U.S. patent application number 16/707109 was filed with the patent office on 2020-04-16 for copolycarbonate compositions having enhanced optical properties, articles formed therefrom, and methods of manufacture.
The applicant listed for this patent is SABIC GLOBAL TECHNOLOGIES B.V.. Invention is credited to ROLAND SEBASTIAN ASSINK, JOHANNES DE BROUWER, TAMARA MARIJKE EGGENHUISEN, NATHALIE GONZALEZ VIDAL, FABRIZIO MICCICHE, KAZUHIKO MITSUI, SHAHRAM SHAFAEI, ROBERT DIRK VAN DE GRAMPEL, MARK ADRIANUS JOHANNES VAN DER MEE, HENDRIKUS PETRUS CORNELIS VAN HEERBEEK.
Application Number | 20200115548 16/707109 |
Document ID | / |
Family ID | 59325576 |
Filed Date | 2020-04-16 |
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United States Patent
Application |
20200115548 |
Kind Code |
A1 |
VAN DER MEE; MARK ADRIANUS JOHANNES
; et al. |
April 16, 2020 |
COPOLYCARBONATE COMPOSITIONS HAVING ENHANCED OPTICAL PROPERTIES,
ARTICLES FORMED THEREFROM, AND METHODS OF MANUFACTURE
Abstract
A thermoplastic composition comprises: a copolycarbonate
comprising bisphenol A carbonate units and second carbonate units
of the formula ##STR00001## and 2 to 40 ppm of an organosulfonic
stabilizer of the formula ##STR00002## wherein the second carbonate
units are present in an amount of 20 to 49 mol %, preferably 30 to
40 mol % based on the sum of the moles of the copolycarbonate and
the bisphenol A homopolycarbonate, and optionally the
copolycarbonate comprises less than 2 ppm by weight of each of an
ion of lithium, sodium, potassium, calcium, magnesium, ammonium,
chlorine, bromine, fluorine, nitrite, nitrate, phosphite,
phosphate, sulfate, formate, acetate, citrate, oxalate,
trimethylammonium, and triethylammonium, as measured by ion
chromatography; and the thermoplastic composition has: a Vicat B120
of 160.degree. C. or higher measured according to ISO 306; and a
yellowness index of less than 12, measured according to ASTM
D1925.
Inventors: |
VAN DER MEE; MARK ADRIANUS
JOHANNES; (BREDA, NL) ; GONZALEZ VIDAL; NATHALIE;
(BERGEN OP ZOOM, NL) ; MICCICHE; FABRIZIO; (BREDA,
NL) ; ASSINK; ROLAND SEBASTIAN; (MIDDELBURG, NL)
; MITSUI; KAZUHIKO; (MOKA, JP) ; DE BROUWER;
JOHANNES; (OISTERWIJK, NL) ; SHAFAEI; SHAHRAM;
(BERGEN OP ZOOM, NL) ; VAN HEERBEEK; HENDRIKUS PETRUS
CORNELIS; (BERGEN OP ZOOM, NL) ; EGGENHUISEN; TAMARA
MARIJKE; (BREDA, NL) ; VAN DE GRAMPEL; ROBERT
DIRK; (THOLEN, NL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SABIC GLOBAL TECHNOLOGIES B.V. |
Bergen Op Zoom |
|
NL |
|
|
Family ID: |
59325576 |
Appl. No.: |
16/707109 |
Filed: |
December 9, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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16302322 |
Nov 16, 2018 |
|
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PCT/IB2017/053136 |
May 27, 2017 |
|
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16707109 |
|
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62342414 |
May 27, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C08G 64/12 20130101;
C08L 2201/08 20130101; G02B 1/11 20130101; G02B 1/04 20130101; C08L
69/00 20130101; C08K 5/42 20130101; G02B 1/14 20150115; C08L
2205/03 20130101; C08L 2205/025 20130101; G02B 1/041 20130101; C08L
69/00 20130101; C08L 69/00 20130101; G02B 1/041 20130101; C08L
69/00 20130101; C08L 69/00 20130101; C08K 5/42 20130101 |
International
Class: |
C08L 69/00 20060101
C08L069/00; G02B 1/11 20060101 G02B001/11; G02B 1/14 20060101
G02B001/14; C08G 64/12 20060101 C08G064/12; C08K 5/42 20060101
C08K005/42; G02B 1/04 20060101 G02B001/04 |
Claims
1. A thermoplastic composition comprising: a copolycarbonate
comprising bisphenol A carbonate units and second carbonate units
of the formula ##STR00029## wherein R.sup.a and R.sup.b are each
independently a C.sub.1-12 alkyl, C.sub.1-12 alkenyl, C.sub.3-8
cycloalkyl, or C.sub.1-12 alkoxy, each R.sup.3 is independently a
C.sub.1-6 alkyl, R.sup.4 is hydrogen, C.sub.2-6 alkyl or phenyl
optionally substituted with 1 to 5 C.sub.1-6 alkyl groups, p, q,
and j are each independently 0 to 4, optionally a bisphenol A
homopolycarbonate; and 2 to 40 ppm of an organosulfonic stabilizer
of the formula ##STR00030## wherein each R.sup.7 is independently a
C.sub.1-30 alkyl, C.sub.6-30 aryl, C.sub.7-30 alkylarylene,
C.sub.7-30 arylalkylene, or a polymer unit derived from a
C.sub.2-32 ethylenically unsaturated aromatic sulfonic acid or its
ester, and R.sup.8 is C.sub.1-30 alkyl; or R.sup.8 is a group of
the formula --S(.dbd.O).sub.2--R.sup.7; wherein the second
carbonate units are present in an amount of 20 to 49 mol % based on
the sum of the moles of the copolycarbonate and the bisphenol A
homopolycarbonate; and wherein the thermoplastic composition has a
Vicat B120 of 160.degree. C. or higher measured according to ISO
306 and a yellowness index of less than 12, measured according to
ASTM D1925 on a plaque of 2.5 mm thickness molded at a temperature
of 355.degree. C. for a residence time of 10 minutes.
2. The thermoplastic composition of claim 1, wherein the second
carbonate repeating units in the copolycarbonate are of the formula
##STR00031## wherein R.sup.5 is hydrogen, phenyl or methyl.
3. The thermoplastic composition of claim 1, wherein the
copolycarbonate comprises from 15 to 90 mole percent of the
bisphenol A carbonate units and 10 to 85 mole percent of the second
carbonate units, each based on the total number of carbonate units
in the copolycarbonate.
4. The thermoplastic composition of claim 1, wherein the
copolycarbonate comprises from 50 to 90 mole percent of the
bisphenol A carbonate units and 10 to 50 mole percent of the second
carbonate units, and has less than 15 mole percent of the second
carbonate units directly coupled to another second carbonate unit,
each based on the total number of carbonate units in the
copolycarbonate.
5. The thermoplastic composition of claim 1, wherein the
copolycarbonate further comprises at least 5 mole percent of a
third carbonate unit different from the bisphenol A carbonate units
and the second carbonate units, the third carbonate unit comprising
units of the formula ##STR00032## or a combination thereof, wherein
R.sup.c and R.sup.d are each independently a C.sub.1-12 alkyl,
C.sub.1-12 alkenyl, C.sub.3-8 cycloalkyl, or C.sub.1-12 alkoxy,
each R.sup.6 is independently C.sub.1-3 alkyl or phenyl, X.sup.a is
a C.sub.6-12 polycyclic aryl, C.sub.3-18 mono- or
polycycloalkylene, C.sub.3-18 mono- or polycycloalkylidene,
-(Q.sup.1).sub.x-G-(Q.sup.2).sub.y- group wherein Q.sup.1 and
Q.sup.2 are each independently a C.sub.1-3 alkylene, G is a
C.sub.3-10 cycloalkylene, x is 0 or 1, and y is 1, or
--C(P.sup.1)(P.sup.2)-- wherein P.sup.1 is C.sub.1-12 alkyl and
P.sup.2 is C.sub.6-12 aryl, and m and n are each independently 0 to
4.
6. The thermoplastic composition of claim 5 wherein the
copolycarbonate comprises from 15 to 70 mole percent of the
bisphenol A carbonate units, 5 to 50 mole percent of the second
carbonate units, and 5 to 50 mole percent of the third carbonate
units, each based on the total number of carbonate units in the
copolycarbonate.
7. The thermoplastic composition of claim 1, wherein the
copolycarbonate comprises less than 2 ppm by weight of each of an
ion of lithium, sodium, potassium, calcium, magnesium, ammonium,
chlorine, bromine, fluorine, nitrite, nitrate, phosphite,
phosphate, sulfate, formate, acetate, citrate, oxalate,
trimethylammonium, and triethylammonium, as measured by ion
chromatography.
8. The thermoplastic composition of claim 1, wherein in the
organosulfonic stabilizer each R.sup.7 is independently a
C.sub.6-12 aryl, C.sub.7-24 alkylarylene, or a polymer unit derived
from a C.sub.2-14 ethylenically unsaturated aromatic sulfonic acid
or its C.sub.1-30 alkyl ester; and R.sup.8 is C.sub.1-24 alkyl, or
a group of the formula --S(.dbd.O).sub.2--R.sup.7 wherein R.sup.7
is a C.sub.6-12 aryl or C.sub.7-24 alkylarylene.
9. The thermoplastic composition of claim 1, wherein in the
organosulfonic stabilizer R.sup.7 is a C.sub.6-12 aryl, C.sub.7-24
alkylarylene, or a polymer unit derived from a C.sub.2-14
ethylenically unsaturated aromatic sulfonic acid or its ester; and
R.sup.8 is C.sub.1-24 alkyl, or a group of the formula
--S(.dbd.O).sub.2--R.sup.7 wherein R.sup.7 is a C.sub.6-12 aryl or
C.sub.7-24 alkylarylene; or R.sup.7 is a C.sub.7-10 alkylarylene or
a polymer unit derived from a C.sub.2-14 ethylenically unsaturated
aromatic sulfonic acid, and R.sup.8 is C.sub.1-25 alkyl, or a group
of the formula --S(.dbd.O).sub.2--R.sup.7 wherein R.sup.7 is a
C.sub.7-10 alkylarylene; or R.sup.7 is a polymer unit derived from
a C.sub.2-14 ethylenically unsaturated aromatic sulfonic acid; or
R.sup.7 is a C.sub.1-10 alkyl ester of a C.sub.7-12 alkylarylene
sulfonic acid; or R.sup.7 is a group of the formula
--S(.dbd.O).sub.2--R.sup.1 wherein R.sup.7 is a C.sub.6-12 aryl or
C.sub.7-24 alkylarylene.
10. The thermoplastic composition of claim 1, wherein the
organosulfonic stabilizer comprises butyl tosylate, ethyl tosylate,
p-toluenesulfonic anhydride, octadecyl p-toluenesulfonate, or a
combination comprising at least one of the foregoing.
11. The thermoplastic composition claim 1, wherein the stabilizer
is present in an amount of 2 ppm to 20 ppm, based on the total
weight of the thermoplastic composition.
12. The thermoplastic composition of claim 1, wherein the
thermoplastic composition has a bisphenol A purity of equal to or
greater than 99.6%, or of equal to or greater than 99.7% measured
by high performance liquid chromatography.
13. The thermoplastic composition of claim 1, wherein the
polycarbonate homopolymer is present in an amount of 10 to 90 wt %,
based on the total weight of the thermoplastic composition.
14. The thermoplastic composition of claim 1, comprising: a
copolycarbonate comprising bisphenol A carbonate units and second
carbonate units of the formula ##STR00033## wherein R.sup.5 is
hydrogen, phenyl, or methyl; a bisphenol A homopolycarbonate; and 2
to 20 ppm of an organosulfonic stabilizer comprising a C.sub.1-30
alkyl ester of p-toluenesulfonic acid; wherein the thermoplastic
composition has 25 mol % to 49 mol % of second carbonate units
based on the sum of the moles of the copolycarbonate and the
bisphenol A homopolycarbonate.
15. The thermoplastic composition of claim 1, comprising, based on
the total weight of the thermoplastic composition: 60 to 70 wt % of
a copolycarbonate comprising bisphenol A carbonate units and second
carbonate units of the formula ##STR00034## wherein R.sup.5 is
hydrogen, phenyl or methyl; 25 to 40 wt % of a bisphenol A
homopolycarbonate; and 2 to 20 ppm of an organosulfonic stabilizer
comprising a C.sub.1-30 alkyl ester of p-toluenesulfonic acid;
wherein the thermoplastic composition has 25 mol % to 49 mol % of
second carbonate units based on the sum of the moles of the
copolycarbonate and the bisphenol A homopolycarbonate.
16. The thermoplastic composition of claim 1, comprising, based on
the total weight of the thermoplastic composition: 60 to 70 wt % of
a copolycarbonate comprising bisphenol A carbonate units and second
carbonate units of the formula ##STR00035## wherein R.sup.5 is
phenyl or methyl; 25 to 40 wt % of a bisphenol A homopolycarbonate;
and 4 to 10 ppm of an organosulfonic stabilizer comprising butyl
tosylate; wherein the thermoplastic composition has 30 mol % to 40
mol % of second carbonate units based on the sum of the moles of
the copolycarbonate and the bisphenol A homopolycarbonate.
17. The composition of claim 16, wherein the copolycarbonate has a
hydroxyl end group content of less than 200 ppm and the bisphenol A
homopolycarbonate has a hydroxyl end group content of less than 150
ppm.
18. The composition of claim 16, wherein the bisphenol A
homopolycarbonate has a sulfur content of less than 2 ppm, or the
copolycarbonate, the bisphenol A homopolycarbonate, or both are
derived from a bisphenol A having a sulfur content of less than 2
ppm, each as measured by a Total Sulfur Analysis based on
combustion and coulometric detection.
19. An article comprising the copolymer of claim 1, wherein the
article is a molded article, a thermoformed article, an extruded
layer, a layer of a multi-layer article, a substrate for a coated
article, or a substrate for a metallized article.
20. The article of claim 19, wherein the article is a lens, a light
guide, a waveguide, a collimator, an optical fiber, a window, a
door, a visor, a display screen, an electronic device, a scientific
or medical device, a safety shield, a fire shield, wire or cable
sheathing, a mold, a dish, a tray, a screen, an enclosure, glazing,
packaging, a gas barrier, an anti-fog layer, or an anti-reflective
layer.
21. The article of claim 19, wherein the article is a component of
a device comprising a lens, a device comprising a light guide, a
device comprising a waveguide, a device comprising a collimator, a
device comprising an optical fiber, a device comprising a lighting
element, a device comprising a window, a device comprising a door,
or the article is a structural component of a vehicle, a building,
or an appliance, or the article is a component of a medical device,
a component of a display screen, a component of an electronic
device, a component of a safety device, a component of a screen, a
component of conveyor, a component of a mold, a component of a
dish, a component of an enclosure, a component of packaging, a
component of a gas barrier, a component of an encapsulant, a
component of a label, a component of a gas barrier, a component of
an anti-fog assembly, or a component of an anti-reflective
assembly.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Non-Provisional
application Ser. No. 16/302,322, filed on Nov. 16, 2018, which is a
National Stage application of PCT/IB2017/053136, filed May 27,
2017, which claims the benefit of U.S. Provisional Application No.
62/342,414, filed May 27, 2016, all of which are incorporated by
reference in their entirety herein.
BACKGROUND
[0002] This disclosure generally relates to polycarbonate
compositions, and more particularly, to high heat copolycarbonate
compositions having enhanced optical properties, methods of
manufacture, and uses thereof.
[0003] Polycarbonates are useful in the manufacture of articles and
components for a wide range of applications, from automotive parts
to electronic devices. Because of their broad use, particularly in
lenses, optical films, and healthcare products requiring high heat
sterilization, it is desirable to provide polycarbonates with high
heat performance combined with good optical properties,
particularly after processing and after exposure to real life
conditions such as prolonged exposure to high temperatures.
[0004] Some known "high heat" copolycarbonates can have high glass
transition temperatures of 150.degree. C. or higher. But such
polycarbonates are typically more yellow after processing and have
lower transmission values. There accordingly remains a need for
polycarbonate compositions having improved balance of high heat
performance and optical properties.
SUMMARY
[0005] A thermoplastic composition comprises: a copolycarbonate
comprising bisphenol A carbonate units and second carbonate units
of the formula
##STR00003##
wherein R.sup.a and R.sup.b are each independently a C.sub.1-12
alkyl, C.sub.1-12 alkenyl, C.sub.3-8 cycloalkyl, or C.sub.1-12
alkoxy, each R.sup.3 is independently a C.sub.1-6 alkyl, R.sup.4 is
hydrogen, C.sub.2-6 alkyl or phenyl optionally substituted with 1
to 5 C.sub.1-6 alkyl groups, p, q, and j are each independently 0
to 4, optionally a bisphenol A homopolycarbonate; and 2 to 40 ppm
of an organosulfonic stabilizer of the formula
##STR00004##
wherein each R.sup.7 is independently a C.sub.1-30 alkyl,
C.sub.6-30 aryl, C.sub.7-30 alkylarylene, C.sub.7-30 arylalkylene,
or a polymer unit derived from a C.sub.2-32 ethylenically
unsaturated aromatic sulfonic acid or its ester, and R.sup.8 is
hydrogen; or R.sup.8 is C.sub.1-30 alkyl; or R.sup.8 is a group of
the formula --S(.dbd.O).sub.2--R.sup.7; wherein the second
carbonate units are present in an amount of 20 to 49 mol %,
preferably 30 to 40 mol % based on the sum of the moles of the
copolycarbonate and the bisphenol A; and wherein the thermoplastic
composition has: a Vicat B120 of 160.degree. C. or higher measured
according to ISO 306; and a yellowness index of less than 12,
preferably less than 8, more preferably less than 6 measured
according to ASTM D1925 on a plaque of 2.5 mm thickness molded at a
temperature of 355.degree. C. for a residence time of 10
minutes.
[0006] In another embodiment, an article comprises the
above-described thermoplastic composition. The article can be a
molded article, a thermoformed article, an extruded layer, a layer
of a multi-layer article, a substrate for a coated article, or a
substrate for a metallized article.
