Compositions and articles of manufacture containing branched polycarbonate

{
  "publication_number": "US9896581B2",
  "country": "US",
  "kind": "B2",
  "title": "Compositions and articles of manufacture containing branched polycarbonate",
  "abstract": "A polycarbonate containing composition comprising a peak melt viscosity of at least 8,000 poise when measured using a parallel plate melt rheology test at a heating rate of 10° C./min at a temperature of between about 350° C. to about 450° C., and wherein a molded article of the composition has a UL 94 V0 rating at a thickness of 1.0 mm, 1.5 mm, 2.0 mm, or between 1.0 mm and 2.0 mm is disclosed.",
  "claims": [
    "1. A composition comprising: a polycarbonate of the following formula wherein at least 60 percent of the total number of R 1 groups contain aromatic groups and the balance thereof are aliphatic or alicyclic groups; wherein the polycarbonate was formed in the presence of an end-capping agent and the end-capping agent is not cyanophenol; wherein the polycarbonate has a branching level of at least about 2%; wherein the polycarbonate has a weight average molecular weight of between about 20,000 g/mole to 54,843 g/mole as measured by gel permeation chromatography using polycarbonate standards; and wherein the polycarbonate has a peak melt viscosity of at least 25,000 poise when measured using a parallel plate melt rheology test at a heating rate of 10° C./min at a temperature of between about 350° C. to about 450° C. at a frequency of 3 rad/s and strain amplitude of 9%; and a flame retardant; and a thermoplastic polymer that is different than the polycarbonate; wherein a molded article of the polycarbonate and the flame retardant has a UL94 V0 rating at a thickness of 1.0 mm; and wherein a molded article of the composition has a UL94 V0 rating at a thickness of 1.5 mm.",
    "2. The composition of claim 1, wherein the polycarbonate has a weight average molecular weight of between about 20,000 g/mole to about 40,000 g/mole as measured by gel permeation chromatography using polycarbonate standards.",
    "3. The composition of claim 1, wherein the end-capping agent has a pKa between about 8.3 and about 11.",
    "4. The composition of claim 1, wherein the end-capping agent is selected from at least one of the following: a phenol and a phenol containing one or more substitutions with at least one of the following: an aliphatic group, an olefinic group, an aromatic group, a halogen, an ester group, and an ether group.",
    "5. The composition of claim 1, wherein the end-capping agent is selected from at least one of the following: phenol, p-t-butylphenol, and p-cumylphenol.",
    "6. The composition of claim 1, wherein the polycarbonate of said composition has a branching level of at least about 3%.",
    "7. The composition of claim 1, wherein the flame retardant comprises at least one of the following: alkali metal salts of perfluorinated C 1-16 alkyl sulfonates; potassium perfluorobutane sulfonate; potassium perfluoroctane sulfonate; tetraethylammonium perfluorohexane sulfonate; and potassium diphenylsulfone sulfonate.",
    "8. The composition of claim 1, wherein the thermoplastic polymer is a second polycarbonate comprising a repeating structure of wherein the second polycarbonate is different from said polycarbonate, and wherein at least 60 percent of the total number of R 1 groups contain aromatic groups and the balance thereof are aliphatic or alicyclic groups; and wherein at least a portion of the R 1 groups are derived from bisphenol-A.",
    "9. The composition of claim 1, wherein the composition has a haze value of less than 1.5% at 3.2 mm thickness by ASTM D1003.",
    "10. The composition of claim 1, wherein the polycarbonate is derived from bisphenol-A.",
    "11. The composition of claim 1, wherein the thermoplastic polymer is a second polycarbonate derived from bisphenol-A.",
    "12. The composition of claim 1, wherein the polycarbonate is selected from at least one of the following: a homopolycarbonate derived from a bisphenol; a copolycarbonate derived from more than one bisphenol; and a copolymer derived from one or more bisphenols and comprising one or more aliphatic ester units, aromatic ester units, and siloxane units.",
