Polycarbonate blends having improved electroplate adhesion
View Patent ↗The present disclosure relates to thermoplastic polycarbonate blends compositions having, among other characteristics, improved electroplate adhesion properties. In particular, the disclosure relates to such polycarbonate compositions comprising a polycarbonate component, a primary ABS impact modifier, and a secondary impact modifier chemically different from the primary impact modifier. Also included herein are methods for preparing and/or using the same, as well as articles formed from such compositions/blends.
1. A thermoplastic composition with improved electroplate adhesion comprising from about 40 wt % to about 75 wt % of two or more polycarbonate resins, from about 24 wt % to about 53 wt % of a first impact modifier, and from about 1 wt % to about 7 wt % of a second impact modifier; wherein the thermoplastic composition further comprises a hydrolytic stabilizer comprising an inorganic buffer, and wherein the combined weight percent value of all components does not exceed 100 wt %; wherein all weight percent values are based on the total weight of the composition; and wherein the composition exhibits an adhesion value at least 10% greater than that of a reference composition consisting essentially of substantially the same proportions of the same polycarbonate polymers and the same first impact modifier.
2. The composition of claim 1 , wherein the polycarbonate resins are present in an amount from about 45 wt % to about 55 wt %.
3. The composition of claim 1 , wherein the first impact modifier is present in an amount from about 40 wt % to about 48 wt %.
4. The composition of claim 1 , wherein the first impact modifier is an acrylonitrile butadiene styrene terpolymer.
5. The composition of claim 4 , wherein acrylonitrile butadiene styrene terpolymer has a butadiene content of about 25 wt % to about 55 wt %.
6. The composition of claim 1 , wherein the second impact modifier is present in an amount from about 3 wt % to about 6 wt %.
7. The composition of claim 1 , wherein the second impact modifier is methyl methacrylate butadiene styrene.
8. The composition of claim 7 , wherein the methyl methacrylate butadiene styrene has a butadiene content of about 70 wt % to 78 wt %.
9. The composition of claim 1 , wherein the second impact modifier is emulsion polymerized acrylonitrile-butadiene-stryrene.
10. The composition of claim 1 , wherein the second impact modifier is an acrylonitrile butadiene styrene terpolymer.
11. The composition of claim 10 , wherein acrylonitrile butadiene styrene terpolymer has a butadiene content of about 40 wt % to about 65 wt %.
12. The composition of claim 1 , wherein the first impact modifier is an acrylonitrile butadiene styrene terpolymer; and wherein the second impact modifier is an acrylonitrile butadiene styrene terpolymer different than the first impact modifier.
13. The composition of claim 1 , wherein the first impact modifier is an acrylonitrile butadiene styrene terpolymer; and wherein the second impact modifier is a methyl methacrylate butadiene styrene.
14. The composition of claim 1 , wherein the composition exhibits an adhesion value at least 20% greater than that of a reference composition.
15. The composition of claim 1 , wherein the composition exhibits an adhesion value of greater than or equal to 6 lbs/in.
16. The composition of claim 1 , wherein the hydrolytic stabilizer further comprises one or more hydrotalcites comprising a magnesium hydrotalcite.
17. An article comprising the composition of claim 1 .
18. An article of claim 17 , wherein the article is used in automotive applications.
19. An article of claim 18 , wherein the article is selected from the group consisting of an instrument panel, overhead console, interior trim, center console, panel, quarter panel, rocker panel, trim, fender, door, deck lid, trunk lid, hood, bonnet, roof, bumper, fascia, grille, minor housing, pillar appliqué, cladding, body side molding, wheel cover, hubcap, door handle, spoiler, window frame, headlamp bezel, headlamp, tail lamp, tail lamp housing, tail lamp bezel, license plate enclosure, roof rack, and running board.
