Polycarbonate composite material, imitation flocked master batch and preparation method and application thereof

Abstract

The application relates to a polycarbonate composite material, a suede-like master batch and a preparation method and application thereof. According to mass percentage, the preparation raw material of the polycarbonate composite material comprises 80-95% of a resin base and 5-20% of a suede-like master batch; the resin base contains a first PC resin; according to 100% of the total mass percentage of the suede-like master batch, the suede-like master batch comprises 65.3-90% of a second PC resin, 5.3-30% of wool and 1.4-4.7% of an auxiliary agent. The polycarbonate composite material has good suede-like effect and good flame retardance and mechanical properties.

Description

Technical Field

[0001] This application relates to the field of polycarbonate materials, and in particular to a polycarbonate composite material, a flocking-inspired masterbatch, its preparation method, and its application. Background Technology

[0002] In recent years, the application scope of polycarbonate (PC) resin materials has been gradually expanding in fields such as consumer goods, electronics, and security monitoring. In traditional applications, polycarbonate is used as a substrate, and surface painting is often required to achieve a certain effect. However, surface painting has problems such as complex processes, long time consumption, high overall costs, significant pollution of the production line environment, high defect rates, and exposure of the substrate after paint damage and peeling. Paint-free materials can inject the desired effect components and resin into the product in one injection molding process, satisfying both the aesthetics and application performance of plastic parts. Moreover, the product does not require post-painting treatment, is energy-saving and environmentally friendly, has a short production cycle, and high production efficiency, which can significantly reduce the overall industrialization cost. At the same time, it can give the product surface a rich aesthetic appearance, meeting different application scenarios and the increasing demand for personalization.

[0003] Plastic products with unique aesthetic effects are becoming increasingly popular. Among them, the flocked effect is widely favored by consumers and manufacturers due to its unique and elegant texture, realistic three-dimensional fiber feel, and soft, skin-friendly visual effect. However, current paint-free polycarbonate products still struggle to simultaneously achieve a good flocked effect with flame retardancy and mechanical properties, limiting their further application. Summary of the Invention

[0004] Based on this, some embodiments of this application provide a polycarbonate composite material with both good flocking effect and good flame retardancy and mechanical properties, and a method for preparing the same.

[0005] In addition, some other embodiments of this application also provide a flocking-like masterbatch, its preparation method, and its application.

[0006] A polycarbonate composite material, wherein the raw materials for preparing the polycarbonate composite material, by weight percentage, include: 80%~95% resin base and 5%~20% flocking masterbatch;

[0007] The resin base contains a first PC resin; based on the total mass percentage of the imitation flocking masterbatch as 100%, the imitation flocking masterbatch includes: 65.3%~90% of the first PC resin, 5.3%~30% of the flocking fibers, and 1.4%~4.7% of the additives.

[0008] In some embodiments, the flocking mass percentage in the flocked masterbatch is 10% to 25%.

[0009] In some embodiments, the second PC resin comprises 72% to 87% by mass in the flocked masterbatch.

[0010] In some embodiments, the raw materials for preparing the polycarbonate composite material, by weight percentage, include: 80% to 90% resin base and 10% to 20% flocking masterbatch.

[0011] In some embodiments, the additives include a second antioxidant of 0.1% to 0.3% by mass of the flocked masterbatch, a second lubricant of 0.1% to 0.4% by mass of the second lubricant, a second flame retardant of 0.2% to 1% by mass of the second white masterbatch, and a second white masterbatch of 1% to 3% by mass of the second white masterbatch.

[0012] In some embodiments, the fluff includes one or more of fiber filaments, marble filaments, and injection-molded fiber fluff.

[0013] In some embodiments, the average fiber diameter of the fluff is 0.015 mm to 0.15 mm, and the average fiber length is 0.5 mm to 1.5 mm.

[0014] In some embodiments, the down comprises a mixture of down fibers with different average fiber lengths and / or average fiber diameters.

[0015] In some embodiments, the fibers include a first fiber, a second fiber, and a third fiber in a mass ratio of 1:(0.5~1.5):(0.5~1), wherein the average fiber diameter of the first fiber is less than the average fiber diameter of the second fiber and the average fiber diameter of the third fiber, and the average fiber length of the first fiber is greater than the average fiber length of the second fiber and the average fiber length of the third fiber.

[0016] In some embodiments, the resin base material comprises, by weight parts: 80 to 95 parts of first PC resin, 0 to 1 part of first antioxidant, 0 to 4 parts of first lubricant, 0 to 2 parts of first flame retardant, 1 to 3 parts of first white masterbatch, and 0.001 to 0.01 parts of color powder.

[0017] In some embodiments, the resin base material comprises, by weight parts: 80 to 90 parts of first PC resin, 0.1 to 0.3 parts of first antioxidant, 0.1 to 0.4 parts of first lubricant, 0.2 to 1 part of first flame retardant, 1 to 3 parts of first white masterbatch, and 0.001 to 0.01 parts of color powder.

