WO2020100008A1

WO2020100008A1 - Method of injection molding a thermoplastic article

Info

Publication number: WO2020100008A1
Application number: PCT/IB2019/059670
Authority: WO
Inventors: Young Joon Choi; Jong-Min Choi
Original assignee: Sabic Global Technologies B.V.
Priority date: 2018-11-13
Filing date: 2019-11-11
Publication date: 2020-05-22

Abstract

A method of injection molding a thermoplastic article includes applying ultrasonic energy to a chamber having pellets disposed therein wherein the ultrasonic energy is effective to provide melted pellets, applying a force to the melted pellets such that the melted pellets are forced into a mold having a desired shape to provide a molded part, and recovering the molded part. The pellets include a thermoplastic composition including a poly(imide), a poly(etherimide), a poly(carbonate), or a combination thereof.

Description

METHOD OF INJECTION MOLDING A THERMOPLASTIC ARTICLE

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of European Application No. 18205832.1 filed on November 13, 2018, the contents of which are incorporated herein by reference in their entirety.

BACKGROUND

[0001] Thermoplastic polymers, including poly(carbonates), poly(etherimides) and poly(imides), are useful in the manufacture of articles and components for a wide range of applications, from automotive parts to electronic appliances. Because of beneficial properties such as transparency and impact resistance, thermoplastic poly(carbonates), poly(etherimides) and poly(imides) have also been used in optical applications including as sensor lenses, optical interconnectors, transceivers, light guides, camera lenses, eyeglass and safety glass lenses, illumination lenses such as light fixtures, flashlight and lantern lenses, and motor vehicle headlight lenses and covers. Since many optical articles are used in a high-temperature environment or have to be processed under harsh conditions, it is desirable for the materials to have the ability to withstand elevated temperatures without deformation or discoloration, and the ability to maintain good optical properties even when processed using conventional molding processes.

[0002] Therefore, there is a continuing need in the art for an improved molding process for thermoplastic materials such as poly(carbonates), poly(etherimides), and poly(imides). It would be particularly advantageous to provide an improved process for preparing molded articles for optical application from thermoplastic poly(carbonates), poly(etherimides), and poly(imides).

SUMMARY

[0003] A method of injection molding a thermoplastic article comprises applying ultrasonic energy to a chamber having pellets disposed therein, the pellets comprising a thermoplastic composition comprising a poly(imide), a poly(etherimide), a poly(carbonate), or a combination thereof, wherein the ultrasonic energy is effective to provide melted pellets;

applying a force to the melted pellets such that the melted pellets are forced into a mold having a desired shape to provide a molded part; and recovering the molded part. [0004] A thermoplastic article made by the method is also described.

[0005] The above described and other features are exemplified by the following figure and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The following figure represents an exemplary embodiment.

[0007] FIG. 1 is a schematic illustration showing the phases of the ultrasonic molding process including (a) feeding pellets into a plasticization chamber, (b) initiating vibration using a sonotrode, (c) plasticization and cavity filling, and (d) packing and cooling to provide a molded part.

DETAILED DESCRIPTION

[0008] The present inventors have found that use of ultrasonic injection molding can provide an improved process for injection molding a thermoplastic article comprising a poly(imide), a poly(etherimide), a poly(carbonate), or a combination thereof. Advantageously, use of ultrasonic injection molding of a poly(imide), a poly(etherimide), a poly(carbonate), or a combination thereof can provide a method that reduces or eliminates thermal degradation of the thermoplastic material since thermal melting of the thermoplastic polymers is not required. Additionally, the process can provide short cycle and residence times, in particular because no pre-heating process is required. The process can further provide improved mold filling performance compared to other injection molding processes. Molded articles can exhibit enhanced dimensional stability along the flow- and cross-directions, low residual stress, low birefringence, and low optical distortion. Without wishing to be bound by theory, it is believed that improved properties in the molded articles stem from randomization of the polymer chain orientation due to the ultrasonic vibration.

[0009] Ultrasonic injection molding uses ultrasonic vibrations to melt the thermoplastic material and fill the mold cavity. Thermoplastic pellets are introduced directly inside a plasticization chamber, and melted due to the ultrasonic energy applied by a sonotrode. The sonotrode also acts as a plunger, pushing the molten thermoplastic material inside the mold cavity. An exemplary ultrasonic injection molding process can be as described in FIG. 1, where the process can be divided into four stages. First, the thermoplastic material (e.g., in the form of pellets) can be placed into the plasticization chamber as shown in FIG. 1(a). The process is initiated and the sonotrode moves until the tip reaches the pellets as shown in FIG. 1(b). The sonotrode starts to vibrate and move down applying a compression force to the pellets, which can be a combination of melted and unmelted pellets, as shown in FIG. 1(c). Without wishing to be bound by theory, the pellets melt because the sonotrode vibrational energy increases the internal heat and friction between the pellets. The sonotrode also acts as a plunger and forces the molten thermoplastic material to flow into and fill the mold cavity. When the mold cavity is filled, ultrasonic vibration is stopped while the sonotrode remains in its final position to maintain the pressure during a cooling stage as shown in FIG. 1(d). Finally, the sonotrode can return to its initial position and the molded part can be extracted. A suitable ultrasonic injection molding apparatus can be, for example, as described in U.S. Patent numbers 8,328,548 and 8,758,000, which are incorporated by reference herein in their entirety.

