Polycarbonate compositions having enhanced optical properties, methods of making and articles comprising the polycarbonate compositions

• US 9,957,351 B2
• Filed: 02/29/2016
• Issued: 05/01/2018
• Est. Priority Date: 08/05/2011
• Status: Active Grant

• Current Assignee: SABIC Global Technologies BV (Government of Saudi Arabia)
• Original Assignee: SABIC Global Technologies BV (Government of Saudi Arabia)
• Inventors: de Brouwer, Johannes, Eijsbouts, Paulus Johannes Maria, Belfadhel, Hatem Abdallah, van den Bogerd, Jos Arie
• Primary Examiner(s): Yoon, Tae H
• Application Number:
  US15/055,916
• Publication Number:
  US 20160289377A1
• Time in Patent Office: 792 Days
• Field of Search: None
• CPC Class Codes: C08G 64/06 not containing aliphatic unsaturation
• CPC Class Codes: C08G 64/24 and phenols
• CPC Class Codes: C08G 64/28 and phenols
• CPC Class Codes: C08J 2369/00 Characterised by the use of polycarbonates; Derivatives of polycarbonates
• CPC Class Codes: C08J 5/18 Manufacture of films or sheets
• CPC Class Codes: C08L 69/00 Compositions of polycarbonates; Compositions of derivatives of polycarbonates
• CPC Class Codes: H01L 33/56 Materials, e.g. epoxy or silicone resin

Abstract

In some embodiments, a method of making a polycarbonate composition comprises: polymerizing by an interfacial polymerization, reactants comprising a starting material comprising a bisphenol-A to form a bisphenol-A polycarbonate, wherein the bisphenol-A has a purity of greater than or equal to 99.65 wt % and a sulfur content of less than or equal to 2 ppm. The polycarbonate composition has a free hydroxyl content of less than or equal to 150 ppm, and wherein a molded article of the polycarbonate composition has transmission level greater than or equal to 90.0% at 2.5 mm thickness as measured by ASTM D1003-00 and a yellow index (YI) less than or equal to 1.5 as measured by ASTM D1925.

Claims

1. A method of making a polycarbonate composition comprising:

polymerizing by an interfacial polymerization, reactants comprising a starting material comprising a bisphenol-A to form a bisphenol-A polycarbonate, wherein the bisphenol-A has a purity of greater than or equal to 99.65 wt % and a sulfur content of less than or equal to 2 ppm;

wherein the polycarbonate composition has a free hydroxyl content of less than or equal to 150 ppm, and wherein a molded article of the polycarbonate composition has transmission level greater than or equal to 90.0% at 2.5 mm thickness as measured by ASTM D1003-00 and a yellow index (YI) less than or equal to 1.5 as measured by ASTM D1925, and wherein the molded article comprises an increase in yellow index (YI) of less than 2 during 2,000 hours of heat aging at 130°

C.

2. The method as in claim 1, comprising dissolving a reactant in an aqueous caustic material, adding the resultant mixture to a solvent medium, and contacting the reactants with a carbonate precursor in presence of a catalyst.

3. The method as in claim 1, further comprising adding an end-capping agent.

4. The method as in claim 3, wherein the end-capping agent comprises at least one of the following:

phenol or a phenol containing one or more substitutions with at least one of the following;

aliphatic groups, olefinic groups, aromatic groups, halogens, ester groups, and ether groups.

5. The method as in claim 4, wherein the end-capping agent comprises at least one of the following:

phenol, p-t-butylphenol, and p-cumylphenol.

6. The method as in claim 1, wherein the method excludes use of a melt polymerization process to make the polycarbonate.

7. The method of claim 1, wherein the bisphenol-A polycarbonate is a homopolycarbonate derived from bisphenol-A.

8. The method of claim 7, wherein the bisphenol-A polycarbonate is a linear homopolycarbonate derived from bisphenol-A.

9. The method of claim 1, further comprising adding a second polycarbonate derived from bisphenol-A polycarbonate, wherein the second polycarbonate is different than the bisphenol-A polycarbonate.