[0018] In some embodiments, the resin base material comprises, by weight parts: 80 to 90 parts of first PC resin, 0.1 to 0.3 parts of first antioxidant, 0.1 to 0.4 parts of first lubricant, 0.7 to 1 part of first flame retardant, 2 to 3 parts of first white masterbatch, and 0.005 to 0.01 parts of color powder.

[0019] In some embodiments, the resin base material includes a first PC resin, a first antioxidant, a first lubricant, a first flame retardant, a first white masterbatch, and color powder; by mass parts, the raw materials for preparing the polycarbonate composite material include: 5 to 20 parts of flocked imitation masterbatch, 80 to 95 parts of the first PC resin, 0 to 1 part of the first antioxidant, 0 to 4 parts of the first lubricant, 0 to 2 parts of the first flame retardant, 1 to 3 parts of the first white masterbatch, and 0.001 to 0.01 parts of color powder.

[0020] In some embodiments, the raw materials for preparing the polycarbonate composite material, by weight, include: 10 to 20 parts of flocked masterbatch, 80 to 90 parts of first PC resin, 0.1 to 0.3 parts of first antioxidant, 0.1 to 0.4 parts of first lubricant, 0.2 to 1 part of first flame retardant, 1 to 3 parts of first white masterbatch, and 0.001 to 0.01 parts of color powder.

[0021] In some embodiments, the raw materials for preparing the polycarbonate composite material, by weight, include: 10 to 20 parts of flocked masterbatch, 80 to 90 parts of first PC resin, 0.1 to 0.3 parts of first antioxidant, 0.1 to 0.4 parts of first lubricant, 0.7 to 1 part of first flame retardant, 2 to 3 parts of first white masterbatch, and 0.005 to 0.01 parts of color powder.

[0022] In some embodiments, under test conditions of 300°C and a load of 1.2 kg, the melt flow index of the first PC resin and the second PC resin are each independently 3 g / 10 min to 65 g / 10 min.

[0023] In some embodiments, under test conditions of 300°C and a load of 1.2 kg, the melt flow index of the first PC resin and the second PC resin are each independently 5 g / 10 min to 40 g / 10 min.

[0024] In some embodiments, under test conditions of 300°C and a load of 1.2 kg, the melt flow index of the first PC resin and the second PC resin are each independently 7 g / 10 min to 30 g / 10 min.

[0025] A method for preparing a polycarbonate composite material includes the following steps:

[0026] The following raw materials are obtained by weight percentage: 80%~95% resin base and 5%~20% imitation flocking masterbatch; wherein, the resin base contains a first PC resin; and based on the total weight percentage of the imitation flocking masterbatch as 100%, the imitation flocking masterbatch comprises: 65.3%~90% first PC resin, 5.3%~30% flocking fibers, and 1.4%~4.7% additives;

[0027] The composite material is prepared by mixing the flocking masterbatch and the resin base and injection molding.

[0028] In some embodiments, the preparation steps of the flocking-like masterbatch include:

[0029] At a first rotation speed, the fluff and a portion of the second PC resin are mixed, and the remaining second PC resin and the additives are added and the mixture is continued.

[0030] The resulting mixture was extruded and granulated to prepare the flocking-like masterbatch;

[0031] Wherein, the first rotational speed is less than the second rotational speed, and the second rotational speed is the rotational speed in the step of mixing the imitation flocking masterbatch and the resin base material.

[0032] In some embodiments, the first rotational speed is 50 rpm to 80 rpm, and the second rotational speed is 100 rpm to 200 rpm.

[0033] In some embodiments, a portion of the second PC resin accounts for 40% to 60% of the total mass of the second PC resin.

[0034] In some embodiments, during the extrusion granulation step, the extrusion temperature is 270°C to 300°C and the screw speed is 200 rpm to 1000 rpm.

[0035] In some embodiments, during the injection molding step, the injection temperature is 290℃~310℃, the injection pressure is 50MPa~65MPa, and the speed of the injection molding machine is 200rpm~500rpm.

[0036] Applications of the polycarbonate composite materials described above, or polycarbonate composite materials prepared by the methods described above, in the fields of electronics and electrical engineering, security monitoring, home appliance casings, or consumer products.

[0037] In some embodiments, the polycarbonate composite material is used in the manufacture of electronic and electrical products, security monitoring products, appliance housings, or consumer products.

[0038] A method for preparing a flocking-inspired masterbatch includes the following steps:

[0039] The following raw materials are obtained by weight percentage: 65.3%~90% second PC resin, 5.3%~30% fluff, and 1.4%~4.7% additives;

[0040] At a speed of 50 rpm to 80 rpm, the fluff and a portion of the second PC resin are mixed, and the remaining second PC resin and the additives are added and mixed further.

[0041] The resulting mixture was extruded and granulated to prepare the flocking-like masterbatch.

[0042] In some embodiments, during the extrusion granulation step, the extrusion temperature is 270°C to 300°C and the screw speed is 200 rpm to 1000 rpm.

[0043] In some embodiments, a portion of the second PC resin accounts for 40% to 60% of the total second PC resin by mass.

