Polycarbonate resin composition and molded articles with the same
A polycarbonate composition and its use as a molded article and as housing or a part of electronic device are disclosed. The polycarbonate composition includes a polycarbonate resin, a liquid crystalline polymer resin, a core-shell grafted copolymer and a low molecular weight polyolefin. The composition has an impact strength of at least about 68 kg·cm/cm when a specimen of the composition is subject to a chemical treatment and the chemically treated specimen is tested according to the standard ASTM D256 (⅛″ notched). The composition has an impact resistance of exhibiting substantially no cracking when a specimen of the composition is subject to a chemical treatment and the chemically treated specimen is tested at 0.6 m according to the standard ASTM D3029. The chemical treatment includes submerging the specimen in paint thinner for 20 seconds and thereafter drying the specimen at 70° C. for 5 minutes. Further, the composition has a fatigue resistance of at least about 130,000 when a specimen of the composition is tested at 4000 psi at 5 times per second according to the standard ASTM D638.
1. A polycarbonate composition comprising:
80 to 98 parts by weight of a polycarbonate resin;
0.3 to 10 parts by weight of a liquid crystalline polymer resin;
0.5 to 10 parts by weight of a core-shell grafted copolymer; and
0.1 to 4 parts by weight of a polyolefin having a number average molecular weight of from about 1,000 g/mol to less than 10,000 g/mol.
2. The composition of claim 1 , wherein the composition has an impact strength of at least about 68 kg·cm/cm when a specimen of the composition is subject to a chemical treatment and the chemically treated specimen is tested according to the standard ASTM D256 (⅛″ notched) at 23° C., and wherein the chemical treatment comprises submerging the specimen in paint thinner for 20 seconds and thereafter drying the specimen at 70° C. for 5 minutes.
3. The composition of claim 1 , wherein the composition has an impact resistance of exhibiting substantially no cracking when a specimen of the composition is subject to a chemical treatment and the chemically treated specimen is tested at 0.6 m according to the standard ASTM D3029, wherein the specimen is prepared according to the standard ASTM D256 with a hemispheric notch having a radius of 0.25±0.05 mm, and wherein the chemical treatment comprises submerging the specimen in paint thinner for 20 seconds and thereafter drying the specimen at 70° C. for 5 minutes.
4. The composition of claim 1 , wherein the composition has a fatigue resistance of at least about 130,000 when a specimen of the composition is tested at 4000 psi at 5 times per second according to the standard ASTM D638.
5. A molded article comprising the composition of claim 1 .
6. The molded article of claim 5 , comprising a pellet of the composition or a structure for use as a body or housing of an electronic device.
7. The composition of claim 2 , wherein the composition has an impact strength of at least 70 kg·cm/cm when the chemically treated specimen is tested according to the standard ASTM D256 (⅛″ notched).
8. The composition of claim 2 , wherein the composition is in the form of a molded article.
9. The composition of claim 8 , wherein the molded article comprises a surface, and wherein the surface is coated with a coating layer comprising an oil-based coating material.
10. A method of making an electronic device, comprising:
providing the molded article coated with the coating layer according to claim 9 ;
providing at least one electrical part of an electronic device; and
connecting the molded article with the at least one electrical part.
11. An electronic device produced by the method of claim 10 .
12. An electronic device comprising:
a molded article comprising 80 to 98 parts by weight of a polycarbonate resin, 0.3 to 10 parts by weight of a liquid crystalline polymer resin, 0.5 to 10 parts by weight of a core-shell grafted copolymer and 0.1 to 4 parts by weight of a low molecular weight polyolefin having a number average molecular weight of from about 1,000 g/mol to less than 10,000 g/mol, wherein the molded article further comprising a surface; and
a coating layer formed on the surface of the molded article, the coating layer comprising a residual amount of an organic solvent;
wherein the molded article coated with the coating layer has an impact strength of at least about 68 kg·cm/cm when a specimen of the composition is tested according to the standard ASTM D256 (⅛″ notched).
13. The composition of claim 3 , wherein the composition has an impact resistance of exhibiting substantially no cracking when the chemically treated specimen is tested at 0.8 m according to the standard ASTM D3029.
14. The composition of claim 3 , wherein the composition has an impact resistance of exhibiting substantially no cracking when the chemically treated specimen is tested at 1 m according to the standard ASTM D3029.
15. The composition of claim 3 , wherein the composition is in the form of a molded article.
16. The composition of claim 15 , wherein the molded article comprises a surface, and wherein the surface is coated with a coating layer comprising an oil-based coating material.
17. A method of making an electronic device, comprising:
providing the molded article coated with the coating layer according to claim 16 ;
providing at least one electrical part of an electronic device; and
connecting the molded article with the at least one electrical part.
18. An electronic device produced by the method of claim 17 .
19. An electronic device comprising:
a molded article comprising 80 to 98 parts by weight of a polycarbonate resin, 0.3 to 10 parts by weight of a liquid crystalline polymer resin, 0.5 to 10 parts by weight of a core-shell grafted copolymer and 0.1 to 4 parts by weight of a low molecular weight polyolefin having a number average molecular weight of from about 1,000 g/mol to less than 10,000 g/mol, wherein the molded article further comprising a surface; and
a coating layer formed on the surface of the molded article, the coating layer comprising a residual amount of an organic solvent;
wherein the molded article has an impact resistance of exhibiting substantially no cracking when a specimen of the molded article is tested at 0.6 m according to the standard ASTM D3029, and wherein the specimen is prepared according to the standard ASTM D256 with a hemispheric notch having a radius of 0.25±0.05 mm.