[0007] In still another embodiment, a method of manufacture of an
article comprises injection molding, injection-compression molding,
heat-cool molding, extrusion, rotational molding, blow molding, or
thermoforming the above-described thermoplastic composition into an
article.
[0008] The above described and other features are exemplified by
the following drawings, detailed description, examples, and
claims.
DETAILED DESCRIPTION
[0009] Surprisingly, it has now been found that a thermoplastic
composition comprising phthalimidine copolycarbonates such as
N-phenylphenolphthaleinyl bisphenol, 2,2-bis(4-hydro)-bisphenol A
copolycarbonate ("PPPBP-BPA"), optionally a bisphenol A
homopolymer, and an organosulfonic acid, acid ester, or acid
anhydride stabilizer has desirable high glass transition
temperature and enhanced optical properties. In particular, the
thermoplastic composition may not only have good initial color and
transmission after molding under standard conditions, but also
lower color change after molding at aggressive conditions. This
would allow using these compositions in more demanding
applications, for example tool designs requiring high melt
temperatures to completely fill the tool or articles that have
demanding requirements on color stability during part lifetime
under one or more of high heat, hydro (high moisture), and high
ultraviolent (UV) conditions.
[0010] As used herein, phthalimidine copolycarbonates are high heat
copolycarbonates having a glass transition temperature of
155.degree. C. or higher, and comprising bisphenol A carbonate
units and second carbonate units of formula (1)
##STR00005##
wherein R.sup.a and R.sup.b are each independently a C.sub.1-12
alkyl, C.sub.1-12 alkenyl, C.sub.3-8 cycloalkyl, or C.sub.1-12
alkoxy, preferably a C.sub.1-3 alkyl, each R.sup.3 is independently
a C.sub.1-6 alkyl, R.sup.4 is hydrogen, C.sub.1-6 or C.sub.2-6
alkyl or phenyl optionally substituted with 1 to 5 C.sub.1-6 alkyl
groups, and p and q are each independently 0 to 4, preferably 0 to
1. For example, second carbonate units can be of formula (1a)
##STR00006##
wherein R.sup.5 is hydrogen, phenyl optionally substituted with up
to five C.sub.1-6 alkyl groups, or C.sub.1-4 alkyl, such as methyl
or C.sub.2-4 alkyl. In an embodiment, R.sup.5 is hydrogen or
phenyl, preferably phenyl. Carbonate units (1a) wherein R.sup.5 is
phenyl can be derived from 2-phenyl-3,3'-bis(4-hydroxy
phenyl)phthalimidine (also known as
3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one or N-phenyl
phenolphthalein or "PPPBP"). Bisphenol A carbonate units have
formula (2).
##STR00007##
[0011] The copolycarbonate comprises 15 to 90 mole percent (mol %)
of the bisphenol A carbonate units and 10 mol % to 85 mol % of the
second carbonate units, preferably the copolycarbonate comprises
from 50 to 90 mol % of the bisphenol A carbonate units and 10 to 50
mol % of the second carbonate units, and more preferably the
copolycarbonate comprises from 50 to 70 mol % of the bisphenol A
carbonate units and 30 to 50 mol %, or 60 to 70 mol % of the
bisphenol A carbonate units and 30 to 40 mol % of the second
carbonate units, each based on the total number of carbonate units
in the copolycarbonate.
[0012] In some embodiments, the high heat copolycarbonates further
include third carbonate units different from bisphenol A carbonate
units and second carbonate units. The third carbonate units can
have the formula
##STR00008##
or a combination thereof, wherein R.sup.c and R.sup.d are each
independently a C.sub.1-12 alkyl, C.sub.1-12 alkenyl, C.sub.3-8
cycloalkyl, or C.sub.1-12 alkoxy, each R.sup.6 is independently
C.sub.1-3 alkyl or phenyl, preferably methyl, X.sup.a is a
C.sub.6-12 polycyclic aryl, C.sub.3-18 mono- or polycycloalkylene,
C.sub.3-18 mono- or polycycloalkylidene,
-(Q.sup.1).sub.x-G-(Q.sup.2).sub.y- group wherein Q.sup.1 and
Q.sup.2 are each independently a C.sub.1-3 alkylene, G is a
C.sub.3-10 cycloalkylene, x is 0 or 1, and y is 1, or
--C(P.sup.1)(P.sup.2)-- wherein P.sup.1 is C.sub.1-12 alkyl and
P.sup.2 is C.sub.6-12 aryl; and m and n are each independently 0 to
4.
[0013] Exemplary third carbonate units include the following
##STR00009## ##STR00010##
or a combination thereof, wherein R.sup.c and R.sup.d are the same
as defined herein for formulas (3) to (5), each R.sup.1 is
independently hydrogen or C.sub.1-4 alkyl, each R.sup.2 is
independently C.sub.1-4 alkyl, and g is 0 to 10. Preferably, each
R.sup.1 is independently hydrogen or methyl, each R.sup.2 is
independently methyl or hydrogen, g is 0 to 2, and m and n are 0.
In a specific embodiment the third carbonate units are
1,1-bis(4-hydroxyphenyl)-3,3,5-trimethyl-cyclohexane carbonate
units, 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane, or a
combination thereof. Preferably, the third carbonate units are
1,1-bis(4-hydroxyphenyl)-3,3,5-trimethyl-cyclohexane (BPA TMC)
carbonate units.
[0014] When the third carbonate units are present, the
copolycarbonates can comprise 10 to 70 mol % of the bisphenol A
carbonate units, 5 to 50 mol % of the second carbonate units, and 5
to 50 mol % of the third carbonate units, each based on the sum of
moles of the bisphenol A carbonate units, second carbonate units,
and third carbonate units. Preferably, the copolycarbonates
comprise 30 to 60 mol % of the bisphenol A carbonate units, 5 to 35
mol % of the second carbonate units, 5 to 35 mol % of the third
carbonate units, each based on the sum of the moles of the
bisphenol A carbonate units, second carbonate units, and third
carbonate units.
[0015] In an embodiment, the copolycarbonates are highly random
copolymers, which have less than 15 mol % or less than 10 mol % of
the second carbonate units directly coupled to another second
carbonate unit based on the total number of carbonate units in the
copolycarbonates. The molar percent can be determined by nuclear
magnetic resonance spectroscopy (NMR). Without wishing to be bound
by theory, it is believed that by keeping the randomness of the
high heat polymer, the properties of the high heat polymer remains
consistent from batch to batch.
[0016] To further enhance the optical properties of the
thermoplastic compositions, the high heat copolycarbonates are
essentially free of certain metal ions, and preferably, low
molecular weight molecules (those having a molecular weight of less
than 150 Dalton) arising from the starting materials or process to
manufacture of the copolymers. In an embodiment, the
copolycarbonates comprise less than 2 ppm of each of triethyl
amine, calcium ions, magnesium ions, potassium ions, iron ions, and
chloride ions. In another embodiment, the high heat
copolycarbonates comprise less than 2 ppm of each chloride, sodium,
calcium, iron, nickel, copper, and zinc ions as residual
impurities.
[0017] In another embodiment, which is preferred, the
copolycarbonates have a very low residual impurity content, in
particular less than 2 ppm by weight of each of lithium, sodium,
potassium, calcium, magnesium, ammonium, chloride, bromide,
fluoride, nitrite, nitrate, phosphite, phosphate, sulfate, acetate,
citrate, oxalate, trimethylammonium, and triethylammonium. It is to
be understood that the foregoing residual impurities can exist in
the copolycarbonate compositions in un-ionized form (for example as
triethylamine or formic acid), but are determined based on their
ionized form.
[0018] The residual impurity content can be determined by methods
known in the art, for example those described in US 2016/0237210
and U.S. Pat. No. 9,287,471 via ion chromatography. For example,
determination can be accomplished via ion exchange, of a sample
obtained by dissolving 2.4 gram of copolycarbonate in 20 mL of
dichloromethane and extracting with 10 mL of distilled, deionized
water for 1 hour. The water layer is analyzed by ion chromatography
with respect to the desired anions, cations, and amines, in
particular fluoride, acetate, formate, chloride, nitrite, bromide,
nitrate, phosphite, sulphate, oxalate, phosphate, citrate, lithium,
sodium, potassium, ammonium, magnesium, calcium, and diethylamine,
and triethylamine. In another embodiment of quantitative analysis
of ions, the sample can be submerged in de-ionized water kept at
55.degree. C. for 24 hours, the anions released into the water then
analyzed via ion chromatography, e.g., with a Dionex DX500 Ion
Chromatograph. Alternatively, quantitative analysis of metals and
other compounds can be carried out by conventional inductively
coupled plasma emission spectroscopy (ICP) methods to determine the
presence of each constituent to the parts per billion (ppb)
level.
[0019] The high heat copolycarbonates have a weight average
molecular weight (Mw) of 10,000 to 50,000 Daltons (Da), preferably
16,000 to 30,000 Da, as measured by gel permeation chromatography
(GPC), using a crosslinked styrene-divinylbenzene column and
calibrated to bisphenol A homopolycarbonate references. GPC samples
are prepared at a concentration of 1 mg per ml, and are eluted at a
flow rate of 1.5 ml per minute.
[0020] The high heat copolycarbonates have a high glass transition
temperature (Tg). The Tg of the high heat copolycarbonates is 155
to 280.degree. C., more preferably 165 to 260.degree. C., even more
preferably 185 to 230.degree. C., determined by differential
scanning calorimetry (DSC) as per ASTM D3418 with a 20.degree.
C./min heating rate.
[0021] The high heat copolycarbonates can have high heat
resistance. The heat deflection temperature (HDT) of the high heat
copolycarbonates is 145 to 270.degree. C., more preferably 155 to
260.degree. C., even more preferably 175 to 220.degree. C.,
measured flat on a 80.times.10.times.4 mm bar with a 64 mm span at
0.45 MPa according to ISO 75/Bf.
[0022] The high heat copolycarbonates can have high Vicat softening
temperature. In an embodiment, the high heat copolycarbonates have
a Vicat B120 of 150 to 275.degree. C., preferably 160 to
255.degree. C., even more preferably 180 to 225.degree. C.,
measured according to ISO 306.
[0023] The high heat copolycarbonates can be present in an amount
of 10 to 99 wt %, 90 to 99.8 wt %, 20 to 80 wt %, 40 to 70 wt %, or
50 to 70 wt % based on the total weight of the thermoplastic
compositions. Preferably the second carbonate units of the high
heat copolycarbonates are present in the composition in an amount
of 20 to 49 mol %, preferably 30 to 40 mol % based on the sum of
the moles of the copolycarbonate and the bisphenol A
homopolycarbonate.
[0024] The high heat copolycarbonates can be produced using a BPA
monomer having both a high level of organic purity (e.g., measured
by high pressure liquid chromatography (HPLC) of greater than or
equal to 99.7 wt %) and a sulfur level of less than or equal to 2
parts per million (ppm) as measured by a commercially available
Total Sulfur Analysis based on combustion and coulometric
detection. The organic purity can be defined as 100 wt % minus the
sum of known and unknown impurities detected using ultraviolet (UV)
(see HPLC method in Nowakowska et al., Polish J. Appl. Chem.,
XI(3), 247-254 (1996)). In addition, an end-capping agent is
present during manufacture of the high heat copolycarbonate such
that high heat copolycarbonate comprises a free hydroxyl level less
than or equal to 250 ppm, preferably less than or equal to 200 ppm,
more preferably less than or equal to 150 ppm.
[0025] Optionally, the thermoplastic compositions include a
bisphenol A homopolycarbonate. The bisphenol A homopolymer
carbonate can be derived from a bisphenol A monomer having a purity
less than 99.7% determined by HPLC. Alternatively, the bisphenol A
homopolycarbonate can be derived from a high purity bisphenol A
monomer having a purity equal to or greater than 99.7% determined
by HPLC.
[0026] It has been found by the inventors hereof that the optical
properties of the thermoplastic composition can be further improved
using bisphenol A homopolycarbonates having specific additional
properties. In an embodiment, the bisphenol A homopolycarbonate is
manufactured via an interfacial process using a BPA monomer having
both a high level of organic purity (e.g., measured by HPLC of
greater than or equal to 99.7 wt %) and a sulfur level of less than
or equal to 2 parts per million (ppm) as measured by a commercially
available Total Sulfur Analysis based on combustion and coulometric
detection. The organic purity can be defined as 100 wt % minus the
sum of known and unknown impurities detected using ultraviolet (UV)
(see HPLC method in Nowakowska et al., Polish J. Appl. Chem.,
XI(3), 247-254 (1996)). In addition, an end-capping agent is
present during manufacture of the bisphenol A homopolycarbonate
such that bisphenol A homopolycarbonate comprises a free hydroxyl
level less than or equal to 150 ppm. Bisphenol A homopolycarbonates
of high purity, suitable for use in the present compositions, can
also be manufactured via the melt process.
[0027] These bisphenol A homopolycarbonates are characterized by
specific properties. In particular, the preferred bisphenol A
homopolycarbonates have a low yellowness index and are heat stable.
For example, a molded sample comprising the bisphenol A
homopolycarbonate has a yellowness index (YI) of 2.5 or less, 2.0
or less, 1.5 or less, 1.2 or less, or 1.1 or less as measured by
ASTM D1925 on a plaque with 2.5 mm thickness. The bisphenol A
homopolycarbonates can further be characterized by a molded sample
thereof with a thickness of 2.5 mm having an increase in YI
(.DELTA.YI) of less than 12, less than 12, or less than 10 after
5,000 hours of heat aging at 130.degree. C. as measured by ASTM
D1925. Alternatively, or in addition, the bisphenol A
homopolycarbonates can have an increase in YI (.DELTA.YI) of less
than 3, less than 2.5, or less than 2 after 2,000 hours of heat
aging at 130.degree. C.
[0028] The preferred bisphenol A homopolycarbonates are also
transparent in the absence of any light diffusers or other fillers.
For example, a molded article of the bisphenol A homopolycarbonate
has transmission level greater than or equal to 90.0% at 2.5
millimeter (mm) thickness as measured by ASTM D1003-00, Procedure
A, measured, e.g., using a HAZE-GUARD DUAL from BYK-Gardner, using
and integrating sphere (0.degree./diffuse geometry), wherein the
spectral sensitivity conforms to the International Commission on
Illumination (CIE) standard spectral value under standard lamp
D65.
[0029] In an embodiment, the bisphenol A polycarbonate homopolymer
is a linear bisphenol A polycarbonate homopolymer having an Mw of
10,000 to 100,000 Da, specifically 15,000 to 50,000 Da, more
specifically 17,000 to 35,000 Da, as measured by gel permeation
chromatography (GPC), using a crosslinked styrene-divinylbenzene
column and calibrated to bisphenol A homopolycarbonate references.
GPC samples are prepared at a concentration of 1 mg per ml, and are
eluted at a flow rate of 1.5 ml per minute.
[0030] More than one bisphenol A polycarbonate homopolymer can be
present. For example, the polycarbonate compositions can comprise a
first bisphenol A polycarbonate homopolymer having an Mw of 20,000
Da to 25,000 Da and a second bisphenol A polycarbonate homopolymer
having an Mw of 28,000 to 32,000 Daltons, or a second bisphenol A
polycarbonate homopolymer having an Mw of 16,000 Daltons to 20,000
Daltons, each measured by GPC using bisphenol A homopolycarbonate
standards. The weight ratio of the first bisphenol A polycarbonate
homopolymer relative to the second bisphenol A polycarbonate
homopolymer is 10:1 to 1:10, specifically 5:1 to 1:5, more
specifically 3:1 to 1:3 or 2:1 to 1:2.
[0031] The polycarbonate homopolymer can be present in an amount of
10 to 90 wt %, preferably 10 to 80 wt %, 10 to 60 wt %, 15 to 50 wt
%, or 20 to 45 wt %, based on the total weight of the thermoplastic
composition.
[0032] In an embodiment, the bisphenol A (BPA) purity of the
thermoplastic composition is equal to or greater than 99.6% or
equal or greater than 99.7% measured using HPLC. As used herein,
the bisphenol A purity of the thermoplastic composition refers to
the overall purity of the bisphenol A monomer used to prepare the
high heat copolycarbonate and the bisphenol A homopolymer, if
present. The bisphenol A purity of a thermoplastic composition can
be determined by a mild depolymerization followed by a HPLC
analysis. For example, about 200 milligrams (mg) of the
thermoplastic composition is dissolved in 5 ml of tetrahydrofuran
(THF) and 2 ml of a 10% solution of potassium hydroxide diluted in
methanol. The depolymerization of polycarbonate is carried out with
the use of these solvents. The solution is shaken for 2 hours.
Then, 2 milliliters (ml) of acetic acid are added to protonate the
BPA carbonate salts and decrease the pH. The solution is shaken
again for half an hour for homogenization and dissolution of all
precipitates. The sample is analyzed by HPLC. The wt % of BPA
impurities in the thermoplastic composition can be calculated
by:
wt % of impurities in BPA = wt % of impurities * 254 228 . (
equation 1 ) ##EQU00001##
[0033] In equation 1, wt % of impurities refers to the impurities
measured by HPLC after depolymerization. Because the BPA molar mass
is different from the carbonated BPA, the wt % of impurities is
multiplied by 254 grams per mole (g/mol) and divided by 228 g/mol.
An amount of 254 g/mol and 228 g/mol correspond to the BPA
carbonate the BPA molar mass, respectively.
