Laser direct structuring materials with improved plating performance and acceptable mechanical properties

1. A blended thermoplastic composition, comprising:

a) a polymer blend comprising:

i. a polycarbonate polymer in an amount from about 40 wt % to about 70 wt % based on the total weight of the blended thermoplastic composition; and

ii. a high rubber graft acrylonitrile-butadiene-styrene (HRG-ABS) copolymer in an amount from about 10 wt % to about 25 wt % based on the total weight of the blended thermoplastic composition, wherein the HRG-ABS copolymer comprises rubber in an amount from about 50 wt % to about 85 wt % of the total weight of the HRG-ABS copolymer and styrene-acrylonitrile in an amount from about 15 wt % to about 50 wt % of the total weight of the HRG-ABS copolymer;

b) a styrene-acrylonitrile (SAN) copolymer in an amount from about 5 wt. % to about 30 wt % based on the total weight of the blended thermoplastic composition, wherein the SAN copolymer comprises styrene in an amount from about 65 wt % to about 80 wt % of the total weight of the SAN copolymer;

c) a talc in an amount from about 1 wt % to about 10 wt % based on the total weight of the blended thermoplastic composition; and

d) a laser direct structuring (LDS) additive in an amount from about 5 wt % to about 15 wt % based on the total weight of the blended thermoplastic composition;

wherein the composition is capable of being plated after being activated with a laser and exhibits a notched impact strength greater than about 400 J/m as measured at 23° C. according to ASTM D256; and

wherein the combined weight percent value of all components does not exceed 100 wt % wherein at least 45% of the styrene-acrylonitrile in the composition is grafted to the rubber of the rubber component of the HRG-ABS.

2. The blended thermoplastic composition of claim 1 , wherein polycarbonate polymer is present in an amount from about 44 wt % to about 49 wt %.

3. The blended thermoplastic composition of claim 1 , wherein polycarbonate polymer is present in an amount of about 44 wt %.

4. The blended thermoplastic composition of claim 1 , wherein polycarbonate polymer is present in an amount of about 49 wt %.

5. The blended thermoplastic composition of claim 1 , wherein the HRG-ABS copolymer is present in an amount from about 12 wt % to about 20 wt %.

6. The blended thermoplastic composition of claim 1 , wherein the HRG-ABS copolymer is present in an amount of about 14 wt %.

7. The blended thermoplastic composition of claim 1 , wherein the HRG-ABS copolymer is present in an amount of about 19 wt %.

8. The blended thermoplastic composition of claim 1 , wherein the SAN copolymer (b) is present in an amount from about 12 wt % to about 22 wt %.

9. The blended thermoplastic composition of claim 1 , wherein the SAN copolymer (b) is present in an amount of about 12 wt %.

10. The blended thermoplastic composition of claim 1 , wherein the SAN copolymer (b) is present in an amount of about 22 wt %.

11. The blended thermoplastic composition of claim 1 , wherein the laser direct structuring (LDS) additive comprises copper chromium oxide.

12. The blended thermoplastic composition of claim 1 , wherein the laser direct structuring (LDS) additive is present in an amount from about 8 wt % to about 12 wt %.

13. The blended thermoplastic composition of claim 1 , wherein the laser direct structuring (LDS) additive is present in an amount of about 10 wt %.

14. The blended thermoplastic composition of claim 1 , wherein the talc is present in an amount of about 3 wt %.

15. The blended thermoplastic composition of claim 1 , wherein the talc is present in an amount of about 5 wt %.

16. The blended thermoplastic composition of claim 1 , further comprising a mold release agent.

17. The blended thermoplastic composition of claim 16 , wherein the mold release agent is present in an amount from about 0.01 wt % to about 0.5 wt %.

18. The blended thermoplastic composition of claim 1 , further comprising an anti-oxidant.

19. The blended thermoplastic composition of claim 18 , wherein the anti-oxidant is present in an amount from about 0.01 wt % to about 0.5 wt %.

20. The blended thermoplastic composition of claim 1 , further comprising a stabilizer.

21. The blended thermoplastic composition of claim 20 , wherein the stabilizer is present in an amount from about 0.01 wt % to about 0.5 wt %.