[0044] A flocking-like masterbatch is prepared by the above-described preparation method.

[0045] This study found that due to the high processing temperature of polycarbonate, if the flocking is directly mixed with polycarbonate resin and additives using traditional processes, the flocking will be damaged during subsequent processing and molding due to its poor shear and heat resistance. This results in problems such as fragmentation and difficulty in maintaining a good appearance after dyeing, leading to poor flocking-like effects in paint-free polycarbonate products. Traditional techniques typically increase the amount of flocking added to improve the flocking effect; however, this significantly reduces the flame retardancy and mechanical properties of the polycarbonate material. Therefore, it is difficult for polycarbonate materials using traditional techniques to simultaneously achieve good flocking-like effects and good flame retardancy and mechanical properties. Based on this, some embodiments of this application provide a polycarbonate composite material, including a resin base and a flocking masterbatch. The resin base contains a first PC resin, and the flocking masterbatch includes a certain proportion of flock, a second PC resin, and additives. By adding the flock in the form of a flocking masterbatch to the polycarbonate composite material and adjusting the proportions of each component, it is not easily sheared during high-temperature, high-shear-heat processing. With a smaller addition amount than traditional technologies, a good and obvious matte flocking surface effect is achieved, which can present a realistic rock texture from various viewing angles. At the same time, it ensures good mechanical properties and flame retardant properties, and solves the contradiction between the flocking effect with good length retention and the mechanical and flame retardant properties of the material. It provides a polycarbonate material with a flocking-free effect that combines a distinct, unique, elegant texture, a simulated three-dimensional fiber feel, and a soft, skin-friendly visual effect, as well as excellent flame retardant and mechanical properties. Attached Figure Description

[0046] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0047] Figure 1 This is a schematic diagram of a process flow for preparing polycarbonate composite materials according to some embodiments of this application;

[0048] Figure 2 This is an image showing the appearance of the polycarbonate composite material prepared in Example 1 of this application;

[0049] Figure 3 This is an image showing the appearance of the polycarbonate composite material prepared in Example 3 of this application;

[0050] Figure 4 The image shows the appearance of the polycarbonate composite material prepared in Comparative Example 1 of this application.

[0051] Figure 5 This is an image showing the appearance of the polycarbonate composite material prepared in Comparative Example 2 of this application. Detailed Implementation

[0052] To facilitate understanding of this application, a more comprehensive description of the application will be provided below in conjunction with specific embodiments. Preferred embodiments of the application are given in the specific embodiments. However, this application can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this application.

[0053] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein in the specification of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0054] Unless otherwise stated or in case of conflict, the terms or phrases used in this application shall have the following meanings:

[0055] In this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" and "second" may explicitly or implicitly include at least one of those features.

[0056] In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise expressly and specifically limited.

[0057] In this application, "one or more" refers to any one, any two, or any two or more of the listed items. "Several" refers to any two or more.

[0058] Unless otherwise specified, all percentage concentrations mentioned in this application refer to the final concentration. The final concentration refers to the proportion of the added component in the system after the addition of that component.

[0059] In this document, terms such as "further," "even further," "especially," "for example," "as," "example," and "exemplary" are used for descriptive purposes to indicate a connection in the coverage of different technical solutions presented earlier and later. However, they should not be construed as limitations on the preceding technical solution or on the scope of protection of this document. Unless otherwise specified, A (as in B) indicates that B is a non-limiting example of A, and it can be understood that A is not limited to B.

[0060] In this document, "optionally," "optionally," and "optional" mean that something is optional, that is, it is selected from either "present" or "absent." If multiple "options" appear in a technical solution, unless otherwise specified and there are no contradictions or mutual constraints, each "option" is independent. In this application, descriptions such as "optionally contains" and "optionally includes" indicate "contains or does not contain." "Optional component X" indicates whether component X exists or does not exist, or whether component X is contained or not.

[0061] When a numerical range is disclosed in this application, the range is considered continuous and includes the minimum and maximum values ​​of the range, as well as every value between the minimum and maximum values. Furthermore, when the range refers to an integer, it includes every integer between the minimum and maximum values ​​of the range. Additionally, when multiple ranges are provided to describe a feature or characteristic, the ranges may be merged. In other words, unless otherwise specified, all ranges disclosed in this application should be understood to include any and all subranges to which they are included.

[0062] In this application, the technical features described in an open-ended manner include both closed technical solutions consisting of the listed features and open technical solutions that include the listed features.

[0063] The terms "comprising" and "having," and any variations thereof, used in the embodiments of this application, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the steps or units listed, but may optionally include steps or units not listed, or may optionally include other steps or components inherent to such processes, methods, products, or devices.

[0064] In this application, the reference to "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a mutually exclusive, independent, or alternative embodiment. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described in this application can be combined with other embodiments.