[0034] In some embodiments, it can be advantageous to use
copolycarbonates and bisphenol A homopolycarbonates with very low
residual contents of volatile impurities. For example, the polymer
components can have a content of chlorobenzene and other aromatic
chlorine compounds of less than 10 ppm, preferably less than 5 ppm
and more preferably less than 2 ppm, dichloromethane of less than 1
ppm, preferably less than 0.5 ppm, monohydric phenols such as
phenol, tert-butylphenol and cumylphenol of less than 15 ppm,
preferably less than 5 ppm and more preferably less than 2 ppm, and
alkanes of less than 10 ppm, preferably less than 5 ppm. In other
embodiments, the polymers can preferably have residual contents of:
carbon tetrachloride of less than 0.01 ppm, diaryl carbonates, in
particular diphenyl carbonate and di-tert-butyl phenolcarbonate, of
less than 5 ppm, preferably less than 2 ppm, bisphenol A and other
bisphenols of less than 5 ppm, preferably less than 2 ppm and more
preferably less than 0.5 ppm, sodium and other alkali metals and
alkaline earth metals of less than 0.05 ppm, cresols of less than 1
ppm, preferably less than 0.2 ppm, phenolic OH groups of less than
300 ppm, preferably less than 200 ppm, more preferably less than
100 ppm, alkaline earth metals of less than 0.1 ppm, more
preferably less than 0.05 ppm, pyridine of less than 1 ppm,
preferably less than 0.1 ppm, nonhalogenated aromatic compounds
such as xylene and toluene of less than 10 ppm, preferably less
than 5 ppm. Methods for obtaining and measuring these amount are
described, for example, in US2012/0157653.
[0035] The polycarbonates can be manufactured by processes such as
interfacial polymerization and melt polymerization, which are
known, and are described, for example, in WO 2013/175448 A1 and WO
2014/072923 A1. An end-capping agent (also referred to as a chain
stopper agent or chain terminating agent) can be included during
polymerization to provide end groups, for example monocyclic
phenols such as phenol, p-cyanophenol, and C.sub.1-C.sub.22
alkyl-substituted phenols such as p-cumyl-phenol, resorcinol
monobenzoate, and p- and tertiary-butyl phenol, monoethers of
diphenols, such as p-methoxyphenol, monoesters of diphenols such as
resorcinol monobenzoate, functionalized chlorides of aliphatic
monocarboxylic acids such as acryloyl chloride and methacryoyl
chloride, and mono-chloroformates such as phenyl chloroformate,
alkyl-substituted phenyl chloroformates, p-cumyl phenyl
chloroformate, and toluene chloroformate. Combinations of different
end groups can be used. Branched polycarbonate blocks can be
prepared by adding a branching agent during polymerization, for
example trimellitic acid, trimellitic anhydride, trimellitic
trichloride, tris-p-hydroxyphenylethane, isatin-bis-phenol,
tris-phenol TC (1,3,5-tris((p-hydroxyphenyl)isopropyl)benzene),
tris-phenol PA (4(4(1,1-bis(p-hydroxyphenyl)-ethyl) alpha,
alpha-dimethyl benzyl)phenol), 4-chloroformyl phthalic anhydride,
trimesic acid, and benzophenone tetracarboxylic acid. The branching
agents can be added at a level of 0.05 to 2.0 wt %. Combinations
comprising linear polycarbonates and branched polycarbonates can be
used.
[0036] It has been found that without any organosulfonic
stabilizers, a thermoplastic composition containing the high heat
polymer and the optional bisphenol A homopolycarbonate can have
less than desirable color stability when the thermoplastic
composition is molded under aggressive conditions for example at
temperatures equal to or greater than 340.degree. C., or equal to
or greater than 350.degree. C., or greater than 360.degree. C.,
especially when the residence time in the molding is equal to or
greater than 5 min, or equal to or greater than 10 min. Typical
upper limits include 450.degree. C. and 20 minutes.
[0037] Surprisingly it has been found that including an
organosulfonic stabilizer as described herein in a thermoplastic
composition containing the high heat copolycarbonate and the
optional bisphenol A homopolycarbonate improves the color stability
of the composition after the composition is molded under aggressive
conditions, typically at high melt temperatures, such as
350.degree. C. or higher, or prolonged residence times during
molding, such as times exceeding 7.5 or 10 minutes, or both. In
some embodiments it is possible to simultaneously improve the
initial color of the thermoplastic composition and the color
stability of the composition after the composition is molded under
aggressive conditions, typically at high melt temperatures, such as
350.degree. C. or higher, or prolonged residence times during
molding, such as times exceeding 7.5 or 10 minutes, or both.
[0038] For example, a molded part of the composition with a
thickness of 2.5 mm has a YI determined according to ASTM D1925 at
least 30% lower, or at least 50% lower, or at least 60% lower, as
compared to a reference sample of an otherwise identical
composition except for not containing the organosulfonic
stabilizer, when both the sample and the reference sample are
molded at a temperature of equal to or greater than 340.degree. C.
In another embodiment, a molded article of the composition, when
tested at thickness of 2.5 mm determined according to ASTM D1925,
has a change in YI of less than 20, preferably less than 10, more
preferably less than 5, following molding under aggressive
conditions as compared to a reference article of an identical
composition molded under standard process conditions. As used
herein, aggressive molding conditions include a molding temperature
of equal to or greater than 330.degree. C., and standard molding
conditions include a molding temperature equal to or of less than
330.degree. C.
[0039] The molded article can further have high heat
copolycarbonates can have high Vicat softening temperature. In an
embodiment, the thermoplastic composition can have a Vicat B120 of
160.degree. C. or higher, preferably 160 to 275.degree. C.,
preferably 160 to 255.degree. C., even more preferably 180 to
225.degree. C., each measured according to ISO 306.
[0040] Moreover, the improvement on the color and color stability
provided by the inclusion of the organosulfonic stabilizer is more
significant than the improvement provided by other acid stabilizers
such as H.sub.3PO.sub.3.
[0041] The organosulfonic stabilizer can be an aryl or aliphatic
sulfonic acid, including a polymer thereof, an aryl or an aliphatic
sulfonic acid anhydride, or an aryl or aliphatic ester of an aryl
or aliphatic sulfonic acid, or a polymer thereof. In particular,
the organosulfonic stabilizer is a C.sub.1-30 alkyl sulfonic acid,
a C.sub.6-30 aryl sulfonic acid, a C.sub.7-30 alkylarylene sulfonic
acid, a C.sub.7-30 arylalkylene sulfonic acid, or an aromatic
sulfonic acid polymer; an anhydride of a C.sub.1-30 alkyl sulfonic
acid, a C.sub.6-30 aryl sulfonic acid, a C.sub.7-30 alkylarylene
sulfonic acid, or a C.sub.7-30 arylalkylene sulfonic acid; or a
C.sub.6-30 aryl ester of a C.sub.1-30 alkyl sulfonic acid, a
C.sub.6-30 aryl sulfonic acid, a C.sub.7-30 alkylarylene sulfonic
acid, a C.sub.7-30 arylalkylene sulfonic acid, or an aromatic
sulfonic acid polymer; or a C.sub.1-30 aliphatic ester of a
C.sub.1-30 alkyl sulfonic acid, a C.sub.6-30 aryl sulfonic acid, a
C.sub.7-30 alkylarylene sulfonic acid, a C.sub.7-30 arylalkylene
sulfonic acid, or an aromatic sulfonic acid polymer. A combination
of one or more of the foregoing can be used.
[0042] In preferred embodiments, the organosulfonic stabilizers are
represented by formula (8)
##STR00011##
[0043] In formula (8), R.sup.7 is each independently a C.sub.1-30
alkyl, C.sub.6-30 aryl, C.sub.7-30 alkylarylene, C.sub.7-30
arylalkylene, or a polymer unit derived from a C.sub.2-32
ethylenically unsaturated aromatic sulfonic acid or its
corresponding C.sub.1-32 alkyl ester. The C.sub.2-32 ethylenically
unsaturated aromatic sulfonic acid can be of the formula
##STR00012##
wherein R.sup.9 is hydrogen or methyl, and R.sup.8 is as defined in
formula (8). Preferably the ethylenically unsaturated group and the
sulfonic acid or ester group are located para on the phenyl
ring.
[0044] Further in formula (8), R.sup.8 is hydrogen; or R.sup.8 is
C.sub.1-30 alkyl; or R.sup.8 is a group of the formula
--S(.dbd.O).sub.2--R.sup.7. When R.sup.8 is a group of the formula
--S(.dbd.O).sub.2--R.sup.7, each R.sup.7 in the compound of formula
(8) can be the same or different, but preferably each R.sup.7 is
the same.
[0045] In an embodiment in formula (8), R.sup.7 is a C.sub.6-12
aryl, C.sub.7-24 alkylarylene, or a polymer unit derived from a
C.sub.2-14 ethylenically unsaturated aromatic sulfonic acid or its
ester; and R.sup.8 is hydrogen, C.sub.1-24 alkyl, or a group of the
formula --S(.dbd.O).sub.2--R.sup.7 wherein R.sup.7 is a C.sub.6-12
aryl or C.sub.7-24 alkylarylene.
[0046] In a preferred embodiment, R.sup.7 is a C.sub.7-10
alkylarylene or a polymer unit derived from a C.sub.2-14
ethylenically unsaturated aromatic sulfonic acid, and R.sup.8 is a
hydrogen, C.sub.1-25 alkyl, or a group of the formula
--S(.dbd.O).sub.2--R.sup.7 wherein R.sup.7 is a C.sub.7-10
alkylarylene. In a specific embodiment, R.sup.7 is a C.sub.7-10
alkylarylene and R.sup.8 is a hydrogen or C.sub.1-6 alkyl. In still
another embodiment, R.sup.7 is a C.sub.7-10 alkylarylene and
R.sup.8 is a hydrogen or C.sub.12-25 alkyl, or R.sup.8 is a
C.sub.14-20 alkyl.
[0047] In specific embodiment, R.sup.7 is a polymer unit derived
from a C.sub.2-14 ethylenically unsaturated aromatic sulfonic acid,
preferably p-styrene sulfonic acid or para-methyl styrene sulfonic
acid, such that in formula (8) R.sup.8 is hydrogen.
[0048] In an embodiment, the organosulfonic stabilizer is a
C.sub.1-10 alkyl ester of a C.sub.7-12 alkylarylene sulfonic acid,
preferably of p-toluene sulfonic acid. More preferably the
stabilizer is a C.sub.1-6 alkyl ester of p-toluene sulfonic acid,
and even more preferably is butyl tosylate.
[0049] In another embodiment, the organosulfonic stabilizer is an
anhydride of a C.sub.7-12 alkylarylene sulfonic acid, preferably
para-toluene sulfonic anhydride as shown in Table 13.
[0050] In still another embodiment, R.sup.7 is a C.sub.11-24
alkylarylene sulfonic acid, and R.sup.8 is hydrogen. Alternatively,
R.sup.7 is a C.sub.16-22 alkylarylene sulfonic acid, and R.sup.8 is
hydrogen.
[0051] The organosulfonic stabilizer can be used in an amount of 2
to 40 ppm, more preferably 2 to 20 ppm, still more preferably 4 to
15 ppm, or 4 to 10 ppm, or 4 to 8 ppm by weight based on the total
weight of the organic components of the thermoplastic
composition.
[0052] The thermoplastic composition can also contain an epoxy
additive. The inclusion of an epoxy compound can be used as a chain
extender to improve molecular weight stability of the thermoplastic
composition after hydroaging (for instance at 85.degree. C. and 85%
relative humidity) or autoclaving at temperatures of 121.degree.
C., 134.degree. C., 155.degree. C., or other temperatures above
100.degree. C. Epoxy compounds useful as additives include epoxy
modified acrylic oligomers or polymers (such as a
styrene-acrylate-epoxy polymer, prepared from for example a
combination of: a substituted or unsubstituted styrene such as
styrene or 4-methylstyrene; an acrylate or methacrylate ester of a
C.sub.1-22 alkyl alcohol such as methyl acrylate, methyl
methacrylate, ethyl acrylate, butyl acrylate, or the like; and an
epoxy-functionalized acrylate such as glycidyl acrylate, glycidyl
methacrylate, 2-(3,4-epoxycyclohexyl)ethyl acrylate,
2-(3,4-epoxycyclohexyl)ethyl methacrylate, or the like), or an
epoxy carboxylate oligomer based on cycloaliphatic epoxides (such
as, for example,
3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexylcarboxylate, or the
like). Specific commercially available exemplary epoxy
functionalized stabilizers include Cycloaliphatic Epoxide Resin
ERL-4221 supplied by Union Carbide Corporation (a subsidiary of Dow
Chemical), Danbury, Conn.; and epoxy modified acrylates such as
JONCRYL ADR-4300 and JONCRYL ADR-4368, available from BASF. Epoxy
additives are typically used in amounts of up to 1 wt %,
specifically 0.001 to 1 wt %, more specifically 0.001 to 0.5 wt %,
based on the total weight of the thermoplastic composition. In an
embodiment, the epoxy additive can be included in an amount of
0.001 to 0.3 wt %, specifically 0.01 to 0.3 wt %, and more
specifically 0.1 to 0.3 wt %, based on the total weight of the
thermoplastic composition. Use of greater amounts of epoxy compound
may cause more splay, i.e., mold lines which fan outward from the
point of injection into the mold, and observable to the unaided eye
in molded articles comprising the thermoplastic composition.
[0053] The thermoplastic compositions can include various additives
ordinarily incorporated into polymer compositions of this type,
with the proviso that the additive(s) are selected so as to not
significantly adversely affect the desired properties of the
thermoplastic composition, in particular melt flow, thermal,
transparency, and surface properties. Such additives can be mixed
at a suitable time during the mixing of the components for forming
the composition. Additives include fillers, reinforcing agents,
antioxidants, heat stabilizers, light stabilizers, ultraviolet (UV)
light stabilizers, plasticizers, lubricants, mold release agents,
antistatic agents, colorants such as titanium dioxide, carbon
black, and organic dyes, surface effect additives, radiation
stabilizers, flame retardants, anti-drip agents, and impact
modifiers. In an embodiment, the thermoplastic composition further
comprises a processing aid, a heat stabilizer, an ultraviolet light
absorber, a colorant, a flame retardant, an impact modifier, or a
combination thereof. A combination of additives can be used, for
example a combination of a heat stabilizer, mold release agent, and
ultraviolet light stabilizer. In general, the additives are used in
the amounts generally known to be effective. For example, the total
amount of the additives (other than any impact modifier, filler, or
reinforcing agents) can be 0 to 5 wt % or 0.01 to 5 wt %, based on
the total weight of the thermoplastic composition.
[0054] Antioxidant additives include organophosphites such as
tris(nonyl phenyl)phosphite, tris(2,4-di-t-butylphenyl)phosphite,
bis(2,4-di-t-butylphenyl)pentaerythritol diphosphite, distearyl
pentaerythritol diphosphite; alkylated monophenols or polyphenols;
alkylated reaction products of polyphenols with dienes, such as
tetrakis[methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate)]
methane; butylated reaction products of para-cresol or
dicyclopentadiene; alkylated hydroquinones; hydroxylated
thiodiphenyl ethers; alkylidene-bisphenols; benzyl compounds;
esters of beta-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid
with monohydric or polyhydric alcohols; esters of
beta-(5-tert-butyl-4-hydroxy-3-methylphenyl)-propionic acid with
monohydric or polyhydric alcohols; esters of thioalkyl or thioaryl
compounds such as distearylthiopropionate, dilaurylthiopropionate,
ditridecylthiodipropionate,
octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate,
pentaerythrityl-tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate;
amides of beta-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid,
or combinations comprising at least one of the foregoing
antioxidants. Antioxidants are used in amounts of 0.01 to 0.1 parts
by weight, based on 100 parts by weight of the total composition,
excluding any filler.
[0055] Heat stabilizer additives include organophosphites such as
triphenyl phosphite, tris-(2,6-dimethylphenyl)phosphite,
tris-(mixed mono- and di-nonylphenyl)phosphite; phosphonates such
as dimethylbenzene phosphonate, phosphates such as trimethyl
phosphate, or combinations comprising at least one of the foregoing
heat stabilizers. Heat stabilizers are used in amounts of 0.01 to
0.1 parts by weight, based on 100 parts by weight of the total
composition, excluding any filler.
[0056] Light stabilizers, including ultraviolet light (UV)
absorbers, can also be used. Light stabilizers include
benzotriazoles such as 2-(2-hydroxy-5-methylphenyl)benzotriazole
and 2-(2-hydroxy-5-tert-octylphenyl)-benzotriazole,
2-hydroxy-4-n-octoxy benzophenone, or combinations comprising at
least one of the foregoing light stabilizers. UV absorbing
additives include hydroxybenzophenones; hydroxybenzotriazoles;
hydroxybenzotriazines; cyanoacrylates; oxanilides; benzoxazinones;
2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol
(CYASORB* 5411); 2-hydroxy-4-n-octyloxybenzophenone (CYASORB* 531);
2-[4,6-bis(2,4-dimethylphenyl)-1,3,5-triazin-2-yl]-5-(octyloxy)-phenol
(CYASORB* 1164); 2,2'-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one)
(CYASORB* UV-3638);
1,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[[(2-cyano-3,3-diphenyl-
acryloyl)oxy]methyl]propane (UVINUL* 3030); 2,2'-(1,4-phenylene)
bis(4H-3,1-benzoxazin-4-one);
1,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[[(2-cyano-3,3-diphenyl-
acryloyl)oxy]methyl]propane; phenol,
2-(2H-benzotriazol-2-yl)-4,6-bis(1-methyl-1-phenylethyl)- (TINUVIN*
234); BCAP bismalonate from Clariant; nano-size inorganic materials
such as titanium oxide, cerium oxide, and zinc oxide, all with
particle size less than or equal to 100 nanometers; or combinations
comprising at least one of the foregoing UV absorbers. Light
stabilizers are used in amounts of 0.01 to 5 parts by weight, based
on 100 parts by weight of the thermoplastic composition, excluding
any filler.
