Polyphenyl sulfone / polycarbonate alloy and preparation method thereof

Abstract

The invention discloses a high-flowability and flame-retardant polyphenyl sulfone / polycarbonate alloy and a preparation method thereof. Polyphenyl sulfone is compounded with polycarbonate to reduce the viscosity of the whole product, and then polysulfone resin is utilized to improve the thermodynamic compatibility of the polyphenyl sulfone and the polycarbonate; glass flake filler is ingeniously adopted to improve the flame retardance of the alloy, and finally the high-flowability flame-retardant polyphenyl sulfone polycarbonate alloy material is obtained and can be widely applied to the field of aviation.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of high polymer materials, in particular to a kind of polyphenyl sulfone / polycarbonate alloy and preparation method thereof. BACKGROUND

[0002] Polyphenyl sulfone (PPSU) is a kind of special engineering plastics, with excellent high temperature resistance, intrinsic flame retardant, resistance to chemical, mechanical strength, biocompatibility and other advantages, is widely used in medical, food, aerospace and other fields;But the material also has the short board such as high viscosity, high processing temperature, high cost, easy stress cracking. Polycarbonate (PC) is one of the five general engineering plastics, with heat resistance, transparency, flame retardant and many other advantages, is widely used in electronic appliances, automobiles, food and other industries;However, the product has relatively low heat resistance, relatively poor chemical resistance, low flame retardant grade and other short boards. The two materials have great difference in many aspects, and the polyphenyl sulfone / polycarbonate alloy material prepared by simply melt blending the two materials cannot be prepared to meet the application conditions due to the incompatibility of thermodynamics and kinetics.

[0003] At present, the material requirement in aviation field is very high, PPSU material has been maturely applied in cabin ceiling, side wall plate and other components, which are large area flat structure and have no complex structure design, so ordinary PPSU dyeing material can meet the use requirement;But there are many complex structure small parts in aviation field, which are difficult to be directly injection molded, have small amount and high injection molding cost, so it is urgent to develop a material with excellent flame retardant performance and high flowability for additive manufacturing.

[0004] In the prior art, due to the excellent characteristics of polyphenyl sulfone material, the alloy preparation is generally based on polyphenyl sulfone / polyether ether ketone (PEEK) and other special material alloy, and there is no mature alloy material solution to improve the flowability.

[0005] Although CN109071933A provides a PPSU / PC alloy solution, the two materials are only mixed and extruded by direct melt blending in the patent, without considering the compatibility of the materials, and the development target is suitable for electronic industry, without considering the flame retardant performance of the product.

[0006] Therefore, in view of the limitations of the prior art, it is urgent to develop a high flow and excellent flame retardant product suitable for small part additive manufacturing in aviation field. SUMMARY

[0007] The present application is to overcome the defects of the above scheme, and to prepare a polyphenyl sulfone (PPSU) / polycarbonate (PC) alloy material with excellent flame retardant performance and flowability.

[0008] To achieve the above purpose, the present application is realized by the following technical scheme:

[0009] In a first aspect, the present application provides a high flow, flame retardant polyphe- nylsulfone / polycarbonate alloy comprising:

[0010] polysulfone 2-10%;

[0011] polysulfone 2-10%;

[0012] polycarbonate 10-30%;

[0013] antioxidant 0.1-0.5%;

[0014] glass flake 0.5-1.5% by weight of the total alloy.

[0015] The polyphehylsulfone of the present application has a melt flow index of 10-30 g / 10 min, preferably 10-20 g / 10 min, at a test condition of 365°C, 5.0 kg. In specific embodiments, alternative polyphehylsulfone commercially available products include WANAFOE series products from Wanhua Chemical, etc.

[0016] The polysulfone of the present application has a melt flow index of 5-20 g / 10 min, at a test condition of 343°C, 2.16 kg. In specific embodiments, alternative polyphehylsulfone commercially available products include WANAFOE series products from Wanhua Chemical, etc.