[0065] The first aspect of this application provides a polycarbonate composite material, wherein the raw materials for preparing the polycarbonate composite material, by weight percentage, include: 80%~95% resin base and 5%~20% flocking masterbatch;

[0066] The resin base contains a first PC resin; based on the total mass percentage of the imitation flocking masterbatch as 100%, the imitation flocking masterbatch includes: 65.3%~90% of a second PC resin, 5.3%~30% of flocking fibers, and 1.4%~4.7% of additives.

[0067] This study found that due to the high processing temperature of polycarbonate, if the flocking material is directly mixed with polycarbonate resin and additives using traditional processes, the flocking material suffers from poor shear and heat resistance during subsequent molding. This leads to problems such as fragmentation and difficulty in maintaining a good appearance after dyeing, resulting in poor flocking-like effects in paint-free polycarbonate products. To improve the flocking-like effect, the amount of flocking material added is usually increased; however, this significantly reduces the flame retardancy and mechanical properties of the polycarbonate material, thus affecting its application in demanding fields such as electronics, security monitoring, appliance housings, and consumer goods. Therefore, it is difficult for polycarbonate materials using traditional techniques to simultaneously achieve good flocking-like effects and good flame retardancy and mechanical properties.

[0068] Based on this, some embodiments of this application provide a polycarbonate composite material, including a resin base and a flocking masterbatch. The resin base contains a first PC resin, and the flocking masterbatch includes a certain proportion of flock, a second PC resin, and additives. By adding the flock in the form of a flocking masterbatch to the polycarbonate composite material and adjusting the proportions of each component, it is not easily sheared during high-temperature, high-shear-heat processing. With a smaller addition amount than traditional technologies, a good and obvious matte flocking surface effect is achieved, presenting a realistic rock texture from various viewing angles, adding aesthetic appeal to paint-free products. At the same time, it ensures good mechanical and flame-retardant properties, resolving the contradiction between the flocking effect with good length retention and the material's mechanical and flame-retardant properties. It provides a polycarbonate material with a distinct, unique, elegant texture, a simulated three-dimensional fiber feel, and a soft, skin-friendly visual effect, achieving both a flocking paint-free effect and excellent flame-retardant and mechanical properties. It can be used in fields with stringent requirements for appearance, production processes, and performance, such as electronics, security monitoring, home appliance casings, and consumer goods, and has good economic development prospects and broad industrial application value.

[0069] In one example, the mass percentage of the resin base in the raw materials for preparing the polycarbonate composite material may be, but is not limited to, 80%, 82%, 84%, 85%, 86%, 88%, 90%, 92%, 94%, 95%, or any combination of these values. Optionally, the mass percentage of the resin base in the raw materials for preparing the polycarbonate composite material is 80% to 90%.

[0070] In one example, the mass percentage of the flocking masterbatch in the raw materials for preparing the polycarbonate composite material may be, but is not limited to, 5%, 6%, 8%, 10%, 12%, 14%, 15%, 16%, 18%, 20%, or any combination of these values. Optionally, the mass percentage of the flocking masterbatch in the raw materials for preparing the polycarbonate composite material is 10% to 20%.

[0071] In one embodiment, the raw materials for preparing the polycarbonate composite material, by weight percentage, include: 80% to 90% resin base and 10% to 20% flocking masterbatch.

[0072] In some embodiments, the resin base material includes a first PC resin, a first antioxidant, a first lubricant, a first flame retardant, a first white masterbatch, and a colorant. In some embodiments, the resin base material includes, by weight parts: 80 to 95 parts of the first PC resin, 0 to 1 part of the first antioxidant, 0 to 4 parts of the first lubricant, 0 to 2 parts of the first flame retardant, 1 to 3 parts of the first white masterbatch, and 0.001 to 0.01 parts of the colorant.

[0073] Optionally, by weight, the resin base material includes: 80 to 90 parts of first PC resin, 0.1 to 0.3 parts of first antioxidant, 0.1 to 0.4 parts of first lubricant, 0.2 to 1 part of first flame retardant, 1 to 3 parts of first white masterbatch, and 0.001 to 0.01 parts of color powder.

[0074] Optionally, by weight, the resin base material includes: 80 to 90 parts of first PC resin, 0.1 to 0.3 parts of first antioxidant, 0.1 to 0.4 parts of first lubricant, 0.7 to 1 part of first flame retardant, 2 to 3 parts of first white masterbatch, and 0.005 to 0.01 parts of color powder.

[0075] Furthermore, by weight, the resin base material includes: 80 to 90 parts of the first PC resin, 0.2 parts of the first antioxidant, 0.2 parts of the first lubricant, 0.7 to 1 part of the first flame retardant, 2 to 3 parts of the first white masterbatch, and 0.0062 parts of color powder.

[0076] In one example, the mass percentage of the second PC resin in the flocking-simulated masterbatch may be, but is not limited to, 65.3%, 68%, 70%, 72%, 75%, 80%, 85%, 86%, 87%, 88%, 89%, 90%, or any combination of these values. Optionally, the mass percentage of the second PC resin in the flocking-simulated masterbatch is 72% to 87%.

