Thermoplastic compositions, 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; optionally a branching agent; an impact modifier; 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;
an impact modifier; and
a flame retardant.
2. The thermoplastic composition of claim 1 , wherein the polycarbonate further comprises a branching agent.
3. The thermoplastic composition of claim 2 , wherein the branching agent is a structure derived from a triacid trichloride of the formula
wherein Z is 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 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.
4. The thermoplastic composition of claim 1 , wherein the flame retardant is a phosphorous containing flame retardant, a flame retardant salt, or a cyclic siloxane or a combination of two or more of the foregoing.
5. The thermoplastic composition of claim 1 , wherein the cyanophenyl endcapping groups are present in an amount of 2 to 20 cyanophenyl carbonate units per 100 R 1 units.
6. The thermoplastic composition of claim 2 , wherein the branching agent groups are present in an amount of 0.3 to 6 branching units per 100 R 1 units.
7. The thermoplastic composition of claim 2 , wherein the branching agent has formula
wherein z is 0.
8. The thermoplastic composition of claim 2 , wherein the branching agent has formula
wherein T is methyl and s is 0.
9. The thermoplastic composition of claim 1 , wherein the cyanophenol is p-cyanophenol, 3,4-dicyanophenol, or a combination comprising at least one of the foregoing phenols.
10. 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.
11. The thermoplastic composition of claim 10 , 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.
12. The thermoplastic composition of claim 11 , wherein p is 0, and R c and R d are each a methyl group.
13. The thermoplastic composition of claim 1 , wherein the impact modifier is selected from the group consisting of ABS, MBS, Bulk ABS, AES, ASA, MABS, polycarbonate-polysiloxane copolymer and combinations thereof.
14. An article comprising the composition of claim 6 .
15. The article of claim 14 , wherein the article is capable of achieving a UL94 rating of V0 at a thickness of 0.75 mm.
16. The article of claim 14 , wherein the article is capable of achieving a UL94 rating of 5VB at a thickness of 1.2 mm.
17. A method of manufacturing an article comprising:
extruding the thermoplastic composition of claim 1 ; and
molding the extruded composition into an article.
18. 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;
an impact modifier; and
a flame retardant,
wherein the composition is capable of achieving a UL94 V0 rating at 0.75 mm and a UL94 5VB rating at 1.2 mm thickness.
19. The thermoplastic composition of claim 18 , wherein the flame retardant is a phosphorous containing flame retardant, a flame retardant salt, or a cyclic siloxane or a combination of two or more of the foregoing.
20. The thermoplastic composition of claim 18 , wherein the polycarbonate further comprises a branching agent wherein the branching agent groups are present in an amount of 0.3 to 6 branching units per 100 R 1 units.
21. 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 cyanophenyl endcapping groups are present in an amount of 2 to 20 cyanophenyl carbonate units per 100 R 1 units, and wherein the cyanophenol is p-cyanophenol, 3,4-dicyanophenol, or a combination comprising at least one of the foregoing phenols;
an impact modifier; and
a flame retardant,
wherein the composition is capable of achieving a UL94 V0 rating at 0.75 mm and a UL94 5VB rating at 1.2 mm thickness.
22. The thermoplastic composition of claim 20 , wherein the polycarbonate further comprises a branching agent wherein the branching agent groups are present in an amount of 0.3 to 6 branching units per 100 R 1 units.
23. 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 cyanophenyl endcapping groups are present in an amount of 2 to 20 cyanophenyl carbonate units per 100 R 1 units, and wherein the cyanophenol is p-cyanophenol, 3,4-dicyanophenol, or a combination comprising at least one of the foregoing phenols; and wherein
the polycarbonate comprises a branching agent wherein the branching agent groups are present in an amount of 0.3 to 6 branching units per 100 R 1 units,
wherein the branching agent is a structure derived from a triacid trichloride of the formula
wherein Z is 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 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;
an impact modifier; and
a flame retardant,
wherein the composition is capable of achieving a UL94 V0 rating at 0.75 mm and a UL94 5VB rating at 1.2 mm thickness.