HIGH WELD LINE STRENGTH POLYETHYLENE/POLYCARBONATE ALLOY AND PREPARATION METHOD THEREOF

Abstract

The present invention discloses a high weld line strength polyethylene/polycarbonate alloy, including the following components in parts by weight: 5 parts to 40 parts of a polyethylene; 40 parts to 85 parts of a polycarbonate; and 1 part to 15 parts of an ethylene copolymer compatibilizer. The high weld line strength polyethylene/polycarbonate alloy has the advantages of high weld line strength, a good melt index and a good thermal aging resistance.

Claims

1. A high weld line strength polyethylene/polycarbonate alloy, comprising the following components in parts by weight: 5 parts to 40 parts of a polyethylene, 40 parts to 85 parts of a polycarbonate, and 1 part to 15 parts of an ethylene copolymer compatibilizer.

2. The high weld line strength polyethylene/polycarbonate alloy according to claim 1, wherein the polyethylene is selected from a polyethylene with a branching rate being 5 to 300 branched chains per 1000 carbon atoms, and the branched chain has 1 to 10 carbon atoms.

3. The high weld line strength polyethylene/polycarbonate alloy according to claim 1, wherein the ethylene copolymer compatibilizer is selected from at least one of an ethylene copolymer of acrylic acid, an ethylene-vinyl acetate copolymer, a styrene-butadiene-styrene copolymer, a styrene-ethylene-butadiene-styrene copolymer, and a styrene-ethylene-propylene-styrene copolymer; and the ethylene copolymer of acrylic acid is selected from at least one of an ethylene-methacrylic acid copolymer, an ethylene-ethyl acrylate copolymer, and an ethylene-butyl acrylate copolymer.

4. The high weld line strength polyethylene/polycarbonate alloy according to claim 3, wherein the ethylene copolymer compatibilizer is selected from the ethylene copolymer of acrylic acid.

5. The high weld line strength polyethylene/polycarbonate alloy according to claim 1, wherein the ethylene copolymer compatibilizer is selected from an ethylene copolymer compatibilizer containing a reactive active group, wherein an ethylene copolymer is selected from at least one of an ethylene copolymer of acrylic acid, an ethylene-vinyl acetate copolymer, a styrene-butadiene-styrene copolymer, a styrene-ethylene-butadiene-styrene copolymer, and a styrene-ethylene-propylene-styrene copolymer, the reactive active group is at least one of a maleic anhydride group and an epoxy group, and a grafting ratio of the reactive active group is 0.1% to 15%; the ethylene copolymer of acrylic acid is selected from at least one of an ethylene-methacrylic acid copolymer, an ethylene-ethyl acrylate copolymer, and an ethylene-butyl acrylate copolymer.

6. The high weld line strength polyethylene/polycarbonate alloy according to claim 5, wherein the ethylene copolymer is selected from the ethylene copolymer of acrylic acid.

7. The high weld line strength polyethylene/polycarbonate alloy according to claim 1, wherein the polycarbonate is selected from an aromatic polycarbonate, an aliphatic polycarbonate, and an aromatic-aliphatic polycarbonate; the polycarbonate has a weight average molecular weight of 18,000 to 28,000; and in parts by weight, 0 part to 10 parts of a processing aid and/or an additive are further comprised.

8. The high weld line strength polyethylene/polycarbonate alloy according to claim 1, wherein the high weld line strength polyethylene/polycarbonate alloy has a weld line strength of 65% or more, and a weld line strength test is according to ASTM D638 standard test.

9. A preparation method of the high weld line strength polyethylene/polycarbonate alloy of claim 7, comprising the following steps: mixing the polycarbonate, polyethylene, the ethylene copolymer compatibilizer, and a processing aid and/or an additive evenly according to a ratio in a high-speed mixer; then adding into a twin-screw extruder, melt mixing at a temperature of 220° C. to 240° C., and then granulating, cooling and drying to obtain the high weld line strength polyethylene/polycarbonate alloy.

10. The preparation method of the high weld line strength polyethylene/polycarbonate alloy according to claim 9, wherein the polyethylene has a melt index of 40 g/10 min to 150 g/10 min under a test condition of 230° C., 2.16 kg; and the ethylene copolymer compatibilizer has a melt index of 0.2 g/10 min to 50 g/10 min under a test condition of 190° C., 2.16 kg.

11. The high weld line strength polyethylene/polycarbonate alloy according to claim 2, wherein the high weld line strength polyethylene/polycarbonate alloy has a weld line strength of 65% or more, and a weld line strength test is according to ASTM D638 standard test.