[0077] In one example, the mass percentage of flock in the flocking masterbatch can be, but is not limited to, 5.3%, 6%, 7%, 8%, 9%, 10%, 15%, 20%, 25%, 30%, or any combination of these values. Optionally, the mass percentage of flock in the flocking masterbatch is 10% to 25%.

[0078] In some embodiments, based on a total mass percentage of 100% of the flocking masterbatch, the flocking masterbatch comprises: 72% to 87% of the second PC resin, 10% to 25% of the flocking material, and 1.4% to 4.7% of the additives.

[0079] In some embodiments of this application, by optimizing the content of flocking fibers and the amount of flocking masterbatch, the prepared polycarbonate composite material can possess both good flocking effect and mechanical and flame-retardant properties. Specifically, when the flocking content is too low, it is easily covered by additives such as white masterbatch and color powder, resulting in a lack of rich simulated three-dimensional fiber texture and soft, skin-friendly visual effect; when the flocking content is too high, the flame-retardant properties of the polycarbonate composite material decrease significantly. In addition, the long residence time of the flocking fibers in the screw leads to greater shear heat accumulation, which can cause the flocking color to fall off, resulting in a change in the base color of the part. At the same time, the average molecular weight of the prepared polycarbonate composite material decreases, the melt index increases, and the impact resistance of the material weakens.

[0080] In some embodiments, the flocking includes one or more of fiber filaments, marble filaments, and injection-molded fiber filaments. When applied to polycarbonate composites, this flocking can achieve a three-dimensional, rich flocking appearance.

[0081] In some embodiments, the average fiber diameter of the fluff is 0.015 mm to 0.15 mm, and the average fiber length is 0.5 mm to 1.5 mm. For example, the average fiber diameter of the fluff may be, but is not limited to, 0.015 mm, 0.02 mm, 0.03 mm, 0.05 mm, 0.06 mm, 0.08 mm, 0.1 mm, 0.12 mm, 0.14 mm, 0.15 mm, or any combination of these values. The average fiber length may be, but is not limited to, 0.5 mm, 0.6 mm, 0.8 mm, 1 mm, 1.2 mm, 1.4 mm, 1.5 mm, or any combination of these values.

[0082] In some embodiments, the down comprises a mixture of down fibers with different average fiber lengths and / or average fiber diameters.

[0083] Optionally, the pile includes a first pile, a second pile, and a third pile in a mass ratio of 1:(0.5~1.5):(0.5~1), wherein the average fiber diameter of the first pile is less than the average fiber diameter of the second pile and the average fiber diameter of the third pile, and the average fiber length of the first pile is greater than the average fiber length of the second pile and the average fiber length of the third pile.

[0084] The above-mentioned flocking compounding method is beneficial to further improve the flocking effect, mechanical properties, and flame retardant properties of the prepared polycarbonate composite material.

[0085] In some embodiments, the additives include 0.1% to 0.3% by weight of a second antioxidant, 0.1% to 0.4% by weight of a second lubricant, 0.2% to 1% by weight of a second flame retardant, and 1% to 3% by weight of a second white masterbatch. Specifically, by weight percentage, the flocking masterbatch comprises: 65.3% to 90% second PC resin, 5.3% to 30% flocking, 0.1% to 0.3% second antioxidant, 0.1% to 0.4% second lubricant, 0.2% to 1% second flame retardant, and 1% to 3% second white masterbatch.

[0086] In some embodiments, the first PC resin and the second PC resin each independently comprise one or more of aromatic polycarbonate, aliphatic polycarbonate, and aromatic-aliphatic polycarbonate. Specifically, under test conditions of 300°C and a load of 1.2 kg, the melt flow index (MFR) of the first PC resin and the second PC resin each independently ranges from 3 g / 10 min to 65 g / 10 min. For example, under test conditions of 300°C and a load of 1.2 kg, the melt flow index of the first PC resin and the second PC resin each independently ranges from 3 g / 10 min, 5 g / 10 min, 7 g / 10 min, 10 g / 10 min, 15 g / 10 min, 20 g / 10 min, 25 g / 10 min, 30 g / 10 min, 35 g / 10 min, 40 g / 10 min, 45 g / 10 min, 50 g / 10 min, 60 g / 10 min, 65 g / 10 min, or any combination of these values. Furthermore, under test conditions of 300℃ and a load of 1.2kg, the melt flow indices of the first PC resin and the second PC resin were each independently between 5g / 10min and 40g / 10min. Even further, under test conditions of 300℃ and a load of 1.2kg, the melt flow indices of the first PC resin and the second PC resin were each independently between 7g / 10min and 30g / 10min.

[0087] In one embodiment, the first PC resin and the second PC resin each independently comprise bisphenol A type polycarbonate. For example, the first PC resin and the second PC resin each independently comprise one or more of Wanhua Chemical 2100, Wanhua Chemical 2150, and Wanhua Chemical 2220.

[0088] It is understood that in this application, the first PC resin and the second PC resin may be the same or different. The terms "first" and "second" are used only to distinguish between the PC resin in the resin base and the flocking masterbatch, and should not be construed as indicating or implying relative importance or implicitly specifying the number of the indicated technical features. Similarly, the terms "first antioxidant," "second antioxidant," etc., have similar meanings and will not be elaborated further.

