POLYCARBONATE ALLOY AND PREPARATION METHOD THEREOF AND APPLICATION

Abstract

The present invention provides a polycarbonate alloy including the following components in parts by weight: 50 parts to 80 parts of a polycarbonate; 1 part to 50 parts of a crystalline polyester; 0.01 part to 4 parts of a maleic anhydride polymer; and 0.01 part to 4 parts of a metal phosphate. The polycarbonate alloy of the present invention has advantages of good alloy stability, and a continuous and uniform distribution of the crystalline polyester in the alloy.

Claims

1. A polycarbonate alloy, comprising the following components in parts by weight: a polycarbonate of 50 parts to 80 parts; a crystalline polyester of 1 part to 50 parts; a maleic anhydride polymer of 0.01 part to 4 parts; and a metal phosphate of 0.01 part to 4 parts.

2. The polycarbonate alloy according to claim 1, comprising the following components in parts by weight: the polycarbonate of 50 parts to 80 parts; the crystalline polyester of 1 part to 50 parts; the maleic anhydride polymer of 0.1 part to 2 parts; and the metal phosphate of 0.1 part to 2 parts.

3. The polycarbonate alloy according to claim 1, wherein the crystalline polyester is selected from at least one of polyethylene terephthalate, poly(ethylene terephthalate-co-ethylene adipate), polybutylene terephthalate, polypropylene terephthalate, polycyclohexylene dimethylene terephthalate, polytrimethylene terephthalate, poly(1,4-cyclohexylene dimethylene terephthalate-co-isophthalate), glycol-modified polycyclohexylene dimethylene terephthalate, and glycol-modified polyethylene terephthalate.

4. The polycarbonate alloy according to claim 1, wherein the maleic anhydride polymer is a maleic anhydride graft polymer with a grafting ratio of 3% to 25%.

5. The polycarbonate alloy according to claim 1, wherein the metal phosphate is selected from at least one of sodium phosphate, sodium hydrogen phosphate, sodium dihydrogen phosphate, disodium dihydrogen pyrophosphate, zinc phosphate, calcium phosphate, zinc hydrogen phosphate, and zinc dihydrogen phosphate.

6. The polycarbonate alloy according to claim 1, wherein a weight ratio of the maleic anhydride polymer to the metal phosphate is 3:1 to 1:2.

7. The polycarbonate alloy according to claim 1, wherein in parts by weight, the polycarbonate alloy further comprises 0 part to 20 parts of a flame retardant; the flame retardant is selected from a compound of a brominated flame retardant and a flame-retardant synergist; the brominated flame retardant is selected from at least one of octabromoether, decabromodiphenyl ethane, brominated epoxy, brominated polystyrene, brominated triazine, brominated polycarbon, and tetrabromobisphenol A; the flame-retardant synergist is selected from at least one of an antimony compound-containing flame-retardant synergist and a metal borate; and in parts by weight, the polycarbonate alloy further comprises 0 part to 10 parts of an anti-dripping agent.

8. The polycarbonate alloy according to claim 1, wherein in parts by weight, the polycarbonate alloy further comprises 0 part to 10 parts of an auxiliary agent; and the auxiliary agent is selected from at least one of an antioxidant, a lubricant, and a weather-resistant agent.

9. A preparation method of the polycarbonate alloy according to claim 1, comprising the following steps: adding the polycarbonate, the crystalline polyester, the maleic anhydride polymer and the metal phosphate according to a ratio into a high-speed mixer to mix evenly, and then adding into a twin-screw extruder for extrusion and granulation, with a screw temperature being 220° C. to 250° C., to obtain the polycarbonate alloy.

