Processes for designing cross-linkable polycarbonates and articles formed therefrom

Patent metadata

Field	Value
Publication number	US-2017166708-A1
Application number	US-201515320133-A
Country	US
Kind code	A1
Filing date	Jun 19, 2015
Priority date	Jun 20, 2014
Publication date	Jun 15, 2017
Grant date	—

Abstract

Articles having improved flame retardance and chemical resistance properties can be made from blends containing a cross-linkable polycarbonate resin having repeating units derived from a dihydroxybenzophenone. Predictive equations can be used to relate properties of the blend and the polycarbonate resin to the fmal properties of the article, and permit design of articles with desired combinations of properties.

First claim

1 . A process for preparing an article that has a high probability of passing a UL94 V0 test, comprising:
(A) providing a polymeric composition to be exposed to a dosage (D) of UVA radiation, wherein the polymeric composition comprises:
(i) a cross-linkable polycarbonate resin including repeating units derived from a dihydroxybenzophenone;
(ii) a flame retardant; and
(iii) optionally one or more polymeric base resins;
(iv) wherein the cross-linkable polycarbonate resin contains a molar percentage of the dihydroxybenzophenone (MOL %); and
(v) wherein the polymeric composition has:
(a) a molecular weight increase of polymeric components therein after exposure to UV radiation (MW_I),
(b) a melt flow rate (MF), and
(c) a weight percentage of the cross-linkable polycarbonate resin (WP);

(B) forming an article from the polymeric composition; and (C) exposing the formed article to the dosage;
wherein D, MOL %, MW_I, MF, and WP are determined based on a flame performance equation as follows:
Sqrt(V0_Avg)=−0.62315+(9.21942×10 −3 ×WP)+(0.041498×D)+(4.34876×10 −5 ×MW_I)+(6.55546×10 −3 ×MOL %)+(0.089017×MF)+(9.87122×10 −4 ×WP×D)−(4.36994×10 −6 ×WP×MW_I)−(2.43440×10 −3 ×WP×MOL %)+(2.08870×10 −3 ×WP×MF)−(4.40362×10 −6 ×D×MW_I)−(2.32567×10 −3 ×D×MOL %)−(3.75290×10 −3 ×D×MF)+(2.05611×10 −5 ×MW_I×MF)+(5.61409×10 −3 ×MOL %×MF)+(2.98567×10 −9 ×(MW_I) 2 )+(6.17229×10 −3 ×(MOL %) 2 )−(0.017115×(MF) 2 )

wherein the article has an average V0 (V0_Avg) that is the average of:
(i) the probability of a first time pass in a UL94 V0 test at a thickness of 1.2 mm after UV exposure measured after 2 days of aging at room temperature, and
(ii) the probability of a first time pass in a UL94 V0 test at a thickness of 1.2 mm after UV exposure measured after 7 days of aging at 70° C.; and

wherein V0_Avg is at least 0.7; and
wherein D is measured in J/cm 2 of UVA radiation.

2 . The process of claim 1 , wherein (a) D, MOL %, MW_I, WP, and MF are also determined based on a percentage retention of tensile elongation equation as follows:
Sqrt(% RE)=+1.37235+(0.077638×WP)+(0.67685×D)−(2.39234×10 −3 ×MW_I)−(0.23516×MOL %)−(0.57165×MF)−(9.18615×10 −3 ×WP×MF)−(6.66016×10 −5 ×D×MW_I)−(0.019526×D×MOL %)+(2.07809×10 −4 ×MW_I×MOL %)+(2.79873×10 −7 ×(MW_I) 2 )+(0.056758×(MF) 2 )

wherein % RE is the percentage retention of tensile elongation after exposure to acetone at a thickness of 3.2 mm; and % RE is at least 85; or
(b) wherein D, MOL %, and MW_I are also determined based on a Delta YI equation as follows:
Ln(D_YI)=−0.047177+(0.062393×D+1.81716×10 −4 ×MW_I)+(0.017370×MOL %)−(5.48288×10 −6 ×D×MW_I)

wherein D_YI is the change in YI after exposure to the dosage D, measured before UVA exposure and at least 48 hours after UVA exposure; and D_YI is 6 or less; or
(c) wherein D, MOL %, MW_I, and MF are also determined based on a Delta % T equation as follows:
(D_% T+8.90) 2.65 =+343.92310−(6.75832×D)−(0.022788×MW_I)+(0.43933×MOL %)−(3.84042×MF)+(5.56692×10 −4 ×D×MW_I)−(8.77565×10 −4 ×MW_I×MOL %)+(8.94844×10 −4 ×MW_I×MF)

wherein D_% T is the change in light transmission after exposure to the dosage D, measured before UVA exposure and at least 48 hours after UVA exposure; and D_% T is 3.5 or less; or
(d) wherein D, MOL %, MW_I, MF, and WP are also determined based on a gel thickness equation as follows:
Sqrt(GEL)=+2.69872−(0.093035×WP)+(0.31583×D)−(5.37830×10 −4 ×MW_I)+(0.28207×MOL %)−(0.092447×MF)−(2.29409×10 −3 ×WP×D)+(2.03257×10 −5 ×WP×MW_I)+(0.010073×WP×MOL %)−(1.01623×10 −7 ×(MW_I) 2 )−(0.043959×(MOL %) 2 )

wherein GEL is the gel thickness on a surface of the article, measured in microns, and is at least 5.