[0057] Flame retardants can also be used. Flame retardants include
flame retardant salts such as alkali metal salts of perfluorinated
C.sub.1-16 alkyl sulfonates such as potassium perfluorobutane
sulfonate (Rimar salt), potassium perfluoroctane sulfonate,
tetraethylammonium perfluorohexane sulfonate, potassium
diphenylsulfone sulfonate (KSS), and the like, sodium benzene
sulfonate, sodium toluene sulfonate (NATS) and the like; and salts
formed by reacting for example an alkali metal or alkaline earth
metal (for example lithium, sodium, potassium, magnesium, calcium
and barium salts) and an inorganic acid complex salt, for example,
an oxo-anion, such as alkali metal and alkaline-earth metal salts
of carbonic acid, such as Na.sub.2CO.sub.3, K.sub.2CO.sub.3,
MgCO.sub.3, CaCO.sub.3, and BaCO.sub.3 or fluoro-anion complex such
as Li.sub.3AlF.sub.6, BaSiF.sub.6, KBF.sub.4, K.sub.3AlF.sub.6,
KAlF.sub.4, K.sub.2SiF.sub.6, and/or Na.sub.3AlF.sub.6 or the like.
Rimar salt and KSS and NATS, alone or in combination with other
flame retardants, are particularly useful in the compositions
disclosed herein. Flame retardant salts are typically used in
amounts of 0.01 to 1.0 parts by weight, based on 100 parts by
weight of the thermoplastic composition.
[0058] Organophosphorus flame retardants can be used.
Organophosphorus compounds include aromatic organophosphorus
compounds having at least one organic aromatic group and at least
one phosphorus-containing group, as well as organic compounds
having at least one phosphorus-nitrogen bond.
[0059] In the aromatic organophosphorus compounds that have at
least one organic aromatic group, the aromatic group can be a
substituted or unsubstituted C.sub.3-30 group containing one or
more of a monocyclic or polycyclic aromatic moiety (which can
optionally contain with up to three heteroatoms (N, O, P, S, or
Si)) and optionally further containing one or more nonaromatic
moieties, for example alkyl, alkenyl, alkynyl, or cycloalkyl. The
aromatic moiety of the aromatic group can be directly bonded to the
phosphorus-containing group, or bonded via another moiety, for
example an alkylene group. The aromatic moiety of the aromatic
group can be directly bonded to the phosphorus-containing group, or
bonded via another moiety, for example an alkylene group. In an
embodiment the aromatic group is the same as an aromatic group of
the polycarbonate backbone, such as a bisphenol group (e.g.,
bisphenol A), a monoarylene group (e.g., a 1,3-phenylene or a
1,4-phenylene), or a combination thereof.
[0060] The phosphorus-containing group can be a phosphate
(P(.dbd.O)(OR).sub.3), phosphite (P(OR).sub.3), phosphonate
(RP(.dbd.O)(OR).sub.2), phosphinate (R.sub.2P(.dbd.O)(OR)),
phosphine oxide (R.sub.3P(.dbd.O)), or phosphine (R.sub.3P),
wherein each R in the foregoing phosphorus-containing groups can be
the same or different, provided that at least one R is an aromatic
group. A combination of different phosphorus-containing groups can
be used. The aromatic group can be directly or indirectly bonded to
the phosphorus, or to an oxygen of the phosphorus-containing group
(i.e., an ester).
[0061] In an embodiment the aromatic organophosphorus compound is a
monomeric phosphate. Representative monomeric aromatic phosphates
are of the formula (GO).sub.3P.dbd.O, wherein each G is
independently an alkyl, cycloalkyl, aryl, alkylarylene, or
arylalkylene group having up to 30 carbon atoms, provided that at
least one G is an aromatic group. Two of the G groups can be joined
together to provide a cyclic group. In some embodiments G
corresponds to a monomer used to form the polycarbonate, e.g.,
resorcinol. Exemplary phosphates include phenyl bis(dodecyl)
phosphate, phenyl bis(neopentyl) phosphate, phenyl
bis(3,5,5'-trimethylhexyl) phosphate, ethyl diphenyl phosphate,
2-ethylhexyl di(p-tolyl) phosphate, bis(2-ethylhexyl) p-tolyl
phosphate, tritolyl phosphate, bis(2-ethylhexyl) phenyl phosphate,
tri(nonylphenyl) phosphate, bis(dodecyl) p-tolyl phosphate, dibutyl
phenyl phosphate, 2-chloroethyl diphenyl phosphate, p-tolyl
bis(2,5,5'-trimethylhexyl) phosphate, 2-ethylhexyl diphenyl
phosphate, and the like. A specific aromatic phosphate is one in
which each G is aromatic, for example, triphenyl phosphate,
tricresyl phosphate, isopropylated triphenyl phosphate, and the
like.
[0062] Di- or polyfunctional aromatic phosphorus-containing
compounds are also useful, for example, compounds of the formulas
below
##STR00013##
wherein each G.sup.1 is independently a C.sub.1-30 hydrocarbyl;
each G.sup.2 is independently a C.sub.1-30 hydrocarbyl or
hydrocarbyloxy; each X is independently a bromine or chlorine; m is
0 to 4, and n is 1 to 30. Di- or polyfunctional aromatic
phosphorus-containing compounds of this type include resorcinol
tetraphenyl diphosphate (RDP), the bis(diphenyl) phosphate of
hydroquinone and the bis(diphenyl) phosphate of bisphenol A,
respectively, their oligomeric and polymeric counterparts, and the
like.
[0063] Specific aromatic organophosphorus compounds have two or
more phosphorus-containing groups, and are inclusive of acid esters
of the formula (9)
##STR00014##
wherein R.sup.16, R.sup.17, R.sup.18, and R.sup.19 are each
independently C.sub.1-8 alkyl, C.sub.5-6 cycloalkyl, C.sub.6-20
aryl, or C.sub.7-12 arylalkylene, each optionally substituted by
C.sub.1-12 alkyl, specifically by C.sub.1-4 alkyl and X is a mono-
or poly-nuclear aromatic C.sub.6-30 moiety or a linear or branched
C.sub.2-30 aliphatic radical, which can be OH-substituted and can
contain up to 8 ether bonds, provided that at least one of
R.sup.16, R.sup.17, R.sup.18, R.sup.19, and X is an aromatic group.
In some embodiments R.sup.16, R.sup.17, R.sup.18, and R.sup.19 are
each independently C.sub.1-4 alkyl, naphthyl,
phenyl(C.sub.1-4)alkylene, or aryl groups optionally substituted by
C.sub.1-4 alkyl. Specific aryl moieties are cresyl, phenyl,
xylenyl, propylphenyl, or butylphenyl. In some embodiments X in
formula (9) is a mono- or poly-nuclear aromatic C.sub.6-30 moiety
derived from a diphenol. Further in formula (9), n is each
independently 0 or 1; in some embodiments n is equal to 1. Also in
formula (9), q is from 0.5 to 30, from 0.8 to 15, from 1 to 5, or
from 1 to 2. Specifically, X can be represented by the following
divalent groups (9), or a combination comprising one or more of
these divalent groups.
##STR00015##
[0064] In these embodiments, each of R.sup.16, R.sup.17, R.sup.18,
and R.sup.19 can be aromatic, i.e., phenyl, n is 1, and p is 1-5,
specifically 1-2. In some embodiments at least one of R.sup.16,
R.sup.17, R.sup.18, R.sup.19, and X corresponds to a monomer used
to form the polycarbonate, e.g., bisphenol A or resorcinol. In
another embodiment, X is derived especially from resorcinol,
hydroquinone, bisphenol A, or diphenylphenol, and R.sup.16,
R.sup.17, R.sup.18, R.sup.19, is aromatic, specifically phenyl. A
specific aromatic organophosphorus compound of this type is
resorcinol bis(diphenyl phosphate), also known as RDP. Another
specific class of aromatic organophosphorus compounds having two or
more phosphorus-containing groups are compounds of formula (10)
##STR00016##
wherein R.sup.16, R.sup.17, R.sup.18, R.sup.19, n, and q are as
defined for formula (9) and wherein Z is C.sub.1-7 alkylidene,
C.sub.1-7 alkylene, C.sub.5-12 cycloalkylidene, --O--, --S--,
--SO.sub.2--, or --CO--, specifically isopropylidene. A specific
aromatic organophosphorus compound of this type is bisphenol A
bis(diphenyl phosphate), also known as BPADP, wherein R.sup.16,
R.sup.17, R.sup.18, and R.sup.19 are each phenyl, each n is 1, and
q is from 1 to 5, from 1 to 2, or 1.
[0065] Organophosphorus compounds containing at least one
phosphorus-nitrogen bond includes phosphazenes, phosphorus ester
amides, phosphoric acid amides, phosphonic acid amides, phosphinic
acid amides, and tris(aziridinyl) phosphine oxide. Phosphazenes
(11) and cyclic phosphazenes (12)
##STR00017##
in particular can used, wherein w1 is 3 to 10,000 and w2 is 3 to
25, specifically 3 to 7, and each R.sup.w is independently a
C.sub.1-12 alkyl, alkenyl, alkoxy, aryl, aryloxy, or
polyoxyalkylene group. In the foregoing groups at least one
hydrogen atom of these groups can be substituted with a group
having an N, S, O, or F atom, or an amino group. For example, each
R.sup.w can be a substituted or unsubstituted phenoxy, an amino, or
a polyoxyalkylene group. Any given R.sup.w can further be a
crosslink to another phosphazene group. Exemplary crosslinks
include bisphenol groups, for example bisphenol A groups. Examples
include phenoxy cyclotriphosphazene, octaphenoxy
cyclotetraphosphazene decaphenoxy cyclopentaphosphazene, and the
like. A combination of different phosphazenes can be used. A number
of phosphazenes and their synthesis are described in H. R. Allcook,
"Phosphorus-Nitrogen Compounds" Academic Press (1972), and J. E.
Mark et al., "Inorganic Polymers" Prentice-Hall International, Inc.
(1992).
[0066] Depending on the particular organophosphorus compound used,
the thermoplastic compositions can comprise 0.5 to 15 wt % or 3.5
to 12 wt % of the organophosphorus flame retardant, each based on
the total weight of the composition. Specifically, the
organophosphorus compounds can be bisphenol A bis(diphenyl
phosphate), triphenyl phosphate, resorcinol bis(diphenyl
phosphate), tricresyl phosphate, or a combination thereof.
[0067] The thermoplastic compositions can further comprise a cyclic
siloxane and/or a linear siloxane to impart fire/flame-retardant
properties. The cyclic siloxane can include those with the general
formula below
##STR00018##
wherein each R in the cyclic siloxane is independently C.sub.1-36
alkyl, fluorinated or perfluorinated C.sub.1-36 alkyl, C.sub.1-36
alkoxy, C.sub.6-14 aryl, aryloxy of 6 to 14 carbon atoms,
arylalkoxy of 7 to 36 carbon atoms, or C.sub.1-36 alkyl-substituted
aryl of 6 to 14 carbon atoms. In an embodiment, at least one R can
be a phenyl. Examples of cyclic siloxanes include, but not limited
to, a cyclic phenyl containing siloxane,
octaphenylcyclotetrasiloxane, hexamethylcyclotrisiloxane,
octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane,
dodecamethylcyclohexasiloxane, trimethyltriphenylcyclotrisiloxane,
and tetramethyltetraphenylcyclotetrasiloxane.
Octaphenylcyclotetrasiloxane is specifically mentioned.
[0068] Linear siloxanes can also be used. The linear siloxanes can
be a linear phenyl containing siloxane such as a
poly(phenylmethylsiloxane). In an embodiment, the thermoplastic
compositions contain 0.01% to 1% of a cyclic siloxane, a linear
siloxane, or a combination thereof.
[0069] The thermoplastic compositions can be manufactured by
various methods known in the art. For example, powdered
polycarbonate, and other optional components are first blended,
optionally with any fillers, in a high speed mixer or by hand
mixing. The blend is then fed into the throat of a twin-screw
extruder via a hopper. Alternatively, at least one of the
components can be incorporated into the composition by feeding it
directly into the extruder at the throat and/or downstream through
a sidestuffer, or by being compounded into a masterbatch with a
desired polymer and fed into the extruder. The extruder is
generally operated at a temperature higher than that necessary to
cause the composition to flow. The extrudate can be immediately
quenched in a water bath and pelletized. The pellets so prepared
can be one-fourth inch long or less as desired. Such pellets can be
used for subsequent molding, shaping, or forming.
[0070] In certain embodiments, the thermoplastic compositions can
have a low residual impurity content, in particular less than 2 ppm
by weight of each of lithium, sodium, potassium, calcium,
magnesium, ammonium, chloride, bromide, fluoride, nitrite, nitrate,
phosphite, phosphate, sulfate, acetate, citrate, oxalate,
trimethylammonium, and triethylammonium. It is to be understood
that the foregoing residual impurities can exist in the
thermoplastic compositions in un-ionized form (for example as
triethylamine or formic acid), but are determined based on their
ionized form.
[0071] The thermoplastic compositions can be molded under standard
molding conditions in range of 300 to 350.degree. C. depending on
the glass transition temperature of the composition. For example,
the thermoplastic compositions can be molded at a temperature of
100 to 175.degree. C. above the glass transition temperature of the
thermoplastic composition for a residence time of 2 to 20
minutes.
[0072] The thermoplastic compositions can have a glass transition
temperature of 155.degree. C. or higher, preferably 155.degree. C.
to 280.degree. C., more preferably 165 to 260.degree. C., and even
more preferably 185 to 230.degree. C., determined by differential
scanning calorimetry (DSC) as per ASTM D3418 with a 20.degree.
C./min heating rate.
[0073] The thermoplastic compositions can have a heat deflection
temperature of 160.degree. C. or higher as measured on a
80.times.10.times.4 mm bar with a 64 mm span at 0.45 MPa according
to ISO 75/Bf.
[0074] The thermoplastic compositions can have excellent
transparency. In an embodiment, the thermoplastic compositions can
have a haze less of less than 15%, more preferably less than 10%,
more preferably less than 5%, even more preferably less than 1.5%,
or less than 1.0%, and a transmission greater than 86%, more
preferably greater than 87%, more preferably greater than 88%, even
more preferably greater than 90% each measured according to ASTM
D1003-00 on a molded plaque with a 1.0 mm thickness. In another
embodiment, the thermoplastic compositions can have a haze of less
than 15%, more preferably less than 10%, more preferably less than
5%, even more preferably less than 1.5%, or less than 1.0% and a
total transmission greater than 84% or greater than 86%, each
measured according to ASTM D1003-00 on a molded plaque with a 3.0
mm thickness.
[0075] The thermoplastic compositions can have a transmission at
wavelength of 400 nm of greater than 75%, or greater than 80% or
greater than 85% measured with Perkin Elmer 950 spectrometer
equipped with 15 cm integrated sphere on a molded plaque with a
thickness of 1 mm.
[0076] The thermoplastic compositions can have a transmission at
wavelength of 550 nm of greater than 85%, or greater than 87% or
greater than 88% measured with Perkin Elmer 950 spectrometer
equipped with 15 cm integrated sphere on a molded plaque with a
thickness of 1 mm.
[0077] The thermoplastic compositions can have excellent
transparency in the infrared wavelength range. In an embodiment,
the compositions have a transmission at wavelength of 940 nm of
greater than 88.0%, preferably greater than 89.0%, more preferably
greater than 90.0%, as measured with Perkin Elmer 950 spectrometer
equipped with 15 cm integrated sphere on 1 mm.
[0078] In still another embodiment, the thermoplastic compositions
can have a refractive index of greater than 1.59 or greater than
1.60 at 587.6 nm or a refractive index of greater than 1.57 or
greater than 1.58 at 940 nm measured according to ISO 489 on a
molded plaque with a thickness of 1 mm.
[0079] The thermoplastic compositions can have an Abbe number of
less than 32 or less than 30 measured according to ISO 489 on a
molded plaque with a thickness of 1 mm.
[0080] The thermoplastic compositions can have excellent color
after molding under demanding conditions. In an embodiment, the
thermoplastic compositions have a YI of less than 12, preferably
less than 8, more preferably less than 6 as measured by ASTM D1925
on a 2.5 mm plaque. For example, the thermoplastic compositions are
molded at a temperature of 100 to 175.degree. C. above the glass
transition temperature of the thermoplastic composition for a
residence time of 2 to 20 minutes. Typical conditions would be
molding at melt temperatures of 350.degree. C. or higher and
residence times of 3 minutes or longer. In a specific embodiment,
the thermoplastic compositions have a YI of less than 12,
preferably less than 8, more preferably less than 6 measured
according to ASTM D1925 on a plaque of 2.5 mm thickness molded at a
temperature of 355.degree. C. for a residence time of 10
minutes.
[0081] The thermoplastic compositions have excellent color
stability during exposure for prolonged time at elevated
temperatures in the absence of moisture, referred to further as
heat ageing. The thermoplastic compositions can have an increase in
YI of less than 5, more preferably less than 4, more preferably
less than 3, during 1500 hours of heat aging at 140.degree. C., as
measured by ASTM D1925 on a 1.0 mm thick molded plaque. In an
embodiment, the thermoplastic compositions can have an increase in
YI of less than 10, more preferably less than 8, more preferably
less than 6, during 1500 hours of heat aging at 155.degree. C., as
measured by ASTM D1925 on a 1.0 mm thick molded plaque. In another
embodiment, the thermoplastic compositions can have an increase in
YI of less than 20, more preferably less than 10, more preferably
less than 5, during 1000 hours of heat aging at 160.degree. C., as
measured by ASTM D1925 on a 2.5 mm thick molded plaque. In still
another embodiment, the thermoplastic compositions can have an
increase in YI of less than 20, more preferably less than 10, more
preferably less than 5, during 500 hours of heat aging at
170.degree. C., as measured by ASTM D1925 on a 2.5 mm thick molded
plaque.
[0082] The thermoplastic compositions have excellent color
stability during exposure for prolonged time at elevated
temperatures in the presence of moisture, referred to herein as
hydroaging. In an embodiment, the thermoplastic compositions can
have an increase in YI of less than 5, more preferably less than 3,
more preferably less than 1, after 1000 hours of hydroaging at
80.degree. C. and 85% relative humidity, as measured by ASTM D1925
on a 2.5 mm thick molded plaque. Alternatively, the thermoplastic
compositions can have an increase in YI of less than 0.5, or of
less than 0.3 after 100 hours of hydroaging at 121.degree. C. in an
autoclave, as measured by ASTM D1925 on a 2.5 mm thick molded
plaque.
