WEATHERABLE TRANSPARENT HIGH HEAT POLYCARBONATE COPOLYMER COMPOSITION

• US 20200131362A1
• Filed: 10/28/2019
• Published: 04/30/2020
• Est. Priority Date: 10/29/2018
• Status: Active Grant

• Current Assignee: SHPP Global Technologies BV (Government of Saudi Arabia)
• Original Assignee: SABIC Global Technologies BV (Government of Saudi Arabia)
• Inventors: VAN DER MEE, MARK ADRIANUS JOHANNES, ASSINK, ROLAND SEBASTIAN, VAN HEERBEEK, HENDRIKUS PETRUS CORNELIS
• Granted Patent: US 11,572,468 B2
• Time in Patent Office: Days
• CPC Class Codes: C08K 5/005 Stabilisers against oxidation, heat, light, ozone
• CPC Class Codes: C08K 5/42 Sulfonic acids; Derivatives thereof
• CPC Class Codes: C08K 5/521 Esters of phosphoric acids, e.g. of H3PO4
• CPC Class Codes: C08K 5/524 Esters of phosphorous acids, e.g. of H3PO3
• CPC Class Codes: C08L 69/00 Compositions of polycarbonates; Compositions of derivatives of polycarbonates
• CPC Class Codes: C08L 69/005 Polyester-carbonates
• CPC Class Codes: G02B 1/111 using layers comprising organic materials
• CPC Class Codes: G02B 1/14 Protective coatings, e.g. hard coatings

Abstract

A thermoplastic composition comprising: a copolycarbonate comprising bisphenol A (BPA) carbonate units and 10-50 mol % of second carbonate units different from the BPA carbonate units; a poly(carbonate-arylate ester) copolymer comprising BPA carbonate units and 5-50 mol % of monoaryl arylate ester units; and optionally a BPA homopolycarbonate; wherein the thermoplastic composition has at least one of: a Vicat B120 softening temperature of 155° C. or greater; or a yellowness index of less than 10 on a plaque having a thickness of 3 mm and molded at a temperature of 360° C. for 5 minutes; or an increase in yellowness index of less than 5 after 600 hours of weathering per ISO 11341 on a molded plaque having a thickness of 1 mm.

Claims

1. A thermoplastic composition comprising:

a copolycarbonate comprising bisphenol A carbonate units and second carbonate units different from the bisphenol A carbonate units, wherein the second carbonate units are present in an amount of 10-50 mol %, based on a sum of moles of bisphenol A carbonate units and second carbonate units;

a poly(carbonate-arylate ester) copolymer comprising bisphenol A carbonate units and monoaryl arylate ester units, wherein the monoaryl arylate ester units are present in an amount of 5-50 mol %, based on the sum of moles of bisphenol A carbonate units and monoaryl arylate ester units; and

optionally a bisphenol A homopolycarbonate;

wherein the thermoplastic composition has one or more of;

a Vicat B120 softening temperature of 155°

C. or greater, as measured according to ISO 306; and

a yellowness index of less than 10, as measured according to ASTM D1925 on a plaque having a thickness of 3 mm and molded at a temperature of 360°

C. for a residence time of 5 minutes; and

an increase in yellowness index of less than 5, after 600 hours of weathering in accordance with ISO 11341 on a molded plaque having a thickness of 1 mm.

2. The composition of claim 1, wherein the thermoplastic composition comprises:

10-85 wt % of the copolycarbonate; and

10-50 wt % of the poly(carbonate-arylate ester) copolymer,

each based on the total weight of the thermoplastic composition.

3. The thermoplastic composition of claim 1, wherein the second carbonate units are of formula (1):

4. The thermoplastic composition of claim 1, wherein the poly(carbonate-arylate ester) copolymer comprises monoaryl arylate ester units of formula (8):

5. The thermoplastic composition of claim 1, wherein the copolycarbonate further comprises at least 5 mol % of a third carbonate unit different from the bisphenol A carbonate units and the second carbonate units, wherein the third carbonate unit is of formulas (3) to (7):

6. The thermoplastic composition of claim 5, wherein the copolycarbonate comprises 25-70 mol % of the bisphenol A carbonate units, 10-35 mol % of the second carbonate units, and 5-65 mol % 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 poly(carbonate-arylate ester) copolymer further comprises 1-20 mol % of

resorcinol carbonate units of formula (10):

8. The thermoplastic composition of claim 1, further comprising 1 ppm to 20 ppm of an acid stabilizer, wherein the acid stabilizer is a Bronsted acid, a Lewis acid, an acid or an ester thereof containing a sulfur atom, or a combination thereof.