20. The composition of claim 4 , wherein the composition has a fatigue resistance of at least about 130,000 when the specimen is subject to a chemical treatment and the chemically treated specimen is tested at 4000 psi at 5 times per second according to the standard ASTM D638, and wherein the chemical treatment comprises submerging the specimen in paint thinner for 20 seconds and thereafter drying the specimen at 70° C. for 5 minutes.
21. The composition of claim 4 , wherein the composition has a fatigue resistance of at least about 150,000 when the specimen is subject to a chemical treatment and the chemically treated specimen is tested at 4000 psi at 5 times per second according to the standard ASTM D638, and wherein the chemical treatment comprises submerging the specimen in paint thinner for 20 seconds and thereafter drying the specimen at 70° C. for 5 minutes.
22. The composition of claim 4 , wherein the composition has a fatigue resistance of at least about 170,000 when the specimen is tested at 4000 psi at 5 times per second according to the standard ASTM D638 without a chemical treatment prior to testing.
23. The composition of claim 4 , wherein the composition is in the form of a molded article.
24. The composition of claim 23 , wherein the molded article comprises a surface, and wherein the surface is coated with a coating layer comprising an oil-based coating material.
25. A method of making an electronic device, comprising:
providing the composition of claim 23 in the form of the molded article coated with the coating layer on the surface;
providing at least one electrical part of an electronic device; and
connecting the molded article with the at least one electrical part.
26. An electronic device produced by the method of claim 25 .
27. An electronic device comprising:
a molded article comprising 80 to 98 parts by weight of a polycarbonate resin, 0.3 to 10 parts by weight of a liquid crystalline polymer resin, 0.5 to 10 parts by weight of a core-shell grafted copolymer and 0.1 to 4 parts by weight of a low molecular weight polyolefin having a number average molecular weight of from about 1,000 g/mol to less than 10,000 g/mol, wherein the molded article further comprising a surface; and
a coating layer formed on the surface of the molded article, the coating layer comprising a residual amount of an organic solvent;
wherein the molded article has a fatigue resistance of at least about 130,000 when a specimen of the molded article is tested at 4000 psi at 5 times per second according to the standard ASTM D638.
28. The composition of claim 1 , wherein:
said polycarbonate resin comprises a 2,2-bis(4-hydroxyphenyl)propane polycarbonate compound;
said liquid crystalline polymer comprises a polymer including a unit of Formula 11
said core-shell grafted copolymer comprises a butadiene rubber core and a shell polymer derived from a C 1 -C 8 methacrylic acid alkyl ester.
29. A molded article comprising the composition of claim 28 .
30. The composition of claim 2 , wherein:
said polycarbonate resin comprises a 2,2-bis(4-hydroxyphenyl)propane polycarbonate compound;
said liquid crystalline polymer comprises a polymer including a unit of Formula 11
said core-shell grafted copolymer comprises a butadiene rubber core and a shell polymer derived from a C 1 -C 8 methacrylic acid alkyl ester.
31. The electronic device of claim 12 , wherein:
said polycarbonate resin comprises a 2,2-bis(4-hydroxyphenyl)propane polycarbonate compound;
said liquid crystalline polymer comprises a polymer including a unit of Formula 11
said core-shell grafted copolymer comprises a butadiene rubber core and a shell polymer derived from a C 1 -C 8 methacrylic acid alkyl ester.
32. The composition of claim 13 , wherein:
said polycarbonate resin comprises a 2,2-bis(4-hydroxyphenyl)propane polycarbonate compound;
said liquid crystalline polymer comprises a polymer including a unit of Formula 11
said core-shell grafted copolymer comprises a butadiene rubber core and a shell polymer derived from a C 1 -C 8 methacrylic acid alkyl ester.
33. The electronic device of claim 19 , wherein:
said polycarbonate resin comprises a 2,2-bis(4-hydroxyphenyl)propane polycarbonate compound;
said liquid crystalline polymer comprises a polymer including a unit of Formula 11
said core-shell grafted copolymer comprises a butadiene rubber core and a shell polymer derived from a C 1 -C 8 methacrylic acid alkyl ester.
34. The composition of claim 20 , wherein:
said polycarbonate resin comprises a 2,2-bis(4-hydroxyphenyl)propane polycarbonate compound;
said liquid crystalline polymer comprises a polymer including a unit of Formula 11
said core-shell grafted copolymer comprises a butadiene rubber core and a shell polymer derived from a C 1 -C 8 methacrylic acid alkyl ester.
35. The electronic device of claim 27 , wherein:
said polycarbonate resin comprises a 2,2-bis(4-hydroxyphenyl)propane polycarbonate compound;
said liquid crystalline polymer comprises a polymer including a unit of Formula 11
said core-shell grafted copolymer comprises a butadiene rubber core and a shell polymer derived from a C 1 -C 8 methacrylic acid alkyl ester.
36. The composition of claim 1 , wherein said polyolefin has a number average molecular weight of 9,000 g/mol or less.
37. The composition of claim 36 , wherein said polyolefin has a number average molecular weight of 4,000 g/mol or less.
38. The molded article of claim 5 , wherein said polyolefin has a number average molecular weight of 9,000 g/mol or less.
39. The molded article of claim 38 , wherein said polyolefin has a number average molecular weight of 4,000 g/mol or less.