IP Library Granted Patent US 9,169,391
Granted Patent B2
US 9,169,391 · App. 13/983,084 · Granted Oct 27, 2015

Polycarbonate composition

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Quick Facts
Patent No.
US 9,169,391
App. No.
13/983,084
Granted
Oct 27, 2015
Kind
B2
Abstract

A composition includes at least one poly(aliphatic ester)-polycarbonate copolymer, a polysiloxane-polycarbonate copolymer, and glass fibers. The composition exhibits good flow, aesthetic, and impact properties.

Claims (131)

1. A composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 40,000;

a polysiloxane-polycarbonate copolymer present in an amount less than the weight percentage of the first poly(aliphatic ester)-polycarbonate copolymer; and

glass fibers;

wherein the composition has a flexural modulus measured according to ISO 178 of at least 3000 MPa,

wherein the composition comprises up to about 75 wt % of the first poly(aliphatic ester)-polycarbonate copolymer.

2. The composition of claim 1 , wherein an ester repeat unit of the first poly(aliphatic ester)-polycarbonate copolymer is derived from sebacic acid.

3. A composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 40,000;

a polysiloxane-polycarbonate copolymer present in an amount less than the weight percentage of the first poly(aliphatic ester)-polycarbonate copolymer; and

glass fibers;

wherein the composition has a flexural modulus measured according to ISO 178 of at least 3000 MPa; where the composition further comprises a second poly(aliphatic ester)-polycarbonate copolymer; and

wherein a weight average molecular weight of the second poly(aliphatic ester)-polycarbonate copolymer is greater than the weight average molecular weight of the first poly(aliphatic ester)-polycarbonate copolymer.

4. The composition of claim 3 , wherein the composition has a melt volume rate measured according to ASTM D1238 of at least 4 cm 3 /10 min.

5. The composition of claim 3 , wherein a weight ratio of the first poly(aliphatic ester)-polycarbonate copolymer to the second poly(aliphatic ester)-polycarbonate copolymer is at least 2:1.

6. The composition of claim 3 , wherein the second poly(aliphatic ester)-polycarbonate copolymer has a weight average molecular weight of from about 30,000 to about 40,000.

7. The composition of claim 3 , comprising from about 15 to about 75 wt % of the first poly(aliphatic ester)-polycarbonate copolymer.

8. The composition of claim 3 , comprising from about 5 to about 50 wt % of the second poly(aliphatic ester)-polycarbonate copolymer.

9. The composition of claim 1 , comprising from about 5 to about 35 wt % of the glass fibers.

10. The composition of claim 1 , wherein the composition exhibits a gloss measured according to ASTM D2457 (at 60°) of at least 40.

11. The composition of claim 1 , wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm 3 /10 min; and a notched Izod impact strength measured according to ASTM D256 of at least 150 J/m.

12. The composition of claim 1 , wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm 3 /10 min; a flexural modulus measured according to ISO 178 of at least 3000 MPa; and a notched Izod impact strength measured according to ASTM D256 of from about 150 J/m to about 300 J/m.

13. The composition of claim 1 , A composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 40,000;

a polysiloxane-polycarbonate copolymer present in an amount less than the weight percentage of the first poly(aliphatic ester)-polycarbonate copolymer; and

glass fibers;

wherein the composition has a flexural modulus measured according to ISO 178 of at least 3000 MPa; and wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm 3 /10 min; a flexural modulus measured according to ISO 178 of at least 3000 MPa; and a notched Izod impact strength measured according to ASTM D256 of at least 200 J/m.

14. The composition of claim 13 , wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 CM 3 /10 min; a flexural modulus measured according to ISO 178 of at least 3500 MPa; and a notched Izod impact strength measured according to ASTM D256 of at least 250 J/m.

15. The composition of claim 13 , wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 9 CM 3 /10 min; a flexural modulus measured according to ISO 178 of at least 3000 MPa; and a notched Izod impact strength measured according to ASTM D256 of at least 250 J/m.

16. The composition of claim 1 , comprising from about 5 to about 25 wt % of the polysiloxane-polycarbonate copolymer.

17. The composition of claim 1 , wherein the aliphatic ester is derived from an aliphatic dicarboxylic acid that has a total of from 8 to 12 carbon atoms.

