Poly(aliphatic ester)-polycarbonate copolymer/polylactic acid blend
View Patent ↗The present invention is directed to a blended composition comprising one or more polycarbonates wherein at least one of the polycarbonates is a polyesterpolycarbonate having at least one unit derived from a soft block ester unit, e.g., sebacic acid, and at least one unit derived from bisphenol A, and a polylactic polymer wherein the composition has an overall biocontent of at least 10% according to ASTMD6866.
1. A blended composition comprising:
(a) one or more polycarbonates wherein at least one of the polycarbonates is a poly(aliphatic ester)-polycarbonate comprising:
(i) soft block ester units of the formula
wherein m is 4 to 40; and
(ii) at least one unit derived from bisphenol A; and
(b) a polylactide polymer having the following structural unit wherein n is between 1000 and 3000;
wherein the composition has an overall biocontent of at least 10 weight % according to ASTM D6866.
2. The composition of claim 1 , wherein at least one unit of the poly(aliphatic ester)-polycarbonate is derived from sebacic acid; and m is 4 to 18.
3. The composition of claim 1 , wherein the sebacic acid derived polycarbonate biocontent is at least 5 weight % according to ASTM D6866.
4. The composition of claim 1 , wherein the soft block ester has a glass transition temperature of 120 to 140° C.
5. The composition of claim 1 , wherein m of the soft block ester of (i) is 8 to 10.
6. The composition of claim 1 , wherein the composition comprises 2 to 10 weight % soft block ester units.
7. The composition of claim 1 , wherein the composition comprises 75 to 95 weight % poly(aliphatic ester)-polycarbonate.
8. The composition of claim 1 , wherein the composition comprises 5 to 45 weight % of polylactide polymer.
9. The composition of claim 1 , wherein at least one poly(aliphatic ester)-polycarbonate has (a) a molecular weight of 16,000 to 27,000 g/mole [ +/− 1000 g/mole] as measured by gel permeation chromatography using bisphenol A polycarbonate standards and 5.0 mole % (of total composition) to 7.0 mole % sebacic acid; or (b) a molecular weight of 30,000 to 42,000 g/mole [ +/− 1000 g/mole] as measured by gel permeation chromatography using bisphenol A polycarbonate standards, and 7.0 mole % to 9.0 mole % sebacic acid.
10. The composition of claim 9 , wherein at least one poly(aliphatic ester)-polycarbonate of (a) is at a molecular weight of 19,000 to 24,000 g/mole [ +/− 1000 g/mole] as measured by gel permeation chromatography using bisphenol A polycarbonate standards.
11. The composition of claim 9 , wherein at least one poly(aliphatic ester)-polycarbonate of (b) is at a molecular weight of 33,000 to 39,000 g/mole [ +/− 1000 g/mole] as measured by gel permeation chromatography using bisphenol A polycarbonate standards.
12. The composition of claim 9 , wherein the polylactide content is 5 to 25 weight % of (a) and (b), and a molecular weight of 100,000 to 300,000 g/mole [ +/− 1000 g/mole], 150,000 to 250,000 g/mole [ +/− 1000 g/mole], or 175,000 to 225,000 g/mole [ +/− 1000 g/mole] as measured by gel permeation chromatography using polystyrene standards.
13. The composition of claim 12 , wherein the polylactide content is 5 to 25 weight % of (a) and (b), and a molecular weight of 160,000 g/mole to 200,000 g/mole [ +/− 1000 g/mole] as measured by gel permeation chromatography using polystyrene standards.
14. The composition of claim 12 , wherein the polylactide has a melting point (Tm) of 165° C. [ +/− 10° C.] and a glass transition temperature of 60° C. [ +/− 10° C.].
15. The composition of claim 10 , wherein the composition has a melt volume rate of 28 cm 3 /10 minutes to 35 cm 3 /10 minutes according to ISO1133 (5 kg/5 minutes at 240° C.).
16. The composition of claim 15 , wherein the polylactide content is 5 to 25 weight % of (a) and (b) and a molecular weight ranging of 160,000 g/mole to 200,000 g/mole as measured by gel permeation chromatography using polystyrene standards.
17. The composition of claim 11 , wherein the composition has a melt volume rate of 2.50 cm 3 /10 minutes to 6.50 cm 3 /10 minutes according to ISO1133 (5 kg/5 minutes at 240° C.).
18. The composition of claim 17 , wherein the polylactide content is 2.5 to 15 weight % of (a) and (b).
19. The composition of claim 11 , wherein the composition has a melt volume rate of 7.50 cm 3 /10 minutes to 18.00 cm 3 /10 minutes according to ISO1133 (5 kg/5 minutes at 265° C.).
20. The composition of claim 15 , wherein the composition has an impact strength average of greater than 60 kJ/m 2 [ +/− 5 kJ/m 2 ] at 23° C. according to ISO 180.
