Heat resistance in polycarbonate compositions
View Patent ↗Disclosed herein are methods and compositions of blended polycarbonate compositions with improved heat resistance. The resulting compositions, comprising a first polycarbonate polymer, a second polycarbonate polycarbonate, an impact modifier, optionally a flow promoter, and optionally a flame retardant, can be used in the manufacture of articles while still retaining the advantageous physical properties of blended polycarbonate compositions with improved heat resistance. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present invention.
1. A blended polycarbonate composition with improved heat resistance comprising:
(a) from about 0 pph to about 90 pph of a first polycarbonate polymer;
(b) from about 1 pph to about 90 pph of a second polycarbonate polymer, wherein the second polycarbonate polymer is a high heat polycarbonate polymer and is a copolymer of bisphenol A and 4,4′-(1-phenylethylidene)bisphenol;
(c) from about 1 pph to about 25 pph of at least one impact modifier composition;
(d) from about 0 pph to about 25 pph of a polystyrene acrylonitrile copolymer;
(e) from about 0 pph to about 25 pph of a flame retardant; and
(f) pph balance of one or more of a polymer composition additive.
2. The composition of claim 1 , wherein the first polycarbonate polymer is present in an amount from about 45 pph to about 95 pph.
3. The composition of claim 1 , wherein the first polycarbonate polymer is a bisphenol A polycarbonate.
4. The composition of claim 1 , wherein the second polycarbonate polymer is present in an amount from about 35 pph to about 90 pph.
5. The composition of claim 1 , further comprising a third polycarbonate polymer.
6. The composition of claim 5 , wherein the third polycarbonate polymer is selected from a brominated polycarbonate, a polyester carbonate copolymer, and a polycarbonate siloxane copolymer.
7. The composition of claim 1 , wherein the impact modifier is an acrylonitrile butadiene styrene polymer composition.
8. The composition of claim 7 , wherein the butadiene content is from about 20% to about 75%.
9. The composition of claim 7 , wherein the acrylonitrile content is from about 5% to about 25%.
10. The composition of claim 1 , wherein the polystyrene acrylonitrile copolymer comprises from about 10 pph to about 40 pph.
11. The composition of claim 1 , wherein the flame retardant is selected from oligomeric phosphate, polymeric phosphate, oligomeric phosphonate, or mixed phosphate/phosphonate ester flame retardant compositions.
12. The composition of claim 1 , wherein the flame retardant is selected from triphenyl phosphate; cresyldiphenylphosphate; tri(isopropylphenyl)phosphate; resorcinol bis(diphenylphosphate); and bisphenol-A bis(diphenyl phosphate).
13. The composition of claim 1 , wherein the flame retardant is bisphenol-A bis(diphenyl phosphate).
14. The composition of claim 1 , wherein the flame retardant is present in an amount from about 7 pph to about 20 pph.
15. The composition of claim 1 , wherein the composition further comprises an anti-drip agent.
16. The composition of claim 15 , wherein the anti-drip agent is a polytetrafluoroethylene styrene acrylonitrile copolymer.
17. The composition of claim 15 , wherein the anti-drip agent is present in an amount from about 4 pph to about 14 pph.
18. The composition of claim 1 , wherein blended polycarbonate composition further comprises a filler.
19. The composition of claim 18 , wherein the filler is present in an amount from greater than about 0 pph to about 25 pph.
20. The composition of claim 18 , wherein the filler is selected from talc, silica, wollastonite, mica, clay, and titanium dioxide.
21. The composition of claim 1 , wherein the polymer composition additive comprises one or more of a colorant, anti-oxidant, mold release agent, lubricant, flame retardant agent, smoke suppressor agent, or anti-drip agent.
22. The composition of claim 1 , further comprising a primary antioxidant in an amount from about 0.001 pph to about 0.500 pph.
23. The composition of claim 22 , wherein the primary antioxidant is selected from hindered phenols, phosphites, phosphonates, and any mixture thereof.
24. The composition of claim 1 , further comprising a secondary antioxidant in an amount from about 0.001 pph to about 0.500 pph.
25. The composition of claim 24 , wherein the secondary antioxidant is a thioester or thioether.
26. A blended polycarbonate composition with improved heat resistance comprising:
(a) from about 1 pph to about 90 pph of a first polycarbonate polymer;
(b) from greater than about 0 pph to about 90 pph of a second polycarbonate polymer, wherein the second polycarbonate polymer is a high heat polycarbonate polymer and is a copolymer of bisphenol A and 4,4′-(1-phenylethylidene)bisphenol;
(c) from about 1 pph to about 25 pph of at least one impact modifier composition;
(d) from about 0 pph to about 25 pph of a polystyrene acrylonitrile copolymer;
(e) from about 0 pph to about 25 pph of a flame retardant; and
(f) pph balance of one or more of a polymer composition additive,
wherein the composition exhibits heat resistance with at least about 10% greater heat deflection temperature than that of a reference composition consisting essentially of substantially the same proportions of the first polycarbonate polymer; the impact modifier; the flow promoter; if present; the flame retardant, if present; and, in the absence of the same second polycarbonate polymer.
27. The composition of claim 26 , wherein the flame retardant is bisphenol-A bis(diphenyl phosphate).
28. The composition of claim 26 , wherein the flame retardant is present in an amount from about 7 pph to about 20 pph.
29. The composition of claim 26 , wherein the flame retardant is present in an amount from about 4 pph to about 14 pph.
30. A blended polycarbonate composition with improved heat resistance comprising:
(a) from about 35 pph to about 90 pph of a first polycarbonate polymer;
(b) from about 10 pph to about 70 pph of a second polycarbonate polymer, wherein the second polycarbonate polymer is a high heat polycarbonate polymer and is a copolymer of bisphenol A and 4,4′-(1-phenylethylidene)bisphenol;
(c) from about 1 pph to about 25 pph of at least one impact modifier composition;
(d) from about 0 pph to about 25 pph of a polystyrene acrylonitrile copolymer;
(e) from about 0 pph to about 25 pph of a flame retardant; and
(f) pph balance of one or more of a polymer composition additive.
31. The composition of claim 30 , wherein the flame retardant is bisphenol-A bis(diphenyl phosphate).
32. The composition of claim 30 , wherein the flame retardant is present in an amount from about 7 pph to about 20 pph.
33. The composition of claim 30 , wherein the flame retardant is present in an amount from about 4 pph to about 14 pph.
34. A blended polycarbonate composition with improved heat resistance comprising:
(a) from about 25 pph to about 45 pph of a first polycarbonate polymer;
(b) from about 25 pph to about 45 pph of a second polycarbonate polymer, wherein the second polycarbonate polymer is a high heat polycarbonate polymer and is a copolymer of bisphenol A and 4,4′-(1-phenylethylidene)bisphenol;
(c) from about 1 pph to about 25 pph of at least one impact modifier composition;
(d) from about 0 pph to about 25 pph of a polystyrene acrylonitrile copolymer;
(e) from about 0 pph to about 25 pph of a flame retardant; and
(f) pph balance of one or more of a polymer composition additive.
35. The composition of claim 34 , wherein the flame retardant is bisphenol-A bis(diphenyl phosphate).
36. The composition of claim 34 , wherein the flame retardant is present in an amount from about 7 pph to about 20 pph.
37. The composition of claim 34 , wherein the flame retardant is present in an amount from about 4 pph to about 14 pph.