18. The composition of claim 1 , wherein the first poly(aliphatic ester)-polycarbonate copolymer contains from about 2 to about 13 mol % of aliphatic ester units.

19. The composition of claim 18 , wherein the first poly(aliphatic ester)-polycarbonate copolymer contains from about 87 to about 98 mol % of carbonate units derived from bisphenol-A.

20. The composition of claim 18 , wherein the aliphatic ester units are derived from sebacic acid.

21. The composition of claim 1 , wherein a siloxane block chain length of the polysiloxane-polycarbonate copolymer is from about 35 to about 55.

22. The composition of claim 1 , wherein a siloxane block chain length of the polysiloxane-polycarbonate copolymer is from about 30 to about 100.

23. The composition of claim 1 , wherein the polysiloxane-polycarbonate copolymer has a siloxane block content of from about 15 wt % to about 25 wt %.

24. A composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 40,000;

a polysiloxane-polycarbonate copolymer present in an amount less than the weight percentage of the first poly(aliphatic ester)-polycarbonate copolymer; and

glass fibers;

wherein the composition has a flexural modulus measured according to ISO 178 of at least 3000 MPa; and wherein the polysiloxane-polycarbonate copolymer has a siloxane block content of from greater than zero to about 25 wt %.

25. The composition of claim 1 wherein the composition has a total softblock content of less than 3.5 wt. %.

26. The composition of claim 1 , wherein the composition comprises from about 0.5 wt % to about 6 wt % of siloxane originating from the polysiloxane-polycarbonate copolymer.

27. The composition of claim 1 , wherein the glass fibers are non-bonding glass fibers.

28. An article made from composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 40,000;

a polysiloxane-polycarbonate copolymer present in an amount less than the weight percentage of the first poly(aliphatic ester)-polycarbonate copolymer; and

glass fibers;

wherein the composition has a flexural modulus measured according to ISO 178 of at least 3000 MPa, wherein the article has a wall with a thickness of at least 0.3 mm and less than 1 mm.

29. The article of claim 28 , wherein the article is a part of a cellphone, a MP3 player, a computer, a laptop, a camera, a video recorder, an electronic tablet, a hand receiver, a kitchen appliance, or an electrical housing.

30. A composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 25,000;

a second poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 30,000 to about 40,000;

a polysiloxane-polycarbonate copolymer present in an amount less than the combined weight percentage of the first and second poly(aliphatic ester)-polycarbonate copolymers; and

glass fibers;

wherein the composition has a flexural modulus measured according to ISO 178 of at least 3000 MPa.

31. The composition of claim 30 , wherein the first poly(aliphatic ester)-polycarbonate copolymer and the second poly(aliphatic ester)-polycarbonate copolymer both include ester units derived from sebacic acid.

32. The composition of claim 30 , comprising from about 55 to about 85 wt % of the first poly(aliphatic ester)-polycarbonate copolymer and the second poly(aliphatic ester)-polycarbonate copolymer.

33. The composition of claim 30 , wherein a weight ratio of the first poly(aliphatic ester)-polycarbonate copolymer to the second poly(aliphatic ester)-polycarbonate copolymer is from about 1.5 to about 15.

34. The composition of claim 30 , wherein the first poly(aliphatic ester)-polycarbonate copolymer contains from about 4 to about 7 mol % of aliphatic ester units.

35. The composition of claim 34 , wherein the first poly(aliphatic ester)-polycarbonate copolymer contains from about 93 to about 96 mol % of carbonate units derived from bisphenol-A.

36. The composition of claim 34 , wherein the aliphatic ester units are derived from sebacic acid.

37. The composition of claim 30 , wherein the second poly(aliphatic ester)-polycarbonate copolymer contains from about 7 to about 13 mol % of aliphatic ester units.

38. The composition of claim 30 , wherein the second poly(aliphatic ester)-polycarbonate copolymer contains from about 87 to about 93 mol % of carbonate units derived from bisphenol-A.

39. The composition of claim 37 , wherein the aliphatic ester units are derived from sebacic acid.

40. The composition of claim 30 , wherein both the first poly(aliphatic ester)-polycarbonate copolymer and the second poly(aliphatic ester)-polycarbonate copolymer contain aliphatic ester units derived from sebacic acid and carbonate units derived from bisphenol-A.

