PC / SAS composite material and preparation method and application thereof

Abstract

This invention relates to a PC / SAS composite material, its preparation method, and its applications. The PC / SAS composite material comprises the following components in parts by weight: polycarbonate, SAS resin, elastomer, glass fiber, and other additives. This invention improves the rigidity and hydrolysis resistance of the PC / SAS composite material through the combination of glass fiber, elastomer, and SAS resin with a specific melt flow rate, while maintaining good tensile strength under humid and hot conditions.

Description

Technical Field

[0001] This invention relates to the field of modified plastics technology, and more specifically, to a PC / SAS composite material, its preparation method, and its applications. Background Technology

[0002] PC (polycarbonate) is a polyester derived from carbonic acid. It is not easily scratched and possesses excellent overall mechanical properties. As a nearly colorless, glassy, ​​amorphous polymer, PC material has excellent optical properties and is commonly used in outdoor high-power electrical appliance components, such as new energy charging facilities, inverters, and combiner boxes. Furthermore, to meet the application requirements of high-power electrical appliances, flame retardants are typically added to PC material to enhance its flame-retardant properties.

[0003] The main performance defect of PC materials is their insufficient hydrolysis resistance. Long-term exposure to humid and hot environments will cause hydrolysis, leading to a decrease in tensile strength. This is because the ester bonds in the PC molecular chain are prone to hydrolysis with carboxylic acids or water under humid and hot conditions, causing molecular chain breakage, which in turn leads to a decrease in the overall performance of PC materials and a shortened service life.

[0004] In addition, in the application scenarios of new energy charging facilities, inverters and combiner boxes, because these components carry high voltage and have very high requirements for safety protection performance, metal materials were often used before. However, the current environment requires plastic to replace steel, so if PC materials are to be used as a substitute, PC materials must also have good rigidity.

[0005] The prior art describes a polycarbonate composition and its preparation method that improves the rigidity of the material by controlling the length and content distribution of the fibrous filler, but it does not focus on the hydrolysis resistance of the material.

[0006] Therefore, new technologies need to be developed to solve the problems of poor hydrolysis resistance and poor rigidity of PC materials. Summary of the Invention

[0007] The primary objective of this invention is to overcome the poor hydrolysis resistance and rigidity of current PC materials and to provide a PC / SAS composite material. This invention improves the rigidity and hydrolysis resistance of the PC / SAS composite material by combining glass fiber, elastomer, and SAS resin with a specific melt flow rate, while maintaining good tensile strength under humid and hot conditions.

[0008] A further object of the present invention is to provide a method for preparing the above-mentioned PC / SAS composite material.

[0009] A further object of the present invention is to provide the application of the above-mentioned PC / SAS composite material in the manufacture of outdoor high-power electrical appliances.

[0010] The above-mentioned objective of the present invention is achieved through the following technical solution:

[0011] A PC / SAS composite material comprises the following components in parts by weight:

[0012]

[0013] The melt volume flow rate of the SAS resin at 220°C and 10kg load is 3–25 cm⁻¹. 3 / 10min.

[0014] In this invention, SAS resin refers to silicone copolymer AS resin (styrene-acrylonitrile-silicone copolymer).

[0015] In this invention, the addition of glass fiber can improve the rigidity of PC / SAS composite material.

[0016] The inventors of this invention have discovered that adding SAS resin to glass fiber reinforced polycarbonate resin can impart moisture and heat resistance to the material, thereby improving the material's hydrolysis resistance and increasing the retention rate of tensile strength under hydrothermal conditions, since SAS resin contains siloxane groups.

[0017] In the formulation system of this invention, the combination of SAS resin and elastomer ensures good compatibility with glass fiber reinforced polycarbonate resin, allowing SAS resin to be better dispersed in PC / SAS composite material, resulting in more uniform dispersion of siloxane groups and better hydrolysis resistance.

[0018] In addition, the amount of SAS resin used also needs to be controlled. If too much is used, it will affect the compatibility between glass fiber and polycarbonate, thereby reducing the rigidity of the material.

[0019] This invention improves the rigidity and hydrolysis resistance of PC / SAS composite materials by combining glass fiber, elastomer, and SAS resin with a certain melt volume flow rate, and the tensile strength of the material can be maintained well under humid and hot conditions.

[0020] In this invention, the amount of polycarbonate used can be 45, 48, 50, 55, 58, 60, 62, 65, 68 or 70 parts by weight; the amount of SAS resin used can be 5, 6, 10, 12 or 15 parts by weight; and the amount of glass fiber used can be 15, 18, 20, 22, 25, 28, 30, 32, 35, 38 or 40 parts by weight.

[0021] Preferably, the PC / SAS composite material comprises the following components in parts by weight:

[0022]

[0023]

[0024] Optionally, the polycarbonate is at least one of phosgene-processed polycarbonate or transesterification-processed polycarbonate.

[0025] Optionally, the polycarbonate is at least one of bisphenol A type polycarbonate or silicon copolymer polycarbonate.

