Polycarbonate composition and associated article and method of additive manufacturing

Patent metadata

Field	Value
Publication number	US-11834577-B2
Application number	US-201917280244-A
Country	US
Kind code	B2
Filing date	Apr 25, 2019
Priority date	Sep 26, 2018
Publication date	Dec 5, 2023
Grant date	Dec 5, 2023

Abstract

A composition includes specific amounts of a reinforcing filler and a copolycarbonate containing bisphenol A carbonate units and second carbonate units of the formula wherein R a , R b , R 3 , R 4 , j, p, and q are defined herein. The composition is useful for fabricating articles that exhibit a desirable balance of heat resistance, printability in large format additive manufacturing, and good surface appearance in printed parts. Also described is a method of additive manufacturing utilizing the composition.

First claim

The invention claimed is:

1. A composition, comprising, based on the weight of the composition:
40 to 75 weight percent of a copolycarbonate comprising, based on 100 mole percent total carbonate units, 60 to 75 mole percent bisphenol A carbonate units and to 25 to 40 mole percent of second carbonate units of the formula

wherein
R 4 is phenyl, and p, q, and j are each zero;
10 to 45 weight percent of a bisphenol A polycarbonate having a melt volume flow rate of 15 to 150 cubic centimeters per 10 minutes determined according to ASTM D1238-13 at 300° C. and 1.2 kilogram load; and
15 to 25 weight percent of carbon fiber having a diameter of 4 to 100 micrometers;
wherein the composition excludes polycarbonate-polysiloxane copolymers; and
wherein the composition exhibits a melt flow rate less than or equal to 20 grams per 10 minutes, determined according to ASTM D-1238-13 at 300° C. and 1.2 kilogram load.

2. An article comprising the composition of claim 1 .

3. A method of additive manufacturing, the method comprising:
melt extruding the composition of claim 1 to form a first molten extrusion;
depositing the first molten extrusion in a predetermined pattern to form a first layer comprising an upper surface;
further melt extruding the same composition to form a second molten extrusion; and
depositing the second molten extrusion in a predetermined pattern to form a second layer comprising a lower surface in contact with the upper surface of the first layer.

Assignees

• Shpp Global Tech Bv
• Sabic Global Technologies Bv

Inventors

• Geng Eddie Kebin
• Elleithy Rabeh
• Allessio Timothy
• Vollenberg Peter
• Thompson Walter R
• Voorde David

Classifications

• C08L69/00 Primary

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

• B29C64/165

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• C08G64/12

  containing nitrogen · CPC title

• C08K7/06

  Elements · CPC title

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title