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US 2014/0275368 A1Published application
Blended polymer compositions with improved mold release properties
OwnerYuanqing He, Rama Konduri Durvasula +1inventors
InventorsYuanqing He, Rama Konduri Durvasula, James Louis DeRudder
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Abstract
Disclosed herein are methods and compositions of blended polycarbonate compositions with improved mold release characteristics. The resulting compositions, comprising one or more polycarbonate polymers, an impact modifier, a polycarbonate-siloxane copolymer, and an alkyl sulfonate salt, can be used in the manufacture of articles requiring improved mold release characteristics while still retaining the advantageous physical properties of blended polycarbonate compositions. 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.
Claims61
A thermoplastic composition with improved mold release properties comprising:
- a) from about 10 wt % to about 70 wt % of a first polycarbonate component;
- b) from about 10 wt % to about 70 wt % of a second polycarbonate component;
- c) from about 2 wt % to about 10 wt % of an impact modifier component;
- d) from about 5 wt % to about 30 wt % of a mineral filler component;
- e) from about 0 wt % to about 25 wt % of a polycarbonate-polysiloxane copolymer component;
- and
- f) from about 0.1 wt % to about 4.0 wt % of an alkyl sulfonate salt component;
- wherein the combined weight percent value of the first polycarbonate component and the second polycarbonate component is from greater than 10 wt % to about 70 wt %;
- wherein the combined weight percent value of all components does not exceed about 100 wt %;
- wherein all weight percent values are based on the total weight of the composition;
- and
- wherein molded sample of the thermoplastic composition exhibits a lower mold ejection pressure compared to a reference composition consisting essentially of substantially the same proportions of the same polycarbonate polymer component, the same mineral filler, and the same impact modifier component, in the absence of the polycarbonate-polysiloxane copolymer component and the alkyl sulfonate salt.
9 more elements
A thermoplastic composition with improved mold release properties comprising:
- a) from about 15 wt % to about 35 wt % of a first polycarbonate component;
- b) from about 20 wt % to about 50 wt % of a second polycarbonate component;
- c) from about 2 wt % to about 8 wt % of an impact modifier component comprising an acrylonitrile-butadiene-styrene (ABS) polymer composition, a bulk polymerized ABS (BABS), or a methacrylate-butadiene-styrene (MBS) polymer composition;
- d) from about 10 wt % to about 25 wt % of a mineral filler component;
- e) from about 1 wt % to about 25 wt % of a polycarbonate-polysiloxane copolymer component;
- and
- f) from about 0.5 wt % to about 2.0 wt % of an alkyl sulfonate salt component;
- wherein the first polycarbonate polymer component has a melt volume flow rate (MFR) from about 20 grams/10 minutes to about 30 grams/10 minutes when measured at 300° C. and under a load of 1.2 kg according to ASTM D1238;
- wherein the second polycarbonate polymer component has a melt volume flow rate (MFR) from about 4.0 grams/10 minutes to about 8.0 grams/10 minutes when measured at 300° C. and under a load of 1.2 kg according to ASTM D1238;
- wherein the alkyl sulfonate salt component comprises one or more structures represented by a formula:
- (CnH2n+1)—(SO3−M+)p,
- wherein for each alkyl sulfonate salt present, n is independently an integer from 6 to 17;
- p is independently an integer from 1 to 5;
- and each M is independently an alkali or alkaline earth metal;
- wherein the combined weight percent value of the first polycarbonate component and the second polycarbonate component is from greater than 45 wt % to about 70 wt %;
- wherein the combined weight percent value of all components does not exceed about 100 wt %;
- wherein all weight percent values are based on the total weight of the composition;
- and
- wherein a molded sample of the thermoplastic composition exhibits a 3-fold lower mold ejection pressure compared to a reference composition consisting essentially of substantially the same proportions of the same polycarbonate polymer component, the same mineral filler, and the same impact modifier component, in the absence of the polycarbonate-polysiloxane copolymer component and the alkyl sulfonate salt.