[0026] Optionally, the polycarbonate has a melt flow rate of 0.1 to 30 g / 10 min at 300°C and 1.2 kg load; this can be measured according to the ASTM D1238-2010 standard procedure.

[0027] Preferably, the polycarbonate is a silicon-copolymer polycarbonate, wherein the siloxane content is 3-5 wt%. Using a silicon-copolymer polycarbonate improves the compatibility between SAS resin and the resulting PC / SAS composite material, leading to better hydrolysis resistance.

[0028] Typically, the SAS resin contains 10–35 wt% acrylonitrile and 25–52% styrene.

[0029] Preferably, the melt volume flow rate of the SAS resin at 220°C and 10 kg load is 20–22 cm⁻¹. 3 / 10min. Using SAS resin with this melt volumetric flow rate results in PC / SAS composites with better hydrolysis resistance.

[0030] Preferably, the elastomer is at least one of acrylate elastomer or high-polymer powder.

[0031] Preferably, the average diameter of the glass fiber is 10–20 μm.

[0032] Preferably, the SAS resin has a mass percentage of 11-20% relative to polycarbonate. Within this content range, the resulting PC / SAS composite material exhibits better hydrolysis resistance.

[0033] Preferably, the other additives are at least one of weather-resistant agents or antioxidants.

[0034] Optionally, the weathering agent is at least one of benzotriazole weathering agents or triazine weathering agents.

[0035] Optionally, the antioxidant includes at least one of phosphate ester antioxidants, thioester antioxidants, and hindered phenolic antioxidants.

[0036] Preferably, the PC / SAS composite material further includes 5-10 parts of phosphazene flame retardant and 0.2-1 part of anti-dripping agent.

[0037] The PC / SAS composite material of the present invention, even with the addition of phosphazene flame retardants and anti-dripping agents, still maintains good rigidity and hydrolysis resistance, and has better flame retardant properties, thus better meeting the application requirements of outdoor high-power electrical components.

[0038] In this invention, polycarbonate is used as the main resin, and its content in the PC / SAS composite material is preferably more than 35 wt%.

[0039] The preparation method of the above PC / SAS composite material includes the following steps: mixing the components, melt extrusion, and granulation to obtain the PC / SAS composite material.

[0040] Preferably, the temperature of each section of the melt extrusion extruder is 250–280°C. Specifically, the temperature of the extruder is divided into ten zones, with zones one and two having a temperature of 240–250°C, zones three to five having a temperature of 250–265°C, and zones six to ten having a temperature of 255–280°C.

[0041] The application of the aforementioned PC / SAS composite material in the manufacture of outdoor high-power electrical components is also within the scope of protection of this invention.

[0042] Generally, the outdoor high-power electrical components mentioned are new energy charging facilities, inverters, or combiner boxes.

[0043] Compared with the prior art, the beneficial effects of the present invention are:

[0044] This invention improves the rigidity and hydrolysis resistance of PC / SAS composite materials by combining glass fiber, elastomer, and SAS resin with a certain melt volume flow rate, and the tensile strength of the material can be maintained well under humid and hot conditions. Detailed Implementation

[0045] To more clearly and completely describe the technical solution of the present invention, the present invention will be further described in detail below through specific embodiments. It should be understood that the specific embodiments described herein are only for explaining the present invention and are not intended to limit the present invention. Various changes can be made within the scope of the claims of the present invention.

[0046] The reagents used in the various embodiments and comparative examples of this invention are described below:

[0047] Polycarbonate 1#: PC: Mitsubishi PC S-2000F; Bisphenol A type polycarbonate, melt index of 10g / 10min at 300℃ and 1.2kg load;

[0048] Polycarbonate 2#: Silicon copolymer PC (Si-PC): Formosa Plastics AC9144, with a melt index of 13g / 10min at 300℃ and 1.2kg load, and a siloxane content of 4wt%; the siloxanes in the silicon copolymer PC can be quantitatively determined by SEM / EDX analysis.

[0049] SAS resin #1: UMG S351 from Japan, with a melt volumetric flow rate of 21 cm³ / s at 220°C and a 10 kg load. 3 / 10min;

[0050] SAS resin #2: UMG TW15G from Japan, with a melt volumetric flow rate of 3 cm³ at 220°C and a 10 kg load. 3 / 10min;

[0051] AS resin (AS): Melt flow rate 21 cm⁻¹ 3 / 10min; prepared by blending KFA-130 and KFA-180 in a 1:1 mass ratio, wherein KFA-130 and KFA-180 are commercially available in Liaoning Jinfeng.

[0052] Glass fiber #1: China Jushi Glass Fiber E7CS10-03-534A, with an average cross-sectional diameter of 11μm;

[0053] Glass fiber #2: China Jushi Glass Fiber ECS13-4.5-510H, with an average cross-sectional diameter of 13μm;

[0054] Phosphazene flame retardant: Commercially available HPCTP, the same one is used in both the embodiments and comparative examples of this invention;

[0055] Elastomer 1#: Acrylic toughening agent: Kaneka M-210 (Japan);

[0056] Elastomer #2: High-polymer powder, Kumho HR181;

[0057] Anti-dripping agent: Commercially available polytetrafluoroethylene, the same one used in both the embodiments and comparative examples of this invention.

