Polycarbonate-polyester composition and article

Patent metadata

Field	Value
Publication number	US-2017190904-A1
Application number	US-201515308678-A
Country	US
Kind code	A1
Filing date	Jul 8, 2015
Priority date	Aug 8, 2014
Publication date	Jul 6, 2017
Grant date	—

Abstract

A composition includes specific amounts of a polyester with 1,4 cyclohexanedimethylene terephthalate repeat units, a halogen-free aromatic polycarbonate, a brominated aromatic polycarbonate, and an unsubstituted or substituted C 2 C 18 hydrocarbyl sulfonate salt. The composition exhibits an improved balance of flame retardancy and transparency relative to a corresponding composition without the sulfonate salt. The composition can be used to fabricate articles that benefit from its transparency and flame retardancy

First claim

1 . A composition comprising, based on the total weight of polymers and flame retardants:
20 to 74.95 weight percent of a polyester comprising 10 to 100 mole percent 1,4-cyclohexanedimethylene terephthalate repeat units; 20 to 50 weight percent of a halogen-free aromatic polycarbonate; 5 to 50 weight percent of a brominated aromatic polycarbonate; 0.05 to 1 weight percent of an unsubstituted or substituted C 2 -C 18 -hydrocarbyl sulfonate salt; and 0 to 1 weight percent of polyestercarbonates, polycarbonate-polysiloxane block copolymers, polyamides, polyimides, fluorinated polymers, and combinations thereof.

2 . The composition of claim 1 , wherein the polyester further comprises 1 to 90 mole percent of repeat units selected from 1,4-cyclohexanedimethylene isophthalate, ethylene terephthalate, 1,4-butylene terephthalate, and combinations thereof.

3 . The composition of claim 1 , wherein the polyester comprises greater than 50 to 99 mole percent 1,4-cyclohexanedimethylene terephthalate repeat units and further comprises 1 to less than 50 mole percent ethylene terephthalate repeat units.

4 . The composition of claim 1 , wherein the halogen-free aromatic polycarbonate comprises repeat units having the formula

wherein at least 60 percent of the total number of R 1 groups are aromatic.

5 . The composition of claim 4 , wherein at least 90 percent of the total number of R 1 groups have the formula

6 . The composition of claim 1 , wherein the brominated polycarbonate comprises repeat units having the formula

or a combination thereof; wherein n is 1, 2, 3, or 4; p and q are each independently 0, 1, 2, 3, or 4, provided that the sum of p and q is at least 1; R a is independently at each occurrence halogen, or unsubstituted or substituted C 1-10 hydrocarbyl, provided that at least one occurrence of R a per molecule is bromine; and X a is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, or C 1-18 hydrocarbylene, which can be cyclic or acyclic, aromatic or non-aromatic, and can further comprise one or more heteroatoms selected from halogens, oxygen, nitrogen, sulfur, silicon, and phosphorus.

7 . The composition of claim 1 , wherein the brominated polycarbonate comprises repeat units having the formula

8 . The composition of claim 1 , wherein the brominated polycarbonate contributes 2 to 20 weight percent bromine to the composition.

9 . The composition of claim 1 , wherein the unsubstituted or substituted C 2 -C 18 -hydrocarbyl sulfonate salt comprises
an alkali metal cation, an alkaline earth metal cation, or a combination thereof; and a C 2 -C 18 perfluoroalkyl sulfonate, an unsubstituted or substituted C 6 -C 20 aryl sulfonate, or a combination thereof.

10 . The composition of claim 1 , wherein the unsubstituted or substituted C 2 -C 18 -hydrocarbyl sulfonate salt comprises potassium 3-(phenylsulfonyl)benzene sulfonate, sodium 3-(phenylsulfonyl)benzene sulfonate, potassium perfluorobutane sulfonate, sodium perfluorobutane sulfonate, sodium toluene sulfonate, potassium perfluorobutane sulfonate, potassium perfluoroctane sulfonate, tetraethylammonium perfluorohexane sulfonate, or a combination thereof.

