Back to results
US 9,023,973 B2Granted
Cross-linked polycarbonate resin with improved chemical and flame resistance
AssigneeSabic Global Technologies B.V.
InventorsJean-Francois Morizur, Paul Dean Sybert, James Franklin Hoover, Derek Lake
Life of this patent
Estimating the term…
Abstract
Disclosed herein are compositions including a cross-linked polycarbonate. The cross-linked polycarbonate may be derived from a polycarbonate having about 0.5 mol % to about 5 mol % endcap groups derived from a monohydroxybenzophenone. A plaque including the composition can achieve a UL94 5VA rating. Also disclosed herein are articles including the compositions, methods of using the compositions, and processes for preparing the compositions.
Claims64
A composition comprising:
- a cross-linkable polycarbonate resin comprising about 0.5 mole % to about 5.0 mole % endcap groups derived from a monohydroxybenzophenone, wherein the cross-linkable polycarbonate resin is made from an interfacial polymerization process comprising the steps of:
- (i) forming a mixture comprising bisphenol-A, a monohydroxybenzophenone, and a tertiary amine catalyst in a water-immiscible solvent and water solvent system;
- (ii) stirring the mixture of (i) while maintaining a pH from about 8 to about 9 by the addition of a basic solution to form a stirred mixture;
- (iii) charging the stirred mixture of (ii) with phosgene, while simultaneously adding a basic solution to maintain the pH between about 8.5 to about 10 to form a reaction mixture containing the cross-linkable polycarbonate resin;
- (iv) separating the organic layer from the reaction mixture;
- (v) washing the organic layer of (iv) with an aqueous acid;
- (vi) washing the acid-washed organic layer of (v) with deionized water to achieve a neutral pH;
- and
- (vii) isolating the cross-linkable polycarbonate resin from the neutral organic layer of (vi);
- wherein the cross-linkable polycarbonate resin has a weight-average molecular weight of between 17,000 and 35,000 Daltons and has a polydispersity index (PDI) of between 3.0 and 7.3 as measured by GPC using a UV-VIS detector and polycarbonate standards;
- and
- wherein the cross-linkable polycarbonate resin does not contain any soft block segments.
9 more elements
A composition comprising a cross-linkable polycarbonate resin,
- wherein the cross-linkable polycarbonate resin comprises about 0.5 mol % to about 5 mol % endcap groups derived from a monohydroxybenzophenone;
- wherein the cross-linkable polycarbonate resin has a weight-average molecular weight of between 17,000 and 35,000 Daltons and has a polydispersity index (PDI) of between 3.0 and 7.3 as measured by GPC using a UV-VIS detector and polycarbonate standards;
- wherein when a plaque of about 0.5 mm thickness formed from the cross-linkable polycarbonate resin is exposed to UV radiation, the resin increases in molecular weight by at least 15%;
- and
- wherein the cross-linkable polycarbonate resin does not contain any soft block segments.
2 more elements
A composition comprising a cross-linkable polycarbonate resin,
- wherein the cross-linkable polycarbonate resin comprises about 0.5 mol % to about 5 mol % endcap groups derived from a monohydroxybenzophenone;
- wherein the cross-linkable polycarbonate resin has a polydispersity index (PDI) of between 3.0 and 7.3 as measured by GPC using a UV-VIS detector and polycarbonate standards;
- wherein the composition has a melt volume flow rate of 2 to 12 cc/10 minutes at 300° C./1.2 kg;
- wherein a plaque made from the composition has a transparency of 70% to 90% at a thickness of 3.2 mm, measured according to ASTM-D1003-00;
- wherein a plaque that is made from the composition and exposed to UV radiation can achieve a UL94 5VA rating at a thickness of 2.0 mm (±10%);
- and
- wherein the cross-linkable polycarbonate resin does not contain any soft block segments.