[0058] Other additives #1: Antioxidant, RIANOX 1010 and RIANOX 168 are mixed in a mass ratio of 1:1, both RIANOX 1010 and RIANOX 168 are commercially available;

[0059] Other additives #2: Weather resistance, hindered amine light stabilizer Tinuvin 770DF, commercially available;

[0060] Unless otherwise specified, all components (e.g., anti-dripping agents, processing aids) used in each parallel embodiment and comparative example are the same commercially available products.

[0061] The PC / SAS composite materials provided in the embodiments and comparative examples of this invention were subjected to performance testing according to the following test methods:

[0062] (1) Hydrolysis resistance: Select a 100T injection molding sample, boil the ASTM mechanical sample at 70℃ for 7 days, and test the tensile strength before and after boiling according to ASTM D638-2014 (tensile rate is 10mm / min), and calculate the tensile strength retention rate.

[0063] The calculation method is as follows: retention rate = tensile strength after boiling / tensile strength before boiling.

[0064] (2) Rigidity: The flexural modulus of the ASTM D790 mechanical specimen of the material is used as an indicator of rigidity.

[0065] The PC / SAS composite material of this invention is prepared by the following method: the components are mixed evenly according to the formula to obtain a premix; the premix is ​​added to a twin-screw extruder for melt blending and extrusion granulation to obtain the PC / SAS composite material; the temperature of the first and second zones of the extruder is 240°C, the temperature of the third and fifth zones is 250°C, and the temperature of the sixth and tenth zones is 255°C.

[0066] Examples 1-11

[0067] Examples 1-11 provide a series of PC / SAS composite materials, the formulations of which are shown in Table 1.

[0068] Table 1. Formulations (parts by weight) for Examples 1-10

[0069]

[0070]

[0071] Comparative Examples 1-5

[0072] Comparative Examples 1-5 provide a series of PC / SAS composite materials, the formulations of which are shown in Table 2, and the preparation methods are the same as in Example 1.

[0073] Table 2

[0074]

[0075] Table 3. Performance test results of PC / SAS composite materials in each example and comparative example.

[0076]

[0077]

[0078] As can be seen from Table 3:

[0079] The flexural modulus of the PC / SAS composite materials in Examples 1-11 are all above 5300 MPa, and the tensile strength retention rate is all above 70%, indicating that the PC / SAS composite materials of the present invention have good rigidity and hydrolysis resistance. Furthermore, since flame retardants were added to the PC / SAS composite materials of the examples, they all exhibit good flame retardant properties.

[0080] Compared with Example 1: Comparative Example 1, without the addition of SAS resin, showed poor hydrolysis resistance in the PC / SAS composite material; Comparative Example 2, with the addition of excessive SAS resin, showed a decrease in the rigidity of the PC / SAS composite material; Comparative Example 3, without the addition of glass fiber, showed a decrease in all properties of the PC / SAS composite material, with a significantly poor flexural modulus; Comparative Example 4, with the addition of AS resin, showed a decrease in the hydrolysis resistance of the PC / SAS composite material; Comparative Example 5, without the addition of elastomer, showed a decrease in the hydrolysis resistance of the PC / SAS composite material.

[0081] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A PC / SAS composite material, characterized in that, The components include the following parts by weight: 45 parts polycarbonate 12-13 parts of SAS resin, 3-4 parts elastomer 38-40 parts glass fiber Other auxiliary agents: 1-5 parts; The melt volume flow rate of the SAS resin at 220°C and 10kg load is 20~22cm. 3 / 10min; The polycarbonate is at least one of bisphenol A type polycarbonate or silicon copolymer polycarbonate.

2. The PC / SAS composite material according to claim 1, characterized in that, The polycarbonate is a silicon copolymer polycarbonate, wherein the mass content of siloxane is 3~5wt%.

3. The PC / SAS composite material according to claim 1, characterized in that, The elastomer is at least one of acrylate elastomer or high-polymer powder.

4. The PC / SAS composite material according to claim 1, characterized in that, The average diameter of the glass fiber is 10~20μm.

5. The PC / SAS composite material according to claim 1, characterized in that, The SAS resin has a mass percentage of 11-20% relative to polycarbonate.

6. The PC / SAS composite material according to claim 1, characterized in that, The other additives are at least one of weather-resistant agents or antioxidants.

7. The PC / SAS composite material according to claim 1, characterized in that, The PC / SAS composite material also includes 5-10 parts of phosphazene flame retardant and 0.2-1 part of anti-dripping agent.

8. A method for preparing the PC / SAS composite material according to any one of claims 1 to 7, characterized in that, The process includes the following steps: mixing the components, melt extrusion, and granulation to obtain the PC / SAS composite material.

9. The application of the PC / SAS composite material according to any one of claims 1 to 7 in the preparation of outdoor high-power electrical appliances.

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