Thermoplastic compostions, methods of making, and articles formed therefrom
View Patent ↗A thermoplastic composition comprises a polycarbonate having repeating structural carbonate units of the formula (1): wherein at least 60 percent of the total number of R 1 groups contain aromatic organic groups and the balance thereof are aliphatic, alicyclic, or aromatic groups; and wherein the polycarbonate comprises terminal groups derived from reaction with a cyanophenol of the formula wherein Y is a halogen, C 1-3 alkyl group, C 1-3 alkoxy group, C 7-12 arylalkyl, C 7-12 alkylaryl, or nitro group, y is 0 to 4, and c is 1 to 5, provided that y+c is 1 to 5; a branching agent; and a flame retardant. The compositions are useful in the manufacture of a wide variety of parts, particularly those having a thin wall.
1. A thermoplastic composition comprising:
a polycarbonate having repeating structural carbonate units of the formula
wherein at least 60 percent of the total number of R 1 groups contain aromatic organic groups and the balance thereof are aliphatic, alicyclic, or aromatic groups; and wherein
the polycarbonate comprises cyanophenyl carbonate endcapping groups derived from reaction with a cyanophenol of the formula
wherein Y is a halogen, C 1-3 alkyl group, C 1-3 alkoxy group, C 7-12 arylalkyl, alkylaryl, or nitro group, y is 0 to 4, and c is 1 to 5, provided that y+c is 1 to 5;
wherein the polycarbonate comprises a branching agent; and
a flame retardant.
2. The thermoplastic composition of claim 1 , wherein the branching agent is a structure derived from a triacid trichloride of the formula
wherein Z is hydrogen, a halogen, C 1-3 alkyl group, C 1-3 alkoxy group, C 7-12 arylalkyl, alkylaryl, or nitro group, and z is 0 to 3; or wherein the branching agent is a structure derived from a tri-substituted phenol of the formula
wherein T is a C 1-20 alkyl group, C 1-20 alkyleneoxy group, C 7-12 arylalkyl, or alkylaryl group, S is hydrogen, a halogen, C 1-3 alkyl group, C 1-3 alkoxy group, C 7-12 arylalkyl, alkylaryl, or nitro group, s is 0 to 4; or wherein the branching agent comprises a structure of the formula
or a combination of comprising one or more of the branching agents.
3. The thermoplastic composition of claim 1 , wherein the branching agent groups are present in an amount of 0.75 to 5 branching units per 100 R 1 units.
4. The thermoplastic composition of claim 1 , wherein the branching agent is trimellitic trichloride (TMTC), tris-(hydroxyphenyl) ethane (THPE), isatin-bis-phenol or a combination of a least one of the foregoing branching agents.
5. The thermoplastic composition of claim 1 , wherein the flame retardant is a flame retardant salt or a cyclic siloxane or a combination of a salt and a cyclic siloxane.
6. A thermoplastic composition comprising:
a polycarbonate having repeating structural carbonate units of the formula
wherein at least 60 percent of the total number of R 1 groups contain aromatic organic groups and the balance thereof are aliphatic, alicyclic, or aromatic groups; and wherein
the polycarbonate comprises cyanophenyl carbonate endcapping groups derived from reaction with a cyanophenol of the formula
wherein Y is a halogen, C 1-3 alkyl group, C 1-3 alkoxy group, C 7-12 arylalkyl, alkylaryl, or nitro group, y is 0 to 4, and c is 1 to 5, provided that y+c is 1 to 5;
wherein the polycarbonate comprises a branching agent, wherein the branching agent is a structure derived from a triacid trichloride of the formula
wherein Z is hydrogen, a halogen, C 1-3 alkyl group, C 1-3 alkoxy group, C 7-12 arylalkyl, alkylaryl, or nitro group, and z is 0 to 3; or wherein the branching agent is a structure derived from a tri-substituted phenol of the formula
wherein T is a C 1-20 alkyl group, C 1-20 alkyleneoxy group, C 7-12 arylalkyl, or alkylaryl group, S is hydrogen, a halogen, C 1-3 alkyl group, C 1-3 alkoxy group, C 7-12 arylalkyl, alkylaryl, or nitro group, s is 0 to 4; or a combination of comprising one or more of the branching agents; and
a flame retardant.
7. The thermoplastic composition of claim 6 , wherein the cyanophenyl endcapping groups are present in an amount of 3 to 12 cyanophenyl carbonate units per 100 R 1 units.
8. The thermoplastic composition of claim 6 , wherein the branching agent groups are present in an amount of 0.75 to 5 branching units per 100 R 1 units.