[0089] In some embodiments, the first antioxidant and the second antioxidant each independently comprise one or more of hindered phenols, phosphites, thioesters, benzofurans, acryloyl-modified phenols, and hydroxylamines. In one embodiment, the first antioxidant and the second antioxidant each independently comprise one or more of hindered phenols and phosphites. In one example, the first antioxidant and the second antioxidant each independently comprise one or more of antioxidant 1076, antioxidant 1010, and antioxidant 168. Antioxidants 1076, 1010, and 168 can be commercially available; for example, the first antioxidant and the second antioxidant each independently comprise one or more of BASF's Irganox 1076, Irganox 1010, and Irganox 168. In a specific example, the first antioxidant and the second antioxidant each independently comprise antioxidant 1076 and antioxidant 168.

[0090] In some embodiments, the first lubricant and the second lubricant each independently comprise one or more of fatty alcohols, metallic soaps, fatty acids, fatty acid esters, lignite and its derivatives, amide waxes, saturated hydrocarbons, polyolefin waxes and their derivatives, organosilicon and silicone powders, and organofluorine compounds. In one embodiment, the first lubricant and the second lubricant each independently comprise one or more of fatty acid esters and organosilicones. Further, the first lubricant and the second lubricant each independently comprise fatty acid esters. For example, the first lubricant and the second lubricant each independently comprise pentaerythritol stearate (PETS).

[0091] In some embodiments, the first flame retardant and the second flame retardant each independently comprise one or more of phosphorus-based flame retardants, silicone-based flame retardants, sulfonate-based flame retardants, and brominated flame retardants. Phosphorus-based flame retardants include one or more of ammonium phosphate and phosphonate esters. In one example, the first flame retardant and the second flame retardant each independently comprise one or more of sulfonate-based flame retardants. For example, the first flame retardant and the second flame retardant each independently comprise one or more of KSS and KFR-KKS.

[0092] In some embodiments, the colorant includes one or more of carbon black and titanium yellow pigment. In one example, the colorant includes carbon black 50L and titanium yellow pigment 1038. It is understood that only two common colorants are given above, but the invention is not limited to these, and the type of colorant can be adjusted according to the color, application, etc., of the polycarbonate composite material to be prepared.

[0093] It is understood that, unless otherwise specified, all raw materials and reagents used in this application can be purchased through commercial channels.

[0094] In some embodiments, the resin base material includes a first PC resin, a first antioxidant, a first lubricant, a first flame retardant, a first white masterbatch, and a color powder; by mass parts, the raw materials for preparing the polycarbonate composite material include: 5 to 20 parts of flocked masterbatch, 80 to 95 parts of the first PC resin, 0 to 1 part of the first antioxidant, 0 to 4 parts of the first lubricant, 0 to 2 parts of the first flame retardant, 1 to 3 parts of the first white masterbatch, and 0.001 to 0.01 parts of color powder.

[0095] Optionally, the raw materials for preparing the polycarbonate composite material, by mass parts, include: 10 to 20 parts of flocked masterbatch, 80 to 90 parts of first PC resin, 0.1 to 0.3 parts of first antioxidant, 0.1 to 0.4 parts of first lubricant, 0.2 to 1 part of first flame retardant, 1 to 3 parts of first white masterbatch, and 0.001 to 0.01 parts of color powder.

[0096] Optionally, the raw materials for preparing the polycarbonate composite material, by mass parts, include: 10 to 20 parts of flocked masterbatch, 80 to 90 parts of first PC resin, 0.1 to 0.3 parts of first antioxidant, 0.1 to 0.4 parts of first lubricant, 0.7 to 1 part of first flame retardant, 2 to 3 parts of first white masterbatch, and 0.001 to 0.01 parts of color powder.

[0097] Furthermore, by mass parts, the raw materials for preparing polycarbonate composite materials include: 10 to 20 parts of flocked masterbatch, 80 to 90 parts of first PC resin, 0.2 parts of first antioxidant, 0.2 parts of first lubricant, 0.7 to 1 part of first flame retardant, 2 to 3 parts of first white masterbatch, and 0.0062 parts of color powder.

[0098] By optimizing the composition and ratio of polycarbonate composite materials, it is possible to achieve better paint-free flocking effect, mechanical properties, and flame retardant properties.

[0099] The raw materials for the above-mentioned polycarbonate composite material can be processed by injection molding to produce a paint-free appearance part with a flocked effect. It can achieve a good and obvious matte flocked surface effect during high temperature and high shear heat processing. It can present a realistic rock texture from various viewing angles, adding aesthetics to paint-free products, and can maintain good mechanical properties and flame retardant properties. It can be used in fields with strict requirements for appearance, production process and performance, such as electronics, security monitoring, home appliance shells, and consumer products.

