Thermoplastic composition, method of manufacture thereof, and articles derived therefrom
View Patent ↗Disclosed herein is a thermoplastic composition comprising a combination of 10 to 80 wt. % of a polyester, more than 0 to 50 wt. % of a polycarbonate, and 10 to 90 wt. % of at least one polyester-polycarbonate copolymer comprising, based on the total weight of the copolymer, 15 to 95 wt. % of arylate ester units, and 5 to 85 wt. % of aromatic carbonate units. Also disclosed is a method of forming the compositions, and articles prepared therefrom, for example transparent covers.
1. A composition, based on the total weight of polymer components in the composition, comprising a transparent blend of:
(a) from 10 to 80 wt. % of a polyester comprising units of the formula
wherein T is a residue derived from cyclohexanedicarboxylic acid, terephthalic acid, isophthalic acid, a chemical equivalent of the foregoing, or a combination thereof, and D is a residue derived from a C 6 -C 12 aromatic or C 2 -C 12 aliphatic diol or chemical equivalent;
(b) from more than 0 to 60 wt. % of a polycarbonate comprising units of the formula
wherein each R 1 is independently a divalent organic radical, and at least about 60% of the organic radicals are aromatic; and
(c) from 10 to 90 wt. % of at least one polyester-polycarbonate copolymer comprising, based on the total weight of the copolymer, from 15 to 95 wt. % of arylate ester units of the formula
wherein each R 4 is independently halogen or C 1-4 alkyl and p is 0 to 3, and
from 5 to 85 wt. % of aromatic carbonate units of the formula
wherein each R 1 is independently a divalent organic radical, and at least about 60% of the organic radicals are aromatic, and further wherein
the polyester-polycarbonate copolymer comprises terminal groups derived from reaction with a phenolic compound the formula
wherein each R 5′ is independently halogen, C 1-22 alkyl, C 6-10 aryl, C 7-22 alkylaryl, C 7-22 arylalkyl, or C 1-22 alkoxy, and q is 0 to 4.
2. The composition of claim 1 , wherein an extruded pellet comprising the composition is transparent.
3. The composition of claim 2 , wherein the extruded pellet is colorless.
4. The composition of claim 1 , further comprising a quencher.
5. The composition of claim 4 , wherein the quencher is selected from the group consisting of zinc phosphate, monozinc phosphate, phosphorous acid, phosphoric acid diluted in water, sodium acid pyrophosphate, tetrapropylorthosilicate, tetrakis-(2-methoxyethoxy)silane), sodium lauryl sulphate, boric acid, citric acid, oxalic acid, a cyclic iminoether containing compound, and combinations thereof.
6. The composition of claim 1 , wherein a molded article derived from the composition and having a thickness of 2.5 millimeters has a haze of less than or equal to 10 percent, measured in accordance with ASTM D 1003-00.
7. The composition of claim 1 , wherein a molded article derived from the composition and having a thickness of 2.5 millimeters has a total luminous transmittance of greater than or equal to 80 percent, measured in accordance with ASTM D1003-00.
8. The composition of claim 1 , wherein D is derived from a member selected from the group consisting of 1,4-cyclohexanedimethanol, C 2-4 diols, chemical equivalents of the foregoing diols, and combinations thereof.
9. The composition of claim 1 , wherein T is derived from cyclohexanedicarboxylic acid or a chemical equivalent thereof and D is derived from 1,4-cyclohexanedimethanol or a chemical equivalent thereof.
10. The composition of claim 1 , wherein T is derived from terephthalic acid or a chemical equivalent thereof and D is derived from a mixture of 1,4-cyclohexanedimethanol and ethylene glycol or chemical equivalents thereof.
11. The composition of claim 10 , wherein the mixture of 1,4-cyclohexanedimethanol and ethylene glycol or chemical equivalents thereof comprises up to 25 mole percent ethylene glycol.
12. The composition of claim 1 , wherein R 1 in the polycarbonate is derived from a compound of the formula
wherein R a and R b are each independently a halogen or a C 1-12 alkyl, X a is a singlebond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, or a C 1-18 organic group, and p and q are each independently 0 to 4.
13. The composition of claim 12 , wherein, X a is a C 1-25 alkylidene of the formula —C(R c )(R d )— wherein R c and R d are each independently hydrogen, C 1-12 alkyl, C 1-12 cycloalkyl, C 7-12 arylalkyl, C 1-12 heteroalkyl, or cyclic C 7-12 heteroarylalkyl, or a group of the formula —C(═R e )— wherein R e is a divalent C 1-12 hydrocarbon group.
14. The composition of claim 13 , wherein X a is isopropylidene and p and q are each zero.
15. The composition of claim 1 , wherein the polycarbonate further comprises units of the formulas
wherein each R 2 is independently a C 1-13 monovalent organic group, each Ar is independently a C 6-36 arylene group wherein the bonds are directly connected to an aromatic moiety, each R 3 is independently a divalent C 1-30 organic group, and E is an integer having an average value of 2 to 1,000.