12. The high weld line strength polyethylene/polycarbonate alloy according to claim 3, wherein the high weld line strength polyethylene/polycarbonate alloy has a weld line strength of 65% or more, and a weld line strength test is according to ASTM D638 standard test.

13. The high weld line strength polyethylene/polycarbonate alloy according to claim 4, wherein the high weld line strength polyethylene/polycarbonate alloy has a weld line strength of 65% or more, and a weld line strength test is according to ASTM D638 standard test.

14. The high weld line strength polyethylene/polycarbonate alloy according to claim 5, wherein the high weld line strength polyethylene/polycarbonate alloy has a weld line strength of 65% or more, and a weld line strength test is according to ASTM D638 standard test.

15. The high weld line strength polyethylene/polycarbonate alloy according to claim 6, wherein the high weld line strength polyethylene/polycarbonate alloy has a weld line strength of 65% or more, and a weld line strength test is according to ASTM D638 standard test.

16. The high weld line strength polyethylene/polycarbonate alloy according to claim 7, wherein the high weld line strength polyethylene/polycarbonate alloy has a weld line strength of 65% or more, and a weld line strength test is according to ASTM D638 standard test.

17. The high weld line strength polyethylene/polycarbonate alloy according to claim 2, wherein the polyethylene is selected from a polyethylene with a branching rate being 20 to 100 branched chains per 1000 carbon atoms, and the branched chain has 1 to 10 carbon atoms.

18. The high weld line strength polyethylene/polycarbonate alloy according to claim 8, wherein the high weld line strength polyethylene/polycarbonate alloy has the weld line strength of 70% or more, and the weld line strength test is according to ASTM D638 standard test.

19. The preparation method of the high weld line strength polyethylene/polycarbonate alloy according to claim 10, wherein the polyethylene has the melt index of 60 g/10 min to 150 g/10 min under the test condition of 230° C., 2.16 kg.

20. The preparation method of the high weld line strength polyethylene/polycarbonate alloy according to claim 10, wherein the ethylene copolymer compatibilizer has the melt index of 0.4 g/10 min to 35 g/10 min under the test condition of 190° C., 2.16 kg.

Description

DESCRIPTION OF THE EMBODIMENTS

[0028] The present invention will be further illustrated below by specific implementations, the following embodiments are preferred implementations of the invention, but the implementations of the present invention are not limited by the following embodiments.

[0029] Raw materials of Embodiments and Comparative Examples are commercially available, specifically:

[0030] polyethylene: a branching rate is the number of branched chains contained in 1,000 carbon atoms, and the branching rate in tables is the base number of 1,000 carbon atoms;

[0031] EMA: ethylene-methacrylic acid copolymer;

[0032] EEA: ethylene-ethyl acrylate copolymer;

[0033] EMA-g-GMA: ethylene-methacrylic acid graft epoxy group (GMA is an epoxy group);

[0034] EVA: ethylene-vinyl acetate copolymer;

[0035] SEBS: styrene-ethylene-butadiene-styrene copolymer;

[0036] compatibilizer B: PP-G-MAH (polyethylene graft maleic anhydride);

[0037] polycarbonate A: an aromatic polycarbonate with a weight average molecular weight being 28,000;

[0038] polycarbonate B: an aliphatic polycarbonate with a weight average molecular weight being 18,000;

[0039] polycarbonate C: an aromatic polycarbonate with a weight average molecular weight being 8,000;

[0040] polycarbonate D: an aromatic polycarbonate with a weight average molecular weight being 30,000;

[0041] anti-aging agent: anti-oxidant: anti-ultraviolet aging agent=1:1.

[0042] A preparation method of polyethylene/polycarbonate alloy in Embodiments and Comparative Examples: a polycarbonate, a polyethylene, a compatibilizer, and a processing aid and/or an additive were mixed evenly according to a ratio in a high-speed mixer; then added into a twin-screw extruder, melt mixed at a temperature of 220° C. to 240° C., and then granulated, cooled and dried to obtain a high weld line strength polycarbonate alloy.

[0043] Each test method:

[0044] (1) Alloy Melt Index (MFR): according to a test ASTM D1238, a test condition of the polycarbonate alloy is 260° C., 2.16 kg;

[0045] (2) Weld line strength: characterized by a weld line coefficient Flu:

F.sub.KL=T.sub.SX/TS.sub.0×100%

[0046] TS.sub.X is tensile strength of weld line and TS.sub.0 is tensile strength without the weld line, and an ASTM D638 standard test is applied.

