High heat polycarbonate compositions, methods for the preparation thereof, and articles derived therefrom
View Patent ↗Melt blended compositions, comprising up to 20 wt % of an optional additive, and 80-100 wt % of a copolycarbonate having a Tg of 200° C. or more of (1) wherein the mole ratio of x:y is 35:65 to 90:10, R 1 is derived from a dihydroxy compound (2) wherein R 3 and R 5 are each independently a halogen or a C 1-6 alkyl group, R 4 is a C 1-6 alkyl, phenyl, or phenyl substituted with up to five halogens or C 1-6 alkyl groups, and each c is independently 0 to 4; R 2 is derived from a dihydroxy compound (6): wherein R a and R b are each independently a halogen atom or a monovalent C 1-6 alkyl group; p and q are each independently integers of 0 to 4; and X a is a divalent group; and 95 to 5 wt % of a polycarbonate having a Tg of less than 200° C. of formula (9) wherein R 9 derived from a dihydroxy compound of formula (6); and 0.001 to 0.1 wt % of a transesterification catalyst.
1. A melt-blended composition formed from, based on the total weight of the melt-blended composition,
0 to 20 wt % of an additive; and
to 100 wt % of a polymer composition, wherein the polymer composition comprises, based on the total weight of the polymer composition,
5 to 95 wt % of a high Tg copolycarbonate of formula (1)
wherein the mole ratio of x:y is 35:65 to 90:10,
R 1 is derived from a dihydroxy compound of formula (2)
wherein R 3 and R 5 are each independently a halogen or a C 1-6 alkyl group, R 4 is a C 1-6 alkyl, phenyl, or phenyl substituted with up to five halogens or C 1-6 alkyl groups, and each c is independently 0 to 4;
R 2 is derived from a dihydroxy compound of formula (6):
wherein R a and R b are each independently a halogen atom or a monovalent C 1-6 alkyl group; p and q are each independently integers of 0 to 4; and X a is methylene, cyclohexylmethylene, 2-[2.2.1]-bicycloheptylidene, ethylidene, isopropylidene, neopentylidene, cyclohexylidene, or cyclopentadecylidene; and
wherein the high Tg copolycarbonate has a Tg of 200° C. or more; and
95 to 5 wt % of a polycarbonate of formula (9)
wherein R 9 is derived from a dihydroxy compound of formula (6)
wherein R a and R b are each independently a halogen atom or a monovalent C 1-6 alkyl group; p and q are each independently integers of 0 to 4; and X a is methylene, cyclohexylmethylene, 2-[2.2.1]-bicycloheptylidene, ethylidene, isopropylidene, neopentylidene, cyclohexylidene, or cyclopentadecylidene; and
wherein the polycarbonate of formula (9) has a glass transition temperature of less than 200° C.; and
0.001 to 0.1 wt % of a transesterification catalyst.
2. The melt blended composition of claim 1 , wherein no additive is present.
3. The melt blended composition of claim 1 , wherein the polymer composition consists of high Tg copolycarbonate of formula (1) and the polycarbonate of formula (9).
4. The melt blended composition of claim 1 , wherein the melt blended composition is transparent, wherein the melt blended composition has a haze of less than 10% measured according to ASTM D1003-00 using a molded sample having a thickness of 3.2 mm.
5. The melt blended composition of claim 1 , having a single Tg.
6. The melt blended composition of claim 1 , wherein R 4 is a C 1-6 alkyl or phenyl group.
7. The melt blended composition of claim 1 , wherein each c is zero, and R 4 is a methyl or phenyl group.
8. The melt blended composition of claim 7 , wherein R 9 is derived from a dihydroxy compound of formula (6):
wherein each of p and q is zero and X a is isopropylidene.
9. The melt blended composition of claim 1 , wherein R 9 is derived from a dihydroxy compound of formula (6):
wherein each of p and q is zero and X a is isopropylidene.
10. The melt blended composition of claim 1 , wherein the polycarbonate of formula (9) further comprises repeating units of formula (10):
wherein D is a C 2-10 alkylene group, a C 6-20 alicyclic group, a C 6-20 aromatic group or a polyoxyalkylene group in which the alkylene groups contain 2 to 6 carbon atoms.
11. The melt blended composition of claim 1 , wherein the transesterification catalyst is a tetraorganophosphonium hydroxide, a tetraorganophosphonium carbonate, a tetraorganophosphonium acetate, a tetraorganophosphonium phenolate, a tetraorganophosphonium bisphenolate, a tetraorganoammonium hydroxide, a tetraorganoammonium carbonate, a tetraorganoammonium phosphite, a tetraorganoammonium acetate, a tetraorganoammonium phenolate, a tetraorganoammonium bisphenolate, or a combination comprising at least one of the foregoing transesterification catalysts, wherein each organic group is the same or different, and is a substituted or unsubstituted C 1 -C 10 alkyl, C 3 -C 10 cycloalkyl, C 6 -C 24 aryl, C 7 -C 25 alkylaryl, or C 7 -C 25 arylalkyl, wherein the substitution is a halogen, cyano, hydroxyl, nitro, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, C 1 -C 6 alkoxy, C 6 -C 12 aryloxy, C 1 -C 6 aminoalkyl, C 6 -C 12 aryl, C 7 -C 18 arylalkyl having 1 to 3 separate or fused rings, C 7 -C 18 alkylaryl having 1 to 3 separate or fused rings, or a combination comprising at least one of the foregoing substitutions.
12. The melt blended composition of claim 1 , wherein the transesterification catalyst is a tetraorganophosphonium hydroxide, a tetraorganophosphonium acetate, or a tetraorganophosphonium phenolate, wherein each organic group is the same or different, and is an unsubstituted C 1 -C 10 alkyl, C 6 -C 18 aryl, C 7 -C 25 alkylaryl, or C 7 -C 25 arylalkyl.
