, are characterized as having as aspect ratio of between about 1 and about 5. (e.g, spherical cells). In an article, up to 30%, 40%, 50%, 60%, 70%, 80%, 90% or even all of the cells may be characterized as spherical. In some embodiments, at least 50% of the plurality of cells, by number, are characterized having an aspect ratio of between about 1 and about 5. In an article, up to 30%, 40%, 50%, 60%, 70%, 80%, 90% or even all of the cells may be characterized as having as aspect ratio of between about 1 and about 5.
  • Aspect 21 The article of any of aspects 1-20, wherein upon exposure for 100 hours to 35 kW/m 2 illumination having a peak centered at about 450 nm in a chamber kept at about 90 deg. C, the article has a YI of less than 15 (e.g., 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1).
  • Aspect 22 The article of any of aspects 1-21, wherein the thermoplastic region is substantially free of swirl marks.
  • Aspect 23 The article of any of aspects 1-22, wherein the article is in optical communication with a blue LED characterized by an intensity peak centered at about 450 nm.
  • Aspect 24 The article of aspect 23, wherein the article is characterized as an overhead illuminator, a reflector lamp, a back reflector (in edge lit panels), a flat reflector, a thermoformed reflector, or any combination thereof.
  • Articles may be used in signboards, lighting fixtures, and the like. Suitable articles include also reflectors, housings, collars, and the like. It should be understood that an article may be a film or a sheet in configuration. An article may have an entire through-thickness that has the disclosed characteristics (e.g., a sheet, the entire sheet having the disclosed characteristics).
  • an article may include a region (e.g., a 1 mm thick surface layer that is part of a thicker overall article) that has the disclosed characteristics.
  • the disclosed cellular thermoplastics may even be applied as a layer (e.g., via adhesive, bonding, heat-sealing, or other attachment methods) to an existing article, e.g., a reflector already in service.
  • An article may include a microcellular region (e.g., at the surface) and a region that does not include a cellular structure.
  • a method comprising: illuminating, with a source of illumination having a peak in the range of from about 440 to about 500 nm, an article comprising a region having a cellular structure comprising a plurality of cells, the plurality of cells having a number- average cross-sectional dimension in the range of from about 0.3 micrometers up to about 100 micrometers, and the article having a YI of less than 15 (e.g., 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1) upon exposure for 100 hours to 35 kW/m 2 illumination having a peak centered at about 450 nm.
  • Articles according to any of aspects 1-24 are also considered suitable.
  • Aspect 26 The method of aspect 25, wherein the article has a YI according of less than 15 (e.g., 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1) upon exposure for 200 hours to 35 kW/m 2 illumination having a peak centered at about 450 nm.
  • Aspect 27 The method of aspect 26, wherein the article has a YI according of less than 15 (e.g., 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1) upon exposure for 300 hours to 35 kW/m 2 illumination having a peak centered at about 450 nm.
  • Aspect 28 The method of aspect 27, wherein the article has a YI of less than 15 (e.g., 14, 13, 12, 1 1, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1) upon exposure for 400 hours to 35 kW/m 2 illumination having a peak centered at about 450 nm.
  • Aspect 29 The method of any of aspects 25-28, wherein the region has a reflectivity of at least about 80% for illumination in the range of from about 380 nm to about 420 nm and of at least about 80% for illumination in the range of from about 400 to about 700 nm,
  • Aspect 30 The method of any of aspects 25-29, wherein the article is characterized as injection-molded.
  • Aspect 31 The method of any of aspects 25-30, wherein the region comprises an amount of phosphor.
  • Aspect 32 The method of aspect 31, wherein the amount of phosphor comprises a silicate, a NY AG (Garnet) phosphor, a GAL (aluminate) phosphor, a red nitride phosphor, or any combination thereof.
  • Aspect 33 The method of any of aspects 25-32, wherein at least 50% of the plurality of cells, by number, are characterized as closed cells.
  • Aspect 34 The method of aspect 25, wherein the source of illumination comprises a blue LED characterized by an intensity peak centered at about 450nm.
  • Aspect 35 The method of any of aspects 25-34, wherein the article comprises an additive.
  • Suitable additives are described elsewhere herein, but may include, without limitation, nucleants, clay (including nanoclay materials comprising particles having a cross- sectional dimension of less than about 100 nm), rubber, TPE (thermoplastic elastomer), coupling agents, antioxidants, mold release agents, UV absorbers, light stabilizers, heat stabilizers, lubricants, plasticizers, pigments, dyes, colorants, anti-static agents, nucleating agents, anti-drip agents, acid scavengers, and combinations thereof.
  • the blend thermoplastic compositions of the present invention further comprise at least one polymer additive selected from a flame retardant, a colorant, a primary anti -oxidant, and a secondary anti -oxidant.
  • Aspect 36 The method of aspect 35, wherein the additive comprises ZnS, Ti02, BN, or any combination thereof.
  • a method of improving surface aging performance comprising: in an illumination device having a surface configured to reflect illumination, replacing or covering at least some of said surface with an article comprising a region having a cellular structure comprising a plurality of cells, the plurality of cells having a number-average cross-sectional dimension in the range of from about 0.3 micrometers up to about 100 micrometers, and the article having a YI of less than 15 (e.g., 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1) upon exposure for 100 hours to 35 kW/m 2 illumination having a peak centered at about 450 nm.
  • a user may apply (e.g., via adhesive) an article according to the present disclosure to an existing surface so as to alter the reflectivity characteristics of that surface. This may be done, for example, to re-fit a display arrangement after an illumination source has been changed from, e.g., an incandescent source to a blue LED.
  • Aspect 38 The method of aspect 37, wherein the article is characterized as a film.
  • Aspect 39 The method of aspect 37, further comprising attaching the article to the surface.
  • Aspect 40 The method of aspect 38, further comprising disposing a source of illumination having a peak in the range of from about 440 to about 500 nm so as to be capable of illuminating at least a portion of the reflective article.
  • Aspect 41 The method of aspect 37, wherein the source of illumination comprises a blue LED characterized by an intensity peak centered at about 450 nm.
  • Aspect 42 The method of aspect 37, wherein the article is characterized as being injection molded.
  • Aspect 43 The method of aspect 37, further comprising introducing a blue LED characterized by an intensity peak centered at about 450 nm.
  • Aspect 44 The method of any of claims 25 or 37, wherein the article comprises an amount of phosphor.
  • Aspect 45 The method of aspect 44, wherein the amount of phosphor comprises a silicate, a NY AG (Garnet) phosphor, a GAL (aluminate) phosphor, a red nitride phosphor, or any combination thereof.

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Abstract

L'invention concerne des articles présentant une structure cellulaire et ayant également une meilleure performance de vieillissement sous certains types d'éclairage. L'invention concerne également des procédés d'utilisation des articles selon l'invention.
PCT/IB2016/051911 2015-04-16 2016-04-04 Procédé d'utilisation d'articles comprenant une structure micro-cellulaire et ayant une meilleure performance de vieillissement sous un éclairage à del (bleu) WO2016166633A1 (fr)

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