Process for improving carbon black dispersion

Abstract

A masterbatch comprising pigment and demolding agent is provided. The demolding agent is selected from the group comprising low molecular weight polyolefin oils, low molecular weight polyolefin waxes, montan waxes and aliphatic or aromatic carboxylic acid esters of fatty acids and / or fatty alcohols, wherein the pigment content of the masterbatch is from 3 to 70 wt. %, based on the total weight of the masterbatch. The masterbatch is suitable for preparation of a polymer composition having improved pigment dispersion.

Description

CROSS REFERENCE TO RELATED APPLICATION[0001]This applicationApplication is a reissue of U.S. application Ser. No. 13 / 332,047, filed on Dec. 20, 2011, issued as U.S. Pat. No. 9,056,957, which claims priority to European Patent Application No. 10196932.7, filed Dec. 23, 2010, the content of each of which is incorporated herein by reference in its entirety.BACKGROUND[0002]1. Field of the Invention[0003]The invention provides pigment-containing polycarbonate compounds having improved dispersion of the pigment particles in the polymer matrix, and a process for the preparation of these compounds. Carbon black is preferably used as the pigment, “carbon black” in the present invention representing all particulate pure carbon substrates and carbon compounds, for example colour carbon blacks, conductivity carbon blacks, carbon nanotubes, graphite. The pigment-containing polycarbonate compounds can contain further polymers, such as, for example, elastomers or graft polymers, or further thermop...

AI Technical Summary

Benefits of technology

The present invention provides a novel process for better dispersion of pigments, particularly carbon black, in polycarbonate compounds. A pigment concentrate is isolated and is suitable for easy incorporation into polycarbonate compounds. The use of a pigment concentrate leads to better dispersion of pigments in the polymer matrix compared to using pure pigment powder in a single compounding step. The process can be carried out under standard conditions in conventional mixing units.

Problems solved by technology

A technical problem when incorporating pigments, and carbon black particles in particular, into thermoplastic polymer compositions is that of dispersing the pigment particles completely and uniformly in the polymer matrix.

Incompletely dispersed pigment particles form pigment agglomerates which apart from colour inhomogeneities and inadequate depth of colour also result in particular in defects which have an adverse effect on the mechanical properties of the polymer compositions, such as their strength and ultimate elongation, and also on the surface properties of the materials.

Larger pigment agglomerates lead, for example, to faults and defects on the surface of such compositions such as pitting, streakiness and, ultimately, to an undesirable reduction in the degree of gloss.

In a composite with other materials, such surface defects can additionally also adversely affect the composite adhesion properties (for example lacquer adhesion).

However, the energy input which can be used for pigment dispersion is technically limited in the case of polymer melts, in particular those having a low viscosity, that is to say high melt flowability, as is required for good thermoplastic processability in most fields of application.

In other cases, the energy input is limited by the thermal loading capacity of the polymer melt into which the pigment is to be incorporated.

High specific energy inputs naturally lead to high process temperatures which, depending on the polymer, can lead to undesirable damage, ageing or even decomposition of the polymer.

A further method is the use of a highly concentrated masterbatch of the pigment in a polymer matrix, but the technically achievable concentration of the pigment in the polymer matrix is not high enough for an economic application without the use of further additives / processing aids.

Furthermore, good pigment dispersion in the end product can be achieved with this method only if the pigments are already well dispersed in the masterbatch, which is only insufficiently ensured when using polymer matrices, in particular in polycarbonate.

The disadvantage of the use of such dispersing aids, which have no other necessary action in the composition, is that they remain in the polymer composition that is produced and, as a result, may possibly adversely affect the application-related properties of the target products.

For example, such dispersing aids in multiphase compositions (blends) of different polymers (such as, for example, impact-modified polymers) can adversely affect the phase compatibility of the different polymer components by accumulating at the phase boundaries and thereby adversely affect the mechanical properties of the blend composition.

Likewise, these additives can catalyse undesirable ageing processes in certain polymer systems, for example hydrolytic decomposition reactions in polycondensation polymers.

However, the shear forces which occur under the stirring, spraying or centrifugation conditions mentioned in U.S. Pat. No. 4,484,952 for mixing the pigments with the carrier are too small to achieve sufficiently fine separation and uniform distribution of the pigments in the carrier material in the case of highly agglomerated pigments.

Moreover, U.S. Pat. No. 4,484,952 gives no indication of the quality of the pigment dispersion which can be achieved in thermoplastics with carbon black concentrates so prepared, in particular the dispersion of the carbon black which can be achieved in polycarbonate compositions.

Furthermore, there is no information in U.S. Pat. No. 4,484,952 regarding the process parameters used in the preparation of the pigment concentrates and the energy input as well as the mixing unit used, which have a critical influence on the quality of the dispersion.

However, this is likewise a concentrate form in which only a low energy input for the separation of agglomerated pigments and their uniform distribution in the matrix material occurs.

Such a process is technically too complex and inflexible, however.

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