Cross-linked polycarbonate resin with improved chemical and flame resistance

Patent metadata

Field	Value
Publication number	US-9481761-B2
Application number	US-201514701620-A
Country	US
Kind code	B2
Filing date	May 1, 2015
Priority date	Dec 20, 2012
Publication date	Nov 1, 2016
Grant date	Nov 1, 2016

Abstract

Disclosed herein are compositions including a cross-linked polycarbonate. The cross-linked polycarbonate may be derived from a polycarbonate having about 0.5 mol % to about 5 mol % endcap groups derived from a monohydroxybenzophenone. A plaque including the composition can achieve a UL94 5VA rating. Also disclosed herein are articles including the compositions, methods of using the compositions, and processes for preparing the compositions.

First claim

What is claimed is:

1. A composition comprising:
a cross-linkable polycarbonate resin comprising about 0.5 mole % to about 5.0 mole % endcap groups derived from a monohydroxybenzophenone, wherein the cross-linkable polycarbonate resin is made from an interfacial polymerization process comprising the steps of:
(i) forming a mixture comprising bisphenol-A, a monohydroxybenzophenone, and a tertiary amine catalyst in a water-immiscible solvent and water solvent system;
(ii) stirring the mixture of (i) while maintaining a pH from about 8 to about 9 by the addition of a basic solution to form a stirred mixture;
(iii) charging the stirred mixture of (ii) with phosgene, while simultaneously adding a basic solution to maintain the pH between about 8.5 to about 10 to form a reaction mixture containing the cross-linkable polycarbonate resin;
(iv) separating the organic layer from the reaction mixture;
(v) washing the organic layer of (iv) with an aqueous acid;
(vi) washing the acid-washed organic layer of (v) with deionized water to achieve a neutral pH; and
(vii) isolating the cross-linkable polycarbonate resin from the neutral organic layer of (vi);

wherein the cross-linkable polycarbonate resin has a weight-average molecular weight of between 17,000 and 35,000 Daltons and has a polydispersity index (PDI) of between 3.0 and 7.3 as measured by GPC using a UV-VIS detector and polycarbonate standards.

2. The composition of claim 1 , wherein a second end-capping agent is present in the mixture of (i) in addition to the monohydroxybenzophenone.

3. The composition of claim 2 , wherein the second end-capping agent is selected from the group consisting of phenol, p-t-butylphenol, p-cumylphenol, and 4-cyanophenol.

4. The composition of claim 2 , wherein the cross-linkable polycarbonate resin comprises about 0.5 mole % to about 5.0 mole % endcap groups derived from the second end-capping agent.

5. The composition of claim 1 , wherein the mixture of (i) further comprises a phase transfer catalyst.

6. The composition of claim 5 , wherein the phase transfer catalyst is selected from the group consisting of [CH 3 (CH 2 ) 3 ] 4 NX, [CH 3 (CH 2 ) 3 ] 4 PX, [CH 3 (CH 2 ) 5 ] 4 NX, [CH 3 (CH 2 ) 6 ] 4 NX, [CH 3 (CH 2 ) 4 ] 4 NX, CH 3 [CH 3 (CH 2 ) 3 ] 3 NX, and CH 3 [CH 3 (CH 2 ) 2 ] 3 NX, wherein X is Cl − , Br − , a C 1 -C 8 alkoxy group or a C 6 -C 18 aryloxy group.

7. The composition of claim 1 , wherein the mixture of (i) further comprises a branching agent.

8. A composition comprising a cross-linkable polycarbonate resin,
wherein the cross-linkable polycarbonate resin comprises about 0.5 mol % to about 5 mol % endcap groups derived from a monohydroxybenzophenone;
wherein the cross-linkable polycarbonate resin has a weight-average molecular weight of between 17,000 and 35,000 Daltons and has a polydispersity index (PDI) of between 3.0 and 7.3 as measured by GPC using a UV-VIS detector and polycarbonate standards; and
wherein when a plaque of about 0.5 mm thickness formed from the cross-linkable polycarbonate resin is exposed to UV radiation, the resin increases in molecular weight by at least 15%.