[0010] Accordingly, an aspect of the present disclosure is a method of injection molding a thermoplastic article. The method comprises applying ultrasonic energy to a chamber having pellets disposed therein, the pellets comprising a thermoplastic composition comprising a poly(imide), a poly(etherimide), a poly(carbonate), or a combination thereof, wherein the ultrasonic energy is effective to provide melted pellets; applying a force to the melted pellets such that the melted pellets are forced into a mold having a desired shape to provide a molded part; and recovering the molded part.

[0011] The ultrasonic energy can be applied by a vibration element such as a sonotrode. The ultrasonic frequency utilized can vary, for example, from 10 to 50 kHz. For example, frequencies of 15, 20, 25, 30 or 40 kHz can be used. Advantageously, as described above and as depicted in FIG. 1, the sonotrode can be used to apply the force to the melted pellets and the force the melted pellets into the mold. In some embodiments, when the force is applied, a combination of melted and unmelted pellets can be present in the chamber.

[0012] In some embodiments, the method can include melting the thermoplastic material by ultrasonic energy in a time of less than 30 seconds, or less than 20 seconds, or less than 10 seconds. In some embodiments, the entire cycle time (i.e., from introduction of the

thermoplastic material into the chamber to demolding of the formed article) is less than 2 minutes, or less than 90 seconds, or less than 60 seconds. In some embodiments, the ultrasonic energy induces a temperature effective cause the thermoplastic material to flow. The temperature can therefore be greater than or equal to the glass transition temperature for an amorphous thermoplastic material, or greater than or equal to the melting temperature for a semi crystalline thermoplastic material. In some embodiments, the ultrasonic energy induces a temperature of at least 200°C, or 200 to 300°C in the thermoplastic material. The method can further comprise cooling the molded part prior to recovering the molded part from the mold. [0013] The thermoplastic composition comprises a poly(imide), a poly(etherimide), a poly(carbonate), or a combination thereof. In some embodiments, the thermoplastic

composition comprises the poly(imide). Poly(imides) comprise more than 1, for example 5 to 1000, or 5 to 500, or 10 to 100, structural units of formula (1)

wherein each V is the same or different, and is a substituted or unsubstituted tetravalent C4-40 hydrocarbon group, for example a substituted or unsubstituted C6-20 aromatic hydrocarbon group, a substituted or unsubstituted, straight or branched chain, saturated or unsaturated C2-20 aliphatic group, or a substituted or unsubstituted C4-8 cycloaliphatic group, in particular a substituted or unsubstituted C6-20 aromatic hydrocarbon group. Exemplary aromatic

hydrocarbon groups include any of those of the formulas

wherein W is -O-, -S-, -C(O)-, -SO2-, -SO-, a C1-18 hydrocarbon moiety that can be cyclic, acyclic, aromatic, or non-aromatic, -P(R^a)(=0)- wherein R^a is a Ci-s alkyl or C6-12 aryl, -C_yth_y- wherein y is an integer from 1 to 5 or a halogenated derivative thereof (which includes perfluoroalkylene groups), or a group of the formula -O-Z-O- as described in formula (3) below.

[0014] Each R in formula (1) is the same or different, and is a substituted or

unsubstituted divalent organic group, such as a C6-20 aromatic hydrocarbon group or a halogenated derivative thereof, a straight or branched chain C2-20 alkylene group or a

halogenated derivative thereof, a C3-8 cycloalkylene group or halogenated derivative thereof, in particular a divalent group of formulas (2)

wherein Q¹ is -O-, -S-, -C(O)-, -SO2-, -SO-, -P(R^a)(=0)- wherein R^a is a Ci-s alkyl or C6-12 aryl, - C_yEb_y- wherein y is an integer from 1 to 5 or a halogenated derivative thereof (which includes perfluoroalkylene groups), or -(O_όHio)_z- wherein z is an integer from 1 to 4. In an embodiment R is m-phenylene, p-phenylene, or a diaryl sulfone.

[0015] Poly(etherimide)s are a class of poly(imide)s that comprise more than 1, for example 10 to 1000, or 10 to 500, structural units of formula (3)

wherein each R is the same or different, and is as described in formula (1).

