A polycarbonate composition, its preparation and use

Abstract

The present application relates to a kind of polycarbonate composition and its preparation method and application.The polycarbonate composition includes the following weight parts of component:PC resin 59~96 parts, ultra-high molecular weight polyethylene 5~20 parts, sheet filler 3~8 parts, montan wax 0.1~0.3 parts.The polycarbonate composition of the present application has excellent flatness, excellent toughness and excellent wear resistance to metal simultaneously, and can be used for preparing battery turnover tray.

Description

Technical Field

[0001] This invention relates to the field of polymer material processing technology, and more specifically, to a polycarbonate composition, its preparation method, and its application. Background Technology

[0002] Due to the booming development of the new energy vehicle and energy storage industries in recent years, lithium batteries have become the preferred energy storage option due to their high energy density and long service life. During factory storage and transportation, lithium batteries are supported by plastic pallets. Due to the combined demands, these pallets require a high degree of flatness. Furthermore, the heavy weight of the batteries places stringent requirements on the toughness of the materials.

[0003] Due to its excellent mechanical properties and appearance, PC (polycarbonate) material is widely used in information and communication, consumer electronics, and home appliances. Considering toughness and flatness, PC material is the preferred material for turnover pallets.

[0004] Lithium iron phosphate batteries typically have metal casings. During long-term use, the metal can wear down the plastic trays, causing them to adhere to the battery's metal casing and affecting the battery's packaging and safety performance. Therefore, it is necessary to improve the wear resistance of PC material-made transfer trays to metal.

[0005] A Chinese patent entitled "A Wear-Resistant, Spray-Free Polycarbonate Material and Its Preparation Method and Application" points out that adding aluminum borate whiskers can improve the wear resistance of polycarbonate materials, but aluminum borate whiskers have a significant negative impact on the toughness of the material; and it does not take into account the flatness of the material.

[0006] Therefore, it is necessary to improve the wear resistance of PC materials to metals while taking into account both the flatness and toughness of the materials, so as to meet the requirements for their use in the manufacture of battery turnover trays. Summary of the Invention

[0007] The primary objective of this invention is to overcome the problem that existing PC materials cannot simultaneously achieve flatness, toughness, and wear resistance to metals, thus making them unsuitable for use in the manufacture of battery turnover trays, and to improve a polycarbonate composition.

[0008] A further object of the present invention is to provide a method for preparing the above-described polycarbonate composition.

[0009] A further object of the present invention is to provide the application of the above-described polycarbonate composition in the preparation of battery turnover trays.

[0010] A further object of the present invention is to provide a battery turnover tray.

[0011] The above-mentioned objective of the present invention is achieved through the following technical solution:

[0012] A polycarbonate composition comprising the following components in parts by weight:

[0013]

[0014] The mass ratio of ultra-high molecular weight polyethylene to sheet filler is 1:(0.28~1.1).

[0015] The inventors of this invention discovered through research that ultra-high molecular weight polyethylene (UHMWPE) can improve the smoothness of the surface of polycarbonate compositions, thereby improving the wear resistance of the polycarbonate compositions to metals. However, adding only UHMWPE disrupts the continuity of the main resin, thus deteriorating toughness, and its flexibility also deteriorates the smoothness.

[0016] The inventors of this invention further discovered that by adding sheet filler to the basis of ultra-high molecular weight polyethylene and adjusting the mass ratio of the two, the sheet filler and ultra-high molecular weight polyethylene can be reasonably distributed in the polycarbonate composition system (especially on the surface) to achieve synergy. This not only further improves the wear resistance of the polycarbonate composition to metals, but also improves the smoothness and toughness of the polycarbonate composition.

