High heat polycarbonate compositions

Patent metadata

Field	Value
Publication number	US-10370534-B2
Application number	US-201515302502-A
Country	US
Kind code	B2
Filing date	Apr 15, 2015
Priority date	Apr 15, 2014
Publication date	Aug 6, 2019
Grant date	Aug 6, 2019

Abstract

Polycarbonate blend compositions are disclosed. The compositions include at least one polycarbonate useful for high heat applications. The compositions can include one or more additional polymers. The compositions can include one or more additives. The compositions can be used to prepare articles of manufacture, and in particular, automotive bezels.

First claim

What is claimed is:

1. A metallized article comprising a metallized surface and a thermoplastic composition comprising:
(a) a first polycarbonate that includes structural units derived from at least one of:

wherein R a and R b at each occurrence are each independently halogen, C 1 -C 12 alkyl, C 1 -C 12 alkenyl, C 3 -C 8 cycloalkyl, or C 1 -C 12 alkoxy; p and q at each occurrence are each independently 0 to 4; R 13 at each occurrence is independently a halogen or a C 1 -C 6 alkyl group; c at each occurrence is independently 0 to 4; R 14 at each occurrence is independently a C 1 -C 6 alkyl, phenyl, or phenyl substituted with up to five halogens or C 1 -C 6 alkyl groups; R g at each occurrence is independently C 1 -C 12 alkyl or halogen, or two R g groups together with the carbon atoms to which they are attached form a four-, five-, or six-membered cycloalkyl group; t is 0 to 10; and x:y is 1:99 to 99:1, the first polycarbonate having a Mw of 16,000 g/mol [ ± 1,000 g/mol] to 20,000 g/mol [ ± 1,000 g/mol], as determined by GPC using polycarbonate standards;
(b) 15 to 60 wt % of a second polycarbonate that is a Bisphenol A (BPA) polycarbonate having a Mw of greater than 19,800 g/mol to 40,000 g/mol [ ± 1,000 g/mol], as determined by GPC using BPA polycarbonate standards;
(c) optionally 15 wt % to 45 wt % of a third polycarbonate that is a BPA polycarbonate having a Mw of 17,000 g/mol [ ± 1,000 g/mol] to 40,000 g/mol [ ± 1,000 g/mol], as determined by GPC using BPA polycarbonate standards; provided the third polycarbonate is different from the second polycarbonate; and
(d) 0.5 wt % to 10 wt % of a first polyester of formula

wherein T at each occurrence is independently selected from a divalent aliphatic radical, a divalent alicyclic radical, a divalent aromatic radical, and a polyoxyalkylene radical; D at each occurrence is independently selected from a divalent aliphatic radical, a divalent alicyclic radical, and a divalent aromatic radical; and m is an integer selected from 25 to 1000; provided that the combined wt % value of all components does not exceed 100 wt %;
wherein the composition has a heat deflection temperature of at least 155° C., measured at 0.45 MPa in accordance with ASTM D 648 or ISO 75;
wherein the composition has a melt viscosity of less than 395 Pa s, measured in accordance with ISO 11443 at 300° C. at a shear rate of 1500 s 1 ;
wherein a molded sample of the composition has at least 60% ductility in a multi-axial impact test at 23° C., measured in accordance with ASTM D3763 or ISO 6603; and
wherein the article achieves a GT0 metal adhesion rating when measured in accordance with ASTM 3359/ISO 2409.

2. The metallized article of claim 1 , wherein the article has one or more of the following properties:
a minimum haze onset temperature of 150° C.; and
exhibits 0% corrosion when stored for 240 hours at 98% relative humidity at 40° C., in accordance with DIN 50017.

3. The metallized article of claim 1 , wherein the first polycarbonate comprises at least 18 mol % structural units derived from BPA, and has a Tg of at least 170° C.

4. The metallized article of claim 1 , wherein the first polycarbonate comprises 31 mol % to 35 mol % structural units derived from PPPBP.

5. The metallized article of claim 1 , wherein the first polycarbonate has a Mw of greater than 17,000 g/mol [ ± 1,000 g/mol] and less than 20,000 g/mol [ ± 1,000 g/mol], as determined by GPC using polycarbonate standards.

6. The metallized article of claim 5 , wherein the article has one or more of the following properties:
a minimum haze onset temperature of 150° C.; and
exhibits 0% corrosion when stored for 240 hours at 98% relative humidity at 40° C., in accordance with DIN 50017.