11 . The composition of claim 1 , wherein the unsubstituted or substituted C 2 -C 18 -hydrocarbyl sulfonate salt comprises potassium 3-(phenylsulfonyl)benzene sulfonate.

12 . The composition of claim 1 , comprising 0 to 2 weight percent of any polyester other than the polyester comprising 10 to 100 mole percent 1,4-cyclohexanedimethylene terephthalate repeat units.

13 . The composition of claim 1 , comprising 0 to 2 weight percent of impact modifiers.

14 . The composition of claim 1 , excluding polyestercarbonates, polycarbonate-polysiloxane block copolymers, polyamides, polyimides, and fluorinated polymers.

15 . The composition of claim 1 , comprising 0 to 2 weight percent of flame retardants other than the brominated aromatic polycarbonate and the unsubstituted or substituted C 2 -C 18 -hydrocarbyl sulfonate salt.

16 . The composition of claim 1 , comprising 0 to 2 weight percent of fillers.

17 . The composition of claim 1 ,
wherein the halogen-free aromatic polycarbonate comprises repeat units having the formula

wherein at least 90 percent of the total number of R 1 groups have the formula

wherein the brominated polycarbonate comprises repeat units having the formula

wherein the unsubstituted or substituted C 2 -C 18 -hydrocarbyl sulfonate salt comprises potassium 3-(phenylsulfonyl)benzene sulfonate;
wherein the composition excludes fluorinated polymers, polyesters other than the polyester comprising 10 to 100 mole percent 1,4-cyclohexanedimethylene terephthalate repeat units, impact modifiers, polyestercarbonates, polycarbonate-polysiloxane block copolymers, polyamides, polyimides, flame retardants other than the brominated aromatic polycarbonate and the unsubstituted or substituted C 2 -C 18 -hydrocarbyl sulfonate salt, and fillers; and
wherein the composition comprises
40 to 55 weight percent of the polyester comprising 10 to 100 mole percent 1,4-cyclohexanedimethylene terephthalate repeat units,
30 to 40 weight percent of the halogen-free aromatic polycarbonate,
10 to 20 weight percent of the brominated aromatic polycarbonate, and
0.1 to 0.5 weight percent of the unsubstituted or substituted C 2 -C 18 -hydrocarbyl sulfonate salt.

18 . An article comprising a composition comprising, based on the total weight of polymers and flame retardants:
20 to 74.95 weight percent of a polyester comprising 10 to 100 mole percent 1,4-cyclohexanedimethylene terephthalate repeat units; 20 to 50 weight percent of a halogen-free aromatic polycarbonate; 5 to 50 weight percent of a brominated aromatic polycarbonate; and 0.05 to 1 weight percent of an unsubstituted or substituted C 2 -C 18 -hydrocarbyl sulfonate salt; and 0 to 1 weight percent of polyestercarbonates, polycarbonate-polysiloxane block copolymers, polyamides, polyimides, fluorinated polymers, and combinations thereof.

19 . The article of claim 18 , selected from consumer electronics components, automotive components, mass transportation components, medical device components, electrical components, lighting components, and holders for tea lights or votive candles.

20 . The article of claim 18 ,
wherein the halogen-free aromatic polycarbonate comprises repeat units having the formula

wherein at least 90 percent of the total number of R 1 groups have the formula

wherein the brominated polycarbonate comprises repeat units having the formula

Assignees

• Sabic Global Technologies Bv

Inventors

• Parimal Kumar
• Grieshaber Sarah

Classifications

• C08L67/02 Primary

  Polyesters derived from dicarboxylic acids and dihydroxy compounds (C08L67/06 takes precedence) · CPC title

• C08L69/00

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

• C08L2205/02

  containing two or more polymers of the same C08L -group · CPC title

• C08K5/42

  Sulfonic acids; Derivatives thereof · CPC title

• C07D221/00

  Heterocyclic compounds containing six-membered rings having one nitrogen atom as the only ring hetero atom, not provided for by groups C07D211/00 - C07D219/00 · CPC title