9. The composition of claim 8 , wherein the resin increases in molecular weight by at least 30%.

10. The composition of claim 8 , wherein the resin increases in molecular weight by at least 135%.

11. A composition comprising a cross-linkable polycarbonate resin,
wherein the cross-linkable polycarbonate resin comprises about 0.5 mol % to about 5 mol % endcap groups derived from a monohydroxybenzophenone;
wherein the cross-linkable polycarbonate resin has a polydispersity index (PD)I of between 3.0 and 7.3 as measured by GPC using a UV-VIS detector and polycarbonate standards;
wherein the composition has a melt volume flow rate of 2 to 12 cc/10 minutes at 300° C./1.2 kg;
wherein a plaque made from the composition has a transparency of 70% to 90% at a thickness of 3.2 mm, measured according to ASTM-D1003-00; and
wherein a plaque that is made from the composition and exposed to UV radiation can achieve a UL94 5VA rating at a thickness of 2.0 mm (±10%).

12. A composition comprising a cross-linkable polycarbonate resin,
wherein the cross-linkable polycarbonate resin comprises about 0.5 mol % to about 5 mol % endcap groups derived from a monohydroxybenzophenone;
wherein a plaque made from the composition with a thickness of 3.2 mm has a ductility of 100% after exposure to 2000 mJ/cm 2 of UV radiation;
wherein a plaque made from the composition with a thickness of 2.54 mm has a haze of less than 2%;
wherein a film of about 0.5 mm thickness and exposed to UV radiation has a % gel of 15% or greater; and
wherein a plaque made from the composition with a thickness of 3.2 mm and crosslinked, then submerged in acetone for 5 minutes, does not crack or blister.

13. The composition of claim 12 , wherein a plaque made from the composition with a thickness of 3.2 mm and crosslinked, then submerged in toluene for 5 minutes, does not crack or blister.

14. A composition comprising a cross-linkable polycarbonate resin,
wherein the cross-linkable polycarbonate resin comprises endcap groups derived from a monohydroxybenzophenone;
wherein the composition has a melt volume flow rate of 2 to 12 cc/10 minutes at 300° C./1.2 kg; and
wherein a plaque that is made from the composition and exposed to UV radiation can achieve a UL94 5VA rating at a thickness of 2.0 mm (±10%).

15. A composition comprising a cross-linkable polycarbonate resin and a flame retardant,
wherein the cross-linkable polycarbonate resin comprises endcap groups derived from a monohydroxybenzophenone;
wherein the composition comprises about 0.08 wt % or less of the flame retardant;
wherein the composition has a melt volume flow rate of 2 to 20 cc/10 minutes at 300° C./1.2 kg; and
wherein a plaque that is made from the composition and exposed to UV radiation can achieve a UL94 5VA rating at a thickness of 3.0 mm (±10%).

16. The composition of claim 1 , wherein the cross-linkable polycarbonate resin comprises about 1 mole % to about 3 mole % endcap groups derived from the monohydroxybenzophenone.

17. The composition of claim 1 , wherein a plaque that is made from the composition and exposed to UV radiation can achieve a UL94 5VA rating at a thickness of 2.0 mm (±10%).

18. The composition of claim 1 , wherein a plaque that is made from the composition and exposed to UV radiation can achieve a UL94 5VA rating at a thickness of 1.5 mm (±10%).

19. The composition of claim 11 , wherein the cross-linkable polycarbonate resin has a weight-average molecular weight of between 17,000 and 35,000 Daltons, as measured by GPC using a UV-VIS detector and polycarbonate standards.

20. The composition of claim 12 , wherein the cross-linkable polycarbonate resin has a polydispersity index (PDI) of between 3.0 and 7.3 as measured by GPC using a UV-VIS detector and polycarbonate standards.

21. The composition of claim 1 , wherein the cross-linkable polycarbonate resin has a melt volume flow rate of about 2 to about 12 cc/10 min at 300° C./1.2 kg.

22. The composition of claim 1 , wherein a plaque comprising the composition has a transparency of 70% or greater at a thickness of 3.2 mm, measured according to ASTM-D1003-00.

23. The composition of claim 1 , wherein a plaque comprising the composition has a haze value of less than 2% at a thickness of 2.54 mm, measured according to ASTM D1003-07.

24. The compositio

Assignees

• Sabic Global Technologies Bv

Inventors

• Morizur Jean-Francois
• Sybert Paul Dean
• Hoover James Franklin
• Lake Derek

Classifications

• C08L2201/02

  Flame or fire retardant/resistant · CPC title

• C08G67/00

  Macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing oxygen or oxygen and carbon, not provided for in groups C08G2/00 - C08G65/00 · CPC title

• B29C45/0001

  characterised by the choice of material · CPC title

• C08J3/28

  Treatment by wave energy or particle radiation · CPC title

• C08L69/00

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