41. A composition comprising:

from about 35 wt % to about 75 wt % of a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 25,000;

from about 5 wt % to about 30 wt % of a second poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 30,000 to about 40,000;

from about 9 wt % to about 20 wt % of a polysiloxane-polycarbonate copolymer; and

from about 10 wt % to about 20 wt % of non-bonding glass fibers;

wherein the first poly(aliphatic ester)-polycarbonate copolymer and the second poly(aliphatic ester)-polycarbonate copolymer both comprise ester units derived from sebacic acid;

wherein the composition exhibits a gloss measured according to ASTM D2457 (at 60°) of at least 40.

42. The composition of claim 41 , wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 2 cm 3 /10 min; a flexural modulus according to ISO 178 of at least 3000 MPa; and a notched Izod impact strength measured according to ASTM D256 of at least 90 J/m.

43. The composition of claim 41 , comprising from about 50 to about 65 wt % of the first poly(aliphatic ester)-polycarbonate copolymer.

44. The composition of claim 41 , wherein a weight ratio of the first poly(aliphatic ester)-polycarbonate copolymer to the second poly(aliphatic ester)-polycarbonate copolymer is from about 1.5 to about 15.

45. The composition of claim 44 , wherein a weight ratio of the first poly(aliphatic ester)-polycarbonate copolymer to the second poly(aliphatic ester)-polycarbonate copolymer is from about 2 to about 4.

46. A composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 40,000;

a polysiloxane-polycarbonate copolymer present in an amount less than the weight percentage of the first poly(aliphatic ester)-polycarbonate copolymer; and

glass fibers;

wherein the composition has a flexural modulus measured according to ISO 178 of at least 3000 MPa; and wherein the composition exhibits a gloss measured according to ASTM D2457 (at 60°) of at least 40; and

wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm 3 /10 min; a flexural modulus measured according to ISO 178 of at least 3500 MPa; and a notched Izod impact strength measured according to ASTM D256 of at least 250 J/m.

47. The composition of claim 46 , wherein the composition contains from about 10 wt % to about 20 wt % of the glass fibers.

48. The composition of claim 46 , wherein the composition exhibits a gloss measured according to ASTM D2457 (at 60°) of at least 60.

49. The composition of claim 46 , further comprising a second poly(aliphatic ester)-polycarbonate copolymer;

wherein the first poly(aliphatic ester)-polycarbonate copolymer has a weight average molecular weight of from about 15,000 to about 25,000;

wherein the second poly(aliphatic ester)-polycarbonate copolymer has a weight average molecular weight of from about 30,000 to about 40,000; and

wherein the polysiloxane-polycarbonate copolymer is present in an amount less than the combined weight percentage of the first and second poly(aliphatic ester)-polycarbonate copolymers.

50. The composition of claim 46 , wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 9 cm 3 /10 min.

51. The composition of claim 46 , wherein the first poly(aliphatic ester)-polycarbonate copolymer contains from about 6 to about 8 mol % of aliphatic ester units.

52. The composition of claim 46 , wherein the first poly(aliphatic ester)-polycarbonate copolymer contains from about 2 to about 13 mol % of aliphatic ester units.

53. The composition of claim 52 , wherein the first poly(aliphatic ester)-polycarbonate copolymer contains from about 87 to about 98 mol % of carbonate units derived from bisphenol-A.

54. The composition of claim 51 , wherein the aliphatic ester units are derived from sebacic acid.

55. An article made from the composition of claim 46 .

56. The article of claim 55 , wherein the article is a part of a cellphone, a MP3 player, a computer, a laptop, a camera, a video recorder, an electronic tablet, a hand receiver, a kitchen appliance, or an electrical housing.

57. A composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 25,000;

a second poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 30,000 to about 40,000;

a polysiloxane-polycarbonate copolymer; and

about 10 wt % of glass fibers;

wherein a weight ratio of the first poly(aliphatic ester)-polycarbonate copolymer to the second poly(aliphatic ester)-polycarbonate copolymer is at least 2:1; and

wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 9 cm 3 /10 min; a flexural modulus measured according to ISO 178 of at least 3000 MPa; a notched Izod impact strength measured according to ASTM D256 of at least 250 J/m; and a gloss measured according to ASTM D2457 (at 60°) of at least 40.