3 . The process of claim 1 , wherein the polymeric composition comprises a polymeric base resin.

4 . The process of claim 1 , wherein MOL % is from 2.5 to 20; or wherein MW_I is from about 600 to about 11,000; or wherein MF is from about 5 to about 20; or wherein WP is from 50 to 100.

5 . The process of claim 1 , wherein the cross-linkable polycarbonate resin is a copolymer or a terpolymer.

6 . The article formed by the process of claim 1 , wherein:
(a) the article has a V0_Avg of at least 0.7, a percentage retention of tensile elongation (% RE) of at least 85, and a Delta YI of less than 6; or (b) the article is a molded article, a film, a sheet, a layer of a multilayer film or a layer of a multilayer sheet.

7 . A process for preparing an article that has a desired percentage retention of tensile elongation after exposure to acetone at a thickness of 3.2 mm, comprising:
(A) providing a polymeric composition to be exposed to a dosage (D) of UVA radiation, wherein the polymeric composition comprises:
(i) a cross-linkable polycarbonate resin including repeating units derived from a dihydroxybenzophenone;
(ii) a flame retardant; and
(iii) optionally one or more polymeric base resins;
(iv) wherein the cross-linkable polycarbonate resin contains a selectable molar percentage of the dihydroxybenzophenone (MOL %); and
(v) wherein the polymeric composition has:
(a) a molecular weight increase of polymeric components therein after exposure to UV radiation (MW_I),
(b) a melt flow rate (MF), and
(c) a weight percentage of the cross-linkable polycarbonate resin (WP);

(B) forming an article from the polymeric composition; and (C) exposing the formed article to the dosage;
wherein D, MOL %, MW_I, MF, and WP are determined based on a percentage retention of tensile elongation equation as follows:
Sqrt(% RE)=+1.37235+(0.077638×WP)+(0.67685×D)−(2.39234×10 −3 ×MW_I)−(0.23516×MOL %)−(0.57165×MF)−(9.18615×10 −3 ×WP×MF)−(6.66016×10 −5 ×D×MW_I)−(0.019526×D×MOL %)+(2.07809×10 −4 ×MW_I×MOL %)+(2.79873×10 −7 ×(MW_I) 2 )+(0.056758×(MF) 2 )

wherein % RE is the percentage retention of tensile elongation after exposure to acetone at a thickness of 3.2 mm; and % RE is at least 85.

8 . The process of claim 7 , wherein (a) D, MOL %, MW_I, WP, and MF are also determined based on a flame performance equation as follows:
Sqrt(V0_Avg)=−0.62315+(9.21942×10 −3 ×WP)+(0.041498×D)+(4.34876×10 −5 ×MW_I)+(6.55546×10 −3 ×MOL %)+(0.089017×MF)+(9.87122×10 −4 ×WP×D)−(4.36994×10 −6 ×WP×MW_I)−(2.43440×10 −3 ×WP×MOL %)+(2.08870×10 −3 ×WP×MF)−(4.40362×10 −6 ×D×MW_I)−(2.32567×10 −3 ×D×MOL %)−(3.75290×10 −3 ×D×MF)+(2.05611×10 −5 ×MW_I×MF)+(5.61409×10 −3 ×MOL %×MF)+(2.98567×10 −9 ×(MW_I) 2 )+(6.17229×10 −3 ×(MOL %) 2 )−(0.017115×(MF) 2 )

wherein the article has an average V0 (V0_Avg) that is the average of (i) the probability of a first time pass in a UL94 V0 test at a thickness of 1.2 mm after UV exposure and measured after 2 days of aging at room temperature, and (ii) the probability of a first time pass in a UL94 V0 test at a thickness of 1.2 mm after UV exposure and measured after 7 days of aging at 70° C.; and V0_Avg is at least 0.7; wherein D is measured in J/cm 2 of UVA radiation; or
(b) wherein D, MOL %, and MW_I are also determined based on a Delta YI equation as follows:
Ln(D_YI)=−0.047177+(0.062393×D+1.81716×10 −4 ×MW_I)+(0.017370×MOL %)−(5.48288×10 −6 ×D×MW_I)

wherein D_YI is the change in YI after exposure to the dosage D, measured before UVA exposure and at least 48 hours after UVA exposure; and D_YI is 6 or less; or
(c) wherein D, MOL %, MW_I, and MF are also determined based on a Delta % T equation as follows:
(D_% T+8.90) 2.65 =+343.92310−(6.75832×D)−(0.022788×MW_I)+(0.43933×MOL %)−(3.84042×MF)+(5.56692×10 −4 ×D×MW_I)−(8.77565×10 −4 ×MW_I×MOL %)+(8.94844×10 −4 ×MW_I×MF)

wherein D_% T is the change in light transmission after exposure to the dosage D, measured before UVA exposure and at least 48 hours after UVA exposure; and D_% T is 3.5 or less;

Assignees

• Sabic Global Technologies Bv

Inventors

• Flores Amanda Marie
• Hoover James Franklin
• Johnson Peter
• Morizur Jean-Francois
• Evans Thomas

Classifications

• C08K5/5435

  containing oxygen in a ring · CPC title

• C08K5/42

  Sulfonic acids; Derivatives thereof · CPC title

• C08L2201/02

  Flame or fire retardant/resistant · CPC title

• C08L69/00

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

• C08G64/06

  not containing aliphatic unsaturation · CPC title