[0016] Further in formula (3), T is -O- or a group of the formula -O-Z-O- wherein the divalent bonds of the -O- or the -O-Z-O- group are in the 3,3', 3,4', 4,3', or the 4,4' positions. The group Z in -O-Z-O- of formula (3) is a substituted or unsubstituted divalent organic group, and can be an aromatic Ce-24 monocyclic or polycyclic moiety optionally substituted with 1 to 6 Ci-₈ alkyl groups, 1 to 8 halogen atoms, or a combination comprising at least one of the foregoing, provided that the valence of Z is not exceeded. Exemplary groups Z include groups derived from a dihydroxy compound of formula (4)

wherein R^a and R^b can be the same or different and are a halogen atom or a monovalent Ci-₆ alkyl group, for example; p and q are each independently integers of 0 to 4; c is 0 to 4; and X^a is a bridging group connecting the hydroxy-substituted aromatic groups, where the bridging group and the hydroxy substituent of each Ce arylene group are disposed ortho, meta, or para

(specifically para) to each other on the Ce arylene group. The bridging group X^a can be a single bond, -O-, -S-, -S(O)-, -S(0)₂-, -C(O)-, or a Ci-is organic bridging group. The Ci-is 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_MS organic group can be disposed such that the Ce arylene groups connected thereto are each connected to a common alkylidene carbon or to different carbons of the Ci-is organic bridging group. A specific example of a group Z is a divalent group of formula (4a)

wherein Q is -0-, -S-, -C(O)-, -SO2-, -SO-, or -C_yth_y- wherein y is an integer from 1 to 5 or a halogenated derivative thereof (including a perfluoroalkylene group). In a specific embodiment Z is a derived from bisphenol A, such that Q in formula (3a) is 2,2-isopropylidene.

[0017] In an embodiment in formula (3), R is m-phenylene, p-phenylene, bis(4,4’- phenylene)sulfone, bis(3,4’-phenylene)sulfone, or bis(3,3’-phenylene)sulfone, and T is -O-Z-O- wherein Z is a divalent group of formula (4a). Alternatively, R is m-phenylene, p-phenylene, bis(4,4’-phenylene)sulfone, bis(3,4’-phenylene)sulfone, or bis(3,3’-phenylene)sulfone and T is -O-Z-O wherein Z is a divalent group of formula (4a) and Q is 2,2-isopropylidene.

[0018] In a specific embodiment in formula (3), R is bis(4,4’-phenylene)sulfone and T is -O-Z-O wherein Z is a divalent group of formula (4a) and Q is 2,2-isopropylidene.

[0019] In some embodiments, the poly(etherimide) can be a copolymer, for example, a poly(etherimide) sulfone copolymer comprising structural units of formula (1) wherein at least 50 mole% of the R groups are of formula (2) wherein Q¹ is -SO2- and the remaining R groups are independently p-phenylene or m-phenylene or a combination comprising at least one of the foregoing; and Z is 2,2’-(4-phenylene)isopropylidene.

[0020] Alternatively, the poly(etherimide) copolymer optionally comprises additional structural imide units, for example imide units of formula (1) wherein R and V are as described in formula (1), for example V is

wherein W is a single bond, -0-, -S-, -C(O)-, -SO2-, -SO-, a C1-18 hydrocarbon moiety that can be cyclic, acyclic, aromatic, or non-aromatic, -P(R^a)(=0)- wherein R^a is a Ci-s alkyl or C6-12 aryl, or -C_yH2_y- wherein y is an integer from 1 to 5 or a halogenated derivative thereof (which includes perfluoroalkylene groups). These additional structural imide units preferably comprise less than 20 mol% of the total number of units, and more preferably can be present in amounts of 0 to 10 mol% of the total number of units, or 0 to 5 mol% of the total number of units, or 0 to 2 mole % of the total number of units. In some embodiments, no additional imide units are present in the poly(etherimide). The poly(imide) and poly(etherimide) can be prepared by any of the methods well known to those skilled in the art, including the reaction of an aromatic dianhydride of formula (5a) or formula (5b)

or a chemical equivalent thereof, with an organic diamine of formula (6)

H2N-R-NH2 (6)

wherein V, T, and R are defined as described above. Copolymers of the poly(etherimides) can be manufactured using a combination of an aromatic bis(ether anhydride) of formula (5) and a different bis(anhydride), for example a bis(anhydride) wherein T does not contain an ether functionality, for example T is a sulfone.