[0017] Controlling the mass ratio of ultra-high molecular weight polyethylene (UHMWPE) to sheet filler is crucial. If the amount of UHMWPE relative to the sheet filler is too small, the sheet filler will hinder the continuity of UHMWPE on the material surface, resulting in insufficient improvement in wear resistance. Furthermore, the sheet fillers will overlap, causing anisotropy during injection molding, leading to warping and reduced flatness. Conversely, if the amount of UHMWPE relative to the sheet filler is too large, the sheet filler on the polycarbonate composition surface cannot effectively suppress the flexibility of UHMWPE, resulting in poor material flatness and toughness.

[0018] In addition, the present invention incorporates montmorillonite wax, which reduces friction between resin molecular chains and enhances the rational distribution and dispersion of ultra-high molecular weight polyethylene and fillers on the surface of the polycarbonate composition. This not only makes the wear resistance of the polycarbonate composition excellent, but also makes the smoothness of the polycarbonate composition excellent.

[0019] In this invention, the amount of PC resin used can be 60, 65, 70, 75, 80, 85, 90 or 95 parts by weight; the amount of ultra-high molecular weight polyethylene used can be 5, 7, 9, 11, 13, 15, 17, 19 or 20 parts by weight; and the amount of sheet filler used can be 3, 4, 5, 6, 7 or 8 parts by weight.

[0020] In this invention, PC resin is used as the main resin, and preferably, its content is at least 60 wt% of the polycarbonate composition.

[0021] Preferably, the PC resin is a bisphenol A type PC resin.

[0022] Preferably, the viscosity-average molecular weight of the PC resin is 19,000 to 30,000.

[0023] More preferably, the viscosity-average molecular weight of the PC resin is 24,000 to 28,000. Using PC resins within this viscosity-average molecular weight range results in a polycarbonate composition with better toughness and wear resistance to metals.

[0024] In this invention, the viscosity-average molecular weight of PC resin can be determined by gel permeation chromatography.

[0025] The specific method for determining viscosity-average molecular weight is as follows: Refer to the test standard: GB / T 21863-2008: First, use tetrahydrofuran as the eluent. Mix 1-5 mg of sample with 1 mL of tetrahydrofuran solvent, heat at 80 °C, and after the sample is completely dissolved, inject the sample for testing and obtain the results.

[0026] In this invention, the mass ratio of ultra-high molecular weight polyethylene to sheet filler can be 1:0.3, 1:0.4, 1:0.5, 1:0.6, 1:0.7, 1:0.8, 1:0.9, 1:1 or 1:1.1.

[0027] Preferably, the mass ratio of ultra-high molecular weight polyethylene to sheet filler is 1:(0.5-1). Controlling the mass ratio within this range results in a polycarbonate composition with better wear resistance to metals and better smoothness.

[0028] Preferably, the weight-average molecular weight of the ultra-high molecular weight polyethylene is 3 million to 5.5 million. Specifically, it can be 3.2 million, 3.4 million, 3.5 million, 3.6 million, 3.7 million, 3.8 million, 3.9 million, 4 million, 4.2 million, 4.4 million, 4.5 million, 4.7 million, 4.9 million, or 5 million.

[0029] More preferably, the ultra-high molecular weight polyethylene has a weight-average molecular weight of 3.3 to 3.7 million. Using ultra-high molecular weight polyethylene with this weight-average molecular weight results in a polycarbonate composition with better wear resistance and higher toughness against metals.

[0030] In this invention, the weight-average molecular weight of ultra-high molecular weight polyethylene can be determined by gel permeation chromatography.

[0031] The specific method for determining the weight-average molecular weight is as follows: Referring to the test standard GB / T 21863-2008: First, use 0.025 g / L BHT in o-dichlorobenzene as the eluent. Mix 1–5 mg of sample with 1 mL of 0.025 g / L BHT in o-dichlorobenzene solvent, heat at 160 °C, and after the sample is completely dissolved, inject the sample for testing and obtain the results.

[0032] Preferably, the particle size D50 of the sheet-like filler is 1–18 μm.