[0047] (3) TS retention rate: According to ISO 527-2/1A, for a test rod with a thickness of 4 mm and a width of 10 mm prepared by molding, at a test speed of 5 mm/min, a tensile strength (TS) before and after aging in the air at 23° C. (the average of test results of at least 5 samples with the same composition and shape) is tested, to obtain the tensile strength before the aging T.sub.initial. Hot air aging is carried out using a thermal aging box, at a temperature adjusted to 150° C. After reaching aging time of 1000 hours, the sample is taken out of the aging box, and after cooling to room temperature, it is heat sealed with an aluminum foil bag to prevent absorption of any moisture before an evaluation of a mechanical property. At the test speed of 5 mm/min, the tensile strength (TS) at 23° C. is tested (the average of the test results of at least 5 samples with the same composition and shape), to obtain the tensile strength after the aging T.sub.aging. Compared with the corresponding mechanical property before the aging, a retention rate of the tensile strength is calculated and expressed as a percentage, recorded as a TS retention rate after the aging R1. A calculation of R1 is as follows:

R1=T.sub.aging/T.sub.initial×100%

[0048] In the formula, T.sub.aging and T.sub.initial are the tensile strength after the aging and before the aging, respectively.

[0049] (4) Polyethylene branching rate: C-NMR (nuclear magnetic resonance spectroscopy) method, according to Galland method to test a degree of branching. A calculation formula of the degree of branching is (D+T)/(D+T+L).

Degree of branching(DB)=(D+T)/(D+T+L)

[0050] D represents the number of tree-like units. T represents the number of end units, and L represents the number of linear units.

TABLE-US-00001 TABLE 1 Ingredients and ratios (in parts by weight) and each performance test results of the polyethylene/polycarbonate alloy in Embodiments 1 to 10 Embodi- Embodi- Embodi- Embodi- Embodi- ment 1 ment 2 ment 3 ment 4 ment 5 Polyethylene Branching rate 20 20 20 20 20 Branched chain Methyl Methyl Methyl Methyl Methyl group group group group group MFR, g/10 min 40 40 40 40 40 Amount, parts 15 15 15 15 15 Polycarbonate A, parts 80 80 80 80 80 Compatibilizer A Species of reactive — — — — — active group Grafting rate of — — — — — reactive active group,% Ethylene copolymer EMA EMA EMA EMA EMA MFR, g/10 min 0.2 0.4 5 10 15 Amount, parts 5 5 5 5 5 Anti-aging agent 0.5 0.5 0.5 0.5 0.5 MFR, g/10 min 8 8 10 12 15 Weld line strength, % 70 75 79 83 87 TS retention rate, % 86 88 90 92 93 Embodi- Embodi- Embodi- Embodi- Embodi- ment 6 ment 7 ment 8 ment 9 ment 10 Polyethylene Branching rate 20 20 20 20 20 Branched chain Methyl Methyl Methyl Methyl Methyl group group group group group MFR, g/10 min 40 40 60 80 100 Amount, parts 15 15 15 15 15 Polycarbonate A, parts 80 80 80 80 80 Compatibilizer A Species of reactive — — — — — active group Grafting rate of — — — — — reactive active group,% Ethylene copolymer EMA EMA EMA EMA EMA MFR, g/10 min 35 50 5 5 5 Amount, parts 5 5 5 5 5 Anti-aging agent 0.5 0.5 0.5 0.5 0.5 MFR, g/10 min 20 25 12 14 17 Weld line strength, % 89 73 84 86 87 TS retention rate, % 96 86 92 93 95

TABLE-US-00002 TABLE 2 Ingredients and ratios (in parts by weight) and each performance test results of the polyethylene/polycarbonate alloy in Embodiments 11 to 20 Embodi- Embodi- Embodi- Embodi- Embodi- ment 11 ment 12 ment 13 ment 14 ment 15 Polyethylene Branching rate 20 20 20 20 20 Branched chain Methyl Methyl Methyl Methyl Methyl group group group group group MFR, g/10 min 150 100 100 100 100 Amount, parts 15 15 15 15 15 Polycarbonate A, parts 80 80 80 80 80 Polycarbonate B, parts — — — — — Polycarbonate C, parts — — — — — Polycarbonate D, parts — — — — — Compatibilizer A Species of reactive — GMA GMA GMA — active group Grafting rate of — 0.1 5 15 — reactive active group, % Ethylene copolymer EMA EMA EMA EMA EEA MFR, g/10 min 5 5 5 5 0.2 Amount, parts 5 5 5 5 5 Anti-aging agent 0.5 0.5 0.5 0.5 0.5 MFR, g/10 min 20 13 10 8 9 Weld line strength, % 89 90 91 93 71 TS retention rate, % 97 95 98 98 88 Embodi- Embodi- Embodi- Embodi- Embodi- ment 16 ment 17 ment 18 ment 19 ment 20 Polyethylene Branching rate 20 20 20 20 20 Branched chain Methyl Methyl Methyl Methyl Methyl group group group group group MFR, g/10 min 40 40 100 100 100 Amount, parts 15 15 15 15 15 Polycarbonate A, parts 80 80 — — — Polycarbonate B, parts — — 80 — — Polycarbonate C, parts — — — 80 — Polycarbonate D, parts — — — — 80 Compatibilizer A Species of reactive — — — — — active group Grafting rate of — — — — — reactive active group, % Ethylene copolymer EVA SEBS EMA EMA EMA MFR, g/10 min 0.2 0.2 5 5 5 Amount, parts 5 5 5 5 5 Anti-aging agent 0.5 0.5 0.5 0.5 0.5 MFR, g/10 min 8 8 21 23 14 Weld line strength, % 66 65 88 73 68 TS retention rate, % 85 84 95 87 85