[0021] Illustrative examples of bis(anhydride)s include 3,3-bis[4-(3,4- dicarboxyphenoxy)phenyl]propane dianhydride; 4,4'-bis(3,4-dicarboxyphenoxy)diphenyl ether dianhydride; 4,4'-bis(3,4-dicarboxyphenoxy)diphenyl sulfide dianhydride; 4,4'-bis(3,4- dicarboxyphenoxy)benzophenone dianhydride; 4,4'-bis(3,4-dicarboxyphenoxy)diphenyl sulfone dianhydride; 2,2-bis[4-(2,3-dicarboxyphenoxy)phenyl]propane dianhydride; 4,4'-bis(2,3- dicarboxyphenoxy)diphenyl ether dianhydride; 4,4'-bis(2,3-dicarboxyphenoxy)diphenyl sulfide dianhydride; 4,4'-bis(2,3-dicarboxyphenoxy)benzophenone dianhydride; 4,4'-bis(2,3- dicarboxyphenoxy)diphenyl sulfone dianhydride; 4-(2,3-dicarboxyphenoxy)-4'-(3,4- dicarboxyphenoxy)diphenyl-2, 2-propane dianhydride; 4-(2,3-dicarboxyphenoxy)-4'-(3,4- dicarboxyphenoxy)diphenyl ether dianhydride; 4-(2,3-dicarboxyphenoxy)-4'-(3,4- dicarboxyphenoxy)diphenyl sulfide dianhydride; 4-(2,3-dicarboxyphenoxy)-4'-(3,4- dicarboxyphenoxy)benzophenone dianhydride; and, 4-(2,3-dicarboxyphenoxy)-4'-(3,4- dicarboxyphenoxy)diphenyl sulfone dianhydride, as well as various combinations thereof.

[0022] Examples of organic diamines include hexamethylenediamine, polymethylated 1,6-n-hexanediamine, heptamethylenediamine, octamethylenediamine, nonamethylenediamine, decamethylenediamine, 1,12-dodecanediamine, 1,18-octadecanediamine, 3- methylheptamethylenediamine, 4,4-dimethylheptamethylenediamine, 4- methylnonamethylenediamine, 5-methylnonamethylenediamine, 2,5- dimethylhexamethylenediamine, 2,5-dimethylheptamethylenediamine, 2, 2- dimethylpropylenediamine, N-methyl-bis (3-aminopropyl) amine, 3- methoxyhexamethylenediamine, l,2-bis(3-aminopropoxy) ethane, bis(3-aminopropyl) sulfide, 1,4-cyclohexanediamine, bis-(4-aminocyclohexyl) methane, m-phenylenediamine, p- phenylenediamine, 2,4-diaminotoluene, 2,6-diaminotoluene, m-xylylenediamine, p- xylylenediamine, 2-methyl-4, 6-diethyl- 1,3-phenylene-diamine, 5-methyl-4, 6-diethyl- 1,3- phenylene-diamine, benzidine, 3,3’-dimethylbenzidine, 3,3’-dimethoxybenzidine, 1,5- diaminonaphthalene, bis(4-aminophenyl) methane, bis(2-chloro-4-amino-3,5-diethylphenyl) methane, bis(4-aminophenyl) propane, 2,4-bis(p-amino-t-butyl) toluene, bis(p-amino-t- butylphenyl) ether, bis(p-methyl-o-aminophenyl) benzene, bis(p-methyl-o-aminopentyl) benzene, 1, 3-diamino-4-isopropylbenzene, bis(4-aminophenyl) sulfide, bis-(4-aminophenyl) sulfone (also known as 4,4'-diaminodiphenyl sulfone (DDS)), and bis(4-aminophenyl) ether. Any regioisomer of the foregoing compounds can be used. Combinations of these compounds can also be used. In some embodiments the organic diamine is m-phenylenediamine, p- phenylenediamine, 4,4'-diaminodiphenyl sulfone, 3,4'-diaminodiphenyl sulfone, 3,3'- diaminodiphenyl sulfone or a combination thereof.

[0023] The poly(imides) and poly(etherimides) can have a melt index of 0.1 to 10 grams per minute (g/min), as measured by American Society for Testing Materials (ASTM) D1238 at 340 to 370 °C, using a 6.7 kilogram (kg) weight. In some embodiments, the poly(etherimide) has a weight average molecular weight (Mw) of 1,000 to 150,000 grams/mole (Dalton), as measured by gel permeation chromatography, using polystyrene standards. In some

embodiments the polyetherimide has an Mw of 10,000 to 80,000 Daltons. Such

poly(etherimide) polymers typically have an intrinsic viscosity greater than 0.2 deciliters per gram (dl/g), or, more specifically, 0.35 to 0.7 dl/g as measured in m-cresol at 25 °C.

[0024] In some embodiments, the thermoplastic composition comprises the

poly(carbonate).“Poly(carbonate)” as used herein means a homopolymer or copolymer having repeating structural carbonate units of formula (7)

O

- R¹— O - C - O - (7)

wherein at least 60 percent of the total number of R¹ groups are aromatic, or each R¹ contains at least one C6-30 aromatic group. Specifically, each R¹ can be derived from a dihydroxy compound such as an aromatic dihydroxy compound of formula (8) or a bisphenol of formula

(9).

