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US 9,315,666 B2Granted
Compositions and articles of manufacture containing branched polycarbonate
AssigneeSabic Global Technologies B.V.
InventorsJean-Francois Morizur, Thomas L. Evans
Life of this patent
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Abstract
A polycarbonate containing composition comprising a peak melt viscosity of at least 8,000 poise when measured using a parallel plate melt rheology test at a heating rate of 10° C./min at a temperature of between about 350° C. to about 450° C., and wherein a molded article of the composition has a UL 94 VO rating at a thickness of 1.0 mm, 1.5 mm, 2.0 mm, or between 1.0 mm and 2.0 mm is disclosed.
Claims19
A composition comprising:
- a first polycarbonate, wherein the first polycarbonate comprises
- a repeating structural unit of the following formula
- wherein at least 60 percent of the total number of R1 groups contain aromatic groups and the balance thereof are aliphatic or alicyclic groups;
- wherein the first polycarbonate was formed in the presence of an end-capping agent and the end-capping agent is not cyanophenol;
- wherein the first polycarbonate has a branching level of at least about 2%;
- wherein the polycarbonate has a weight average molecular weight of 20,000 g/mole to 54,843 g/mole as measured by gel permeation chromatography using polycarbonate standards;
- and
- wherein the first polycarbonate is prepared by
- selecting the branching level, the weight average molecular weight, and the end-capping agent such that the first polycarbonate has a calculated peak melt viscosity of at least 25,000 poise as calculated by a peak melt viscosity equation as follows:
- calculated peak melt viscosity=−57135.91+36961.39*BL+14001.13*MW1/3−46944.24*pKa−322.51*BL*MW1/3−2669.19*BL*pKa+215.83*MW1/3*pKa+1125.63*BL2−200.11*MW2/3+2231.15*pKa2,
- wherein BL is determined by dividing a number of moles of branching agent by a total moles of bisphenol from which the first polycarbonate is derived, MW is the weight average molecular weight, and the pKa is the pKa of the end capping agent;
- and
- wherein a molded article of the first polycarbonate has a UL94 V0 rating at a thickness of 1.0 mm;
- a flame retardant;
- and
- a second polycarbonate derived from at least bisphenol-A, wherein the second polycarbonate is different from the first polycarbonate;
- wherein a molded article of the composition has a UL94 V0 rating at a thickness of 1.5 mm.
14 more elements
A method of making a composition, comprising:
- preparing a first polycarbonate by
- selecting a branching level, a desired weight average molecular weight, and an end-capping agent such that the first polycarbonate has a calculated peak melt viscosity of at least 25,000 poise as calculated by a peak melt viscosity equation as follows:
- calculated peak melt viscosity=−57135.91+36961.39*BL+14001.13*MW1/3−46944.24*pKa−322.51*BL*MW1/3−2669.19*BL*pKa+215.83*MW1/3*pKa+1125.63*BL2−200.11*MW2/3+2231.15*pKa2,
- wherein BL is determined by dividing a number of moles of branching agent by a total moles of bisphenol from which the first polycarbonate is derived, the MW is the weight-averaged molecular weight of the first polycarbonate and is 20,000 g/mole to 54,843 g/mole as determined by gel permeation chromatography using polycarbonate standards, and the pKa is the pKa of the end capping agent;
- and
- reacting bisphenol, end-capping agent, branching agent, and a carbonate precursor wherein the first polycarbonate has a repeating structural unit of the following formula
- wherein at least 60 percent of the total number of R1 groups contain aromatic groups and the balance thereof are aliphatic or alicyclic groups;
- wherein the end-capping agent is not cyanophenol;
- wherein the pKa of the end-capping agent is from about 8.3 to about 11;
- and
- wherein a molded article of the first polycarbonate has a UL94 V0 rating at a thickness of 1.0 mm;
- and
- blending with the first polycarbonate a flame retardant and a second polycarbonate derived from at least bisphenol-A different than the first polycarbonate;
- wherein a molded article of the composition has a UL94 V0 rating at a thickness of 1.5 mm.
11 more elements
A method of making an article of manufacture, comprising:
- preparing a first polycarbonate by
- selecting a branching level, BL, a desired weight average molecular weight, and an end-capping agent such that the first polycarbonate has a calculated peak melt viscosity of at least 25,000 poise is calculated by a peak melt viscosity equation as follows:
- calculated peak melt viscosity=−57135.91+36961.39*BL+14001.13*MW1/3−46944.24*pKa−322.51*BL*MW1/3−2669.19*BL*pKa+215.83*MW1/3*pKa+1125.63*BL2−200.11*MW213+2231.15*pKa2,
- wherein BL is determined by dividing a number of moles of branching agent by a total moles of bisphenol from which the first polycarbonate is derived, the MW is the weight-averaged molecular weight of the first polycarbonate and is 20,000 g/mole to 54,843 g/mole as determined by gel permeation chromatography using polycarbonate standards, and the pKa is the pKa of the end capping agent;
- reacting the bisphenol, the end-capping agent, the branching agent, and a carbonate precursor, wherein the first polycarbonate comprises a repeating structural unit of the following formula
- wherein at least 60 percent of the total number of R1 groups contain aromatic groups and the balance thereof are aliphatic or alicyclic groups;
- wherein the end-capping agent that is not cyanophenol;
- wherein an article made from the first polycarbonate has a UL94 V0 rating at a thickness of 1.0 mm;
- blending with the first polycarbonate, a flame retardant, and a second polycarbonate derived from at least bisphenol-A different than the first polycarbonate to form the composition;
- and
- forming the composition into the article;
- wherein an article made from the composition has a UL94 V0 rating at a thickness of 1.5 mm.
9 more elements
Dependencies are inferred from the claim text.