[0033] More preferably, the particle size D50 of the sheet filler is 6-8 μm. Using sheet filler with this particle size D50 results in a polycarbonate composition with better wear resistance to metals and better smoothness.

[0034] In this invention, the particle size D50 of the sheet-like filler can be measured by laser diffraction.

[0035] Preferably, the sheet-like filler is at least one of talc, mica, or barium sulfate.

[0036] Preferably, the polycarbonate composition further includes 2 to 6 parts of a toughening agent.

[0037] More preferably, the toughening agent is at least one of ethylene-butyl acrylate-glycidyl methacrylate copolymer, ethylene-octene-glycidyl methacrylate copolymer, methyl methacrylate-butadiene-styrene copolymer, methyl methacrylate-acrylic acid copolymer, acrylic toughening agent, or organosilicon-acrylic acid copolymer.

[0038] More preferably, the toughening agent is a silicone-acrylic acid copolymer. Using a silicone-acrylic acid copolymer as the toughening agent results in polycarbonate compositions with better overall properties.

[0039] Preferably, the montana wax is at least one of E wax, OP wax, or S wax.

[0040] More preferably, the montana wax is E wax. Using E wax results in superior properties.

[0041] Preferably, the polycarbonate composition further includes 0.1 to 0.3 parts of other additives.

[0042] More preferably, the other additives are at least one of colorants or antioxidants.

[0043] More preferably, the colorant includes, but is not limited to, color powder.

[0044] More preferably, the antioxidant is at least one of hindered phenolic antioxidants or phosphite antioxidants.

[0045] More preferably, the hindered phenolic antioxidant is at least one of N,Nˋ-hexamethylene bis(3,5-di-tert-butyl-4-hydroxyphenylpropionamide (Irganox 1098), pentaerythritol tetrakis[1093,5-di-tert-butyl-4-hydroxyphenyl)propionate] (Irganox 1010), triethylene glycol bis-3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionate (Iragnox 259), octadecyl β-(4-hydroxy-3,5-di-tert-butylphenyl)propionate (Iragno 1076), or spiroethylene glycol bis[β-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionate] (ADK AO-80).

[0046] More preferably, the phosphite antioxidant is at least one of 2,4-di-tert-butylphenol (Irganox 168), pentaerythritol bis(2,6-di-tert-butyl-4-tolyl)phosphite (PEP-36), or 627A.

[0047] The preparation method of the above polycarbonate composition includes the following steps: mixing the components, melt extruding, and granulating to obtain the polycarbonate composition.

[0048] Preferably, the temperature of the melt extrusion is 220–260°C.

[0049] Preferably, the length-to-diameter ratio of the screw in the melt extrusion extruder is 40-50:1, and the screw speed is 400-500 rpm.

[0050] The application of the above-mentioned polycarbonate composition in the preparation of battery turnover trays is also within the scope of protection of this invention.

[0051] A battery turnover tray is made from the above-mentioned polycarbonate composition.

[0052] Compared with the prior art, the beneficial effects of the present invention are:

[0053] The polycarbonate composition of the present invention possesses excellent flatness, excellent toughness, and excellent wear resistance to metals, and can be used to prepare battery turnover trays. Detailed Implementation

[0054] 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.

[0055] The reagents used in the various embodiments and comparative examples of this invention are described below:

[0056] PC resin #1: Mitsubishi Japan, S-2000F, viscosity-average molecular weight is 25000;

[0057] PC resin #2: Mitsubishi Japan, H-3000, viscosity-average molecular weight is 20000;

[0058] PC resin #3: Mitsubishi Japan, E-2000F, viscosity-average molecular weight is 28000;

[0059] UHMWPE1#: Mitsui Chemicals, 340M, weight-average molecular weight is 3.5 million;

[0060] UHMWPE2#: Ticona, GUR4113, with a weight-average molecular weight of 3.7 million;

[0061] UHMWPE3#: Ticona, GUR4120, with a weight-average molecular weight of 4.7 million;