In formula (8), each R^h is independently a halogen atom, for example bromine, a Ci-io hydrocarbyl group such as a CM_O alkyl, a halogen-substituted Ci-io alkyl, a C_6-10 aryl, or a halogen-substituted C6-io aryl, and n is 0 to 4.

[0025] In formula (9), R^a and R^b are each independently a halogen, Ci-₁₂ alkoxy, or Ci-₁₂ alkyl, and p and q are each independently integers of 0 to 4, such that when p or q is less than 4, the valence of each carbon of the ring is filled by hydrogen. In an embodiment, p and q is each 0, or 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. X^a is a bridging group connecting the two hydroxy-substituted aromatic groups, where the bridging group and the hydroxy substituent of each Ce arylene group are disposed ortho, meta, or para (specifically para) to each other on the Ce arylene group, for example, a single bond, -0-, -S-, -S(O)-, -S(0)₂-, -C(O)-, or a Ci-is organic group, which can be cyclic or acyclic, aromatic or non-aromatic, and can further comprise heteroatoms such as halogens, oxygen, nitrogen, sulfur, silicon, or phosphorous. For example, X^a can be a substituted or unsubstituted C3-18 cycloalkylidene; a Ci-25 alkylidene of the formula - C(R^c)(R^d) - wherein R^c and R^d are each independently hydrogen, Ci-12 alkyl, Ci-12 cycloalkyl, C7-12 arylalkyl, Ci-12 heteroalkyl, or cyclic C7-12 heteroarylalkyl; or a group of the

formula -C(=R^e)- wherein R^e is a divalent Ci-12 hydrocarbon group.

[0026] Examples of bisphenol compounds include 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)hexafluoropropane, 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,

1.6-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)fluorene, 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.

[0027] Specific dihydroxy compounds include resorcinol, 2,2-bis(4-hydroxyphenyl) propane (“bisphenol A” or“BPA”), 3,3-bis(4-hydroxyphenyl) phthalimidine, 2-phenyl-3,3’- bis(4-hydroxyphenyl) phthalimidine (also known as N-phenyl phenolphthalein bisphenol, “PPPBP”, or 3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-l-one), l,l-bis(4-hydroxy-3- methylphenyl)cyclohexane, and l,l-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane

(isophorone bisphenol).

[0028] In a specific embodiment, the poly(carbonate) is a poly(carbonate) copolymer comprising bisphenol A and bulky bisphenol carbonate units, i.e., derived from bisphenols containing at least 18 carbon atoms, for example 18 to 60 carbon atoms or 20 to 40 carbon atoms. Examples of such copoly(carbonates) include copoly(carbonates) comprising bisphenol A carbonate units and 2-phenyl-3,3’-bis(4-hydroxyphenyl) phthalimidine carbonate units (a BPA-PPPBP copolymer, commercially available under the trade name XHT or CXT from SABIC), a copolymer comprising bisphenol A carbonate units and l,l-bis(4-hydroxy-3- methylphenyl)cyclohexane carbonate units (a BPA-DMBPC copolymer commercially available under the trade name DMC from SABIC), and a copolymer comprising bisphenol A carbonate units and isophorone bisphenol carbonate units (available, for example, under the trade name APEC from Bayer). In a specific embodiment, the poly(carbonate) comprises bisphenol A carbonate units and 2-phenyl-3,3’-bis(4-hydroxyphenyl) phthalimidine carbonate units. In some embodiments, the bisphenol A carbonate repeat units and the 2 -phenyl-3, 3’-bis(4- hydroxyphenyl) phthalimidine carbonate units can be present in a molar ratio of 1:1 to 3:1, preferably 1.5:1 to 2.5:1, more preferably 1.75:1 to 2.25:1.

[0029] In some embodiments, the poly(carbonate) can comprise bisphenol A carbonate units and 2-phenyl-3,3’-bis(4-hydroxyphenyl) phthalimidine carbonate units (such as that available under the trade name CXT from SABIC), wherein the poly(carbonate) has a transmission of visible light of greater than 87% at a thickness of 3 millimeters, and a transmission in the IR region of greater than 89% at a thickness of 3 millimeters. [0030] Poly(carbonates) can be manufactured by processes such as interfacial polymerization and melt polymerization, which are known, and are described, for example, in WO 2013/175448 A1 and WO 2014/072923 Al. An end-capping agent (also referred to as a chain stopper agent or chain terminating agent) can be included during polymerization to provide end groups, for example monocyclic phenols such as phenol, p-cyanophenol, and Ci-22 alkyl-substituted phenols such as p-cumyl-phenol, resorcinol monobenzoate, and p-and tertiary- butyl phenol, monoethers of diphenols, such as p-methoxyphenol, monoesters of diphenols such as resorcinol monobenzoate, functionalized chlorides of aliphatic monocarboxylic acids such as acryloyl chloride and methacryoyl chloride, and mono-chloroformates such as phenyl chloroformate, alkyl-substituted phenyl chloroformates, p-cumyl phenyl chloroformate, and toluene chloroformate. Combinations of different end groups can be used. Branched polycarbonate blocks can be prepared by adding a branching agent during polymerization, for example trimellitic acid, trimellitic anhydride, trimellitic trichloride, tris-p- hydroxyphenylethane, 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. %. Combinations comprising linear poly(carbonates) and branched poly(carbonates) can be used.

