Container for precision member and method for preparing the same

Patent metadata

Field	Value
Publication number	US-10066055-B2
Application number	US-201414499552-A
Country	US
Kind code	B2
Filing date	Sep 29, 2014
Priority date	Oct 1, 2013
Publication date	Sep 4, 2018
Grant date	Sep 4, 2018

Abstract

A container for precision members is prepared from a polycarbonate resin, wherein a polycarbonate resin solution prepared by immersing the polycarbonate resin in water and leaving the solution has chloride ions (Cl − ), fluoride ions (F − ) and sulfate ions (SO 4 2− ) in a concentration of about 2 ppb or less, independently of each other, as detected by ion chromatography (IC). The container for precision members is capable of preserving and transporting the precision members predisposed to damage by minor amounts of impurities or contaminants without damage.

First claim

What is claimed is:

1. A container for precision members prepared from a polycarbonate resin,
wherein a solution prepared by immersing the polycarbonate resin in water and leaving the solution has chloride ions (Cl − ), fluoride ions (F − ) and sulfate ions (SO 4 2− ) in a concentration of about 2 ppb or less, independently of each other, as detected by ion chromatography (IC),
wherein the concentration of chloride, fluoride and sulfate ions is measured after adding about 35 grams of the polycarbonate resin to about 50 grams of water, maintaining at a temperature of about 50° C. for about 12 hours, and shaking at room temperature for 12 hours, and
wherein when about 4 g of the polycarbonate resin is heated at 150° C. for about 30 minutes, the polycarbonate resin generates gases, wherein the gases have a detected area (total peak area) of about 3.5×10 7 Area/g or less as detected by HS-SPME GC/MS.

2. The container for precision members according to claim 1 , wherein, when heated, the polycarbonate resin generates gases, the gases providing 25 or fewer detected peaks as detected by head space-solid phase microextraction for gas chromatography/mass spectrometry (HS-SPME GC/MS).

3. The container for precision members according to claim 1 , wherein the polycarbonate resin is prepared by melt polymerization of an aromatic dihydroxy compound and a diaryl carbonate.

4. The container for precision members according to claim 1 , wherein the aromatic dihydroxy compound is represented by Formula 1:

where A is a single bond, a substituted or unsubstituted C 1 to C 30 hydrocarbon group, —CO—, —S—, or —SO 2 —; R 1 and R 2 are the same or different and are each independently substituted or unsubstituted C 1 to C 30 alkyl or substituted or unsubstituted C 6 to C 30 aryl; and a and b are the same or different and are each independently an integer ranging from 0 to 4.

5. The container for precision members according to claim 1 , wherein the diaryl carbonate is represented by Formula 2:

wherein Ar 1 and Ar 2 are the same or different and are each independently substituted or unsubstituted C 6 to C 20 aryl.

6. The container for precision members according to claim 1 , wherein a mole ratio of the aromatic dihydroxy compound to the diaryl carbonate (aromatic dihydroxy compound: diaryl carbonate) ranges from about 1:about 0.9 to about 1:about 1.3.

7. The container for precision members according to claim 1 , wherein the polycarbonate resin has a weight average molecular weight (Mw) from about 20,000 g/mol to about 35,000 g/mol.

8. The container for precision members according to claim 1 , wherein the polycarbonate resin has a notched Izod impact strength from about 60 kgf·cm/cm to about 100 kgf·cm/cm, as measured on an about ⅛″ thick specimen in accordance with ASTM D256.

9. The container for precision members according to claim 1 , wherein the polycarbonate resin has a melt flow index from about 5 g/10 minutes to about 80 g/10 minutes, as measured at about 300° C. under a load of about 1.2 kg in accordance with ASTM D1238.

10. A method for preparing a container for precision members, comprising:
preparing a polymerized material through melt polymerization of an aromatic dihydroxy compound and a diaryl carbonate wherein a solution prepared by immersing the polymerized material in water and leaving the solution has chloride ions (Cl − ), fluoride ions (F − ) and sulfate ions (SO 4 2− ) in a concentration of about 2 ppb or less, independently of each other, as detected by ion chromatography (IC),
wherein the concentration of chloride, fluoride and sulfate ions is measured after adding about 35 grams of the polymerized material to about 50 grams of water, maintaining at a temperature of about 50° C. for about 12 hours, and shaking at room temperature for 12 hours, and
wherein when about 4 g of the polymerized material is heated at 150° C. for about 30 minutes, the polymerized material generates gases, wherein the gases have a detected area (total peak area) of about 3.5×10 7 Area/g or less as detected by HS-SPME GC/MS;
preparing a pelletized extrudate by extruding the polymerized material using an extruder; and
molding the pelletized extrudate to form a container for precision members.

11. The method according to claim 10 , wherein the extruder is provided at one end thereof with a vent to perform ventilation during extrusion.

12. The method according to claim 10 , wherein the melt polymerization comprises polymerizing the aromatic dihydroxy compound and the diaryl carbonate to prepare a polycarbonate prepolymer; and melt polymerizing the prepared prepolymer to provide a polycarbonate resin.

13. The container for precision members according to claim 1 , wherein the solution has chloride ions (Cl − ), fluoride ions (F − ) and sulfate ions (SO 4 2− ) in a concentration of about 0.2 ppb to 1.9 ppb, independently of each other, as detected by ion chromatography (IC).

14. The container for precision members according to claim 1 , wherein the gases have a detected area (total peak area) of about 3×10 6 Area/g to about 3.4×10 7 Area/g as detected by HS-SPME GC/MS.

15. The method according to claim 10 , wherein the solution has chloride ions (Cl − ), fluoride ions (F − ) and sulfate ions (SO 4 2− ) in a concentration of about 0.2 ppb to 1.9 ppb, independently of each other, as detected by ion chromatography (IC).

16. The method according to claim 10 , wherein, when heated, the polymerized material generates gases, the gases providing 25 or fewer detected peaks as detected by head space-solid phase microextraction for gas chromatography/mass spectrometry (HS-SPME GC/MS).

17. The method according to claim 10 , wherein the gases have a detected area (total peak area) of about 3×10 6 Area/g to about 3.4×10 7 Area/g as detected by HS-SPME GC/MS.

18. The container for precision members according to claim 2 , wherein the solution has chloride ions (Cl − ), fluoride ions (F − ) and sulfate ions (SO 4 2− ) in a concentration of about 0.2 ppb to 1.9 ppb, independently of each other, as detected by ion chromatography (IC) and wherein the gases have a detected area (total peak area) of about 3×10 6 Area/g to about 3.4×10 7 Area/g, as detected by HS-SPME GC/MS.

19. The method according to claim 16 , wherein the solution has chloride ions (Cl − ), fluoride ions (F − ) and sulfate ions (SO 4 2− ) in a concentration of about 0.2 ppb to 1.9 ppb, independently of each other, as detected by ion chromatography (IC) and wherein the gases have a detected area (total peak area) of about 3×10 6 Area/g to about 3.4×10 7 Area/g, as detected by HS-SPME GC/MS.

Assignees

• Lotte Advanced Mat Co Ltd

Inventors

• Hur Jong Chan
• Chi Jun Ho
• Chei Woo Suk
• Lee Eun Byul

Classifications

• H10P72/10

  using carriers specially adapted therefor, e.g. front opening unified pods [FOUP] · CPC title

• C08G64/307

  and phenols · CPC title

• C08G64/06 Primary

  not containing aliphatic unsaturation · CPC title

• Y10T428/1397

  Single layer [continuous layer] · CPC title

• C08G64/30

  using carbonates · CPC title