22. A blended thermoplastic composition, comprising:

a) a polymer blend comprising:

i. a polycarbonate polymer in an amount from about 40 wt % to about 70 wt % based on the total weight of the blended thermoplastic composition; and

ii. a high rubber graft acrylonitrile-butadiene-styrene (HRG-ABS) copolymer in an amount from about 10 wt % to about 25 wt % based on the total weight of the blended thermoplastic composition, wherein the HRG-ABS copolymer comprises rubber in an amount from about 50 wt % to about 85 wt % of the total weight of the HRG-ABS copolymer and styrene-acrylonitrile in an amount from about 15 wt % to about 50 wt % of the total weight of the HRG-ABS copolymer;

b) a styrene-acrylonitrile (SAN) copolymer in an amount from about 5 wt % to about 30 wt % based on the total weight of the blended thermoplastic composition, wherein the SAN copolymer comprises styrene in an amount from about 65 wt % to about 80 wt % of the total weight of the SAN copolymer;

c) a talc in an amount from about 1 wt % to about 10 wt % based on the total weight of the blended thermoplastic composition; and

d) a laser direct structuring (LDS) additive in an amount from about 5 wt % to about 15 wt % based on the total weight of the blended thermoplastic composition;

wherein the composition is capable of being plated after being activated with a laser and exhibits a notched impact strength greater than about 400 J/m as measured at 23° C. according to ASTM D256; and

wherein the combined weight percent value of all components does not exceed 100 wt % wherein at least 45% of the styrene-acrylonitrile in the composition is grafted to the rubber of the rubber component of the HRG-ABS.

23. A blended thermoplastic composition, comprising:

a) a polymer blend comprising:

i. a polycarbonate polymer in an amount of about 46 wt % based on the total weight of the blended thermoplastic composition; and

ii. a high rubber graft acrylonitrile-butadiene-styrene (HRG-ABS) copolymer in an amount of 19 wt % based on the total weight of the blended thermoplastic composition, wherein the HRG-ABS copolymer comprises rubber in an amount from about 50 wt % to about 85 wt % of the total weight of the HRG-ABS copolymer and styrene-acrylonitrile in an amount from about 15 wt % to about 50 wt % of the total weight of the HRG-ABS copolymer;

b) a styrene-acrylonitrile (SAN) copolymer in an amount of about 22 wt % based on the total weight of the blended thermoplastic composition, wherein the SAN copolymer comprises styrene in an amount from about 65 wt % to about 80 wt % of the total weight of the SAN copolymer;

c) a talc in an amount of about 3 wt % based on the total weight of the blended thermoplastic composition; and

d) a laser direct structuring (LDS) additive comprising copper chromium oxide in an amount of about 10 wt % based on the total weight of the blended thermoplastic composition;

wherein the composition is capable of being plated after being activated with a laser and exhibits a notched impact strength greater than about 400 J/m as measured at 23° C. according to ASTM D256; and

wherein the combined weight percent value of all components does not exceed 100 wt %.

24. A blended thermoplastic composition, comprising:

a) a polymer blend comprising:

i. a polycarbonate polymer in an amount of about 44 wt % based on the total weight of the blended thermoplastic composition; and

ii. a high rubber graft acrylonitrile-butadiene-styrene (HRG-ABS) copolymer in an amount of 19 wt % based on the total weight of the blended thermoplastic composition, wherein the HRG-ABS copolymer comprises rubber in an amount from about 50 wt % to about 85 wt % of the total weight of the HRG-ABS copolymer and styrene-acrylonitrile in an amount from about 15 wt % to about 50 wt % of the total weight of the HRG-ABS copolymer;

b) a styrene-acrylonitrile (SAN) copolymer in an amount of about 22 wt % based on the total weight of the blended thermoplastic composition, wherein the SAN copolymer comprises styrene in an amount from about 65 wt % to about 80 wt % of the total weight of the SAN copolymer;

c) a talc in an amount of about 5 wt % based on the total weight of the blended thermoplastic composition; and

d) a laser direct structuring (LDS) additive comprising copper chromium oxide in an amount of about 10 wt % based on the total weight of the blended thermoplastic composition;

wherein the composition is capable of being plated after being activated with a laser and exhibits a notched impact strength greater than about 400 J/m as measured at 23° C. according to ASTM D256; and

wherein the combined weight percent value of all components does not exceed 100 wt %.

25. A method of improving plating performance of a blended thermoplastic composition, the method comprising the step of combining:

a) a polymer blend comprising:

i. a polycarbonate polymer in an amount from about 40 wt % to about 70 wt % based on the total weight of the blended thermoplastic composition; and

ii. a high rubber graft acrylonitrile-butadiene-styrene (HRG-ABS) copolymer in an amount from about 10 wt % to about 25 wt % based on the total weight of the blended thermoplastic composition, wherein the HRG-ABS copolymer comprises rubber in an amount from about 50 wt % to about 85 wt % of the total weight of the HRG-ABS copolymer and styrene-acrylonitrile in an amount from about 15 wt % to about 50 wt % of the total weight of the HRG-ABS copolymer;

b) a styrene-acrylonitrile (SAN) copolymer in an amount from about 5 wt % to about 30 wt % based on the total weight of the blended thermoplastic composition, wherein the SAN copolymer comprises styrene in an amount from about 65 wt % to about 80 wt % of the total weight of the SAN copolymer;

c) a talc in an amount from about 1 wt % to about 10 wt % based on the total weight of the blended thermoplastic composition; and

d) a laser direct structuring (LDS) additive in an amount from about 5 wt % to about 15 wt % based on the total weight of the blended thermoplastic composition;

wherein the blended thermoplastic composition is capable of being plated after being activated with a laser and exhibits a notched impact strength greater than about 400 J/m as measured at 23° C. according to ASTM D256; and

wherein the combined weight percent value of all components does not exceed 100 wt % wherein at least 45 % of the styrene-acrylonitrile in the composition is grafted to the rubber of the rubber component of the HRG-ABS.