[0031] The thermoplastic composition can optionally further comprise one or more additives selected to achieve a desired property, with the proviso that the additive(s) are also selected so as to not significantly adversely affect a desired property of the thermoplastic composition. The additive composition or individual additives can be mixed at a suitable time during the mixing of the components for forming the composition. The additive composition can include an impact modifier, flow modifier, filler (e.g., a particulate polytetrafluoroethylene (PTFE), glass, carbon, mineral, or metal), reinforcing agent (e.g., glass fibers), antioxidant, heat stabilizer, light stabilizer, ultraviolet (UV) light stabilizer, UV absorbing additive, plasticizer, lubricant, release agent (such as a mold release agent), antistatic agent, anti-fog agent, antimicrobial agent, colorant (e.g, a dye or pigment), surface effect additive, radiation stabilizer, flame retardant, anti-drip agent (e.g., a PTFE-encapsulated styrene- acrylonitrile copolymer (TSAN)), or a combination comprising one or more of the foregoing. For example, a filler, a reinforcing agent, a flame retardant, mold release agent, or a combination thereof can be used. The additives can be used in amounts generally known to be effective. For example, the total amount of the additive composition (other than any impact modifier, filler, or reinforcing agent) can be 0.001 to 10.0 wt%, or 0.01 to 5 wt%, each based on the total weight of the composition.

[0032] The thermoplastic composition can also optionally further comprise a

thermoplastic polymer different that the poly(imide), the poly(etherimide), and the

poly(carbonate). In some embodiments, no additional polymers are present. In some embodiments, the thermoplastic composition can exclude a thermoplastic polymer other than the poly(imide), the poly(etherimide), and the poly(carbonate).

[0033] A thermoplastic article made by the method described above represents another aspect of the present disclosure. As described above, molded articles prepared according to the present disclosure can advantageously have enhanced dimensional stability along the flow- and cross-directions, low residual stress, low birefringence, and low optical distortion. Thus molded articles prepared by the method of the present disclosure can be particularly well suited for use in optical applications.

[0034] The molded part prepared by the method of the present disclosure is preferably an optical component. An optical part or component prepared according to the method can be a thickness of, for example, 5 micrometers to 5 millimeters. The molded article can have a surface that is smooth or textured. Surface features on a textured article can be, for example, 5 nanometers to 5 micrometers. In some embodiments, the process of the present disclosure can be particularly advantageous for preparing long, thin molded articles. For example, optical components having a maximum external dimension (e.g., length or diameter) of less than 35 millimeters, or 5 to 10 millimeters, and a thickness of less than 2.5 millimeters, or 0.025 to 1 millimeter, or 0.025 to 0.3 millimeters.

[0035] In some embodiments, the molded thermoplastic article can be a sensor (e.g., for 3D sensing applications, gesture or facial recognition, time-of-flight applications, and the like), a lens, an optical interconnector, a transceiver, or a light guide.

[0036] This disclosure further encompasses the following aspects.

[0037] Aspect 1: A method of injection molding a thermoplastic article, the method comprising: applying ultrasonic energy to a chamber having pellets disposed therein, the pellets comprising a thermoplastic composition comprising a poly(imide), a poly(etherimide), a poly(carbonate), or a combination thereof, wherein the ultrasonic energy is effective to provide melted pellets; applying a force to the melted pellets such that the melted pellets are forced into a mold having a desired shape to provide a molded part; and recovering the molded part. [0038] Aspect 2: The method of aspect 1, wherein the molded part is an optical component, preferably wherein the optical part has a thickness of 5 micrometers to 5

millimeters.

[0039] Aspect 3: The method of aspect 1 or 2, wherein melted and unmelted pellets are present in the chamber when the force is applied.

[0040] Aspect 4: The method of any of aspects 1 to 3, wherein the ultrasonic energy is applied by a sonotrode.

[0041] Aspect 5: The method of aspect 4, wherein the force is applied to the sonotrode and the sonotrode forces the melted pellets into the mold.

[0042] Aspect 6: The method of any of aspects 1 to 5, further comprising cooling the molded part prior to recovering the molded part.