[0100] A second aspect of this application provides a method for preparing a polycarbonate composite material, comprising the following steps:

[0101] The following raw materials are obtained by weight percentage: 80%~95% resin base and 5%~20% imitation flocking masterbatch; wherein, the resin base contains a first PC resin; and the imitation flocking masterbatch comprises: 65.3%~90% second PC resin, 5.3%~30% flocking fibers, and 1.4%~4.7% additives.

[0102] Composite materials are prepared by mixing and injection molding imitation flocking masterbatch and resin base.

[0103] The above-mentioned method for preparing polycarbonate composite materials involves mixing a resin base material and a flocking-like masterbatch in a certain proportion, followed by injection molding. The flocking is added in the form of the flocking-like masterbatch, achieving a good and obvious matte flocking surface effect during high-temperature, high-shear-heat extrusion and molding. It presents a realistic rock texture from various viewing angles, adding aesthetic appeal to paint-free products while maintaining good mechanical and flame-retardant properties. It also boasts advantages such as high stability in extrusion and molding processes, low overall industrialization cost, and high feasibility for mass production scaling. The resulting paint-free polycarbonate composite material with a flocking-like effect and flame retardancy can be applied in fields with stringent requirements for appearance, production processes, and performance, including electronics, security monitoring, appliance casings, and consumer goods.

[0104] In some embodiments, the preparation steps of the flocking-like masterbatch include:

[0105] At the first rotation speed, the fluff and part of the second PC resin are mixed, and the remaining second PC resin and additives are added and mixed again.

[0106] The resulting mixture was extruded and granulated to prepare a flocking-like masterbatch.

[0107] The first rotational speed is less than the second rotational speed, which is the rotational speed during the step of mixing the flocking masterbatch and the resin base.

[0108] In some embodiments, the first rotational speed is 50 rpm to 80 rpm, and the second rotational speed is 100 rpm to 200 rpm. For example, the first rotational speed can be, but is not limited to, 50 rpm, 55 rpm, 60 rpm, 65 rpm, 70 rpm, 75 rpm, 80 rpm, or any combination of these values. The second rotational speed can be, but is not limited to, 100 rpm, 120 rpm, 140 rpm, 150 rpm, 160 rpm, 180 rpm, 200 rpm, or any combination of these values. With the above settings, the lighter fibers are thoroughly mixed with a portion of the second PC resin powder before extrusion, forming a certain coating, so that the fibers maintain good color and size during the extrusion granulation process.

[0109] In some embodiments, the portion of the second PC resin accounts for 40% to 60% of the total second PC resin by mass. For example, the portion of the second PC resin as a percentage of the total second PC resin by mass may be, but is not limited to, 40%, 42%, 45%, 48%, 50%, 52%, 55%, 58%, 60%, or any combination of these values.

[0110] In some embodiments, the total mixing time is 40 s to 100 s before the resulting mixture is extruded and granulated. For example, the total mixing time may be, but is not limited to, 40 s, 50 s, 60 s, 70 s, 80 s, 90 s, 100 s or any combination of these values.

[0111] In some embodiments, during the extrusion granulation step, the extrusion temperature is 270°C to 300°C, and the screw speed is 200 rpm to 1000 rpm. Specifically, in the extrusion granulation step, the temperature is segmented from the feed port to the die head as follows: the feed port temperature is 245°C to 265°C, and segments one through seven are each independently set at 275°C to 290°C. It is understood that the temperatures of segments one through seven can be the same or different. Optionally, in one example, the temperature of segments one through six is ​​285°C, and the temperature of segment seven is 280°C.

[0112] In one embodiment, during the extrusion granulation step, the vacuum level of the twin-screw metering section vacuum device is controlled to be less than -0.8 bar, and the temperature of the cooling water tank is 30°C to 80°C.

[0113] In some embodiments, the moisture content of the first PC resin and the second PC resin is independently less than 0.5%, or optionally, the moisture content of the first PC resin and the second PC resin is independently less than 0.3%. This configuration helps reduce appearance defects during the molding process. Specifically, the first PC resin and the second PC resin are dried before use to ensure their moisture content meets the above requirements. In one example, the drying temperature is 80°C to 120°C, or optionally, 100°C to 120°C.

[0114] In some embodiments, the mixing time for the step of mixing the flocking masterbatch and the resin base is 30s to 90s. For example, the mixing time may be, but is not limited to, 30s, 40s, 50s, 60s, 70s, 80s, 90s, or any combination of these values.

[0115] In some embodiments, during the injection molding step, the injection temperature is 290°C to 310°C, the injection pressure is 50MPa to 65MPa, and the injection molding machine speed is 200rpm to 500rpm. For example, the injection temperature can be, but is not limited to, 290°C, 295°C, 300°C, 305°C, 310°C, or any combination of these values. The injection pressure can be, but is not limited to, 50MPa, 52MPa, 54MPa, 55MPa, 56MPa, 58MPa, 60MPa, 62MPa, 64MPa, 65MPa, or any combination of these values. The injection molding machine speed can be, but is not limited to, 200rpm, 250rpm, 300rpm, 350rpm, 400rpm, 450rpm, 500rpm, or any combination of these values.