16. The composition of claim 1 , wherein the composition comprises 10 to 40 wt. % of the polycarbonate.
17. The composition of claim 1 , wherein the composition comprises more than 0 and less than 15 wt. % polycarbonate.
18. The composition of claim 1 , wherein the composition comprises more than 0 and less than 5 wt. % polycarbonate.
19. The composition of claim 1 , wherein the arylate ester units are derived from the reaction of a mixture of terephthalic acid and isophthalic acid or a chemical equivalent thereof with 5-methylresorcinol, 5-ethylresorcinol, 5-propylresorcinol, 5-butylresorcinol, 5-t-butylresorcinol, 5-phenylresorcinol, 5-cumylresorcinol, 2,4,5,6-tetrafluororesorcinol, 2,4,5,6-tetrabromoresorcinol, catechol, hydroquinone, 2-methylhydroquinone, 2-ethylhydroquinone, 2-propylhydroquinone, 2-butylhydroquinone, 2-t-butylhydroquinone, 2-phenylhydroquinone, 2-cumylhydroquinone, 2,3,5,6-tetramethylhydroquinone, 2,3,5,6-tetra-t-butylhydroquinone, 2,3,5,6-tetrafluorohydroquinone, 2,3,5,6-tetrabromohydroquinone, a chemical equivalent of the foregoing compounds, or a combination comprising at least one of the foregoing compounds.
20. The composition of claim 1 , wherein R 1 in the polyester-polycarbonate copolymer is derived from a compound of the formula
wherein R a and R b are each independently a halogen or a C 1-12 alkyl, X a is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, or a C 1-18 organic group, and p and q are each independently 0 to 4.
21. The composition of claim 20 , wherein X a is a C 1-25 alkylidene of the formula —C(R c )(R d )— wherein R c and R d are each independently hydrogen, C 1-12 alkyl, C 1-12 cycloalkyl, C 7-12 arylalkyl, C 1-12 heteroalkyl, or cyclic C 7-12 heteroarylalkyl, or a group of the formula —C(═R e )— wherein R e is a divalent C 1-12 hydrocarbon group.
22. The composition of claim 21 , wherein X a is isopropylidene and p and q Are each zero.
23. The composition of claim 1 , wherein the phenolic compound is phenol, p-cumylphenol, p-tertiary-butylphenol, hydroxydiphenyl, hydroquinone, p-methoxyphenol, or a combination comprising at least one of the foregoing phenolic compounds.
24. The composition of claim 1 , further comprising an acid interchange quencher, a compound having an epoxy functionality, an antioxidant, a heat stabilizer, a light stabilizer, an ultraviolet light absorber, a plasticizer, a mold release agent, a lubricant, an antistatic agent, a pigment, a dye, a flame retardant, or a combination comprising at least one of the foregoing compounds.
25. A method of manufacture of the composition of claim 1 , comprising melt blending the components of the composition of claim 1 .
26. An article comprising the composition of claim 1 .
27. The article of claim 26 , wherein the article is an extruded, blow molded, or an injection molded article.
28. The article of claim 26 , in the form of a film.
29. The article of claim 26 , in the form of a fiber.
30. The article of claim 26 , in the form of a lens or a lens cover for a pool and/or spa.
31. A method of forming an article, comprising shaping, extruding, blow molding, or injection molding the composition of claim 1 to form the article.
32. A composition comprising, based on the total weight of polymer components in the composition, a transparent blend of:
(a) from 40 to 80 wt. % of poly(1,4-cyclohexanedimethylene terephthalate)-co-poly(ethylene terephthalate), wherein greater than 50 mol % of the ester groups are 1,4-cyclohexanedimethylene terephthalate groups;
(b) from more than 0 to 60 wt. % of a polycarbonate comprising units derived from Bisphenol A; and
(c) from 10 to 60 wt. % of at least one polyester-polycarbonate copolymer comprising, based on the total weight of the copolymer,
from 85 to 95 wt. % of arylate ester units of the formula
wherein p is 0, and
from to 15 wt. % of aromatic carbonate units derived from Bisphenol A, and further wherein
the polyester-polycarbonate copolymer comprises terminal groups derived from reaction with a phenolic compound the formula
wherein each R 5 is independently halogen, C 1-22 alkyl, C 6-10 aryl, C 7-22 alkylaryl, C 7-22 arylalkyl, or C 1-22 alkoxy, and q is 0 to 4,
wherein a molded article comprising the composition has a haze of less than or equal to 10% and a total luminous transmittance of greater than 80% in accordance with ASTM D1003-00.
33. An article comprising the composition of claim 32 .
34. The article of claim 33 , wherein the article is an extruded, blow molded, or an injection molded article.
35. The article of claim 33 , in the form of a film.
36. A composition comprising, based on the total weight of polymer components in the composition, a transparent blend of:
(a) from 50 to 80 wt. % of poly(1,4-cyclohexanedimethylene terephthalate)
(b) from more than 0 to 60 wt. % of a polycarbonate comprising units derived from Bisphenol A; and
(c) from 10 to 50 wt. % of at least one polyester-polycarbonate copolymer comprising, based on the total weight of the copolymer,
from 85 to 95 wt. % of arylate ester units of the formula
wherein p is 0, and
from to 15 wt. % of aromatic carbonate units derived from Bisphenol A, and further wherein
the polyester-polycarbonate copolymer comprises terminal groups derived from reaction with a phenolic compound the formula
wherein each R 5 ′ is independently halogen, C 1-22 alkyl, C 6-10 aryl, C 7-22 alkylaryl, C 7-22 arylalkyl, or C 1-22 alkoxy, and q is 0 to 4,
wherein a molded article comprising the composition has a haze of less than or equal to 10% and a total luminous transmittance of greater than 80% in accordance with ASTM D1003-00.
37. An article comprising the composition of claim 36 .
38. The article of claim 37 , wherein the article is an extruded, blow molded, or an injection molded article.
39. The article of claim 37 , in the form of a film.