[0083] The thermoplastic compositions have excellent color
stability during exposure for prolonged time to autoclave
conditions or multiple cycle of autoclave sterilization. In an
embodiment, the thermoplastic compositions have an increase in YI
of less than 2, more preferably less than 1, after 100 hours of
autoclaving at 121.degree. C., as measured by ASTM D1925 on a 2.5
mm thick molded plaque. In an embodiment, the thermoplastic
compositions have an increase in YI of less than 5, more preferably
less than 3, more preferably less than 1, after 100 hours of
autoclaving at 134.degree. C., as measured by ASTM D1925 on a 2.5
mm thick molded plaque. In another embodiment, the thermoplastic
compositions have an increase in YI of less than 10, more
preferably less than 5, more preferably less than 3, after 100
hours of autoclaving at 143.degree. C., as measured by ASTM D1925
on a 2.5 mm thick molded plaque.
[0084] In another embodiment, the thermoplastic compositions can
have an increase in yellowness index of less than 10, or of less
than 8 after 500 hours of heat aging at 155.degree. C., as measured
by ASTM D1925 on a 2.5 mm thick molded plaque; or an increase in
yellowness index of less than 10, or of less than 8 during 1000
hours of heat aging at 155.degree. C., as measured by ASTM D1925 on
a 1.0 mm thick molded plaque.
[0085] In another embodiment, the thermoplastic compositions can
have an increase in YI of less than 6, or of less than 5 during
1500 hours of heat aging at 140.degree. C., as measured by ASTM
D1925 on a 1.0 mm thick molded plaque.
[0086] The thermoplastic compositions can have a melt volume flow
rate (MVR) greater than 10 cc/min, measured at 330.degree. C./2.16
Kg at 360 second dwell according to ISO 1133.
[0087] The thermoplastic compositions can have an Izod notched
impact energy of at least 6 kJ/m.sup.2, or of at least 8
kJ/m.sup.2, as measured at 23.degree. C. according to ISO 180/1A
using a multipurpose test specimen in accordance with ISO 3167 TYPE
A. The thermoplastic compositions can have an Izod notched impact
energy of at least 70 J/m, or of at least 88 J/m, as measured at
23.degree. C. according to ASTM D256.
[0088] The thermoplastic compositions can have a UL94-V0 rating at
a thickness of 2.5 mm or higher, for example up to 5.0 mm. The
thermoplastic compositions can have a UL94-V2 rating at a thickness
of 0.8 mm to 2.5 mm.
[0089] Shaped, formed, or molded articles comprising the
thermoplastic compositions are also provided. The compositions can
be molded into useful shaped articles by a variety of methods, such
as injection molding, injection-compression molding, heat-cool
molding, extrusion, rotational molding, blow molding, and
thermoforming. The article can be a molded article, a thermoformed
article, an extruded article, an extruded layer (a film or a
sheet), one or more layers of a multi-layer article, a substrate
for a coated article, or a substrate for a metallized article made
from the thermoplastic composition. The multi-layer article can be
a laminated multi-layer article. The distinction between a film and
a sheet is not critical. A film can have an exemplary thickness of
100 micrometers to 5 millimeter, and the sheet can have an
exemplary thickness of 5 millimeters to 5 centimeters.
[0090] Advantageously, the articles have no significant part
distortion or discoloration when the articles are subjected to a
secondary operation such as over-molding, lead-free soldering, wave
soldering, low temperature soldering, or coating with high
temperature curing, or a combination thereof. High temperature cure
of the coating can be, for example, 100.degree. C. or higher, for
example 100 to 250.degree. C. In some embodiments, "no significant
part distortion" includes a volume distortion of less than 10
volume percent (vol %), or less than 5 vol %, or less than 1 vol %.
Significant discoloration can be detected by the unaided eye at a
distance of 18 inches.
[0091] In some embodiments, at least a portion of a surface of the
article is metallized or is coated with a hardcoat, a UV-protective
coat, an anti-refractive coat, an anti-reflective coat, a
scratch-resistant coat, or a combination comprising at least one of
the foregoing. In some embodiments, the coating is applied or cured
at a temperature of 100.degree. C. or higher, for example 100 to
250.degree. C.
[0092] The article can be a lens (e.g., a camera lens, a mobile
phone camera lens, a table camera lens, a security camera lens, an
automotive camera lens, a scanner lens, a copier lens, an
illumination device lens, a safety glass lens, an ophthalmic
corrective lens, a projector lens, an imaging lens, an auto lens, a
sensor lens (for example a proximity sensor lens, a gesture control
lens, or an infrared sensor lens)), a light guide, a waveguide, a
collimator, an optical fiber, a visor, a window, a door, a display
screen, an electronic device, a scientific or medical device (e.g.,
a blood bag, a solution bag, an intravenous connector, a catheter,
a medical storage tray, medical tubing, a cannula, an implantable
prosthesis, a heart valve, a vascular graft, a pacemaker lead, a
defibrillator lead, an A-V shunt, a Petri dish,), a safety shield,
a fire shield, wire or cable sheathing, a tray, a screen, an
enclosure, a dish, glazing, packaging, a gas barrier, an anti-fog
layer, or an anti-reflective layer.
[0093] In addition, the copolycarbonate compositions can be used as
a component of a wide variety of devices and applications, for
example a component of a device comprising a lens, such as a
camera, a mobile phone camera, a flashlight, a sensor such as a
touch sensor, a proximity sensor, a gesture control sensor, or an
infrared sensor, ophthalmic corrective glasses, safety glasses, an
illumination device, a lighthouse, a light emitting diode (LED), or
a vehicle (e.g., a lens holder, a reflector, a camera flash lens, a
vehicle headlight, running light, foglight, or rearlight). As used
herein a "vehicle" refers to any transportation device, for example
bicycles, scooters, motorcycles, automobiles, buses, trains, boats,
ships, and aircraft.
[0094] Other articles include a device comprising a light guide, a
device comprising a waveguide, a device comprising a collimator, a
device comprising an optical fiber, a device comprising an optical
film, a device comprising a device comprising a lighting element,
including LEDs and OLEDs (e.g., a light bulb, a housing, a cover, a
bezel, a vehicle headlight, running light, foglight, or rearlight,
a flashlight, a reflector, or a signal indicator), a device
comprising a window, such as a domestic appliance, vehicle, or
building, an device comprising a door, such as a domestic
appliance, vehicle, or building, or a device comprising a tray
(e.g., a food tray for a vehicle).
Still other articles include a component of a scientific or medical
device (e.g., a syringe, a blood filter housing, a blood bag, a
solution bag, an intravenous connector, a dialyzer, a catheter, a
medical storage tray, a medical appliance, medical tubing, a
cardiac pacemaker, a cardiac defibrillator, a cannula, an
implantable prosthesis, a cardiac assist device, a heart valve, a
vascular graft, an extra-corporeal device, an artificial organ, a
pacemaker lead, a defibrillator lead, a blood pump, a balloon pump,
an A-V shunt, a membrane for cell encapsulation, a wound dressing,
an artificial joint, an orthopedic implant a Petrie dish, a face
shield, a respirator, a sensor), a component of an electronic
device such as a handheld electronic device, a tablet, a computer,
a monitor, a business machine such as a copier, a fuse, an
analytical device, or a sensor (e.g., a housing, an electrical
connector, for any of the foregoing), a component of a photovoltaic
device, a component of a safety device (e.g., a visor, a safety
goggle, a face shield, a fire shield, a helmet, a respirator, a
knee pad, elbow pad, or other protective body part pad), a
component of a display screen, including a liquid crystal display
screen, or an organic light-emitting diode display screen, a
component of a dish, a component of a heater, such as a
watercooker, a component of a mold, for example for foodstuffs such
as chocolate, a component of a screen such as a mining ore screen,
a component of a conveyor such as a conveyor belt, a component of
an enclosure such as an animal cage, a structural component of a
building, a vehicle, or an appliance such as a pump, a microwave, a
dishwasher, or a stove, a component of packaging, a component of a
gas barrier, a component of an encapsulant, a component of a label,
a component of a gas barrier, a component of an anti-fog assembly,
or a component of an anti-reflective assembly.
[0095] The invention is further illustrated by the following
non-limiting examples.
EXAMPLES
[0096] The materials used in the Examples are described in Table
1.
TABLE-US-00001 TABLE 1 Component Chemical Description Source CPC-1
PPP-BP (N-phenylphenolphthaleinyl bisphenol, 2,2-bis(4-hydro) -
bisphenol A SABIC polycarbonate copolymer, 33 mol % PPP-BP, Mw =
21-25 kDa as determined by GPC using bisphenol A polycarbonate
standards, para-cumylphenol (PCP) end- capped, with BPA carbonate
units derived from BPA having 99.4-99.5% purity CPC-2 PPP-BP
(N-phenylphenolphthaleinyl bisphenol, 2,2-bis(4-hydro) - Bisphenol
A SABIC polycarbonate copolymer, 33 mol % PPP-BP, Mw = 21-25 kDa as
determined by GPC using bisphenol A polycarbonate standards,
para-cumylphenol (PCP) end- capped, with BPA carbonate units
derived from BPA having 99.7% purity PC-1 Linear bisphenol A
polycarbonate, produced via interfacial polymerization from SABIC
BPA having 99.4-99.5% purity as determined by HPLC, Mw = 29-32 kDa
as determined by GPC using bisphenol A polycarbonate standards,
phenol end- capped PC-2 Linear Bisphenol A Polycarbonate, produced
via interfacial polymerization, Mw SABIC of about 21,800 g/mol as
determined by GPC using polycarbonate standards, para- cumylphenol
(PCP) end-capped with BPA carbonate units derived from BPA having
99.4-99.5% purity as determined by HPLC PC-3 Linear bisphenol A
polycarbonate, produced via interfacial polymerization from SABIC
BPA having 99.7% purity as determined by HPLC, Mw = 29-32 kDa as
determined by GPC using bisphenol A polycarbonate standards, phenol
end- capped PC-4 Linear Bisphenol A Polycarbonate, produced via
interfacial polymerization, Mw SABIC of about 21,800 g/mol as
determined by GPC using polycarbonate standards, para- cumylphenol
(PCP) end-capped with BPA carbonate units derived from BPA having
99.7% purity as determined by HPLC PC-5 Linear Bisphenol A
Polycarbonate, produced via interfacial polymerization, Mw SABIC of
about 35,000 g/mol as determined by GPC using polycarbonate
standards, phenol end-capped with BPA carbonate units derived from
BPA having 99.7% purity as determined by HPLC Tosylate Premix of
0.06 wt % of butyl tosylate (source Aldrich) in PC-2 SABIC Premix-1
Tosylate Premix of 0.3 wt % of butyl tosylate (source Aldrich) in
PC-2 SABIC Premix-2 Tosylate Premix of 0.4 wt % of butyl
tosylate(source Aldrich) in PC-2 SABIC Premix-3 P-TSA Premix of
0.34 wt % of polystyrene sulfonic acid (source Aldrich) in PC-2
SABIC premix Et Tosylate Premix of 0.35 wt % of ethyl p-toluene
sulfonate (source Aldrich) in PC-2 SABIC premix Poly p-TSA Premix
of 0.34 wt % of polystyrene sulfonic acid (source Aldrich) in PC-2
SABIC premix OD p-TS Premix of 0.74 wt % of octadecyl
p-toluenesulfonate (source TCI) in PC-2 SABIC premix p-TSAA Premix
of 0.28 wt % of p-toluenesulfonic anhydride (source Aldrich) in
PC-2 SABIC premix 4-DBSA Premix of 0.57 wt % of
4-dodecylbenzenesulfonic acid (source Aldrich) in PC-2 SABIC premix
p-TSA Na Premix of 0.34 wt % of sodium p-toluenesulfonate (source
Aldrich) in PC-2 SABIC premix 10-CSA Premix of 0.41 wt % of
10-camphorsulfonic acid (source Aldrich) in PC-2 SABIC premix Ph
Tosylate Premix of 0.44 wt % of phenyl p-toluenesulfonate (source
TCI) in PC-2 SABIC premix AO-1 Tris(2,4-di-t-butylphenyl)phosphite
(IRGAFOS 168) Ciba AO-2
Octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate IRGANOX
1076 BASF PETS Palmitic/stearic acid (50/50) ester of
dipenta/pentaerythritol (Loxiol EP8578) Cognis Oleochemicals
H.sub.3PO.sub.3 Premix of 0.626 wt % of a 45 wt % phosphorous acid
aqueous solution in PC-1 SABIC Premix UVA 234
2-[2-hydroxy-3,5-di-(1,1-dimethylbenzyl)]-2H-benzotriazol BASF UVA
5411 2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)phenol
CYTEC Epoxy Styreue-acrylate-epoxy oligomer BASF Rimar salt
potassium perfluorobutane sulfonate 3M
Blending, Extrusion, and Molding Conditions
[0097] The compositions were made as follows. All solids were dry
blended off-line as concentrates using one of the primary polymer
powders as a carrier and starve-fed via gravimetric feeder(s) into
the feed throat of the extruder. The remaining polymer(s) were
starve-fed via gravimetric feeder(s) into the feed throat of the
extruder as well. The liquid additives, if any, were fed before the
vacuum using a liquid injection system. It will be recognized by
one skilled in the art that the method is not limited to these
processing steps or processing equipment.
[0098] Extrusion of all materials was performed on a 25 mm
Wemer-Pfleiderer ZAK twin-screw extruder (L/D ratio of 33/1) with a
vacuum port located near the die face. The extruder has 9 zones,
which were set at temperatures of 40.degree. C. (feed zone),
200.degree. C. (zone 1), 250.degree. C. (zone 2), 270.degree. C.
(zone 3), and 290 to 330.degree. C. (zone 4 to 8). Screw speed was
300 rpm and throughput was between 10 and 25 kg/hr. Examples 85 to
101 were extruded on a different machine and conditions. Extrusion
of these materials was performed on a 26 mm Toshiba TEM26SS
single-screw extruder (L/D ratio of 40.41) with a vacuum port
located near the die face. The extruder has 10 zones, which were
set at temperatures of 40.degree. C. (feed zone), 200.degree. C.
(zone 1), 250.degree. C. (zone 2), 270.degree. C. (zone 3), and 290
to 330.degree. C. (zone 4 to 8). Screw speed was 300 rpm and
throughput was between 30 and 35 kg/hr.
[0099] Samples of the compositions were molded after drying at 100
to 110.degree. C. for 6 hours on a 45-ton Engel molding machine
with 22 mm screw or 75-ton Engel molding machine with 30 mm screw
operating at a temperature 310 to 360.degree. C. with a mold
temperature of 80 to 150.degree. C. with a typical residence
between 3 and 15 minutes. Examples 85 to 101 were molded on a
different machine and conditions. For these samples, molding was
done on a 85-ton JSW J85AD molding machine with 25 mm operating at
a temperature 310 to 360.degree. C. with a mold temperature of 80
to 150.degree. C. with a typical residence between 3 and 15
minutes.
Testing Methods
[0100] Yellowness Index (YI) was calculated from the transmission
spectrum from a MacBeth ColorEye7000A according to ASTM D1925.
Parts with thickness of 1 mm or 2.5 mm were used, as specified in
the Examples
[0101] Tensile stress and tensile modulus were measured in
accordance with ISO 527 with speed of 50 mm/min
[0102] Flexural stress and flexural modulus were measured in
accordance with ISO 178.
[0103] ASTM Izod notched impact energy was as measured at
23.degree. C. according to ASTM D256 using a 80 mm.times.10
mm.times.4 mm specimen.
[0104] ISO notched Izod impact was measured at 23.degree. C.
according to ISO 180/1A using a multipurpose test specimen in
accordance with ISO 3167 TYPE.
[0105] A Vicat B120 softening temperature was measured according to
ISO 306.
[0106] Heat deflection temperature (HDT) was measured flat on a 80
mm.times.10 mm.times.4 mm bar with a 64 mm span at 0.45 MPa
according to ISO 75/Bf.
[0107] Melt volume flow rate (MVR) was measured at 330.degree.
C./2.16 Kg at 300 second dwell according to ISO 1133.
[0108] Transmission at 400 nm, 550 nm, 940 nm, or 1310 nm was
measured with Perkin Elmer 950 spectrometer equipped with 15 cm
integrated sphere on a molded plaque with a thickness of 1 mm, 2
mm, or 3 mm.
[0109] Haze was measured according to ASTM D1003-00 on a molded
plaque with thickness of 1 to 3 mm.
[0110] Refractive index was measured according to ISO 489 on a
molded plaque with a thickness of 1 mm.
[0111] Abbe number was measured according to ISO 489 on a molded
plaque with a thickness of 1 mm.
[0112] Flammability tests were performed following the procedure of
Underwriter's Laboratory Bulletin 94 entitled "Tests for
Flammability of Plastic Materials for Parts in Devices and
Appliances" (ISBN 0-7629-0082-2), Fifth Edition, Dated Oct. 29,
1996, incorporating revisions through and including Dec. 12, 2003.
Several ratings can be applied based on the rate of burning, time
to extinguish, ability to resist dripping, and whether or not drips
are burning. According to this procedure, materials can be
classified as HB, UL94 V0, V1, V2, VA, and/or VB.
Examples 1-14
[0113] Examples 1-14 demonstrate the effect of the addition of
butyl tosylate on the color of PPPBP-BPA copolycarbonate/BPA
homopolycarbonate blends, based on polymers produced using BPA with
99.4 to 99.5% purity, with and without ultraviolet light
stabilizers after the blends are molded under different conditions.
Formulations and results are shown in Tables 2 and 3, where the
formulations in Table 2 do not contain any ultraviolet light
stabilizer while the formulations in Table 3 contain an ultraviolet
light stabilizer. All YI measurements were performed on 2.5 mm
thick plaques molded per conditions as specified in Table 2.