16 more elements
A thermoplastic composition with improved mold release properties comprising:
- a) from about 20 wt % to about 30 wt % of a first polycarbonate component;
- b) from about 20 wt % to about 50 wt % of a second polycarbonate component;
- c) from about 3 wt % to about 6 wt % of an impact modifier component comprising an acrylonitrile-butadiene-styrene (ABS) polymer composition, a bulk polymerized ABS (BABS), or a methacrylate-butadiene-styrene (MBS) polymer composition;
- d) from about 12 wt % to about 20 wt % of a mineral filler component;
- e) from about 1 wt % to about 25 wt % of a polycarbonate-polysiloxane copolymer component;
- and
- f) from about 0.5 wt % to about 1.0 wt % of an alkyl sulfonate salt component;
- wherein the first polycarbonate polymer component has a melt volume flow rate (MFR) from about 20 grams/10 minutes to about 30 grams/10 minutes when measured at 300° C. and under a load of 1.2 kg according to ASTM D1238;
- wherein the second polycarbonate polymer component has a melt volume flow rate (MFR) from about 4.0 grams/10 minutes to about 8.0 grams/10 minutes when measured at 300° C. and under a load of 1.2 kg according to ASTM D1238;
- wherein the alkyl sulfonate salt component comprises one or more structures represented by a formula:
- (CnH2n+1)—(SO3M+)p,
- wherein for each alkyl sulfonate salt present, n is independently an integer from 6 to 17;
- p is independently an integer from 1 to 5;
- and each M is independently an alkali or alkaline earth metal;
- wherein the combined weight percent value of the first polycarbonate component and the second polycarbonate component is from greater than 45 wt % to about 70 wt %;
- wherein the combined weight percent value of all components does not exceed about 100 wt %;
- wherein all weight percent values are based on the total weight of the composition;
- and
- wherein a molded sample of the thermoplastic composition exhibits a 3-fold lower mold ejection pressure compared to a reference composition consisting essentially of substantially the same proportions of the same polycarbonate polymer component, the same mineral filler, and the same impact modifier component, in the absence of the polycarbonate-polysiloxane copolymer component and the alkyl sulfonate salt.
16 more elements
A method of improving mold release properties of a thermoplastic composition, the method comprising the step of combining:
- a) from about 10 wt % to about 70 wt % of a first polycarbonate component;
- b) from about 10 wt % to about 70 wt % of a second polycarbonate component;
- c) from about 2 wt % to about 10 wt % of an impact modifier component;
- d) from about 5 wt % to about 30 wt % of a mineral filler component;
- e) from about 1 wt % to about 25 wt % of a polycarbonate-polysiloxane copolymer component;
- and
- f) from about 0.1 wt % to about 4.0 wt % of an alkyl sulfonate salt component;
- wherein the combined weight percent value of the first polycarbonate component and the second polycarbonate component is from greater than 10 wt % to about 70 wt %;
- wherein the combined weight percent value of all components does not exceed about 100 wt %;
- wherein all weight percent values are based on the total weight of the composition;
- and
- wherein a molded sample of the thermoplastic composition exhibits a lower mold ejection pressure compared to a reference composition consisting essentially of substantially the same proportions of the same polycarbonate polymer component, the same mineral filler, and the same impact modifier component, in the absence of the polycarbonate-polysiloxane copolymer component and the alkyl sulfonate salt.