4 more elements
A composition comprising a cross-linkable polycarbonate resin,
- wherein the cross-linkable polycarbonate resin comprises about 0.5 mol % to about 5 mol % endcap groups derived from a monohydroxybenzophenone;
- wherein a plaque made from the composition with a thickness of 3.2 mm has a ductility of 100% after exposure to 2000 mJ/cm2 of UV radiation;
- wherein a plaque made from the composition with a thickness of 2.54 mm has a haze of less than 2%;
- wherein a film of about 0.5 mm thickness and exposed to UV radiation has a % gel of 15% or greater;
- wherein a plaque made from the composition with a thickness of 3.2 mm and crosslinked, then submerged in acetone for 5 minutes, does not crack or blister;
- and
- wherein the cross-linkable polycarbonate resin does not contain any soft block segments.
4 more elements
A composition comprising a cross-linkable polycarbonate resin,
- wherein the cross-linkable polycarbonate resin comprises endcap groups derived from a monohydroxybenzophenone;
- wherein the composition has a melt volume flow rate of 2 to 12 cc/10 minutes at 300° C./1.2 kg;
- wherein a plaque that is made from the composition and exposed to UV radiation can achieve a UL94 5VA rating at a thickness of 2.0 mm (±10%);
- and
- wherein the cross-linkable polycarbonate resin does not contain any soft block segments.
2 more elements
A composition comprising a cross-linkable polycarbonate resin and a flame retardant,
- wherein the cross-linkable polycarbonate resin comprises endcap groups derived from a monohydroxybenzophenone;
- wherein the composition comprises about 0.08 wt % or less of the flame retardant;
- wherein the composition has a melt volume flow rate of 2 to 20 cc/10 minutes at 300° C./1.2 kg;
- wherein a plaque that is made from the composition and exposed to UV radiation can achieve a UL94 5VA rating at a thickness of 3.0 mm (±10%);
- and
- wherein the cross-linkable polycarbonate resin does not contain any soft block segments.
3 more elements
An interfacial polymerization process for making a cross-linkable polycarbonate resin, comprising:
- (i) forming a mixture comprising bisphenol-A, a monohydroxybenzophenone, and a tertiary amine catalyst in a water-immiscible solvent and water solvent system;
- (ii) stirring the mixture of (i) while maintaining a pH from about 8 to about 9 by the addition of a basic solution to form a stirred mixture;
- (iii) charging the stirred mixture of (ii) with phosgene, while simultaneously adding a basic solution to maintain the pH between about 8.5 to about 10 to form a reaction mixture containing the cross-linkable polycarbonate resin;
- (iv) separating the organic layer from the reaction mixture;
- (v) washing the organic layer of (iv) with an aqueous acid;
- (vi) washing the acid-washed organic layer of (v) with deionized water to achieve a neutral pH;
- and
- (vii) isolating the cross-linkable polycarbonate resin from the neutral organic layer of (vi);
- wherein the cross-linkable polycarbonate resin has a weight-average molecular weight of between 17,000 and 35,000 Daltons and has a polydispersity index (PDI) of between 3.0 and 7.3 as measured by GPC using a UV-VIS detector and polycarbonate standards;
- and
- wherein the cross-linkable polycarbonate resin does not contain any soft block segments.
8 more elements
A process for preparing a polycarbonate article, comprising:
- making a cross-linkable polycarbonate resin comprising about 0.5 mol % to about 5 mol % endcap groups derived from a monohydroxybenzophenone;
- compounding the cross-linkable polycarbonate resin with a flame retardant to obtain a composition;
- molding an article from the composition or coating an article with the composition;
- and
- exposing the molded article or coating to UV radiation to affect crosslinking;
- wherein a plaque made from the composition has a transparency of 70% to 90% at a thickness of 3.2 mm, measured according to ASTM-D1003-00;
- wherein a plaque that is made from the composition and exposed to UV radiation can achieve a UL94 5VA rating at a thickness of 2.0 mm (±10%) or less;
- and
- wherein the cross-linkable polycarbonate resin does not contain any soft block segments.
6 more elements
Dependencies are inferred from the claim text.