[0043] Aspect 7: The method of any of aspects 1 to 6, wherein the thermoplastic composition comprises the poly(imide) or the poly(etherimime), preferably wherein the thermoplastic composition comprises the poly(etherimide), more preferably wherein the poly(etherimide) comprises repeating units of the formula

wherein each R is independently a substituted or unsubstituted divalent organic group, such as a substituted or unsubstituted C6-20 aromatic hydrocarbon group, a substituted or unsubstituted straight or branched chain C4-20 alkylene group, or a substituted or unsubstituted C3-8 cycloalkylene group; and T is -O- or a group of the formula -O-Z-O- wherein the divalent bonds of the -O- or the -O-Z-O- group are in the 3,3', 3,4', 4,3', or the 4,4' positions, and Z is an aromatic C6-24 monocyclic or polycyclic moiety optionally substituted with 1 to 6 Ci-s alkyl groups, 1 to 8 halogen atoms, or a combination thereof, provided that the valence of Z is not exceeded; even more preferably wherein each R is independently bis(4,4’-phenylene)sulfone, bis(3,4’-phenylene)sulfone, bis(3,3’-phenylene)sulfone, p-phenylene, or m-phenylene and Z is 2,2-(4-phenylene)isopropylidene.

[0044] Aspect 8: The method of any of aspects 1 to 6, wherein the thermoplastic composition comprises the poly(carbonate), preferably wherein the polycarbonate comprises bisphenol A carbonate units and 2-phenyl-3,3’-bis(4-hydroxyphenyl) phthalimidine carbonate units. [0045] Aspect 9: The method of any of aspects 1 to 8, wherein the thermoplastic composition further comprises an additive, preferably wherein the additive comprises a filler, a reinforcing fiber, a flame retardant, a mold release agent, or a combination thereof.

[0046] Aspect 10: A thermoplastic article made by the method of any of aspects 1 to 9.

[0047] Aspect 11: The thermoplastic article of aspect 10, wherein the article is an optical component.

[0048] Aspect 12: The thermoplastic article of any of claims 10 to 11, wherein the article is a sensor, a lens, an optical interconnector, a transceiver, or a light guide.

[0049] The compositions, methods, and articles can alternatively comprise, consist of, or consist essentially of, any appropriate materials, steps, or components herein disclosed. The compositions, methods, and articles can additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any materials (or species), steps, or components, that are otherwise not necessary to the achievement of the function or objectives of the compositions, methods, and articles.

[0050] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. “Combinations” is inclusive of blends, mixtures, alloys, reaction products, and the like. The terms“first,”“second,” and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms“a” and“an” and“the” do not denote a limitation of quantity, and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly

contradicted by context. “Or” means“and/or” unless clearly stated otherwise. Reference throughout the specification to“some embodiments”,“an embodiment”, and so forth, means that a particular element described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. The term “combination thereof’ as used herein includes one or more of the listed elements, and is open, allowing the presence of one or more like elements not named. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments.

[0051] Unless specified to the contrary herein, all test standards are the most recent standard in effect as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[0052] Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this application belongs. 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.

[0053] Compounds are described using standard nomenclature. For example, any position not substituted by any indicated group is understood to have its valency filled by a bond as indicated, or a hydrogen atom. A dash that is not between two letters or symbols is used to indicate a point of attachment for a substituent. For example, -CHO is attached through carbon of the carbonyl group.

[0054] As used herein, the term“hydrocarbyl”, whether used by itself, or as a prefix, suffix, or fragment of another term, refers to a residue that contains only carbon and hydrogen. The residue can be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated, or unsaturated. It can also contain combinations of aliphatic, aromatic, straight chain, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbon moieties. However, when the hydrocarbyl residue is described as substituted, it may, optionally, contain heteroatoms over and above the carbon and hydrogen members of the substituent residue. Thus, when specifically described as substituted, the hydrocarbyl residue can also contain one or more carbonyl groups, amino groups, hydroxyl groups, or the like, or it can contain heteroatoms within the backbone of the hydrocarbyl residue. The term "alkyl" means a branched or straight chain, unsaturated aliphatic hydrocarbon group, e.g., methyl, ethyl, n-propyl, i-propyl, n-butyl, s-butyl, t-butyl, n- pentyl, s-pentyl, and n- and s-hexyl. “Alkenyl” means a straight or branched chain, monovalent hydrocarbon group having at least one carbon-carbon double bond (e.g., ethenyl (-HC=CH2)). “Alkoxy” means an alkyl group that is linked via an oxygen (i.e., alkyl-O-), for example methoxy, ethoxy, and sec-butyloxy groups. "Alkylene" means a straight or branched chain, saturated, divalent aliphatic hydrocarbon group (e.g., methylene (-CH2-) or, propylene (-(CH2)3- )).“Cycloalkylene” means a divalent cyclic alkylene group, -CiThn-x, wherein x is the number of hydrogens replaced by cyclization(s). “Cycloalkenyl” means a monovalent group having one or more rings and one or more carbon-carbon double bonds in the ring, wherein all ring members are carbon (e.g., cyclopentyl and cyclohexyl). "Aryl" means an aromatic hydrocarbon group containing the specified number of carbon atoms, such as phenyl, tropone, indanyl, or naphthyl. “Arylene” means a divalent aryl group. “Alkylarylene” means an arylene group substituted with an alkyl group. “Arylalkylene” means an alkylene group substituted with an aryl group (e.g., benzyl). The prefix "halo" means a group or compound including one or more of a fluoro, chloro, bromo, or iodo substituent. A combination of different halo groups (e.g., bromo and fluoro), or only chloro groups can be present. The prefix“hetero” means that the compound or group includes at least one ring member that is a heteroatom (e.g., 1, 2, or 3 heteroatom(s)), wherein the heteroatom(s) is each independently N, O, S, Si, or P. “Substituted” means that the compound or group is substituted with at least one (e.g., 1, 2, 3, or 4) substituents that can each independently be a C_1-9 alkoxy, a C_1-9 haloalkoxy, a nitro (-NO₂), a cyano (-CN), a Ci-₆ alkyl sulfonyl (-S(=0)₂-alkyl), a Ce-n aryl sulfonyl (-S(=0)₂-aryl), a thiol (-SH), a thiocyano (-SCN), a tosyl (CH3C6H4SO2-), a C3-12 cycloalkyl, a C2-12 alkenyl, a C5-12