10. The flame-retardant HIPS material according to claim 8, wherein a test method of the nitrogen element weight content is: adopting a Kjeldahl nitrogen determination method, adding 1.0 mL of a protein solution with an appropriate concentration in a flask, adding an analysis sample to a bottom of the flask, adding 0.3 g of potassium sulfate-copper sulfate, 2.0 mL of concentrated sulfuric acid, and 1.0 mL of 30.0% hydrogen peroxide in sequence, bringing to boil over low heat until the substance in the flask becomes carbonized and blackened, performing distillation and absorption of an inorganic nitrogen standard sample, performing distillation and absorption of a sample to be tested and a blank sample, after the samples are processed, performing a titration with 0.0100 mol/L of a standard hydrochloric acid solution by using an acid microburette, recording a number of milliliter of the standard hydrochloric acid solution for each titration, and finally calculating the nitrogen element content of the sample to be tested.

11. The polycarbonate alloy according to claim 2, wherein the crystalline polyester is selected from at least one of polyethylene terephthalate, poly(ethylene terephthalate-co-ethylene adipate), polybutylene terephthalate, polypropylene terephthalate, polycyclohexylene dimethylene terephthalate, polytrimethylene terephthalate, poly(1,4-cyclohexylene dimethylene terephthalate-co-isophthalate), glycol-modified polycyclohexylene dimethylene terephthalate, and glycol-modified polyethylene terephthalate.

12. The polycarbonate alloy according to claim 2, wherein the maleic anhydride polymer is a maleic anhydride graft polymer with a grafting ratio of 3% to 25%.

13. The polycarbonate alloy according to claim 2, wherein the metal phosphate is selected from at least one of sodium phosphate, sodium hydrogen phosphate, sodium dihydrogen phosphate, disodium dihydrogen pyrophosphate, zinc phosphate, calcium phosphate, zinc hydrogen phosphate, and zinc dihydrogen phosphate.

14. The polycarbonate alloy according to claim 2, wherein a weight ratio of the maleic anhydride polymer to the metal phosphate is 3:1 to 1:2.

15. The polycarbonate alloy according to claim 2, wherein in parts by weight, the polycarbonate alloy further comprises 0 part to 20 parts of a flame retardant; the flame retardant is selected from a compound of a brominated flame retardant and a flame-retardant synergist; the brominated flame retardant is selected from at least one of octabromoether, decabromodiphenyl ethane, brominated epoxy, brominated polystyrene, brominated triazine, brominated polycarbon, and tetrabromobisphenol A; the flame-retardant synergist is selected from at least one of an antimony compound-containing flame-retardant synergist and a metal borate; and in parts by weight, the polycarbonate alloy further comprises 0 part to 10 parts of an anti-dripping agent.

16. The polycarbonate alloy according to claim 2, wherein in parts by weight, the polycarbonate alloy further comprises 0 part to 10 parts of an auxiliary agent; and the auxiliary agent is selected from at least one of an antioxidant, a lubricant, and a weather-resistant agent.

17. A preparation method of the polycarbonate alloy according to claim 2, comprising the following steps: adding the polycarbonate, the crystalline polyester, the maleic anhydride polymer and the metal phosphate according to a ratio into a high-speed mixer to mix evenly, and then adding into a twin-screw extruder for extrusion and granulation, with a screw temperature being 220° C. to 250° C., to obtain the polycarbonate alloy.

18. The polycarbonate alloy according to claim 4, wherein the grafting ratio is 5% to 13%.

19. The polycarbonate alloy according to claim 12, wherein the grafting ratio is 5% to 13%.

Description

DESCRIPTION OF THE EMBODIMENTS

[0028] The present invention is further described by the following embodiments, but the present invention is not limited by the following embodiments.

[0029] Sources of raw materials used in the present invention are as follows, but are not limited by the following raw materials.

[0030] PBT: polybutylene terephthalate, a crystalline polyester;

PET: polyethylene terephthalate, a crystalline polyester;
maleic anhydride polymer A: a grafting ratio 5% to 6%, a backbone polyethylene;
maleic anhydride polymer B: a grafting ratio 5% to 6%, a backbone polypropylene;
maleic anhydride polymer C: a grafting ratio 11% to 13%, a backbone polyethylene;
maleic anhydride polymer D: a grafting ratio 3% to 4%, a backbone polyethylene;
maleic anhydride polymer E: a grafting ratio 15% to 17%, a backbone polyethylene;
maleic anhydride polymer F: a grafting ratio 0.8% to 1%, a backbone polyethylene;
pigment: red 8206.