TABLE-US-00002 TABLE 2 Unit CEx 1 Ex 2 Ex 3 Ex 4 Ex 5 Ex 6 CEx 7
Component CPC-1 Wt % 63.70 63.70 63.70 63.70 63.70 63.70 63.7 PC-1
Wt % 11.30 11.30 11.30 11.30 11.30 11.30 11.3 PC-2 Wt % 24.58 24.25
23.91 23.58 22.91 22.08 24.5 PETS Wt % 0.30 0.30 0.30 0.30 0.30
0.30 0.3 AO-1 Wt % 0.08 0.08 0.08 0.08 0.08 0.08 0.08 AO-2 Wt %
0.04 0.04 0.04 0.04 0.04 0.04 0.04 Tosylate premix-1 Wt % 0.33 0.67
1.00 1.67 2.50 H.sub.3PO.sub.3 Premix Wt % 0.11 Total Wt % 100 100
100 100 100 100 100 Sulfonic stabilizer content ppm 0 2 4 6 10 15
H.sub.3PO.sub.3 content ppm 3 Property YI after molding at
310.degree. C./5 min 2.1 2.1 2.1 2.1 2.1 2.1 1.94 YI after molding
at 335.degree. C./10 min 9.7 3.1 2.6 2.7 2.7 2.7 4.99 YI after
molding at 355.degree. C./5 min 8.9 3.6 3 2.8 2.7 2.7 YI after
molding at 355.degree. C./10 min 18.9 8.9 6.1 5.7 5.0 5 16.57 YI
after molding at 355.degree. C./15 min 25.2 14.1 9.5 9.7 7.9 7.9 YI
improvement* at 310.degree. C./5 min % -- 0 0 0 0 0 -8 YI
improvement* at 335.degree. C./10 min % -- -68 -73 -72 -72 -72 -49
YI improvement* at 355.degree. C./5 min % -- -60 -66 -69 -70 -70 NA
YI improvement* at 355.degree. C./10 min % -- -53 -68 -70 -74 -74
-12 YI improvement* at 355.degree. C./15 min % -- -44 -62 -62 -69
-69 NA *Vs. CEx1
TABLE-US-00003 TABLE 3 Unit CEx 8 Ex 9 Ex 10 Ex 11 Ex 12 Ex 13 CEx
14 Component CPC-1 Wt % 63.70 63.70 63.70 63.70 63.70 63.70 63.7
PC-1 Wt % 11.30 11.30 11.30 11.30 11.30 11.30 11.3 PC-2 Wt % 24.28
23.95 23.61 23.28 22.61 21.78 24.2 PETS Wt % 0.30 0.30 0.30 0.30
0.30 0.30 0.3 AO-1 Wt % 0.08 0.08 0.08 0.08 0.08 0.08 0.08 AO-2 Wt
% 0.04 0.04 0.04 0.04 0.04 0.04 0.04 UVA 234 Wt % 0.30 0.30 0.30
0.30 0.30 0.30 0.3 Tosylate premix-1 Wt % 0.00 0.33 0.67 1.00 1.67
2.50 H.sub.3PO.sub.3 Premix 0.11 Total Wt % 100 100 100 100 100 100
Organosulfonic content ppm 0 2 4 6 10 15 H.sub.3PO.sub.3 content
ppm 3 Property YI after molding at 310.degree. C./5 min 3.2 3.0 3 3
2.9 2.9 2.8 YI after molding at 335.degree. C./10 min 10.4 4.4 4
3.7 3.6 3.7 3.7 YI after molding at 355.degree. C./5 min 10.5 4.2
4.1 3.9 3.6 3.7 YI after molding at 355.degree. C./10 min 19.8 8.6
6.9 6.8 5.4 5.7 10.4 YI after molding at 355.degree. C./15 min 26.7
14.3 10.3 11 7 7.7 YI improvement* at 310.degree. C./5 min % -- -6
-6 -6 -9 -9 -13 YI improvement* at 335.degree. C./10 min % -- -58
-62 -64 -65 -64 -64 YI improvement* at 355.degree. C./5 min % --
-60 -61 -63 -66 -65 YI improvement* at 355.degree. C./10 min % --
-57 -65 -66 -73 -71 -47 YI improvement* at 355.degree. C./15 min %
-- -46 -61 -59 -74 -71 *vs CEx8
[0114] The data in Tables 2 and 3 indicates that the addition of as
little as 2 ppm of butyl tosylate significantly improves YI when
the blends are molded at 335 to 355.degree. C. for 5 to 15 minutes
compared to a reference that does not contain the tosylate
regardless whether an ultraviolet light stabilizer is present
(CEx8) or not (CEx1). The improvement on color is more pronounced
when the blends are molded at higher temperatures for longer time.
Generally increasing the amount of butyl tosylate to up to 15 ppm
further improves the color stability of the blends, comparing for
instance Examples 3-6 with Example 2, and comparing Examples 10-13
with Example 9. Loadings of 4 ppm of butyl tosylate are desired for
better color, higher than 6 ppm of loading provides further
improved color. Typically color improvements of 50% or higher, or
60% or higher are achieved compared to the reference composition
not containing the butyl tosylate at 335 or 355.degree. C.
[0115] The data also shows that H.sub.3PO.sub.3 is far less
efficient in improving the color of the PPPBP-BPA
copolycarbonate/BPA homopolycarbonate blends after abusive molding
as compared to butyl tosylate, especially at most abusive
conditions at melt temperature of 355.degree. C.
Examples 15-19
[0116] Examples 15-19 compare the color stability of high purity
PPPBP-BPA copolycarbonate/BPA homopolycarbonate blends that contain
butyl tosylate, H.sub.3PO.sub.3, or citric acid after samples are
molded under various process conditions at a thickness of 2.5 mm.
Formulations and results are shown in Table 4.
TABLE-US-00004 TABLE 4 Component Unit CEx15 CEx17 Ex18 CEx19 CPC-2
Wt % 44.8 44.8 44.88 44.8 PC-3 Wt % 8.69 8.685 8.68 8.67 PC-5 Wt %
46.09 46.09 46.09 46.09 PETS Wt % 0.3 0.3 0.3 0.3 AO-1 Wt % 0.08
0.08 0.08 0.08 AO-2 Wt % 0.04 0.04 0.04 0.04 H.sub.3PO.sub.3 Premix
0.11 Tosylate Premix-1 Wt % 0.067 Citric acid Wt % 0.01 Total Wt %
100 100 100 100 Property YI after molding at 290.degree. 1.9 1.7
1.8 4 C./5 min YI after molding at 290.degree. 1.8 1.6 1.9 5.6
C./10 min YI after molding at 340.degree. 3.2 2.6 2.1 16 C./5 min
YI after molding at 340.degree. 8.9 4.5 2.9 23.6 C./10 min YI
improvement vs CEx15 % -- -11 -5 111 at 290.degree. C./5 min YI
improvement vs CEx15 % -- -11 6 211 at 290.degree. C./10 min YI
improvement vs CEx15 % -- -19 -34 400 at 340.degree. C./5 min YI
improvement vs CEx8 % -- -49 -67 165 at 340.degree. C./10 min
[0117] The data in Table 4 shows that the addition of butyl
tosylate significantly improves YI of blends containing a high
purity PPPBP-BPA copolycarbonate and a BPA homopolycarbonate when
the blends are molded at 340.degree. C. for 10 minutes compared to
a control that does not contain any organosulfonic stabilizer
(CEx15), or reference blends either contain phosphoric acid (CEx17)
or citric acid (CEx19).
Examples 20-35
[0118] Examples 20-35 illustrate the effects of butyl tosylate on
the color of blends containing PPPBP-BPA copolycarbonate and a BPA
homopolycarbonate having various BPA purities (STD=99.4-99.5%
purity, HP=99.7% purity) after the samples are molded under various
processing conditions. Formulations and results are shown in Tables
5 and 6.
TABLE-US-00005 TABLE 5 CEx 20 Ex 21 Ex 22 Ex 23 CEx 24 Ex 25 Ex 26
Ex 27 Component (wt %) CPC-1 63.7 63.7 63.7 63.7 CPC-2 63.7 63.7
63.7 63.7 PC-1 24.6 23.3 23.0 22.6 24.6 23.3 23.0 22.6 PC-2 11.3
11.3 11.3 11.3 11.3 11.3 11.3 11.3 PETS 0.3 0.3 0.3 0.3 0.3 0.3 0.3
0.3 AO-1 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 AO-2 0.04 0.04
0.04 0.04 0.04 0.04 0.04 0.04 UVA 234 0.3 0.3 0.3 0.3 0.3 0.3 0.3
0.3 Tosylate premix-1 0 1.00 1.33 1.67 0 1.00 1.33 1.67 Total 100
100 100 100 100 100 100 100 Sulfonic content 0 6 8 10 0 6 8 10
(ppm) CPC/PC purity STD/ STD/ STD/ STD/ HP/ HP/ HP/ HP/ STD STD STD
STD STD STD STD STD Property YI after molding* at 310.degree. C./5
min 3.1 3.0 3.0 3.0 3.3 3.2 3.1 3.2 at 335.degree. C./10 min 8.6
3.6 3.7 3.7 8.2 3.8 3.7 3.6 at 355.degree. C./10 min 20.7 6.1 6.1
5.1 16.6 6.0 5.5 6.5 YI improvement at -- -3** -3** -3** -3***
-6*** -3*** 310.degree. C./5 min YI improvement at -- -58** -57**
-57** -54*** -55*** -56*** 335.degree. C./10 min YI improvement at
-- -71** -71** -75** -64*** -67*** -61*** 355.degree. C./10 min
*2.5 mm sample **vs. CEx 20 ***vs. CEx 24
TABLE-US-00006 TABLE 6 CEx 28 Ex 29 Ex 30 Ex 31 CEx 32 Ex 33 Ex 34
Ex 35 Component (wt %) CPC-1 63.7 63.7 63.7 63.7 CPC-2 63.7 63.7
63.7 63.7 PC-3 24.6 23.3 23.0 22.6 24.6 23.3 23.0 22.6 PC-4 11.3
11.3 11.3 11.3 11.3 11.3 11.3 11.3 PETS 0.3 0.3 0.3 0.3 0.3 0.3 0.3
0.3 AO-1 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 AO-2 0.04 0.04
0.04 0.04 0.04 0.04 0.04 0.04 UVA 234 0.3 0.3 0.3 0.3 0.3 0.3 0.3
0.3 Tosylate premix-1 0 1.00 1.33 1.67 0 1.00 1.33 1.67 Total 100
100 100 100 100 100 100 100 Sulfonic content (ppm) 0 6 8 10 0 6 8
10 CPC/PC purity STD/ STD/ STD/ STD/ HP/ HP/ HP/ HP/ HP HP HP HP HP
HP HP HP Property YI after molding* at 310.degree. C./5 min 3.4 3.0
3.0 3.1 3.9 3.3 3.2 3.1 at 335.degree. C./10 min 8.7 3.8 3.6 3.6
8.3 3.9 3.6 3.3 at 355.degree. C./10 min 18.5 5.6 4.8 4.9 18.3 6.5
5.9 4.7 YI improvement at -- -12** -12** -9** -- -15*** -18***
-21*** 310.degree. C./5 min YI improvement at -- -56** -59** -59**
-- -53*** -57*** -60*** 335.degree. C./10 min YI improvement at --
-70** -74** -74** -- -64*** -68*** -74*** 355.degree. C./10 min
*2.5 mm sample **vs. CEx 28 ***vs. CEx 32
[0119] The data in Tables 5 and 6 shows that adding butyl tosylate
to PPPBP-BPA copolycarbonate/BPA homopolycarbonate blends improves
the abusive YI (335.degree. C./10 minutes and 355.degree. C./10
minutes) for any BPA purity in the copolycarbonate and the
homopolycarbonate, using any combination of standard and high
purity resins, comparing for instance Ex21, Ex25, Ex29 and Ex33
(all containing 6 ppm butyl tosylate) with CEx20, CEx24, CEx28 and
CEx32 respectively (same composition, but without the butyl
tosylate), achieving YI reductions versus the comparative examples
of 50-75%. The data also indicates that loadings of 6-10 ppm of
butyl tosylate provide similar results in color stability, all
achieving comparable improvements.
Examples 36-47
[0120] Examples 36-47 illustrate the effects of different loadings
of butyl tosylate on the color of PPPBP-BPA copolycarbonate derived
from high purity BPA (99.7% purity) without ultraviolet light
stabilizers after the samples are molded under different
conditions. Formulation and results are shown in Table 7.
TABLE-US-00007 TABLE 7 CEx 36 Ex 37 Ex 38 Ex 39 Ex 40 Ex 41 Ex 42
Ex 43 Ex 44 CEx 45 CEx 46 CEx 47 Component (wt %) CPC-2 99.59 98.91
98.58 98.25 99.31 99.25 99.18 99.05 98.91 99.47 99.42 99.36 PETS
0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 AO-1 0.08 0.08 0.08
0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 AO-2 0.04 0.04 0.04
0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 H.sub.3PO.sub.3 premix
0.11 0.165 0.22 Tosylate premix-1 0.67 1.00 1.33 Tosylate premix-2
0.27 0.33 0.40 0.53 0.67 Total 100 100 100 100 100 100 100 100 100
100 100 100 Sulfonic content 0 4 6 8 8 10 12 16 20 (ppm)
H.sub.3PO.sub.3 content 0 0 0 0 0 0 0 0 0 3 4.5 6 (ppm) Property YI
after molding* at 330.degree. C./5 min 5.9 3.2 2.9 2.8 3.2 3.2 3.1
3.2 3.1 3.4 3.3 2.6 at 350.degree. C./7.5 min 19.6 5.7 4.7 4.9 4.6
4.2 4.1 4.0 3.9 13.6 13.8 13.1 at 355.degree. C./10 min 24.9 10.4
7.6 6.5 6.9 6.9 6.1 5.8 6.0 21.1 19.1 19.3 at 350.degree. C./12.5
min 33.9 18.6 14.9 9.3 28.3 26.6 25.4 YI improvement vs CEx 36 at
330.degree. C./5 min -- -46 -51 -53 -46 -46 -47 -46 -47 -42 -44 -56
at 350.degree. C./7.5 min -- -71 -76 -75 -77 -79 -79 -80 -80 -31
-30 -33 at 355.degree. C./10 min -- -58 -69 -74 -72 -72 -76 -77 -76
-15 -23 -22 at 350.degree. C./12.5 min -- -45 -56 -73 -17 -22 -25
*2.5 mm sample
[0121] The data in Table 7 shows that the addition of 4-20 ppm of
butyl tosylate significantly improves YI of high purity PPPBP-BPA
copolycarbonate without ultraviolet light stabilizers when the
samples are molded at 330.degree. C., 350.degree. C., and
355.degree. C. for 5-12.5 minutes compared to a control that does
not contain butyl tosylate (CEx36), achieving color reductions
between 45 and 75% depending on the conditions as well as reference
samples containing H.sub.3PO.sub.3 instead of butyl tosylate
(CEx45-47), which are having improvements of 30% or less. The
improvement is more pronounced when the samples are molded under
more abusive conditions.
Examples 48-60
[0122] Examples 48-60 illustrate the effects of different loadings
of butyl tosylate on the color of PPPBP-BPA copolycarbonate derived
from high purity BPA (99.7% purity) with ultraviolet light
stabilizers after the samples are molded under different
conditions. Formulation and results are shown in Table 8.
TABLE-US-00008 TABLE 8 CEx 48 Ex 50 Ex 51 Ex 52 CEx 53 CEx 54 CEx
58 Ex 59 Ex 60 Component (wt %) CPC-2 99.28 99.15 99.08 99.01 99.22
99.17 99.58 99.01 98.88 PETS 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
AO-1 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 AO-2 0.04 0.04
0.04 0.04 0.04 0.04 0.04 0.04 0.04 UVA 234 0.3 0.3 0.3 0.3 0.3 0.3
0.3 0.3 0.3 UVA 5411 H.sub.3PO.sub.3 premix 0.055 0.11 Tosylate
premix-2 0.134 0.200 0.267 0.267 0.4 0.667 Total 100 100 100 100
100 100 100 100 100 Sulfonic content (ppm) 0 4 6 8 0 0 0 8 12
H.sub.3PO.sub.3 content (ppm) 0 0 0 0 1.5 3 0 0 0 Property YI after
molding 330.degree. C./5 min/2.5 mm 6.2 3.9 3.8 330.degree. C./5
min/1 mm 4.9 2.5 2.4 2.3 2.8 2.6 350.degree. C./7.5 min/2.5 mm 14.7
5.2 4.9 355.degree. C./10 min/2.5 mm 22.9 6.1 5.8 355.degree. C./10
min/1 mm 14.8 7.1 5.8 7.1 12.4 10.9 YI improvement vs CEx Vs. Vs.
Vs. Vs. CEx 48 Vs. CEx 48 Vs. CEx 58 Vs. CEx 58 CEx 48 CEx 48 CEx
48 330.degree. C./5 min/2.5 mm -37 -39 330.degree. C./5 min/1 mm
-49 -51 -53 -43 -47 350.degree. C./7.5 min/2.5 mm -65 -67
355.degree. C./10 min/2.5 mm -73 -75 355.degree. C./10 min/1 mm -52
-61 -52 -16 -26
[0123] The data in Table 8 shows that the addition of 4 to 20 ppm
of butyl tosylate (Ex50 to 52 and Ex59 to 60) significantly
improves YI of high purity PPPBP-BPA copolycarbonate with
ultraviolet light stabilizer when the samples are molded at
330.degree. C., 350.degree. C., and 355.degree. C. for 5 to 12.5
minutes compared to a control that does not contain butyl tosylate
(CEx48 or CEx58), achieving color reductions between 40 and 61%
depending on the conditions, as well as compared to reference
samples containing H.sub.3PO.sub.3 instead of butyl tosylate (CEx53
to 54), which show improvements of 30% or less. The improvement is
more pronounced when the samples are molded under more abusive
conditions.
Examples 62-67
[0124] Examples 62-67 illustrate the effects of different loadings
of butyl tosylate on the color of PPPBP-BPA copolycarbonate derived
from standard purity BPA without ultraviolet light stabilizers
after the samples are molded under different conditions.