[0062] Ordinary polyethylene 1#: Model T0504F, purchased from Sinopec, with a weight-average molecular weight of 400,000;

[0063] Ordinary polyethylene #2: Model HTA108, purchased from ExxonMobil, with a weight-average molecular weight of 100,000;

[0064] Flaky filler #1: Talc, HY-TA08, Shenzhen Haiyang Powder, particle size D50 is 7.7μm;

[0065] Flaky filler #2: Talc, HY-TA05, Shenzhen Haiyang Powder, particle size D50 is 4.0μm;

[0066] Flaky filler #3: Talc, HY-TA10, Shenzhen Haiyang Powder, particle size D50 is 11.2μm;

[0067] Flaky filler #4: Mica, GM-6, Anhui Green New Material Technology Co., Ltd., particle size D50 is 17.0μm;

[0068] Non-flaky filler #1: fibrous, wollastonite, WFC5-4101, Hubei Fengjiashan Silicon Fiber Co., Ltd., particle size D50 is 5.9μm;

[0069] Non-flaky filler #2: granular, calcium carbonate, Omyacarb 5T-JI, particle size D50 is 4.9μm;

[0070] Toughening agent 1#: SX-005, Mitsubishi Rayon, silicone-acrylic acid copolymer;

[0071] Toughening agent 2#: M-701, Mitsubishi, Japan, methyl methacrylate-butadiene-styrene copolymer;

[0072] Toughening agent 3#: PTW, DuPont, ethylene-butyl acrylate-glycidyl methacrylate copolymer;

[0073] Montana Wax 1#: Montana Wax, E Wax, Clariant, Licowax E flakes;

[0074] Montana Wax #2: Montana wax, OP wax, Clariant, Licowax OP flake;

[0075] Montana Wax 3#: Montana Wax, S Wax, Clariant, Licowax S;

[0076] Lubricant #1: Silicone powder, Dongguan Shanyi Plastic Chemical Co., Ltd., SY-306A;

[0077] Lubricant #2: Pentaerythritol stearate, hair base, PETS-AHS;

[0078] Other additives #1: Antioxidant 1076, commercially available.

[0079] Unless otherwise specified, all components (e.g., other additives 1#) used in the parallel examples and comparative examples are the same commercially available products.

[0080] The polycarbonate compositions provided in the embodiments and comparative examples of the present invention were subjected to performance testing according to the following test methods:

[0081] 1. Abrasion Resistance: A 200*200*2.2mm rectangular plate was used for evaluation, employing an automotive interior parts abrasion and discoloration testing machine. A 500g weight was applied, the stroke was 100mm, and 1000 strokes were tested. The difference in mass before and after friction was measured in mg; a smaller difference indicates better abrasion resistance.

[0082] 2. Toughness: Cantilever beam notched impact test ISO 180-2019. The higher the notched impact strength, the better the toughness.

[0083] 3. Flatness: With a 100*100*2.0mm plate, glue is injected from the side with an injection port of 0.5mm. With one corner of the square plate pressed down, observe the height of the diagonal from the countertop on the marble table. The higher the height, in mm, the worse the flatness.

[0084] The preparation process of the polycarbonate compositions of the various embodiments and comparative examples of the present invention is as follows: Each component is weighed according to the formula, mixed, and then extruded in a twin-screw extruder. After the melt granulation process, the polycarbonate composition is obtained. The temperature of the twin-screw extruder is as follows: Zone 1 temperature is 230℃, Zone 2 temperature is 240℃, Zone 3 temperature is 250℃, Zone 4 temperature is 250℃, Zone 5 temperature is 250℃, Zone 6 temperature is 250℃, Zone 7 temperature is 250℃, Zone 8 temperature is 240℃, Zone 9 temperature is 230℃, the die head temperature is 220℃, the screw length-to-diameter ratio is 45:1, and the screw speed is 450 rpm.