9. The thermoplastic composition of claim 6 , wherein the branching agent has formula
wherein Z is hydrogen and z is 3.
10. The thermoplastic composition of claim 6 , wherein the branching agent has formula
wherein T is methyl, S is hydrogen and s is 4.
11. The thermoplastic composition of claim 6 , wherein the cyanophenol is p-cyanophenol, 3,4-dicyanophenol, or a combination comprising at least one of the foregoing phenols.
12. The thermoplastic composition of claim 6 , wherein the branching agent is trimellitic trichloride (TMTC) or tris-(hydroxyphenyl) ethane (THPE) or a combination of a least one of the foregoing branching agents.
13. The thermoplastic composition of claim 6 , wherein R 1 is derived from a bisphenol of the formula:
wherein
R a and R b each represents a halogen atom or a monovalent C 1 -C 12 hydrocarbon group and can be the same or different;
p and q are each independently integers of 0 to 4; and
X a represents a single bond or one of the groups of formula:
wherein
R c and R d each independently represents a hydrogen atom or a monovalent
C 1 -C 8 linear alkyl or cyclic C 4 -C 8 alkylene group; and
R e is a divalent C 1 -C 8 hydrocarbon group.
14. The thermoplastic composition of claim 13 , wherein p is 0, and R c and R d each independently represents a hydrogen atom or a monovalent C 1 -C 8 linear alkyl group.
15. The thermoplastic composition of claim 14 , wherein p is 0, and R c and R d are each a methyl group.
16. The thermoplastic composition of claim 6 , wherein the flame retardant is a flame retardant salt or a cyclic siloxane or a combination of a salt and a cyclic siloxane.
17. The thermoplastic composition of claim 6 , wherein the flame retardant salt is an alkali metal salt of a perfluorinated C 2-16 sulfonic acid.
18. The thermoplastic composition of claim 17 , wherein the flame retardant salt is potassium perfluorobutane sulfonate or potassium diphenylsulfone sulfonate.
19. The thermoplastic composition of claim 16 , wherein the cyclic siloxane is octaphenylcyclotetrasiloxane.
20. The thermoplastic composition of claim 16 , wherein the flame retardant comprises a combination of potassium perfluorobutane sulfonate and octaphenylcyclotetrasiloxane.
21. The thermoplastic composition of claim 6 , wherein the composition has a haze of less than about 3%, measured using 1.0 mm plaques according to ASTM-D1003-00.
22. The thermoplastic composition of claim 6 , wherein the composition has a haze of less than about 6%, measured using 3.2 mm plaques according to ASTM-D1003-00.
23. An article comprising the composition of claim 6 .
24. The article of claim 23 , wherein the article is capable of achieving a UL94 rating of V0 at a thickness of 1.5 mm.
25. The article of claim 23 , wherein the article is capable of achieving a UL94 rating of V0 at a thickness of 1.0 mm.
26. A method of manufacturing an article comprising:
extruding the thermoplastic composition of claim 1 ; and
molding the extruded composition into an article.
27. A thermoplastic composition comprising:
a polycarbonate having repeating structural carbonate units of the formula
wherein at least 60 percent of the total number of R 1 groups contain aromatic organic groups and the balance thereof are aliphatic, alicyclic, or aromatic groups; and wherein
the polycarbonate comprises cyanophenyl carbonate endcapping groups derived from reaction with a cyanophenol of the formula
wherein Y is hydrogen, a halogen, C 1-3 alkyl group, C 1-3 alkoxy group, C 7-12 arylalkyl, alkylaryl, or nitro group, y is 0 to 4, and c is 1 to 5, provided that y+c is 1 to 5;
wherein the polycarbonate comprises a branching agent, wherein the branching agent is a structure derived from a triacid trichloride of the formula
wherein Z is hydrogen and z is 3; or wherein the branching agent is a structure derived from a tri-substituted phenol of the formula
wherein T is methyl, S is hydrogen, s is 4; or a combination of comprising one or more of the branching agents; and
a flame retardant,
wherein the composition has a haze of less than about 3%, measured using 1.0 mm plaques according to ASTM-D1003-00.
28. The thermoplastic composition of claim 27 , wherein the flame retardant is a flame retardant salt or a cyclic siloxane or a combination of a salt and a cyclic siloxane.
29. The thermoplastic composition of claim 27 , wherein the flame retardant is a wherein the flame retardant comprises potassium perfluorobutane sulfonate, octaphenylcyclotetrasiloxane, or a combination of both.
30. An article comprising the thermoplastic composition of claim 27 .