cycloalkenyl, a Ce- aryl, a C_7-13 arylalkylene, a C_4-12 heterocycloalkyl, and a C_3-12 heteroaryl instead of hydrogen, provided that the substituted atom’s normal valence is not exceeded. The number of carbon atoms indicated in a group is exclusive of any substituents. For example - CH₂CH₂CN is a C₂ alkyl group substituted with a nitrile.

[0055] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.

Claims

CLAIMS What is claimed is:

1. A method of injection molding a thermoplastic article, the method comprising:

applying ultrasonic energy to a chamber having pellets disposed therein, the pellets comprising a thermoplastic composition comprising a poly(imide), a poly(etherimide), a poly(carbonate), or a combination thereof, wherein the ultrasonic energy is effective to provide melted pellets;

applying a force to the melted pellets such that the melted pellets are forced into a mold having a desired shape to provide a molded part; and

recovering the molded part.

2. The method of claim 1, wherein the molded part is an optical component, preferably wherein the optical part has a thickness of 5 micrometers to 5 millimeters.

3. The method of claim 1 or 2, wherein melted and unmelted pellets are present in the chamber when the force is applied.

4. The method of any of claims 1 to 3, wherein the ultrasonic energy is applied by a sonotrode.

5. The method of claim 4, wherein the force is applied to the sonotrode and the sonotrode forces the melted pellets into the mold.

6. The method of any of claims 1 to 5, further comprising cooling the molded part prior to recovering the molded part.

7. The method of any of claims 1 to 6, wherein the thermoplastic composition comprises the poly(imide) or the poly(etherimime), preferably wherein the thermoplastic composition comprises the poly(etherimide),

more preferably wherein the poly(etherimide) comprises repeating units of the formula

wherein each R is independently a substituted or unsubstituted divalent organic group, such as a substituted or unsubstituted C6-20 aromatic hydrocarbon group, a substituted or unsubstituted straight or branched chain C4-20 alkylene group, or a substituted or unsubstituted C3-8 cycloalky lene group; and

T is -O- or a group of the formula -O-Z-O- wherein the divalent bonds of the -O- or the - O-Z-O- group are in the 3,3', 3,4', 4,3', or the 4,4' positions, and Z is an aromatic C6-24 monocyclic or polycyclic moiety optionally substituted with 1 to 6 Ci-s alkyl groups, 1 to 8 halogen atoms, or a combination thereof, provided that the valence of Z is not exceeded;

even more preferably wherein each R is independently bis(4,4’-phenylene)sulfone, bis(3,4’-phenylene)sulfone, bis(3,3’-phenylene)sulfone, p-phenylene, or m-phenylene and Z is 2,2-(4-phenylene)isopropylidene.

8. The method of any of claims 1 to 6, wherein the thermoplastic composition comprises the poly(carbonate), preferably wherein the polycarbonate comprises bisphenol A carbonate units and 2-phenyl-3,3’-bis(4-hydroxyphenyl) phthalimidine carbonate units.

9. The method of any of claims 1 to 8, wherein the thermoplastic composition further comprises an additive, preferably wherein the additive comprises a filler, a reinforcing fiber, a flame retardant, a mold release agent, or a combination thereof.

10. A thermoplastic article made by the method of any of claims 1 to 9.

11. The thermoplastic article of claim 10, wherein the article is an optical component.

12. The thermoplastic article of any of claims 10 to 11, wherein the article is a sensor, a lens, an optical interconnector, a transceiver, or a light guide.