9. The thermoplastic composition of claim 1,

wherein the copolycarbonate comprises less than 2 ppm by weight of each of triethylamine, calcium, magnesium, potassium, iron, nickel, copper, zinc, lithium, sodium, ammonium, trimethylammonium, triethylammonium, chloride, bromide, fluoride, nitrite, nitrate, phosphite, phosphate, sulfate, formate, acetate, citrate, and oxalate, based on the weight of the copolycarbonate as measured by ion chromatography;

and

wherein the copolycarbonate, the optional bisphenol A homopolycarbonate, or both are derived from a bisphenol A having a bisphenol A purity of equal to or greater than 99.6 wt %, as measured by high performance liquid chromatography.

10. The thermoplastic composition of claim 1, wherein the thermoplastic composition has one or more of

a haze of less than 1.5%, as measured according to ASTM D1003-00 on a molded plaque with a thickness of 1.0 mm;

a total transmission of greater than 85%, as measured according to ASTM D1003-00 on a molded plaque with a thickness of 1 mm;

a melt volume flow rate greater than 20 cm³/min, as measured at 330°

C./2.16 Kg at 300 second dwell according to ISO 1133;

a Vicat B120 softening temperature of 160°

C. or higher, as measured according to ISO 306;

an Izod notched impact energy of at least 10 kJ/m², as measured at 23°

C. according to ISO 180/1A;

a yellowness index of less than 20, as measured according to ASTM D1925 on a plaque having a thickness of 1 mm and molded at a temperature of 355°

C. for a residence time of 10 minutes;

an increase in yellowness index of less than 8, after 1,600 hours of heat aging at 140°

C., as measured according to ASTM D1925 on a molded plaque having a thickness of 1 mm;

an increase in yellowness index of less than 20, after 2,000 hours of heat aging at 155°

C., as measured by ASTM D1925 on a molded plaque having a thickness of 1 mm;

an increase in yellowness index of less than 5, after 1,000 hours of weathering at 140°

C., as measure according to ISO 11341 on a molded plaque having a thickness of 1 mm;

or

an increase in yellowness index of less than 8, after 1,600 hours of weathering, as measure according to ISO 11341 on a molded plaque having a thickness of 1 mm.

11. The thermoplastic composition of claim 1,

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;

and

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.

12. An article manufactured from the thermoplastic composition of claim 1.

13. The article of claim 12, further comprising an indicium or a coating disposed on at least a portion of a surface of the article.

14. The article of claim 12, wherein the article is an optical lens, wherein the optical lens is a camera lens, a sensor lens, an illumination lens, a safety glass lens, an ophthalmic corrective lens, or an imaging lens.

15. The article of claim 14, further comprising a macrotexture, a microtexture, a nanotexture, or a combination thereof on a surface of the lens.

16. The article of claim 14, further comprising an indicium or a coating disposed on at least a portion of one or both surfaces of the lens.

17. The article of claim 16, wherein the coating is a hard coat, a UV protective coat, an anti-refractive coat, an anti-reflective coat, a scratch resistant coat, or a combination thereof, or wherein at least a portion of a surface of the optical lens is metallized

18. The thermoplastic composition of claim 1, further comprising 1 to 20 ppm of an acid stabilizer, wherein the acid stabilizer is phosphoric acid, phosphorus acid, hypophosphorous acid, pyrophosphoric acid, polyphosphoric acid, an organosulfonic stabilizer of formula (12):

19. The thermoplastic composition of claim 1, comprising

20-80 wt % of the copolycarbonate, wherein the second carbonate units are present in the amount of 20-45 mol %, based on the sum of moles of bisphenol A carbonate units and second carbonate units, and

15-50 wt % of the poly(carbonate-arylate ester) copolymer, wherein the monoaryl arylate ester units are present in the amount of 10-30 mol %, based on the sum of moles of bisphenol A carbonate units and monoaryl arylate ester units.

20. The thermoplastic composition of claim 1, comprising

30-70 wt % of the copolycarbonate, wherein the second carbonate units are present in the amount of 25-35 mol %, based on the sum of moles of bisphenol A carbonate units and second carbonate units, and

15-45 wt % of the poly(carbonate-arylate ester) copolymer, wherein the monoaryl arylate ester units are present in the amount of 10-30 mol %, based on the sum of moles of bisphenol A carbonate units and monoaryl arylate ester units.