26. The method of claim 25 , wherein combining is injection molding.

27. The method of claim 25 , wherein combining is extrusion molding.

28. An extruded or injection molded article, comprising the product of extrusion molding or injection molding a composition comprising:

a) a polymer blend comprising:

i. a polycarbonate polymer in an amount from about 40 wt % to about 70 wt % based on the total weight of the composition; and

ii. a high rubber graft acrylonitrile-butadiene-styrene (HRG-ABS) copolymer in an amount from about 10 wt % to about 25 wt % based on the total weight of the composition, wherein the HRG-ABS copolymer comprises rubber in an amount from about 50 wt % to about 85 wt % of the total weight of the HRG-ABS copolymer and styrene-acrylonitrile in an amount from about 15 wt % to about 50 wt % of the total weight of the HRG-ABS copolymer;

b) a styrene-acrylonitrile (SAN) copolymer in an amount from about 5 wt % to about 30 wt % based on the total weight of the composition, wherein the SAN copolymer comprises styrene in an amount from about 65 wt % to about 80 wt % of the total weight of the SAN copolymer;

c) a talc in an amount from about 1 wt % to about 10 wt % based on the total weight of the blended thermoplastic composition; and

d) a laser direct structuring (LDS) additive in an amount from about 5 wt % to about 15 wt % based on the total weight of the composition;

wherein the article is capable of being plated after being activated with a laser and exhibits a notched impact strength greater than about 400 J/m as measured at 23° C. according to ASTM D256; and

wherein the combined weight percent value of all components does not exceed 100 wt % wherein at least 45 % of the styrene-acrylonitrile in the composition is grafted to the rubber of the rubber component of the HRG-ABS.

29. The article of claim 28 , wherein the article is selected from a computer, a cell phone, communications equipment, a medical application, an RFID component, or an automotive component.

30. The article of claim 28 , the article further comprising a conductive path formed by activation with a laser.

31. The article of claim 30 , the article further comprising a metal layer plated onto the conductive path.

32. The article of claim 31 , wherein the metal layer is a copper layer.

33. The article of claim 31 , wherein the metal layer has a thickness of about 0.8 micrometers or higher as measured according to ASTM B568.

34. An article of manufacture comprising a molded article having a conductive path thereon; and a metal layer plated on the conductive path; wherein the molded article is formed from a composition comprising:

a) a polymer blend comprising:

i. a polycarbonate polymer in an amount from about 40 wt % to about 70 wt % based on the total weight of the composition; and

ii. a high rubber graft acrylonitrile-butadiene-styrene (HRG-ABS) copolymer in an amount from about 10 wt % to about 25 wt % based on the total weight of composition, wherein the HRG-ABS copolymer comprises rubber in an amount from about 50 wt % to about 85 wt % of the total weight of the HRG-ABS copolymer and styrene-acrylonitrile in an amount from about 15 wt % to about 50 wt % of the total weight of the HRG-ABS copolymer;

b) a styrene-acrylonitrile (SAN) copolymer in an amount from about 5 wt % to about 30 wt % based on the total weight of the composition, wherein the SAN copolymer comprises styrene in an amount from about 65 wt % to about 80 wt % of the total weight of the SAN copolymer;

c) a talc in an amount from about 1 wt % to about 10 wt % based on the total weight of the blended thermoplastic composition; and

d) a laser direct structuring (LDS) additive in an amount from about 5 wt % to about 15 wt % based on the total weight of the composition;

wherein the molded article exhibits a notched impact strength greater than about 400 J/m as measured at 23° C. according to ASTM D256;

wherein the combined weight percent value of all components does not exceed 100 wt %; and

wherein the LDS additive is activated with a laser wherein at least 45 % of the styrene-acrylonitrile in the composition is grafted to the rubber of the rubber component of the HRG-ABS.

35. The article of claim 34 , wherein the metal layer comprises a copper layer.

36. The article of claim 34 , wherein the metal layer has a thickness of 0.8 micrometers or higher as measured according to ASTM B568.

37. The article of claim 34 , wherein the article is selected from a computer, a cell phone, communications equipment, a medical application, an RFID component, or an automotive component.