[0017] The polycarbonate of the present application is an aromatic polycarbonate, preferably a bisphenol A type polycarbonate. Preferably, the PC has a melt flow index of 2.5-10 g / 10 min, preferably 2.5-7 g / 10 min, at a test condition of 300°C, 1.2 kg. In specific embodiments, alternative polycarbonate commercially available products include CLARNATE series products from Wanhua Chemical, etc.

[0018] The antioxidant of the present application includes one or more of hindered phenol, phosphite, thioester, benzofuran, acryloyl-modified phenol, hydroxylamine antioxidant.

[0019] The glass flake of the present application is a conventional commercially available glass flake, preferably having an average thickness of 0.5-1.0 μm and an average diameter of 150-200 μm. In specific embodiments, alternative commercially available products include MEG160FY-M02 from Nitto Boseki.

[0020] The above polyphehylsulfone / polycarbonate alloy product can achieve a 1.0 mm V0 level flame retardant performance, a significantly reduced viscosity at 340°C, and a notched impact maintained at 350 J / m (ASTM D256).

[0021] In a second aspect, the present application provides a method for preparing the polyphenylsulfone / polycarbonate alloy as described above, comprising the following steps:

[0022] The polyphenylsulfone, polysulfone, polycarbonate, antioxidant and glass flake are mixed in proportion, extruded, granulated and dried to obtain the polyphenylsulfone / polycarbonate alloy product.

[0023] In the present application, the mixing step can use a mixer, such as mixing for 3-30 minutes, to obtain the mixed raw materials.

[0024] Preferably, the present application uses a twin-screw extruder, and the glass flake is added through side feeding, such as in the seventh zone, and the other raw materials are added through main feeding.

[0025] In the present application, the barrel temperature of the twin-screw extrusion process is set to 310-325℃, and the torque is 60-80%.

[0026] In a third aspect, the present application provides the application of the polyphenylsulfone / polycarbonate alloy product in the field of aviation.

[0027] The present application uses melt blending extrusion means, supplemented by a small amount of polysulfone resin as a compatibilizer to improve the compatibility of polyphenylsulfone and polycarbonate, avoiding the incompatibility of the two in thermodynamics; at the same time, the addition of polysulfone resin reduces the viscosity of polyphenylsulfone resin to some extent, reducing the viscosity difference between polyphenylsulfone and polycarbonate resin; in addition, the addition of a small amount of glass flake and other flaky fillers improves the flame retardant performance, on the one hand, the flaky filler plays a skeleton role in the carbon layer, making the carbon layer more dense and continuous, and on the other hand, the flaky filler also increases the diffusion path of flammable gas and air, further delaying the occurrence of combustion; it is worth noting that the flaky filler is fed through the side and matched with a suitable process to maintain a good aspect ratio, and an improved flame retardant effect is obtained; finally, a high-flow, high-flame-retardant polyphenylsulfone (PPSU) / polycarbonate (PC) alloy material is obtained, which is suitable for application in the field of additive manufacturing in aviation.

[0028] Compared with the prior art, the present application has the following beneficial effects:

[0029] I. By adding polycarbonate resin to polyphenylsulfone, the flowability of the product is improved, and polysulfone resin is used as a third-party compatibilizer to improve the compatibility of polyphenylsulfone and polycarbonate;

[0030] II. Due to the introduction of polycarbonate and polysulfone resin, the overall product flame retardant performance is reduced, and conventional flame retardants cannot pass the multiple flame retardant tests in the aviation field; this patent improves the barrier performance of the carbon layer during resin combustion by adding glass flake and other flaky fillers, so that the product flame retardant performance returns to the 1.0mm V0 level;

[0031] III. The flaky filler retains the flaky structure by side feeding, so as to play a more effective role.

[0032] IV. The final prepared polyphenylsulfone / polycarbonate alloy has excellent flowability and flame retardant properties, and is suitable for additive manufacturing processing. DETAILED DESCRIPTION

[0033] In order to facilitate the understanding of the present application, the present application will be further described below in combination with examples. It should be understood that the following examples are only for better understanding of the present application, and do not mean that the present application is limited to the following examples only.