Formulation and results are shown in Table 9.
TABLE-US-00009 TABLE 9 Ex 62 Ex 63 Ex 64 Ex 65 Ex 66 Ex 67 CEx 68
Component (wt %) CPC-1 99.58 99.25 98.91 98.58 99.31 99.18 99.47
PETS 0.3 0.3 0.3 0.3 0.3 0.3 0.3 AO-1 0.08 0.08 0.08 0.08 0.08 0.08
0.08 AO-2 0.04 0.04 0.04 0.04 0.04 0.04 0.04 H.sub.3PO.sub.3 premix
0.11 Tosylate Premix-1 0.33 0.67 1.00 Tosylate Premix-2 0.27 0.40
Total Organosulfonic 0 2 4 6 8 12 content (ppm) H.sub.3PO.sub.3
content 0 0 0 0 0 0 3 (ppm) Property YI after molding at
330.degree. C./5 min/ 3.72 2.44 3.00 2.84 2.82 2.84 3.55 2.5 mm at
345.degree. C./5 min/ 3.81 3.81 4.29 2.5 mm at 345.degree. C./7.5
min/ 7.77 5.14 10.64 2.5 mm at 350.degree. C./7.5 min/ 28.99 6.93
5.07 4.52 19.63 2.5 mm at 355.degree. C./10 min/ 35.59 15.71 9.25
8.86 26.74 2.5 mm
[0125] The data in Table 9 shows that the addition of 2-12 ppm of
butyl tosylate significantly improves YI of standard purity
PPPBP-BPA copolycarbonate compositions that do not contain an
ultraviolet light stabilizer when the samples are molded at
330.degree. C., 345.degree. C., 350.degree. C., and 355.degree. C.
for five to ten minutes compared to a control that does not contain
butyl tosylate as well as a reference sample containing
H.sub.3PO.sub.3 instead of butyl tosylate. The improvement is more
pronounced when the samples are molded under abusive
conditions.
Examples 68-72
[0126] Examples 68-42 compare the color stability of PPPBP-BPA
copolycarbonate/BPA homopolycarbonate blends that contain butyl
tosylate, or H.sub.3PO.sub.3 stabilizer, or neither butyl tosylate
nor H.sub.3PO.sub.3 stabilizer after autoclaving. Formulations and
results are shown in Table 10.
TABLE-US-00010 TABLE 10 Component (wt %) CEx68 CEx69 CEx70 Ex71
Ex72 CPC-1 63.70 63.70 63.70 63.70 63.70 PC-1 7.0 7.0 7.0 7.0 7.0
PC-2 28.88 28.55 28.44 28.21 27.88 AO-1 0.08 0.08 0.08 0.08 0.08
PETS 0.3 0.3 0.3 0.3 0.3 AO-2 0.04 0.04 0.04 0.04 0.04
H.sub.3PO.sub.3 Premix 0.11 Tosylate premix-1 0.67 0.67 Epoxy 0.33
0.33 0.33 Total 100 100 100 100 100 Tosylate (ppm) 0 0 4 4 Property
YI before autoclaving 2.2 2.9 2.5 2.2 2.2 YI after autoclaving at
2.8 3.8 3.2 2.3 2.2 121.degree. C. for 100 hours YI shift (%) 0.6
0.9 0.7 0.1 0
[0127] The results in Table 10 indicate that butyl tosylate
improves color stability after autoclaving in compositions with and
without JONCRYL epoxy (Ex71 and Ex72). Compositions without
additional organosulfonic stabilizer have a YI shift of 0.5 and
higher (CEx68 and CEx69). A composition with H.sub.3PO.sub.3
stabilizer has a YI shift of 0.7 (CEx70). Surprisingly a
composition containing butyl tosylate has a YI shift of 0.1 (Ex71)
and a composition containing butyl tosylate and an epoxy additive
has no YI shift after autoclaving at 121.degree. C. for 100
hours.
Examples 73-74
[0128] Examples 73-74 compare the effect of butyl tosylate loading
on the color stability of PPPBP-BPA copolycarbonate compositions
having 45 mol % PPPBP carbonate units. The results are summarized
in Table 11.
TABLE-US-00011 TABLE 11 Component CEx73 Ex74 PPPBP carbonate units
(mol. %) 45 45 Butyl tosylate (ppm) 0 8 YI after molding at
350.degree. C./5 min 27.31 21.49 at 370.degree. C./5 min 43.39 36.9
at 370.degree. C./7.5 min 59.05 52.39
The data shows that the addition of butyl tosylate to PPPBP-BPA
copolycarbonate compositions having 45 mol % PPPBP carbonate units
improves color after abusive molding.
Examples 77-84
[0129] Examples 77-84 illustrates various properties of
compositions containing high purity PPPBP-BPA, butyl tosylate, and
optionally a high purity BPA homopolycarbonate. Formulations and
results are shown in Table 12. About 0.0002 wt % of a dye package
was also present.
TABLE-US-00012 TABLE 12 Component Unit Ex 77 Ex 78 Ex 79 Ex 82 Ex
83 Ex 84 CPC-2 wt % 63.7 63.7 63.7 99.31 99.01 98.83 PC4 wt % 28.68
28.38 23.9 0 0 0 PC3 wt % 7 7 11.3 0 0 0 Tosylate premix-2 wt % 0.2
0.2 0.2 0.27 0.27 0.27 AO-1 wt % 0.08 0.08 0.08 0.08 0.08 0.08 AO-2
wt % 0.04 0.04 0.04 0.04 0.04 0.04 PETS wt % 0.3 0.3 0.3 0.3 0.3
0.3 UVA234 wt % 0 0.3 0.3 0 0.3 0.3 Rimar salt wt % 0 0 0.08 0 0
0.08 Octaphenylcyclotetrasiloxane wt % 0 0 0.1 0 0 0.1 Tensile
Modulus, 1 mm/min MPa 2488 2511 2522 2550 2589 2571 Tensile Stress,
yield, 50 mm/min MPa 76 77 77 82 83 82 Tensile Stress, break, 50
mm/min MPa 64 69 67 65 65 65 Tensile Strain, yield, 50 mm/min % 6.4
6.9 6.9 7.3 7.3 7.2 Tensile Strain, break, 50 mm/min % 60 84 78 40
30 27 Flexural Modulus, 2 mm/min MPa 2524 2518 2526 2547 2634 2574
Flexural Stress, yield, 2 mm/min MPa 116 117 114 123 125 124 Izod
Impact, notched, +23.degree. C. J/m 89 83 80 74 72 76 Izod Impact,
notched, -30.degree. C. J/m NA 79 78 73 68 74 Izod Impact, notched*
+23.degree. C. kJ/m.sup.2 8 8 8 8 7 7 Izod Impact, notched*
-30.degree. C. kJ/m.sup.2 NA 6 7 6 6 7 Vicat Softening Temp, B/120
.degree. C. 173.1 171.7 171.6 192.9 191.0 189.7 HDT .degree. C.
164.7 165.5 165.4 186.0 185.0 184.4 MVR at 330.degree. C./2.16 kg,
300 s cm.sup.3/10 min 29.51 30.77 33.27 14.1 15.0 16.7 Transmission
at 400 nm, 1 mm % 86.5 85.5 71.4 82.9 Transmission at 400 nm, 2 mm
% 84.8 82.4 58.7 78.2 Transmission at 400 nm, 3 mm % 82.8 79.6 48.5
73.6 Transmission at 550 nm, 1 mm % 88.1 88.1 87.2 87.8
Transmission at 550 nm, 2 mm % 86.8 86.7 85.2 86.5 Transmission at
550 nm, 3 mm % 85.5 85.3 83.1 85.0 Transmission at 940 nm, 1 mm %
90.3 90.1 90.1 90.0 Transmission at 940 nm, 2 mm % 90.2 90.0 89.9
89.9 Transmission at 940 nm, 3 mm % 89.9 89.8 89.8 89.6
Transmission at 1310 nm, 1 mm % 90.0 89.8 89.8 89.8 Transmission at
1310 nm, 2 mm % 89.3 89.2 89.1 89.1 Transmission at 1310 nm, 3 mm %
88.6 88.5 88.5 88.4 Total transmission, 1 mm % 89.5 89.0 90.0 89.5
88.7 89.3 Total transmission, 2 mm % 88.4 88.7 88.9 88.1 86.6 88.0
Total transmission, 3 mm % 87.1 7.4 87.8 86.8 84.7 86.7 Haze, 1 mm
% 0.4 0.3 0.3 0.4 0.4 0.3 Haze, 2 mm % 0.7 0.3 0.3 0.6 0.6 0.4
Haze, 3 mm % 0.9 0.4 0.4 0.8 0.8 0.5 Refractive index at 587.6 nm
-- 1.602 1.602 NA 1.609 1.609 NA Refractive index at 940 nm --
1.583 1.583 NA 1.589 1.589 NA Refractive index at 1310 nm -- 1.577
1.577 NA 1.583 1.583 NA Abbe number -- 30 30 NA 29 29 NA UL94
rating at 2.5 mm -- NA NA V0 NA NA V0 UL94 rating at 2.0 mm -- NA
NA V2 NA NA V2 UL94 rating at 1.5 mm -- NA NA V2 NA NA V2 UL94
rating at 0.8 mm -- NA NA V2 NA NA V2
Examples 85-101
[0130] Examples 85-101 illustrate the effects of different
organosulfonic stabilizers on the color of PPPBP-BPA
copolycarbonate, optionally blended with a BPA homopolycarbonate
after the samples are molded at 355.degree. C. for 5 minutes or 10
minutes. For these examples, the molding conditions used were a
sample drying time of 140.degree. C. for 5 hours, using a J85AD (85
ton) molding machine by JSW. YI was determined on a 3.2 mm color
plaque using on a MacBeth ColorEye7000A (ASTM D1925) as described
above. The organosulfonic stabilizers screened are shown in Table
13.
TABLE-US-00013 TABLE 13 Name Organosulfonic stabilizer Sodium
p-toluenesulfonic acid (p-TSA Na) ##STR00019## Phenyl
p-toluenesulfonate (Ph tosylate) ##STR00020## 4-
Docecylbenzenesulfonic acid (4-DBSA) ##STR00021## Polystyrene
sulfonic acid (Poly p-TSA) ##STR00022## Butyl tosylate (n-Bu
tosylate) ##STR00023## Ethyl tosylate (Et Tosylate) ##STR00024##
p-Toluenesulfonic anhydride (p-TSAA) ##STR00025## Octadecyl p-
toluenesulfonate (OD p-TS) ##STR00026## Camphorsulfonic acid
(10-CSA) ##STR00027## p-Toluenesulfonic acid (p-TSA)
##STR00028##
[0131] The formulations and results are shown in Table 14 and FIG.
1. The level of organosulfonic stabilizer in the premix was 6 ppm
(0.06 wt %). CEx96 to CEx98 are comparative examples with no
organosulfonic stabilizer.
TABLE-US-00014 TABLE 14 Ex 85 Ex 86 Ex 87 Ex 88 Ex 89 Ex 90 Ex 91
CEx 96 Ex 99 Component (wt %) CPC-1 63.49 63.49 63.49 63.49 63.49
63.49 63.49 63.64 63.49 CPC-2 PC-1 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0
7.0 PC-2 29.0 29.0 29.0 29.0 29.0 29.0 29.0 29.0 29.0 PETS 0.3 0.3
0.3 0.3 0.3 0.3 0.3 0.3 0.3 AO-1 0.08 0.08 0.08 0.08 0.08 0.08 0.08
0.08 0.08 AO-2 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 n-Bu
tosylate 0.15 premix p-TSA 0.15 premix Poly p-TSA 0.15 premix Et
Tosylate 0.15 premix OD p-TS 0.15 premix p-TSAA 0.15 premix 4-DBSA
0.15 premix p-TSA Na 0.15 premix 10-CSA premix Ph tosylate premix
Total 100 100 100 100 100 100 100 100 100 Property YI after
molding* at 355.degree. C./5 min 3.8 3.7 4.9 3.8 3.8 3.7 3.7 7.5
6.3 at 355.degree. C./10 min 9.9 10.6 10.4 9.5 11.5 10.5 9.0 23.5
23.2 Ex Ex CEx CEx 100 101 Ex 92 Ex 93 97 Ex 94 Ex 95 98 Component
(wt %) CPC-1 63.49 63.49 CPC-2 63.49 63.49 63.64 99.49 99.49 99.64
PC-1 7.0 7.0 7.0 7.0 7.0 PC-2 29.0 29.0 29.0 29.0 29.0 PETS 0.3 0.3
0.3 0.3 0.3 0.3 0.3 0.3 AO-1 0.08 0.08 0.08 0.08 0.08 0.08 0.08
0.08 AO-2 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 n-Bu tosylate
0.15 0.15 premix p-TSA 0.15 0.15 premix Poly p-TSA premix Et
Tosylate premix OD p-TS premix p-TSAA premix 4-DBSA premix p-TSA Na
premix 10-CSA 0.15 premix Ph tosylate 0.15 premix Total 100 100 100
100 100 100 100 100 Property YI after molding* at 355.degree. C./5
min 4.5 7.1 3.4 3.5 3.9 5.7 5.9 11.7 at 355.degree. C./10 min 17.9
23.4 4.3 4.3 12.3 9.4 11.3 33.9 *3.2 mm thickness plaque
[0132] Comparison of CEx96, Ex99, and Ex101 show that the sodium
salt of p-toluene sulfonic acid and have very little effect on the
color of a blend of PPPBP-BPA copolycarbonate and phenyl tosylate a
BPA homopolycarbonate after abusive molding. It may be possible to
substitute the phenyl group of phenyl tosylate to improve its
efficacy. For example, it may be that certain substituents that
improve the leaving group capability of the phenyl group can be
used. Ex 100 shows that camphorsulfonic acid provides certain
improvement on color after abusive molding; however, the
improvement is limited. The remaining organosulfonic stabilizers
significantly improve the color of PPP-BPA copolycarbonate or a
blend of PPP-BPA copolycarbonate and a BPA homopolycarbonate, after
abusive molding at 355.degree. C. for 5 minutes or 10 minutes.
[0133] Set forth below are various embodiments of the
disclosure.
Embodiment 1
[0134] A thermoplastic composition comprises: a copolycarbonate
comprising bisphenol A carbonate units and second carbonate units
of formula (1) wherein R.sup.a and R.sup.b are each independently a
C.sub.1-12 alkyl, C.sub.1-12 alkenyl, C.sub.3-8 cycloalkyl, or
C.sub.1-12 alkoxy, each R.sup.3 is independently a C.sub.1-6 alkyl,
R.sup.4 is hydrogen, C.sub.2-6 alkyl or phenyl optionally
substituted with 1 to 5 C.sub.1-6 alkyl groups, p, q, and j are
each independently 0 to 4, optionally a bisphenol A
homopolycarbonate; and 2 to 40 ppm of an organosulfonic stabilizer
of formula (8) wherein each R.sup.7 is independently a C.sub.1-30
alkyl, C.sub.6-30 aryl, C.sub.7-30 alkylarylene, C.sub.7-30
arylalkylene, or a polymer unit derived from a C.sub.2-32
ethylenically unsaturated aromatic sulfonic acid or its ester, and
R.sup.8 is hydrogen; or R.sup.8 is C.sub.1-30 alkyl; or R.sup.8 is
a group of the formula --S(.dbd.O).sub.2--R.sup.7; wherein the
second carbonate units are present in an amount of 20 to 49 mol %,
preferably 30 to 40 mol % based on the sum of the moles of the
copolycarbonate and the bisphenol A homopolycarbonate; and wherein
the thermoplastic composition has: a Vicat B120 of 160.degree. C.
or higher measured according to ISO 306; and a yellowness index of
less than 12, preferably less than 8, more preferably less than 6
measured according to ASTM D1925 on a plaque of 2.5 mm thickness
molded at a temperature of 355.degree. C. for a residence time of
10 minutes.
Embodiment 2
[0135] The thermoplastic composition of embodiment 1, wherein in
the second carbonate units of the copolycarbonate, W and R.sup.b
are each independently a C.sub.1-3 alkyl group, R.sup.3 is each
independently a C.sub.1-6 alkyl group, R.sup.4 is hydrogen,
C.sub.1-6 alkyl or phenyl optionally substituted with 1 to 5
C.sub.1-6 alkyl groups, and p, q, and j are each independently 0 to
4.
Embodiment 3
[0136] The thermoplastic composition of embodiment 1 or embodiment
2, wherein the second carbonate repeating units in the
copolycarbonate are of the formula (1a) wherein R.sup.5 is
hydrogen, phenyl or methyl, preferably phenyl.
Embodiment 4
[0137] The thermoplastic composition of any one or more of
embodiments 1 to 3, wherein the copolycarbonate comprises from 15
to 90 mole percent of the bisphenol A carbonate units and 10 to 85
mole percent of the second carbonate units, each based on the total
number of carbonate units in the copolycarbonate.
Embodiment 5
[0138] The thermoplastic composition of any one or more of
embodiments 1 to 4, wherein the copolycarbonate comprises from 50
to 90 mole percent of the bisphenol A carbonate units and 10 to 50
mole percent of the second carbonate units, and has less than 15
mole percent of the second carbonate units directly coupled to
another second carbonate unit, each based on the total number of
carbonate units in the copolycarbonate.
Embodiment 6
[0139] The thermoplastic composition of any one or more of
embodiments 1 to 5, wherein the copolycarbonate further comprises
at least 5 mole percent of a third carbonate unit different from
the bisphenol A carbonate units and the second carbonate units, the
third carbonate unit comprising units of the formula (3)-(7) or a
combination thereof, wherein R.sup.c and R.sup.d are each
independently a C.sub.1-12 alkyl, C.sub.1-12 alkenyl, C.sub.3-8
cycloalkyl, or C.sub.1-12 alkoxy, each R.sup.6 is independently
C.sub.1-3 alkyl or phenyl, X.sup.a is a C.sub.6-12 polycyclic aryl,
C.sub.3-18 mono- or polycycloalkylene, C.sub.3-18 mono- or
polycycloalkylidene, -(Q.sup.1).sub.x-G-(Q.sup.2).sub.y- group
wherein Q.sup.1 and Q.sup.2 are each independently a C.sub.1-3
alkylene, G is a C.sub.3-10 cycloalkylene, x is 0 or 1, and y is 1,
or --C(P.sup.1)(P.sup.2)-- wherein P.sup.1 is C.sub.1-12 alkyl and
P.sup.2 is C.sub.6-12 aryl, and m and n are each independently 0 to
4.