20. An article of claim 17 , wherein the article exhibits an adhesion value of greater than or equal to 6 lbs/in.
21. A process to improve the electroplate adhesion of a thermoplastic composition, the process comprising combining at least two polycarbonate resins, a first impact modifier, and a second impact modifier;
wherein the at least two polycarbonate resins are combined in an amount of from about 45 wt % to about 55 wt % of the total composition;
wherein the first impact modifier is combined in an amount of from about 40 wt % to about 48 wt %;
wherein the second impact modifier is combined in an amount of from about 1 wt % to about 7 wt %;
wherein the thermoplastic composition further comprises a hydrolytic stabilizer comprising an inorganic buffer, and
wherein the combined weight percent value of all components does not exceed 100 wt %;
wherein all weight percent values are based on the total weight of the composition; and
wherein the composition exhibits an adhesion value at least 10% greater than that of a reference composition consisting essentially of substantially the same proportions of the same polycarbonate polymers and the same first impact modifier.
22. The process of claim 21 , wherein the composition exhibits an adhesion value at least 20% greater than that of a reference composition.
23. The process of claim 21 , wherein the composition exhibits an adhesion value at least 30% greater than that of a reference composition.
24. The process of claim 21 , wherein the composition exhibits an adhesion value at least 40% greater than that of a reference composition.
25. A thermoplastic composition with improved electroplate adhesion comprising from about 45 wt % to about 68 wt % of two or more polycarbonate resins, from about 31 wt % to about 48 wt % of a first impact modifier, and from about 1 wt % to about 7 wt % of a second impact modifier; wherein the thermoplastic composition further comprises a hydrolytic stabilizer comprising an inorganic buffer, and wherein the combined weight percent value of all components does not exceed 100 wt %; wherein all weight percent values are based on the total weight of the composition; and wherein the composition exhibits an adhesion value at least 10% greater than that of a reference composition consisting essentially of substantially the same proportions of the same polycarbonate polymers and the same first impact modifier.
26. A thermoplastic composition with improved electroplate adhesion comprising from about 48 wt % to about 58 wt % of two or more polycarbonate resins, from about 39 wt % to about 45 wt % of a first impact modifier, and from about 1 wt % to about 7 wt % of a second impact modifier; wherein the thermoplastic composition further comprises a hydrolytic stabilizer comprising an inorganic buffer, and wherein the combined weight percent value of all components does not exceed 100 wt %; wherein all weight percent values are based on the total weight of the composition; and wherein the composition exhibits an adhesion value at least 10% greater than that of a reference composition consisting essentially of substantially the same proportions of the same polycarbonate polymers and the same first impact modifier.
27. The composition of claim 1 , wherein the inorganic buffer comprises one or more inorganic salts capable of pH buffering and having a pKa value in aqueous solution of about 5.0 to about 7.0 at a temperature of about 20° C.
28. The composition of claim 1 , wherein the inorganic buffer is essentially free of nitrogen containing species.
29. The composition of claim 1 , wherein at least two polycarbonates differ from one another in terms of molecular weight.
30. The process of claim 21 , wherein at least two polycarbonates differ from one another in terms of molecular weight.
31. The composition of claim 25 , wherein at least two polycarbonates differ from one another in terms of molecular weight.
32. The composition of claim 26 , wherein at least two polycarbonates differ from one another in terms of molecular weight.
33. The process of claim 21 , wherein the first impact modifier is an acrylonitrile butadiene styrene terpolymer; and wherein the second impact modifier is an acrylonitrile butadiene styrene terpolymer different than the first impact modifier.
34. The composition of claim 25 , wherein the first impact modifier is an acrylonitrile butadiene styrene terpolymer; and wherein the second impact modifier is an acrylonitrile butadiene styrene terpolymer different than the first impact modifier.
35. The composition of claim 26 , wherein the first impact modifier is an acrylonitrile butadiene styrene terpolymer; and wherein the second impact modifier is an acrylonitrile butadiene styrene terpolymer different than the first impact modifier.
36. A thermoplastic composition with improved electroplate adhesion comprising from about 40 wt % to about 75 wt % of two or more polycarbonate resins having different molecular weights, from about 24 wt % to about 53 wt % of a first impact modifier, and from about 1 wt % to about 7 wt % of a second impact modifier; and wherein the combined weight percent value of all components does not exceed 100 wt %; wherein all weight percent values are based on the total weight of the composition; and wherein the composition exhibits an adhesion value at least 10% greater than that of a reference composition consisting essentially of substantially the same proportions of the same polycarbonate polymers and the same first impact modifier.