58. The composition of claim 57 , containing up to about 65 wt % of the first poly(aliphatic ester)-polycarbonate copolymer.

59. An article made from the composition of claim 57 .

60. An article made from a composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 25,000;

a second poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 30,000 to about 40,000;

a polysiloxane-polycarbonate copolymer; and

about 20 wt % of glass fibers;

wherein a weight ratio of the first poly(aliphatic ester)-polycarbonate copolymer to the second poly(aliphatic ester)-polycarbonate copolymer is at least 1:1; and

wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm 3 /10 min; a flexural modulus measured according to ISO 178 of at least 5000 MPa; and a notched Izod impact strength measured according to ASTM D256 of at least 190 J/m.

61. A composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 25,000;

a second poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 30,000 to about 40,000;

a polysiloxane-polycarbonate copolymer; and

about 30 wt % of glass fibers;

wherein a weight ratio of the first poly(aliphatic ester)-polycarbonate copolymer to the second poly(aliphatic ester)-polycarbonate copolymer is at least 1:1; and

wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm 3 /10 min; a flexural modulus measured according to ISO 178 of at least 5500 MPa; and a notched Izod impact strength measured according to ASTM D256 of at least 90 J/m.

62. The composition of claim 61 , wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm 3 /10 min; a flexural modulus measured according to ISO 178 of at least 6000 MPa; and a notched Izod impact strength measured according to ASTM D256 of at least 150 J/m.

63. An article made from the composition of claim 61 .

64. A composition comprising:

about 36 wt % of a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 25,000;

about 24 wt % of a second poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 30,000 to about 40,000;

about 20 wt % of a polysiloxane-polycarbonate copolymer; and

about 20 wt % of glass fibers;

wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm 3 /10 min; a flexural modulus measured according to ISO 178 of at least 500 MPa; a notched Izod impact strength measured according to ASTM D256 of at least 150 J/m; and a gloss measured according to ASTM D2457 (at 60°) of at least 40.

65. The composition of claim 52 , wherein the aliphatic ester units are derived from sebacic acid.

66. An article made from the composition of claim 58 .

67. An article made from the composition of claim 62 .

Assignments (5)
CORRECTIVE ASSIGNMENT TO CORRECT THE REMOVE THE APPLICATION NUMBER 15039474 PREVIOUSLY RECORDED AT REEL: 054528 FRAME: 0467. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Recorded Mar 23, 2021
From: SABIC GLOBAL TECHNOLOGIES B.V.
To: SHPP GLOBAL TECHNOLOGIES B.V.
Reel/Frame 057453/0680 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 26, 2020
From: SABIC GLOBAL TECHNOLOGIES B.V.
To: SHPP GLOBAL TECHNOLOGIES B.V.
Reel/Frame 054528/0467 →
CORRECTIVE ASSIGNMENT TO CORRECT THE 12/116841, 12/123274, 12/345155, 13/177651, 13/234682, 13/259855, 13/355684, 13/904372, 13/956615, 14/146802, 62/011336 PREVIOUSLY RECORDED ON REEL 033591 FRAME 0673. ASSIGNOR(S) HEREBY CONFIRMS THE CHANGE OF NAME. Recorded Aug 29, 2014
From: SABIC INNOVATIVE PLASTICS IP B.V.
To: SABIC GLOBAL TECHNOLOGIES B.V.
Reel/Frame 033663/0427 →
CORRECTIVE ASSIGNMENT TO CORRECT REMOVE 10 APPL. NUMBERS PREVIOUSLY RECORDED AT REEL: 033591 FRAME: 0673. ASSIGNOR(S) HEREBY CONFIRMS THE CHANGE OF NAME. Recorded Aug 28, 2014
From: SABIC INNOVATIVE PLASTICS IP B.V.
To: SABIC GLOBAL TECHNOLOGIES B.V.
Reel/Frame 033649/0529 →
CHANGE OF NAME Recorded Aug 22, 2014
From: SABIC INNOVATIVE PLASTICS IP B.V.
To: SABIC GLOBAL TECHNOLOGIES B.V.
Reel/Frame 033591/0673 →