[0031] A preparation method of a polycarbonate alloy: a polycarbonate, a crystalline polyester, a maleic anhydride polymer and a metal phosphate were added according to a ratio into a high-speed mixer to mix evenly, and then were added into a twin-screw extruder for extrusion and granulation, with a screw temperature being 220° C. to 250° C., to obtain the polycarbonate alloy.

[0032] Testing methods for each performance: (1) Dyeing performance test (dyeing uniformity): color quality evaluation: color uniformity of an injection template (2.0 mm) is compared in a same coloring agent system, and a comparison is performed visually. If the color on the template turns uniform, it is judged as excellent; if there are heterochromatic spots on four corners of the injection template, it indicates as general; and if there are long-strip shaped continuous heterochromatic spots on the four corners and a center of the injection template, it indicates not up to standard.

[0033] (2) Thermal retention fluidity: after 20 minutes of retention time in a screw barrel with a preset injection temperature being 250° C., and after 20 g of a melt is extruded through a backpressure, a melt index test is performed under a load of 5 kg at 250° C. according to ISO1133 standard. By comparison with calculation results of a normal test process of ISO1133, the greater the increase in the melt index is, the greater the thermal retention fluidity is and the worse the melt stability is.

[0034] (3) Flame-retardant class: UL94 standard.

TABLE-US-00004 TABLE 1 Ratios (parts by weight) of each component and each performance test results of Embodiments 1 to 10 Embodiment Embodiment Embodiment Embodiment Embodiment 1 2 3 4 5 PC 70 70 70 70 70 PBT 30 30 30 30 30 PET — — — — — Maleic 0.01 0.1 0.15 2 4 anhydride polymer A Sodium 0.01 0.1 0.15 2 4 phosphate Lubricant 0.3 0.3 0.3 0.3 0.3 Antioxidant 0.1 0.1 0.1 0.1 0.1 Pigment 0.4 0.4 0.4 0.4 0.4 Dyeing A few Uniform Uniform Uniform A few uniformity heterochromatic color color color heterochromatic spots spots Thermal 2.1 1.5 1.2 0.8 0.5 retention fluidity, % Embodiment Embodiment Embodiment Embodiment Embodiment 6 7 8 9 10 PC 70 70 70 70 70 PBT 30 30 30 30 — PET — — — — 30 Maleic 0.5 0.45 0.2 0.15 0.15 anhydride polymer A Sodium 0.1 0.15 0.4 0.45 0.15 phosphate Lubricant 0.3 0.3 0.3 0.3 0.3 Antioxidant 0.1 0.1 0.1 0.1 0.1 Pigment 0.4 0.4 0.4 0.4 0.4 Dyeing A few Uniform Uniform A few Uniform uniformity heterochromatic color color heterochromatic color spots spots Thermal 3.6 2.4 3.3 3.8 1.9 retention fluidity, %

TABLE-US-00005 TABLE 2 Ratios (parts by weight) of each component and each performance test results of Embodiments 11 to 16 Embodiment Embodiment Embodiment Embodiment Embodiment Embodiment 11 12 13 14 15 16 PC 70   70   70   70   70 70 PBT 30   30   30   30   30 30 Maleic — — — — — 0.15 anhydride polymer A Maleic  0.15 — — — — — anhydride polymer B Maleic —  0.15 — — — — anhydride polymer C Maleic — —  0.15 — — — anhydride polymer D Maleic — — —  0.15 — — anhydride polymer E Maleic — — — — 0.15 — anhydride polymer F Sodium  0.15  0.15  0.15  0.15 0.15 — phosphate Zinc — — — — — 0.15 phosphate Lubricant 0.3 0.3 0.3 0.3 0.3 0.3 Antioxidant 0.1 0.1 0.1 0.1 0.1 0.1 Color 0.4 0.4 0.4 0.4 0.4 0.4 powder Dyeing Uniform Uniform A few A few A few Uniform uniformity color color hetero- hetero- continuous color chromatic chromatic hetero- spots spots chromatic spots Thermal 1.5 0.9 2.2 0.6 2.6 1.7 retention fluidity, %