Embodiment 6
[0140] The thermoplastic composition of embodiment 6, wherein the
third carbonate units are of the formula (3a)-(3k), or a
combination thereof, wherein R.sup.c and R.sup.d are each
independently a C.sub.1-12 alkyl, C.sub.1-12 alkenyl, C.sub.3-8
cycloalkyl, or C.sub.1-12 alkoxy, each W is independently hydrogen
or C.sub.1-4 alkyl, each R.sup.2 is independently C.sub.1-4 alkyl
or hydrogen, g is 0 to 10, and m and n are each independently 0 to
4.
Embodiment 7
[0141] The thermoplastic composition of embodiment 6 or embodiment
7, wherein each R.sup.1 is independently hydrogen or methyl, each
R.sup.2 is independently methyl or hydrogen, g is 0 to 2, and m and
n are 0.
Embodiment 9
[0142] The thermoplastic composition of anyone or more of
embodiments 6 to 8 wherein the copolycarbonate comprises from 15 to
70 mole percent of the bisphenol A carbonate units, 5 to 50 mole
percent of the second carbonate units, and 5 to 50 mole percent of
the third carbonate units, each based on the total number of
carbonate units in the copolycarbonate.
Embodiment 10
[0143] The thermoplastic composition of any one or more of
embodiments 1 to 9, and optionally wherein the copolycarbonate
comprises less than 2 ppm by weight of each of an ion of lithium,
sodium, potassium, calcium, magnesium, ammonium, chlorine, bromine,
fluorine, nitrite, nitrate, phosphite, phosphate, sulfate, formate,
acetate, citrate, oxalate, trimethylammonium, and triethylammonium,
as measured by ion chromatography, preferably wherein the
thermoplastic composition comprises less than 2 ppm by weight of
each of an ion of lithium, sodium, potassium, calcium, magnesium,
ammonium, chlorine, bromine, fluorine, nitrite, nitrate, phosphite,
phosphate, sulfate, formate, acetate, citrate, oxalate,
trimethylammonium, and triethylammonium, as measured by ion
chromatography.
Embodiment 11
[0144] The thermoplastic composition of any one or more of
embodiment 1 to 10, wherein in the organosulfonic stabilizer each
R.sup.7 is independently a C.sub.6-12 aryl, C.sub.7-24
alkylarylene, or a polymer unit derived from a C.sub.2-14
ethylenically unsaturated aromatic sulfonic acid or its C.sub.1-30
alkyl ester; and R.sup.8 is hydrogen, C.sub.1-24 alkyl, or a group
of the formula --S(.dbd.O).sub.2--R.sup.7 wherein R.sup.7 is a
C.sub.6-12 aryl or C.sub.7-24 alkylarylene.
Embodiment 12
[0145] The thermoplastic composition of any one or more of
embodiments 1 to 11, wherein in the organosulfonic stabilizer
[0146] R.sup.7 is a C.sub.6-12 aryl, C.sub.7-24 alkylarylene, or a
polymer unit derived from a C.sub.2-14 ethylenically unsaturated
aromatic sulfonic acid or its ester; and R.sup.8 is hydrogen,
C.sub.1-24 alkyl, or a group of the formula
--S(.dbd.O).sub.2--R.sup.7 wherein R.sup.7 is a C.sub.6-12 aryl or
C.sub.7-24 alkylarylene; or
[0147] R.sup.7 is a C.sub.7-10 alkylarylene or a polymer unit
derived from a C.sub.2-14 ethylenically unsaturated aromatic
sulfonic acid, and R.sup.8 is a hydrogen, C.sub.1-25 alkyl, or a
group of the formula --S(.dbd.O).sub.2--R.sup.7 wherein R.sup.7 is
a C.sub.7-10 alkylarylene; or
[0148] R.sup.7 is a polymer unit derived from a C.sub.2-14
ethylenically unsaturated aromatic sulfonic acid, preferably
p-styrene sulfonic acid or para-methyl styrene sulfonic acid;
or
[0149] R.sup.7 is a C.sub.1-10 alkyl ester of a C.sub.7-12
alkylarylene sulfonic acid, preferably of p-toluene sulfonic acid,
more preferably butyl tosylate; or
[0150] R.sup.7 is a group of the formula --S(.dbd.O).sub.2--R'
wherein R.sup.7 is a C.sub.6-12 aryl or C.sub.7-24 alkylarylene,
preferably a C.sub.7-10 alkylarylene.
[0151] R.sup.7 is a C.sub.11-24 alkylarylene sulfonic acid, and
R.sup.7 is hydrogen.
Embodiment 13
[0152] The thermoplastic composition any one or more of embodiment
1 to 10, wherein the stabilizer is present in an amount of 2 ppm to
20 ppm, preferably 4 ppm to 15 ppm, based on the total weight of
the thermoplastic composition.
Embodiment 14
[0153] The thermoplastic composition of any one or more of
embodiments 1 to 13, wherein the thermoplastic composition has a
bisphenol A purity of equal to or greater than 99.6%, or of equal
to or greater than 99.7% measured by high performance liquid
chromatography.
Embodiment 15
[0154] The thermoplastic composition of any one or more of
embodiments 1 to 14, wherein the polycarbonate homopolymer is
present in an amount of 10 to 90 wt %, preferably 10 to 65 wt %,
more preferably 15 wt % 50 wt %, most preferably 20 to 45 wt %,
based on the total weight of the thermoplastic composition.
Embodiment 16
[0155] The thermoplastic composition of any or more of embodiments
1 to 15 comprising: a copolycarbonate comprising bisphenol A
carbonate units and second carbonate units of the formula (1a),
wherein R.sup.5 is hydrogen, phenyl or methyl, preferably phenyl,
optionally a bisphenol A homopolycarbonate; and 2 to 20 ppm or 4 to
10 ppm of an organosulfonic stabilizer comprising a C.sub.1-30
alkyl ester of p-toluenesulfonic acid, and more preferably butyl
tosylate; wherein the thermoplastic composition has 25 mol % to 49
mol % or 30 to 40 mol % of second carbonate units based on the sum
of the moles of the copolycarbonate and the bisphenol A
homopolycarbonate.
Embodiment 17
[0156] The thermoplastic composition of any one or more of
embodiments 1 to 15, comprising, based on the total weight of the
thermoplastic composition: 60 to 70 wt % of a copolycarbonate
comprising bisphenol A carbonate units and second carbonate units
of the formula (1a) wherein R.sup.5 is hydrogen, phenyl or methyl,
preferably phenyl, 25 to 40 wt % of a bisphenol A
homopolycarbonate; and 2 to 20 ppm or 4 to 10 ppm or 4 to 8 ppm of
an organosulfonic stabilizer comprising p-toluenesulfonic acid, a
C.sub.1-30 alkyl ester of p-toluenesulfonic acid or a combination
thereof, and more preferably butyl tosylate; wherein the
thermoplastic composition has 25 mol % to 49 mol % or 30 to 40 mol
% of second carbonate units based on the sum of the moles of the
copolycarbonate and the bisphenol A homopolycarbonate.
Embodiment 18
[0157] The thermoplastic composition of any one or more of
embodiments 1 to 15, comprising, based on the total weight of the
thermoplastic composition: 96 to 99.9 wt % of a copolycarbonate
comprising bisphenol A carbonate units and second carbonate units
of the formula (1a) wherein R.sup.5 is hydrogen, phenyl or methyl,
preferably phenyl; and 2 to 20 ppm or 4 to 10 ppm, or 4 to 8 ppm of
an organosulfonic stabilizer comprising a C.sub.1-30 alkyl ester of
p-toluenesulfonic acid, and more preferably butyl tosylate; wherein
the thermoplastic composition has 25 mol % to 49 mol %, or 30 to 40
mol % of second carbonate units based on the moles of the
copolycarbonate.
Embodiment 19
[0158] The thermoplastic composition of any one or more of
embodiments 1 to 18, further comprising a processing aid, a heat
stabilizer, an ultraviolet light absorber, a colorant, a flame
retardant, an impact modifier, an epoxy containing polymer, or a
combination thereof.
Embodiment 20
[0159] The thermoplastic composition of any one or more of
embodiments 1 to 19, wherein the thermoplastic composition has one
or more of the following properties: a heat deflection temperature
of 160.degree. C. or higher as measured on a 80.times.10.times.4 mm
bar with a 64 mm span at 0.45 MPa according to ISO 75/Bf; a haze of
less than 1.5%, or less than 1.0% and a total transmission greater
than 86% or greater than 88%, each measured according to ASTM
D1003-00 on a molded plaque with a 1.0 mm thickness; a haze of less
than 1.5, or less than 1.0 and a total transmission greater than
84% or greater than 86%, each measured according to ASTM D1003-00
on a molded plaque with a 3.0 mm thickness; a transmission at
wavelength of 400 nm of greater than 75%, or greater than 80% or
greater than 85% measured with Perkin Elmer 950 spectrometer
equipped with 15 cm integrated sphere on a molded plaque with a
thickness of 1 mm; a transmission at wavelength of 550 nm of
greater than 85%, or greater than 87% or greater than 88% measured
with Perkin Elmer 950 spectrometer equipped with 15 cm integrated
sphere on a molded plaque with a thickness of 1 mm; a transmission
at wavelength of 940 nm of greater than 88%, or greater than 89% or
greater than 90% measured with Perkin Elmer 950 spectrometer
equipped with 15 cm integrated sphere on a molded plaque with a
thickness of 1 mm; a refractive index of greater than 1.59 or
greater than 1.60 at 587.6 nm or a refractive index of greater than
1.57 or greater than 1.58 at 940 nm measured according to ISO 489
on a molded plaque with a thickness of 1 mm; an Abbe number of less
than 32 or less than 30 measured according to ISO 489 on a molded
plaque with a thickness of 1 mm; melt volume flow rate (MVR)
greater than 10 cc/min, measured at 330.degree. C./2.16 Kg at 360
second dwell according to ISO 1133; an Izod notched impact energy
of at least 6 kJ/m.sup.2, or of at least 8 kJ/m.sup.2, as measured
at 23.degree. C. according to ISO 180/1A using a multipurpose test
specimen in accordance with ISO 3167 TYPE A; an Izod notched impact
energy of at least 70 J/m, or of at least 88 J/m, as measured at
23.degree. C. according to ASTM D256; an increase in yellowness
index of less than 10, or of less than 8 after 500 hours of heat
aging at 155.degree. C., as measured by ASTM D1925 on a 2.5 mm
thick molded plaque; an increase in yellowness index of less than
10, or of less than 8 during 1000 hours of heat aging at
155.degree. C., as measured by ASTM D1925 on a 1.0 mm thick molded
plaque; an increase in yellowness index of less than 6, or of less
than 5 during 1500 hours of heat aging at 140.degree. C., as
measured by ASTM D1925 on a 1.0 mm thick molded plaque; an increase
in yellowness index of less than 0.5, or of less than 0.3 after 100
hours of hydroaging at 121.degree. C. in an autoclave, as measured
by ASTM D1925 on a 2.5 mm thick molded plaque; a UL94-V0 rating at
a thickness of 2.5 mm or higher; or a UL94-V2 rating at a thickness
of 0.8 mm to 1.5 mm.
Embodiment 21
[0160] The composition of any one or more of embodiments 1 to 20,
wherein the copolycarbonate has a hydroxyl end group content of
less than 200 ppm and the optional bisphenol A homopolycarbonate
has a hydroxyl end group content of less than 150 ppm.
Embodiment 22
[0161] The composition of any one or more of embodiments 1 to 21,
wherein the optional bisphenol A homopolycarbonate has a sulfur
content of less than 2 ppm, or the copolycarbonate, the optional
bisphenol A homopolycarbonate, or both are derived from a bisphenol
A having a sulfur content of less than 2 ppm, each as measured by a
Total Sulfur Analysis based on combustion and coulometric
detection, or the optional bisphenol A homopolycarbonate.
Embodiment 23
[0162] An article comprising the copolymer or composition of any
one or more of embodiments 1 to 18, wherein the article is a molded
article, a thermoformed article, an extruded layer, a layer of a
multi-layer article, a substrate for a coated article, or a
substrate for a metallized article.
Embodiment 24
[0163] The article of embodiment 23, wherein the article has no
significant part distortion or discoloration when the article is
subjected to a secondary operation comprising over-molding,
lead-free soldering, wave soldering, low temperature soldering,
wave soldering, coating with a high-temperature cure, or a
combination thereof.
Embodiment 25
[0164] The article of any one or more of embodiments 21 to 23,
wherein the article is a lens, a light guide, a waveguide, a
collimator, an optical fiber, a window, a door, a visor, a display
screen, an electronic device, a scientific or medical device, a
safety shield, a fire shield, wire or cable sheathing, a mold, a
dish, a tray, a screen, an enclosure, glazing, packaging, a gas
barrier, an anti-fog layer, or an anti-reflective layer.
Embodiment 26
[0165] The article of any one or more of embodiments 21 to 23,
wherein the article is a component of a device comprising a lens, a
device comprising a light guide, a device comprising a waveguide, a
device comprising a collimator, a device comprising an optical
fiber, a device comprising a lighting element, a device comprising
a window, a device comprising a door, or the article is a
structural component of a vehicle, a building, or an appliance, or
the article is a component of a medical device, a component of a
display screen, a component of an electronic device, a component of
a safety device, a component of a screen, a component of conveyor,
a component of a mold, a component of a dish, a component of an
enclosure, a component of packaging, a component of a gas barrier,
a component of an encapsulant, a component of a label, a component
of a gas barrier, a component of an anti-fog assembly, or a
component of an anti-reflective assembly.
[0166] The singular forms "a," "an," and "the" include plural
referents unless the context clearly dictates otherwise. "Or" means
"and/or." The endpoints of all ranges directed to the same
component or property are inclusive and independently combinable.
Unless defined otherwise, technical and scientific terms used
herein have the same meaning as is commonly understood by one of
skill in the art to which this invention belongs. As used herein, a
"combination" is inclusive of blends, mixtures, alloys, reaction
products, and the like. A "combination thereof" includes any
combination comprising at least one of the listed components or
properties optionally together with a like component or property
not listed.
[0167] Compounds are described using standard nomenclature. For
example, any position not substituted by any indicated group is
understood to have its valency filled by a bond as indicated, or a
hydrogen atom. A dash ("-") that is not between two letters or
symbols is used to indicate a point of attachment for a
substituent. For example, --CHO is attached through carbon of the
carbonyl group.
[0168] As used herein, the term "hydrocarbyl" and "hydrocarbon"
refers broadly to a substituent comprising carbon and hydrogen,
optionally with 1 to 3 heteroatoms, for example, oxygen, nitrogen,
halogen, silicon, sulfur, or a combination thereof; "alkyl" refers
to a straight or branched chain, saturated monovalent hydrocarbon
group; "alkylene" refers to a straight or branched chain,
saturated, divalent hydrocarbon group; "alkylidene" refers to a
straight or branched chain, saturated divalent hydrocarbon group,
with both valences on a single common carbon atom; "alkenyl" refers
to a straight or branched chain monovalent hydrocarbon group having
at least two carbons joined by a carbon-carbon double bond; "aryl"
refers to an aromatic monovalent group containing only carbon in
the aromatic ring or rings; "arylene" refers to an aromatic
divalent group containing only carbon in the aromatic ring or
rings; "alkylarylene" refers to an aryl group that has been
substituted with an alkyl group as defined above, with
4-methylphenyl being an exemplary alkylarylene group;
"arylalkylene" refers to an alkyl group that has been substituted
with an aryl group as defined above, with benzyl being an exemplary
arylalkylene group.
[0169] Unless otherwise indicated, each of the foregoing groups can
be unsubstituted or substituted, provided that the substitution
does not significantly adversely affect synthesis, stability, or
use of the compound. The term "substituted" as used herein means
that at least one hydrogen on the designated atom or group is
replaced with another group, provided that the designated atom's
normal valence is not exceeded. When the substituent is oxo (i.e.,
.dbd.O), then two hydrogens on the atom are replaced. Combinations
of substituents and/or variables are permissible provided that the
substitutions do not significantly adversely affect synthesis or
use of the compound. Groups that can be present on a substituted
position include (--NO.sub.2), cyano (--CN), halogen, thiocyano
(--SCN), C.sub.2-6 alkanoyl (e.g., acyl (H.sub.3CC(.dbd.O)--);
carboxamido; C.sub.1-6 or C.sub.1-3 alkyl, cycloalkyl, alkenyl, and
alkynyl; C.sub.1-6 or C.sub.1-3 alkoxy; C.sub.6-10 aryloxy such as
phenoxy; C.sub.1-6 alkylthio; C.sub.1-6 or C.sub.1-3 alkylsulfinyl;
C.sub.1-6 or C.sub.1-3 alkylsulfonyl; C.sub.6-12 aryl having at
least one aromatic rings (e.g., phenyl, biphenyl, naphthyl, or the
like, each ring either substituted or unsubstituted aromatic);
C.sub.7-19 arylalkylene having 1 to 3 separate or fused rings and 6
to 18 ring carbon atoms; or arylalkoxy having 1 to 3 separate or
fused rings and 6 to 18 ring carbon atoms. The stated number of
carbon atoms includes any substituents.
[0170] All references cited herein are incorporated by reference in
their entirety. While typical embodiments have been set forth for
the purpose of illustration, the foregoing descriptions should not
be deemed to be a limitation on the scope herein. Accordingly,
various modifications, adaptations, and alternatives can occur to
one skilled in the art without departing from the spirit and scope
herein.
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