Thermoplastic polycarbonate compositions, articles made therefrom and method of manufacture
View Patent ↗A thermoplastic composition, contains a polycarbonate resin, a polycarbonate-polysiloxane copolymer, an aromatic vinyl copolymer, an impact modifier, and a mineral filler, wherein the composition has least about 40% ductility under multiaxial impact strength test conditions per ASTM D3763 at −30° C. Alternatively, a composition contains a polycarbonate resin, a polycarbonate-polysiloxane copolymer in an amount sufficient to provide at least about 2.5 wt. % siloxane by weight of the composition, an aromatic vinyl copolymer comprising SAN, an impact modifier comprising ABS, and a mineral filler. Such compositions may be made by combining, by weight of the composition, polycarbonate resin, a polycarbonate-polysiloxane copolymer, an aromatic vinyl copolymer, an impact modifier, and a mineral filler, wherein the composition has at least 40% ductility under multiaxial impact strength test conditions per ASTM D3763 at −30° C. An article may be made from such a composition, optionally by molding, shaping or forming the composition to form the article.
1. A thermoplastic composition, comprising:
a polycarbonate resin;
a polycarbonate-polysiloxane copolymer;
an aromatic vinyl copolymer;
an impact modifier, wherein the impact modifier is a graft copolymer; and
a mineral filler,
wherein the composition has least about 40% ductility under multiaxial impact strength test conditions per ASTM D3763 at −30° C. determined using a 4-inch (10 cm) diameter, 3.2 millimeter (mm)-thick disk sample, ½-inch (12.7 mm) diameter dart, and an impact velocity of 2.2 meters per second (m/s).
2. The composition of claim 1 , having at least 50% ductility under multiaxial impact strength test conditions per ASTM D3763 at −30° C. determined using a 4-inch (10 cm) diameter, 3.2 millimeter (mm)-thick disk sample, ½-inch (12.7 mm) diameter dart, and an impact velocity of 2.2 meters per second (m/s).
3. The composition of claim 1 , wherein the mineral filler comprises a silane-treated mineral filler.
4. The composition of claim 1 , wherein the mineral filler comprises silane-treated talc.
5. The composition of claim 1 , wherein the impact modifier comprises a grafted rubber copolymer.
6. The composition of claim 1 , wherein the impact modifier comprises ABS.
7. The composition of claim 1 , wherein the aromatic vinyl copolymer comprises SAN.
8. The composition of claim 1 , having full ductility under multiaxial impact test conditions per ASTM D3763 at −30° C. determined using a 4-inch (10 cm) diameter, 3.2 millimeter (mm)-thick disk sample, ½-inch (12.7 mm) diameter dart, and an impact velocity of 2.2 meters per second (m/s).
9. The composition of claim 1 , having at least 50% ductility under multiaxial impact test conditions per ASTM D3763 at −40° C. determined using a 4-inch (10 cm) diameter, 3.2 millimeter (mm)-thick disk sample, ½-inch (12.7 mm) diameter dart, and an impact velocity of 2.2 meters per second (m/s).
10. The composition of claim 1 , wherein the composition is substantially free of phosphate and sulfonate flame retardants.
11. The composition of claim 1 , consisting essentially of the polycarbonate resin, the polycarbonate-polysiloxane copolymer, the aromatic vinyl copolymer, the impact modifier and the mineral filler.
12. The composition of claim 1 , comprising about 2 wt. % to about 25 wt. % aromatic vinyl copolymer, about 0.1 wt. % to about 15 wt. % impact modifier and about 2 wt. % to about 20 wt. % mineral filler, by weight of the composition.
13. The composition of claim 12 , having at least 40% ductility under multiaxial impact test conditions per ASTM D3763 at −30° C. determined using a 4-inch (10 cm) diameter, 3.2 millimeter (mm)-thick disk sample, ½-inch (12.7 mm) diameter dart, and an impact velocity of 2.2 meters per second (m/s).
14. The composition of claim 12 , wherein the mineral filler comprises a silane-treated mineral filler.
15. The composition of claim 12 , wherein the mineral filler comprises silane-treated talc.
16. A thermoplastic composition, comprising:
a polycarbonate resin;
a polycarbonate-polysiloxane copolymer in an amount sufficient to provide at least about 2.5 wt. % siloxane by weight of the composition;
an aromatic vinyl copolymer comprising SAN;
an impact modifier comprising ABS; and
a mineral filler.
17. The composition of claim 16 , wherein the mineral filler comprises silane-treated mineral filler.
18. The composition of claim 16 , comprising about 2 wt. to about 25 wt. % to about 25 wt. % SAN, about 0.1 wt. % to about 15 wt. % ABS and about 2 wt. % to about 20 wt. % mineral filler.
19. A method for making a thermoplastic composition, comprising combining, by weight of the composition, polycarbonate resin, a polycarbonate-polysiloxane copolymer, an aromatic vinyl copolymer, an impact modifier, wherein the impact modifier is a graft copolymer, and a mineral filler, wherein the composition has at least 40% ductility under multiaxial impact strength test conditions per ASTM D3763 at −30° C.
20. The method of claim 19 , wherein the composition has at least 50% ductility under multiaxial impact test conditions per ASTM D3763 at −30° C. determined using a 4-inch (10 cm) diameter, 3.2 millimeter (mm)-thick disk sample, ½-inch (12.7 mm) diameter dart, and an impact velocity of 2.2 meters per second (m/s).
21. An article comprising the composition of claim 1 .
22. A method for forming an article, comprising molding, shaping, extruding or forming the composition of claim 1 to form the article.