    "13. The composition of claim 1, wherein the thermoplastic polymer comprises at least one of polyester, polyamide, polysiloxane, polycarbonate, and a copolymer comprising at least one of the foregoing.",
    "14. The composition of claim 1, wherein the thermoplastic polymer is a polycarbonate copolymer selected from polycarbonate-polysiloxane copolymers, and polyester-polycarbonates.",
    "15. The composition of claim 1, wherein the thermoplastic polymer comprises copolycarbonate-polyester-polysiloxane terpolymer.",
    "16. An article comprising the composition of claim 1.",
    "17. A composition comprising: a first polycarbonate of the following formula wherein at least 60 percent of the total number of R 1 groups contain aromatic groups and the balance thereof are aliphatic or alicyclic groups; wherein the first polycarbonate was formed in the presence of an end-capping agent and the end-capping agent is not cyanophenol; wherein the first polycarbonate has a branching level of at least about 2%; wherein the first polycarbonate has a weight average molecular weight of 20,000 g/mole to 54,843 g/mole as measured by gel permeation chromatography using polycarbonate standards; and wherein the first polycarbonate has a peak melt viscosity of at least 8,000 poise when measured using a parallel plate melt rheology test at a heating rate of 10° C./min at a temperature of between about 350° C. to about 450° C. at a frequency of 3 rad/s and strain amplitude of 9%; and a flame retardant; and a second polycarbonate derived from at least bisphenol-A, wherein the second polycarbonate is different from the first polycarbonate; wherein a molded article of the polycarbonate and the flame retardant has a UL94 V0 rating at a thickness of 1.0 mm; and wherein a molded article of the composition has a UL94 V0 rating at a thickness of 1.5 mm.",
    "18. The composition of claim 17, wherein the peak melt viscosity is at least 22,960 poise.",
    "19. The composition of claim 17, wherein the first polycarbonate of said composition has a branching level of at least about 3%."
  ],
  "description_excerpt": "This disclosure relates to polycarbonate compositions and in particular to endcapped polycarbonate compositions, methods of manufacture, and uses thereof.\n\nPolycarbonate is a high-performance plastic with good impact strength (ductility). However, polycarbonate often has relatively limited flow properties, which is needed in the manufacture of thin walled articles. Medium to high flow polycarbonate grades suffer from the fact that the low temperature ductility is sacrificed for a better flow. Furthermore, polycarbonate compositions often require the use of flame-retardants to find successful use in the manufacture of a variety of articles and components.\n\nThere accordingly remains a need in the art for high flow polycarbonate compositions and articles made from them that are transparent and flame retardant to levels acceptable by industry and in particular for thin-walled 25,000 poise applications, e.g. molded articles with 1.5 mm thickness.\n\nThe present invention provides for a composition comprising: a polycarbonate, wherein the polycarbonate comprises a repeating structural backbone of the following formula\n\nwherein at least 60 percent of the total number of R 1 groups contain aromatic groups and the balance thereof are aliphatic or alicyclic groups; wherein the polycarbonate was formed in the presence of an end-capping agent and the end-capping agent is not cyanophenol; wherein the polycarbonate has a branching level of at least about 2%; and wherein the polycarbonate ...",
  "cpc": [
    "C08L 69/00",
    "C08G 64/14",
    "C08J 5/00",
    "C08K 5/0066",
    "C08K 5/13",
    "C08K 5/42",
    "C08K 5/549",
    "C08L 2201/02",
    "C08L 2201/10",
    "C08L 2205/025"
  ],
  "ipc": [
    "C08L 69/00",
    "C08G 64/14"
  ],
  "assignees": [
    "SABIC Global Technologies BV"
  ],
  "inventors": [
    "Jean-Francois Morizur",
    "Thomas L. Evans"
  ],
  "filing_date": "2016-02-26",
  "publication_date": "2018-02-20",
  "grant_date": "2018-02-20",
  "priority_date": "2010-11-14",
  "application_number": "US-201615054172-A",
  "family_id": "45003093",
  "cited_by_count": 10,
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}