TABLE-US-00006 TABLE 3 Ratios (parts by weight) of each component and each performance test results of Embodiment 17 Embodiment 17 PC 70 PBT 30 Maleic anhydride polymer A 0.15 Sodium phosphate 0.15 Tetrabromobisphenol A 10 Diantimony trioxide 2 Lubricant 0.3 Antioxidant 0.1 Color powder 0.4 Dyeing uniformity A few heterochromatic spots Thermal retention fluidity, % 10.1 Flame-retardant class V-0

TABLE-US-00007 TABLE 4 Ratios (parts by weight) of each component and each performance test results of Comparative Examples Comparative Comparative Comparative Comparative Comparative Comparative Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 PC 70   70 70 70 70 70 PBT 30   30 30 30 30 30 Maleic — 0.15 — — 0.15 — anhydride polymer A Sodium  0.15 — — 0.15 — — phosphate Tetrabromo- — — — 10 10 10 bisphenol A Diantimony — — — 2 2 2 trioxide Lubricant 0.3 0.3 0.3 0.3 0.3 0.3 Antioxidant 0.1 0.1 0.1 0.1 0.1 0.1 Color powder 0.4 0.4 0.4 0.4 0.4 0.4 Dyeing Lots of Lots of Lots of Lots of Lots of Lots of uniformity continuous continuous continuous continuous continuous continuous hetero- hetero- hetero- hetero- hetero- hetero- chromatic chromatic chromatic chromatic chromatic chromatic spots spots spots spots spots spots Thermal 30.2  5.3 39.8 15.2 12.3 59.6 retention fluidity, % Flame- — — — V-1 V-1 V-2 retardant class
It can be seen from Embodiments 1 to 5 that in a preferred dosage (0.1 part to 2 parts of the maleic anhydride polymer and 0.1 part to 2 parts of the metal phosphate), the thermal retention fluidity of the alloy is relatively good and simultaneously the dyeing uniformity is good.

[0035] It can be seen from Embodiments 6 to 9 that a ratio of the maleic anhydride polymer to the metal phosphate also has a relatively great influence on alloy stability and dyeing stability. When the weight ratio of the maleic anhydride polymer to the metal phosphate is 3:1 to 1:2, the alloy stability is relatively good and the dyeing uniformity is also relatively good.

[0036] It can be seen from Embodiment 3 and Embodiments 12 to 15 that when the grafting ratio is within a range of 5% to 13%, overall alloy stability is the best and the dyeing uniformity is also the best. Generally in a thermoplastic resin, the grafting ratio of the maleic anhydride graft polypropylene as a compatilizer is only 0.8% to 1%, each performance of the product is relatively poor, and especially the dyeing uniformity is general. It can be seen from Embodiment 14 that the higher the grafting ratio is, the better the thermal retention fluidity is, but when the grafting ratio is greater than 13%, the dyeing uniformity is decreased instead.

[0037] It can be seen from Embodiment 3 or 17 and Comparative Example 4 or 5 or 6 that a bromine antimony flame-retardant system will seriously reduce the alloy stability and combustion uniformity of the alloy, an addition of the maleic anhydride polymer and the metal phosphate can effectively reduce an effect of the bromine antimony flame-retardant system on alloy performances, and also ensure flame-retardant stability.

[0038] It can be seen from Comparative Examples that only a compounding use of the maleic anhydride polymer and the metal phosphate can have advantages of well improving the alloy stability and the dyeing uniformity. When the maleic anhydride polymer or the metal phosphate is added solely, overall performance is poor, which is difficult to satisfy the use.