13. The melt blended composition of claim 1 , wherein the transesterification catalyst is a tetra C 1 -C 6 alkyl phosphonium hydroxide, a tetra C 1 -C 6 alkyl phosphonium phenoxide, or a combination comprising at least one of the foregoing catalysts.
14. The melt blended composition of claim 1 , further comprising an additional polymer, an impact modifier, a filler, a reinforcing agent, a thermal stabilizer, an antioxidant, a light stabilizer, a gamma-irradiation stabilizer, a plasticizer, a colorant, an antistatic agent, a lubricant, a mold releasing agent, a flame retardant, an anti-drip agent, or a combination comprising at least one of the foregoing additives.
15. The melt blended composition of claim 1 , having a haze of less than 3% measured according to ASTM D1003-00 using a molded sample having a thickness of 3.2 mm.
16. The melt blended composition of claim 1 , having an HDT of 160 to 200° C., measured at 66 psi according to ASTM D648.
17. The melt blended composition of claim 1 , having an MVR, measured at 330° C./2.16 kg according to ASTM D1238-04, of 0.5 to 80 cubic centimeters per 10 minutes.
18. A melt blended composition, consisting essentially, based on the total weight of the composition, of a melt-blended combination of
30 to 70 wt % of a high Tg copolycarbonate of formula (1)
wherein the mole ratio of x:y is 40:60 to 60:40,
R 1 is derived from a dihydroxy compound of formula (2)
wherein R 3 and R 5 are each independently a halogen or a C 1-6 alkyl group, R 4 is a methyl or a phenyl group, and each c is 0 to 1;
R 2 is derived from a dihydroxy compound of formula (3)
HO—R 6 —OH (3),
wherein at least 60% of the R 6 groups are aromatic, and the dihydroxy compound of formula (3) is not the same as the dihydroxy compound of formula (2); and
wherein the high Tg copolycarbonate has a Tg of 200° C. or more; and
60 to 40 wt % of a polycarbonate of formula (9)
wherein at least 60% of the R 9 groups are aromatic, and the polycarbonate has a glass transition temperature of less than 180° C.; and
0.002 to 0.02 wt % of a transesterification catalyst, wherein the transesterification catalyst is a tetra C 1 -C 6 alkyl phosphonium hydroxide, a tetra C 1 -C 6 alkyl phosphonium phenoxide, or a combination comprising at least one of the foregoing catalysts.
19. The melt blended composition of claim 18 , wherein the melt blended composition is transparent, wherein the melt blended composition has a haze of less than 10% measured according to ASTM D1003-00 using a molded sample having a thickness of 3.2 mm.
20. The melt blended composition of claim 18 , wherein each c is zero and R 4 is a phenyl.
21. The melt blended composition of claim 18 , wherein R 9 is derived from a dihydroxy compound of formula (6):
wherein each of p and q is zero and X a is isopropylidene.
22. The melt blended composition of claim 17 , wherein each c is zero and R 4 is a phenyl.
23. A method of manufacture of a melt blended composition, comprising melt-blending a composition comprising, based on the total weight of the melt-blended composition,
0 to 20 wt % of an additive; and
to 100 wt % of a polymer composition, wherein the polymer composition comprises, based on the total weight of the polymer composition,
5 to 95 wt % of a high Tg copolycarbonate of formula (1)
wherein the mole ratio of x:y is 35:65 to 90:10,
R 1 is derived from a dihydroxy compound of formula (2)
wherein R 3 and R 5 are each independently a halogen or a C 1-6 alkyl group, R 4 is a C 1-6 alkyl, phenyl, or phenyl substituted with up to five halogens or C 1-6 alkyl groups, and c is 0 to 4;
R 2 is derived from a dihydroxy compound of formula (6):
wherein R a and R b are each independently a halogen atom or a monovalent C 1-6 alkyl group; p and q are each independently integers of 0 to 4; and X a is methylene, cyclohexylmethylene, 2-[2.2.1]-bicycloheptylidene, ethylidene, isopropylidene, neopentylidene, cyclohexylidene, or cyclopentadecylidene; and
wherein the high Tg copolycarbonate has a Tg of 200° C. or more; and
95 to 5 wt % of a polycarbonate of formula (9)
wherein R 9 is derived from a dihydroxy compound of formula (6)
wherein R a and R b are each independently a halogen atom or a monovalent C 1-6 alkyl group; p and q are each independently integers of 0 to 4; and X a is methylene, cyclohexylmethylene, 2-[2.2.1]-bicycloheptylidene, ethylidene, isopropylidene, neopentylidene, cyclohexylidene, or cyclopentadecylidene; and
wherein the polycarbonate has a glass transition temperature of less than 200° C.; and
0.001 to 0.1 wt % of a transesterification catalyst.
24. A melt-blended melt blended composition formed by the method of claim 23 .
25. An article comprising the melt-blended composition formed by the method of claim 23 .
26. An article comprising the melt-blended composition of claim 1 .
27. The article of claim 26 , in the form of an automotive part.
28. The article of claim 26 , wherein the article is transparent, wherein the melt blended composition has a haze of less than 10% measured according to ASTM D1003-00 using a molded sample having a thickness of 3.2 mm.
29. An article comprising the composition of claim 7 , 8 , 9 , 18 , 19 , 20 , 21 , or 22 .
30. The article of claim 29 in the form of an automotive part.
31. A method of manufacture of an article, comprising
molding, extruding, coating, metallizing, or shaping the melt blended composition of claim 1 into an article.