TABLE-US-00003 TABLE 3 Ingredients and ratios (in parts by weight) and each performance test results of the polyethylene/polycarbonate alloy in Embodiments 21 to 26 and Comparative Examples Embodi- Embodi- Embodi- Embodi- Embodi- Embodi- ment 21 ment 22 ment 23 ment 24 ment 25 ment 26 Polyethylene Branching rate 20 20 25 90 210 20 Branched chain Methyl Methyl Methyl Methyl Methyl Methyl group group group group group group and butyl group MFR, g/10 min 100 100 100 100 100 100 Amount, parts 15 15 15 15 15 15 Polycarbonate A, parts 80 80 80 80 80 80 Compatibilizer A Species of reactive — — — — — — active group Grafting rate of — — — — — — reactive active group, % Ethylene copolymer EMA EMA EMA EMA EMA EMA MFR, g/10 min 5 5 5 5 5 5 Amount, parts 1 15 5 5 5 5 Amount of compatibilizer B, parts — — — — — — Anti-aging agent 0.5 0.5 0.5 0.5 0.5 0.5 MFR, g/10 min 12 20 18 20 13 15 Weld line strength, % 79 92 88 90 82 86 TS retention rate, % 88 98 95 97 91 94 Compara- Compara- Compara- Compara- tive tive tive tive Example 1 Example 2 Example 3 Example 4 Polyethylene Branching rate 20 20 20 20 Branched chain Methyl Methyl Methyl Methyl group group group group MFR, g/10 min 100 100 30 100 Amount, parts 15 15 15 15 Polycarbonate A, parts 80 80 80 80 Compatibilizer A Species of reactive — — — — active group Grafting rate of — — — — reactive active group, % Ethylene copolymer — — EMA EMA MFR, g/10 min — — 5 60 Amount, parts — — 5 5 Amount of compatibilizer B, parts — 5 — — Anti-aging agent 0.5 0.5 0.5 0.5 MFR, g/10 min 10 15 6 28 Weld line strength, % 30 28 46 52 TS retention rate, % 53 50 67 70

[0051] It can be seen from Embodiments 1 to 7 and Comparative Example 4 that as an increase of the melt index of the ethylene copolymer compatibilizer, the melt index of the product increases and the weld line strength is in an inverted U-shape. When the melt index of the ethylene copolymer compatibilizer is 0.4 g/10 min to 35 g/10 min (under a test condition of 190° C., 2.16 kg), the weld line strength of the product is relatively high. When the melt index of the ethylene copolymer compatibilizer is 60 g/10 min (under the test condition of 190° C., 2.16 kg), the weld line strength and the TS retention rate of the product are greatly reduced.

[0052] It can be seen from Embodiments 3, 8 to 11 that as an increase of the melt index of the polyethylene, the weld line strength, the melt index, and the TS retention rate of the product are increased.

[0053] It can be seen from Embodiment 3 and Embodiments 12 to 14 that the ethylene copolymer compatibilizer containing reactive active groups is capable of increasing the weld line strength and the TS retention rate compared with the ethylene copolymer compatibilizer containing no reactive active groups, and as an increase of a content of the reactive active groups, the weld line strength and the TS retention rate of the product are increased.

[0054] It can be seen from Embodiments 10, 23 to 26 that in the Embodiments where the polyethylene has the branching rate of 20 to 100 branched chains per 1000 carbon atoms, the TS retention rate is relatively high.

[0055] It can be seen from Embodiment 8 and Comparative Example 3 that when the melt index of the polyethylene is less than 40 g/10 min (under the test condition of 230° C., 2.16 kg), the weld line strength of the product is considerably decreased and the melt index is relatively low.

[0056] It can be seen from Embodiment 1, 15, 16, 17 that when the ethylene copolymer of acrylic acid is as a compatibilizer, each performance of the product is relatively good.