21. The composition of claim 17 , wherein the composition has an impact strength average of greater than 50 kJ/m 2 [ +/− 5 kJ/m 2 ] at 23° C. according to ISO 180.
22. The composition of claim 19 , wherein the composition has an impact strength average of greater than 85 kJ/m 2 [ +/− 5 kJ/m 2 ] at 10° C. according to ISO 180.
23. The composition of claim 1 , wherein the composition has an overall biocontent of at least 15 weight % according to ASTM D6866.
24. The composition of claim 23 , wherein the composition has an overall biocontent of at least 20 weight % according to ASTM D6866.
25. The composition of claim 24 , wherein the composition has an overall biocontent of at least 30 weight % according to ASTM D6866.
26. The composition of claim 1 , wherein each of the poly(aliphatic ester)-polycarbonates of (a) contains less than 5 mole percent of anhydride as determined by proton nuclear magnetic resonance.
27. The composition of claim 1 , further comprising at least one of heat stabilizers, mold release agents, glass or colorants.
28. An article formed from the composition of claim 1 , wherein the composition has an overall biocontent of 10 to 30 weight % according to ASTM D6866.
29. The article of claim 28 , wherein the article is a computer or business machine housing, a housing for a hand-held electronic device, a component of a lighting fixture or home appliance, a component of a medical application or device, or a component of an interior or exterior component of an automobile.
30. A blended composition comprising:
(a) a poly(aliphatic ester)-polycarbonate comprising
(i) soft block ester units of the formula
wherein m is 4 to 18;
(ii) at least one unit derived from sebacic acid; and
(ii) at least one unit derived from bisphenol A; and;
(b) a polylactide polymer having the following structural unit wherein n is between 1000 and 3000;
wherein the poly(aliphatic ester)-polycarbonate has (a) a molecular weight of 16,000 to 27,000 g/mole [ +/− 1000 g/mole] as measured by gel permeation chromatography using bisphenol A polycarbonate standards and 5.0 mole % (of total composition) to 7.0 mole % sebacic acid; or (b) a molecular weight of 30,000 to 42,000 g/mole [ +/− 1000 g/mole] as measured by gel permeation chromatography using bisphenol A polycarbonate standards, and 7.0 mole % to 9.0 mole % sebacic acid,
wherein the polylactide content is 2.5 to 25 weight % of (a) and (b), and a molecular weight of 160,000 g/mole to 200,000 g/mole [ +/− 1000 g/mole] as measured by gel permeation chromatography using polystyrene standards;
wherein the composition has an overall biocontent of at least 10 weight % according to ASTM D6866.
31. The composition of claim 30 , wherein at least one poly(aliphatic ester)-polycarbonate of (a) is at a molecular weight of 19,000 to 24,000 g/mole [ +/− 1000 g/mole] as measured by gel permeation chromatography using bisphenol A polycarbonate standards.
32. The composition of claim 30 , wherein at least one poly(aliphatic ester)-polycarbonate of (b) is at a molecular weight of 33,000 to 39,000 g/mole [ +/− 1000 g/mole] as measured by gel permeation chromatography using bisphenol A polycarbonate standards.
33. The composition of claim 31 , wherein the composition has a melt volume rate of 28 cm 3 /10 minutes to 35 cm 3 /10 minutes according to ISO1133 (5 kg/5 minutes at 240° C.).
34. The composition of claim 32 , wherein the composition has a melt volume rate of 2.50 cm 3 /10 minutes to 6.50 cm 3 /10 minutes according to ISO1133 (5 kg/5 minutes at 240° C.).
35. The composition of claim 30 , wherein the polylactide content is 5 to 15 weight % of (a) and (b).
36. The composition of claim 33 , wherein the composition has a melt volume rate of 7.50 cm 3 /10 minutes to 12.00 cm 3 /10 minutes according to ISO1133 (5 kg/5 minutes at 265° C.).
37. The composition of claim 33 , wherein the composition has an impact strength average of greater than 60 kJ/m 2 [ +/− 5 kJ/m 2 ] at 23° C. according to ISO 180.
38. The composition of claim 34 , wherein the composition has an impact strength average of greater than 50 kJ/m 2 [ +/− 5 kJ/m 2 ] at 23° C. according to ISO 180.
39. The composition of claim 35 , wherein the composition has an impact strength average of greater than 80 kJ/m 2 [ +/− 5 kJ/m 2 ] at 10° C. according to ISO 180.
40. The composition of claim 30 , wherein the composition has an overall biocontent of at least 15 weight % according to ASTM D6866.
41. The composition of claim 30 , wherein the composition has an overall biocontent of at least 20 weight % according to ASTM D6866.
42. The composition of claim 30 , wherein the composition has an overall biocontent of at least 30 weight % according to ASTM D6866.
43. The composition of claim 1 , wherein the composition further comprises an isosorbide containing polymer.
44. The composition of claim 30 , wherein the composition further comprises an isosorbide containing polymer.