[0034] Main raw material sources

[0035] 2030: Bisphenol A polycarbonate produced by interfacial phosgene method, melt flow index is 2.8 g / 10 min (300℃, 1.2 kg), Wanhua Chemical Group Co., Ltd.;

[0036] 2070: Bisphenol A polycarbonate produced by interfacial phosgene method, melt flow index is 6.0 g / 10 min (300℃, 1.2 kg), Wanhua Chemical Group Co., Ltd.;

[0037] P6070: Polyphenylsulfone, melt flow index is 15 g / 10 min (365℃, 5.0 kg), Wanhua Chemical Group Co., Ltd.;

[0038] P8030: Polyphenylsulfone, melt flow index is 30 g / 10 min (365℃, 5.0 kg), Wanhua Chemical Group Co., Ltd.;

[0039] U4070: Polysulfone, melt flow index is 10 g / 10 min (343℃, 2.16 kg), Wanhua Chemical Group Co., Ltd.;

[0040] U5030: Polysulfone, melt flow index is 15 g / 10 min (343℃, 2.16 kg), Wanhua Chemical Group Co., Ltd.;

[0041] B900: Antioxidant, BASF;

[0042] Glass flake: MEG160FY-M02, Japan Glass.

[0043] Chopped glass fiber: OC415A, OC company.

[0044] Main test method

[0045] Tensile property test is tested according to ASTM-D638-2022 standard;

[0046] Impact performance is tested by ASTM D256 standard, 23℃ normal temperature, notched impact;

[0047] Flame retardant properties were tested using UL94 standard;

[0048] Flowability was tested using a rotational rheometer, ASTM D4440, at a temperature of 340°C and 100 rad / s.

[0049] Examples

[0050]

[0051] Note: In the table, the amount of each material refers to the mass fraction (wt%) of the total polyphenylsulfone / polycarbonate alloy. The glass flake was added through the seventh zone, and the temperature was set to 310°C for the first to third zones, 325°C for the fourth to sixth zones, and 320°C for the seventh to ninth zones, with a torque of 70%.

[0052] Comparative Examples

[0053]

[0054]

[0055] Note: In the table, the amount of each material refers to the mass fraction (wt%) of the total polyphenylsulfone / polycarbonate alloy. The glass flake and glass fiber were added through the seventh zone, and the temperature was set to 310°C for the first to third zones, 325°C for the fourth to sixth zones, and 320°C for the seventh to ninth zones, with a torque of 70%.

[0056] It is easily understood that the above examples are merely illustrative in nature and are in no way intended to limit the application of the application. Based on the above description, other variations or modifications can be made by those of ordinary skill in the art. It is not necessary or possible to exhaust all embodiments. The obvious changes or modifications derived therefrom are still within the scope of protection of the present application.

Claims

1. A polyphenylsulfone / polycarbonate alloy comprising the following components: polyphenylsulfone 58-87.4% poly sulfone 2-10% polycarbonate 10-30% antioxidant 0.1-0.5% glass flake 0.5-1.5% based on the total mass of the alloy. The polyphenylsulfone has a melt flow index of 10-30 g / 10 min, preferably 10-20 g / 10 min, under test conditions of 365°C, 5.0 kg. The poly sulfone has a melt flow index of 5-20 g / 10 min under test conditions of 343°C, 2.16 kg. The polycarbonate is a bisphenol A polycarbonate; preferably, the polycarbonate has a melt flow index of 2.5-10 g / 10 min, preferably 2.5-7 g / 10 min, under test conditions of 300°C, 1.2 kg. The method comprises the following steps: mixing the polyphenylsulfone, poly sulfone, polycarbonate, antioxidant, and glass flake to obtain a mixed raw material; and extruding, granulating, and drying the mixed raw material to obtain the polyphenylsulfone / polycarbonate alloy product. ​ 2. The alloy of claim 1 wherein, ​ 3. The alloy of claim 1 wherein, ​ 4. The alloy of claim 1 wherein, ​ 5. A method of producing the alloy according to any one of claims 1 to 4, characterized in that, ​

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