7. The metallized article of claim 5 , wherein the first polycarbonate comprises at least 18 mol % structural units derived from BPA, and has a Tg of at least 170° C.

8. The metallized article of claim 5 , wherein the first polycarbonate comprises 31 mol % to 35 mol % structural units derived from PPPBP.

9. The metallized article of claim 1 , wherein the first polycarbonate is selected from:
a para-cumylphenol end-capped polycarbonate comprising structural units derived from PPPBP and BPA, having a Mw of 20,000 g/mol [ ± 1,000 g/mol] as determined by GPC using BPA polycarbonate standards;
a para-cumylphenol end-capped polycarbonate comprising structural units derived from PPPBP and BPA, having a Mw of 18,500 g/mol [ ± 1,000 g/mol] as determined by GPC using BPA polycarbonate standards; and
a para-cumylphenol end-capped polycarbonate comprising structural units derived from PPPBP and BPA, having a Mw of 17,000 g/mol [ ± 1,000 g/mol] as determined by GPC using BPA polycarbonate standards.

10. The metallized article of claim 1 , wherein the second polycarbonate and the third polycarbonate are each independently selected from:
a Bisphenol A (BPA) polycarbonate having a Mw of greater than 19,800 g/mol to 22,000 g/mol [ ± 1,000 g/mol], as determined by GPC using BPA polycarbonate standards; and
a BPA polycarbonate having a Mw of 29,000 g/mol [ ± 1,000 g/mol] to 30,000 g/mol [ ± 1,000 g/mol], as determined by GPC using BPA polycarbonate standards.

11. The metallized article of claim 1 , wherein the second polycarbonate and the third polycarbonate are each independently selected from:
a linear BPA polycarbonate having a Mw of 21,700 g/mol [ ± 1,000 g/mol], as determined by GPC using BPA polycarbonate standards;
a phenol end-capped linear BPA polycarbonate having a Mw of 21,800 g/mol as determined by GPC using BPA polycarbonate standards;
a PCP end-capped linear BPA polycarbonate having a Mw of 21,900 g/mol [ ± 1,000 g/mol] as determined by GPC using BPA polycarbonate standards;
a PCP end-capped linear BPA polycarbonate having a Mw of 29,900 g/mol [ ± 1,000 g/mol] as determined by GPC using BPA polycarbonate standards; and
a phenol end-capped linear BPA polycarbonate having a Mw of 30,000 g/mol [ ± 1,000 g/mol] as determined by GPC using BPA polycarbonate standards.

12. The metallized article of claim 1 , wherein the composition comprises
40 wt % to 85 wt % of the first polycarbonate;
15 wt % to 60 wt % of the second polycarbonate;
15 wt % to 45 wt % of the third polycarbonate; and
0.5 wt % to 10 wt % of the first polyester;
provided that the combined wt % value of all components does not exceed 100 wt %.

13. The metallized article according to claim 1 , wherein the composition is selected from the group consisting of (1), (2), and (3):
(1) a composition comprising 65.00 wt % of the first polycarbonate; 29.61 wt % of the second polycarbonate; 5.00 wt % of the first polyester; 0.27 wt % of pentaerythritol tetrastearate; 0.08 wt % of phosphite stabilizer; and 0.04 wt % of hindered phenol;
(2) a composition comprising 65.00 wt % of the first polycarbonate; 32.61 wt % of the second polycarbonate; 2.00 wt % of the first polyester; 0.27 wt % of pentaerythritol tetrastearate; 0.08 wt % of phosphite stabilizer; and 0.04 wt % of hindered phenol; and
(3) a composition comprising 65.00 wt % of the first polycarbonate; 33.61 wt % of the second polycarbonate; 1.00 wt % of the first polyester; 0.27 wt % of pentaerythritol tetrastearate; 0.08 wt % of phosphite stabilizer; and 0.04 wt % of hindered phenol.

Assignees

• Sabic Global Technologies Bv

Inventors

• Grieshaber Sarah E
• Farrell Tony
• Lowery Daniel Francis
• Van Der Mee Mark Adrianus Johannes
• Assink Roland Sebastian
• Van De Grampel Robert Dirk

Classifications

• C08L2205/035

  containing four or more polymers in a blend · CPC title

• C08L69/00 Primary

  Compositions of polycarbonates; Compositions of derivatives of polycarbonates · CPC title

• C08L2205/025

  containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure · CPC title

• B32B15/09

  comprising polyesters · CPC title

• C08L2201/08

  Stabilised against heat, light or radiation or oxydation · CPC title