Polycarbonate compositions for mobile phone housing applications
A polycarbonate composition contains, based on the total weight of the polycarbonate composition: one or more polycarbonate homopolymers; a poly(carbonate-siloxane) copolymer comprising siloxane units with an average block length of 5 to 120, preferably 10 to 100, the poly(carbonate-siloxane) copolymer being present in an amount effective to provide 2.5 to 10 wt % of siloxane units based on the total weight of the polycarbonate composition; 1 to 8 wt % of an elastomer-modified graft copolymer; 0.01 to 5 wt % of a silicone oil; and 0.1 to 8 wt % of an additive; and wherein the composition has a melt mass flow rate higher than 16 g/10 min, determined in accordance with ASTM D1238 under a load of 1.2 kg at 300° C. with a dwelling time of 300 seconds; and an Izod notched impact energy of at least 700 J/m measured at 23° C. on a sample of 3.2 mm thickness according to ASTM D256-10.
1. A polycarbonate composition comprising, based on the total weight of the polycarbonate composition:
one or more polycarbonate homopolymers;
a poly(carbonate-siloxane) copolymer comprising siloxane units with an average block length of 5 to 120, the poly(carbonate-siloxane) copolymer being present in an amount effective to provide 2.5 to 10 wt % of siloxane units based on the total weight of the polycarbonate composition;
1 to 8 wt % of an elastomer-modified graft copolymer comprising the elastomer-modifier graft copolymer comprises a styrene-butadiene-styrene, styrene-butadiene rubber, styrene-ethylene-butadiene-styrene, acrylonitrile-butadiene-styrene, acrylonitrile-ethylene-propylene-diene-styrene, styrene-isoprene-styrene, and methyl methacrylate-butadiene-styrene, a silicone graft copolymer, or a combination comprising at least one of the foregoing;
0.01 to 5 wt % of a silicone oil comprising a polydiphenylsiloxane, a poly(alkylphenyl siloxane), a copolymer thereof, or a combination comprising at least one of the foregoing; and
0.1 to 8 wt % of an additive comprising a processing aid, a heat stabilizer, an antioxidant, an ultra violet light absorber, a flame retardant, an anti-drip agent, or a combination comprising at least one of the foregoing; and
wherein the composition has a melt mass flow rate higher than 16 g/10 min, determined in accordance with ASTM D1238 under a load of 1.2 kg at 300° C. with a dwelling time of 300 seconds; and
an Izod notched impact energy of at least 700 J/m measured at 23° C. on a sample of 3.2 mm thickness according to ASTM D256-10.
2. The polycarbonate composition of claim 1 , wherein the poly(carbonate-siloxane) copolymer comprises siloxane units with an average block length of 10 to 100, and the poly(carbonate-siloxane) copolymer is present in an amount effective to provide 2.5 to 5 wt % of siloxane units based on the total weight of the polycarbonate composition.
3. The polycarbonate composition of claim 1 comprising, based on the total weight of the polycarbonate composition:
50 to 85 wt % of the one or more polycarbonate homopolymers;
12 to 25 wt % of the poly(carbonate-siloxane) copolymer comprising
siloxane units with an average block length of 30 to 100, and
a siloxane content of 15 to 30 wt % based on the total weight of the poly(carbonate-siloxane);
1 to 8 wt % of an elastomer-modified graft copolymer comprising the elastomer-modifier graft copolymer comprises a styrene-butadiene-styrene, styrene-butadiene rubber, styrene-ethylene-butadiene-styrene, acrylonitrile-butadiene-styrene, acrylonitrile-ethylene-propylene-diene-styrene, styrene-isoprene-styrene, and methyl methacrylate-butadiene-styrene, styrene-acrylonitrile, a silicone graft copolymer, or a combination comprising at least one of the foregoing;
0.01 to 5 wt % of a silicone oil comprising a polydialkylsiloxane, a polydiphenylsiloxane, a poly(alkylphenyl siloxane), a copolymer thereof, or a combination comprising at least one of the foregoing; and
0.1 to 8 wt % of an additive comprising a processing aid, a heat stabilizer, an antioxidant, an ultra violet light absorber, a flame retardant, an anti-drip agent, or a combination comprising at least one of the foregoing.
4. The polycarbonate composition of claim 1 , wherein the elastomer-modified graft copolymer comprises acrylonitrile-butadiene-styrene.
5. The polycarbonate composition of claim 1 , wherein the silicone oil is a poly(methylphenylsiloxane).
6. The polycarbonate composition of claim 1 , wherein the silicone oil has 40 to 60 mol % of methyl groups attached to silicon atoms and 60 to 40 mol % of phenyl groups attached to silicon atoms, each based on the total moles of the methyl groups and phenyl groups attached to silicon atoms.
7. The polycarbonate composition of claim 1 , wherein the silicone oil is present in an amount of 0.1 to 1 wt %, based on the total weight of the polycarbonate composition.
8. The polycarbonate composition of claim 1 , wherein the polycarbonate homopolymer is present in an amount of 65 to 85 wt % based on the total weight of the polycarbonate composition.
9. The polycarbonate composition of claim 1 , wherein the polycarbonate homopolymer comprises a bisphenol A homopolycarbonate.
10. The polycarbonate composition of claim 1 , wherein the poly(carbonate-siloxane) comprises bisphenol A carbonate units and siloxane units of the formula
or a combination comprising at least one of the foregoing, wherein E has an average value of 30 to 100.
11. The polycarbonate composition of claim 1 , wherein the poly(carbonate-siloxane) comprises bisphenol A carbonate units and siloxane units of the formula
wherein E has an average value of 30 to 80.
12. The polycarbonate composition of claim 1 , comprising, based on the total weight of the composition:
65 to 75 wt % of the one or more bisphenol A polycarbonate homopolymers;
15 to 20 wt % of the poly(carbonate-siloxane);
2 to 7 wt % of the elastomer-modified graft copolymer which comprises acrylonitrile-butadiene-styrene;
0.1 to 1 wt % of a poly(methylphenylsiloxane); and
5 to 8 wt % of the additive.
13. The polycarbonate composition of claim 1 , wherein E has an average value of 30 to 70.
14. The polycarbonate composition of claim 1 , comprising, based on the total weight of the composition:
75 to 85 wt % of the one or more bisphenol A polycarbonate homopolymers;
12 to 18 wt % of the poly(carbonate-siloxane);
2 to 7 wt % of the elastomer-modified graft copolymer which comprises acrylonitrile-butadiene-styrene;
0.1 to 1 wt % of a poly(methylphenylsiloxane); and
0.1 to 1 wt % of the additive.
15. The polycarbonate composition of claim 14 , wherein the poly(carbonate-siloxane) comprises bisphenol A carbonate units and siloxane units of the formula
wherein E has an average value of 20 to 80.
16. The polycarbonate composition of claim 1 , comprising 1 to 8 wt % of an organophosphorus flame retardant.
17. A molded article, comprising: a decorative film bonded to an injection molded base structure, the injection molded base structure comprising the polycarbonate composition of claim 1 .
18. A method of manufacture of an article, the method comprising:
placing a decorative film into a mold;
injecting a polycarbonate composition of claim 1 into a mold cavity space behind the decorative film to form a single molded article comprising the decorative film and an injection molded base structure comprising the polycarbonate composition.
19. The polycarbonate composition of claim 11 , wherein E has an average value of 30 to 70.
20. The polycarbonate composition of claim 11 , wherein E has an average value of 40 to 50.