[0085] Examples 1-16

[0086] Examples 1-16 provide a series of polycarbonate compositions, the formulations of which are shown in Table 1.

[0087] Table 1. Formulations (parts by weight) for Examples 1-16

[0088]

[0089]

[0090] Continued from Table 1

[0091]

[0092] Comparative Examples 1-10

[0093] Comparative Examples 1-10 provide a series of polycarbonate compositions, the preparation process of which is basically the same as that of Example 1, except for the formulation, which is shown in Table 2.

[0094] Table 2 shows the formulations (parts by weight) for Comparative Examples 1–10.

[0095]

[0096] The properties of the polycarbonate compositions of each embodiment and comparative example were determined according to the test methods mentioned above, and the test results are shown in Table 3.

[0097] Table 3. Performance test results of the polycarbonate compositions of each embodiment and comparative example.

[0098]

[0099]

[0100] As can be seen from Table 3:

[0101] The mass change values ​​in the abrasion resistance tests of the polycarbonate compositions in Examples 1-16 were all less than 5.2 mg, and the impact strength was all greater than 45 kJ / m. 2The height in the flatness test was less than 0.1 mm, indicating that the polycarbonate composition of the present invention has good toughness, good flatness, and good wear resistance to metals, and can be used to prepare battery turnover trays.

[0102] Comparative Examples 1 and 2, containing ordinary polyethylene with a lower molecular weight, resulted in polycarbonate compositions with poor wear resistance to metals. Comparative Examples 3 and 4, containing non-flaky fillers, also resulted in polycarbonate compositions with poor wear resistance and smoothness. Comparative Example 5, containing excessive amounts of ultra-high molecular weight polyethylene relative to the amount of flaky filler, resulted in polycarbonate compositions with poor toughness and smoothness. Comparative Example 6, containing insufficient amounts of ultra-high molecular weight polyethylene relative to the amount of flaky filler, resulted in polycarbonate compositions with poor wear resistance and smoothness. Comparative Example 7, without flaky filler, resulted in polycarbonate compositions with poor wear resistance, toughness, and smoothness. Comparative Example 8, without ultra-high molecular weight polyethylene, also resulted in polycarbonate compositions with poor wear resistance and smoothness. Comparative Examples 9 and 10, using unsuitable lubricants, resulted in polycarbonate compositions with poor wear resistance and smoothness.

[0103] 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 can make other variations or modifications 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 polycarbonate composition characterized in that, The components include the following parts by weight: 60-95 parts of PC resin, 5-20 parts of ultra-high molecular weight polyethylene 3-8 parts of sheet packing 2-6 parts toughening agent Montana wax 0.1~0.3 parts; The mass ratio of ultra-high molecular weight polyethylene to sheet filler is 1:(0.3~1.1).

2. The polycarbonate composition of claim 1, wherein, The viscosity-average molecular weight of the PC resin is 19,000 to 30,000.

3. The polycarbonate composition according to claim 1, characterized in that, The weight-average molecular weight of the ultra-high molecular weight polyethylene is 3 million to 5.5 million.

4. The polycarbonate composition according to claim 1, characterized in that, The particle size D50 of the sheet-like filler is 1~18μm.

5. The polycarbonate composition according to claim 1, characterized in that, The sheet-like filler is at least one of talc, mica, or barium sulfate.

6. The polycarbonate composition according to claim 1, characterized in that, The montana wax is at least one of E wax, OP wax, or S wax.

7. A method for preparing the polycarbonate composition according to any one of claims 1 to 6, characterized in that, The process includes the following steps: mixing the components, melt extruding, and granulating to obtain the polycarbonate composition.

8. The use of the polycarbonate composition according to any one of claims 1 to 6 in the preparation of battery turnover trays.

9. A battery turnover tray, characterized in that, It is prepared from the polycarbonate composition according to any one of claims 1 to 6.

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