9 more elements
A method of improving mold release properties of a thermoplastic composition, the method comprising the step of combining:
- a) from about 15 wt % to about 35 wt % of a first polycarbonate component;
- b) from about 20 wt % to about 50 wt % of a second polycarbonate component;
- c) from about 2 wt % to about 8 wt % of an impact modifier component comprising an acrylonitrile-butadiene-styrene (ABS) polymer composition, a bulk polymerized ABS (BABS), or a methacrylate-butadiene-styrene (MBS) polymer composition;
- d) from about 10 wt % to about 25 wt % of a mineral filler component;
- e) from about 1 wt % to about 25 wt % of a polycarbonate-polysiloxane copolymer component;
- and
- f) from about 0.5 wt % to about 2.0 wt % of an alkyl sulfonate salt component;
- wherein the first polycarbonate polymer component has a melt volume flow rate (MFR) from about 20 grams/10 minutes to about 30 grams/10 minutes when measured at 300° C. and under a load of 1.2 kg according to ASTM D1238;
- wherein the second polycarbonate polymer component has a melt volume flow rate (MFR) from about 4.0 grams/10 minutes to about 8.0 grams/10 minutes when measured at 300° C. and under a load of 1.2 kg according to ASTM D1238;
- wherein the alkyl sulfonate salt component comprises one or more structures represented by a formula:
- (CnH2n+1)—(SO3M+)p,
- wherein for each alkyl sulfonate salt present, n is independently an integer from 6 to 17;
- p is independently an integer from 1 to 5;
- and each M is independently an alkali or alkaline earth metal;
- wherein the combined weight percent value of the first polycarbonate component and the second polycarbonate component is from greater than 45 wt % to about 70 wt %;
- wherein the combined weight percent value of all components does not exceed about 100 wt %;
- wherein all weight percent values are based on the total weight of the composition;
- and
- wherein a molded sample of the thermoplastic composition exhibits a 3-fold lower mold ejection pressure compared to a reference composition consisting essentially of substantially the same proportions of the same polycarbonate polymer component, the same mineral filler, and the same impact modifier component, in the absence of the polycarbonate-polysiloxane copolymer component and the alkyl sulfonate salt.
16 more elements
A method of improving mold release properties of a thermoplastic composition, the method comprising the step of combining
- a) from about 20 wt % to about 30 wt % of a first polycarbonate component;
- b) from about 20 wt % to about 50 wt % of a second polycarbonate component;
- c) from about 3 wt % to about 6 wt % of an impact modifier component comprising an acrylonitrile-butadiene-styrene (ABS) polymer composition, a bulk polymerized ABS (BABS), or a methacrylate-butadiene-styrene (MBS) polymer composition;
- d) from about 12 wt % to about 20 wt % of a mineral filler component;
- e) from about 1 wt % to about 25 wt % of a polycarbonate-polysiloxane copolymer component;
- and
- f) from about 0.5 wt % to about 1.0 wt % of an alkyl sulfonate salt component;
- wherein the first polycarbonate polymer component has a melt volume flow rate (MFR) from about 20 grams/10 minutes to about 30 grams/10 minutes when measured at 300° C. and under a load of 1.2 kg according to ASTM D1238;
- wherein the second polycarbonate polymer component has a melt volume flow rate (MFR) from about 4.0 grams/10 minutes to about 8.0 grams/10 minutes when measured at 300° C. and under a load of 1.2 kg according to ASTM D1238;
- wherein the alkyl sulfonate salt component comprises one or more structures represented by a formula:
- (CnH2n+1)—(SO3−M+)p,
- wherein for each alkyl sulfonate salt present, n is independently an integer from 6 to 17;
- p is independently an integer from 1 to 5;
- and each M is independently an alkali or alkaline earth metal;
- wherein the combined weight percent value of the first polycarbonate component and the second polycarbonate component is from greater than 45 wt % to about 70 wt %;
- wherein the combined weight percent value of all components does not exceed about 100 wt %;
- wherein all weight percent values are based on the total weight of the composition;
- and
- wherein a molded sample of the thermoplastic composition exhibits a 3-fold lower mold ejection pressure compared to a reference composition consisting essentially of substantially the same proportions of the same polycarbonate polymer component, the same mineral filler, and the same impact modifier component, in the absence of the polycarbonate-polysiloxane copolymer component and the alkyl sulfonate salt.
16 more elements
Dependencies are inferred from the claim text.