[0116] In some embodiments, the preparation steps of the resin base can be those commonly used in the art, such as mixing the components and then extruding and granulating them. Specifically, the preparation steps of the resin base include:

[0117] The following raw materials are mixed by mass: 80-95 parts of first PC resin, 0-1 parts of first antioxidant, 0-4 parts of first lubricant, 0-2 parts of first flame retardant, 1-3 parts of first white masterbatch and 0.001-0.01 parts of color powder; the resulting mixture is extruded and granulated to obtain resin base material.

[0118] In one embodiment, during the preparation of the resin base, the color powder and the first white masterbatch are first mixed, and then the first PC resin, the first antioxidant, the first lubricant and the first flame retardant are added and the mixture is stirred and mixed.

[0119] Specifically, in the resin base material preparation step, the extrusion temperature is 270℃~300℃, and the screw speed is 200rpm~1000rpm. Specifically, in the extrusion granulation step, the temperature is segmented from the feed inlet to the die head as follows: feed inlet temperature is 245℃~265℃, and segments one through seven are each independently set at 275℃~290℃. It can be understood that the temperatures of segments one through seven can be the same or different. Optionally, in one example, the temperature of segments one through six is ​​285℃, and the temperature of segment seven is 280℃.

[0120] In one embodiment, during the preparation of the resin base material, the vacuum level of the twin-screw metering section vacuum device is controlled to be less than -0.8 bar, and the temperature of the cooling water tank is 30°C to 80°C.

[0121] Please see Figure 1 In some embodiments, the method for preparing the polycarbonate composite material includes the following steps:

[0122] Step S110: Mix the following raw materials by mass parts: 80-95 parts of first PC resin, 0-1 parts of first antioxidant, 0-4 parts of first lubricant, 0-2 parts of first flame retardant, 1-3 parts of first white masterbatch and 0.001-0.01 parts of color powder; the resulting first mixture is extruded and granulated to obtain resin base material.

[0123] Step S120: Obtain the following raw materials by mass percentage: 65.3%~90% of second PC resin, 5.3%~30% of flocking fibers, and 1.4%~4.7% of additives; mix the flocking fibers and part of the second PC resin at a first rotation speed, add the remaining second PC resin and additives and continue mixing, and granulate the resulting second mixture by extrusion to prepare a flocking masterbatch.

[0124] In one embodiment, the first rotational speed is 50 rpm to 80 rpm. The mixing time in step S120 is 40 s to 100 s.

[0125] Specifically, the mass moisture content of the first PC resin and the second PC resin is each independently less than 0.5%, and optionally, the mass moisture content of the first PC resin and the second PC resin is each independently less than 0.3%.

[0126] Specifically, in the extrusion granulation steps S110 and S120, the extrusion temperature is independently 270℃~300℃, and the screw speed is independently 200rpm~1000rpm. Specifically, in the extrusion granulation step, the temperature from the feed port to the die head is segmented as follows: feed port temperature is 245℃~265℃, and segments one through seven are independently 275℃~290℃. It can be understood that the temperatures of segments one through seven can be the same or different. Optionally, in one example, the temperature of segments one through six is ​​285℃, and the temperature of segment seven is 280℃.

[0127] In one embodiment, during the extrusion granulation steps S110 and S120, the vacuum level of the twin-screw metering section vacuum device is controlled to be less than -0.8 bar, and the temperature of the cooling water tank is 30°C to 80°C.

[0128] Step S130: Obtain the following raw materials by mass percentage: 80%~95% resin base and 5%~20% imitation flocking masterbatch; mix the imitation flocking masterbatch and resin base at the second rotation speed.

[0129] In one embodiment, the second rotational speed is 100 rpm to 200 rpm. The mixing time in step S130 is 30 s to 90 s.

[0130] Step S140: The mixture of flocking masterbatch and resin base material is injection molded to prepare polycarbonate composite material.

[0131] The injection temperature is 290℃~310℃, the injection pressure is 50MPa~65MPa, and the injection molding machine speed is 200rpm~500rpm.

[0132] The preparation method of the polycarbonate composite material in the above embodiments solves the contradiction between the flocking effect with good length retention and the mechanical and flame-retardant properties of the material. It provides a polycarbonate material with a flocking-free effect that has a distinct, unique and elegant texture, a simulated three-dimensional fiber feel and a soft and skin-friendly visual effect, as well as excellent flame-retardant and mechanical properties, thus overcoming the application limitations of traditional technologies.

[0133] It should be understood that, Figure 1 This is a schematic flowchart of a method for preparing a polycarbonate composite material according to an embodiment of this application. Figure 1 The steps in the flowchart shown are displayed sequentially according to the arrows. However, these steps are not necessarily performed in the order indicated by the arrows. Unless explicitly stated otherwise, there is no strict order restriction on the execution of these steps; they can be executed in other orders. For example, steps S110 and S120 can be performed simultaneously, or step S120 can be performed first and then step S110. Figure 1 At least some of the steps in the process may include multiple sub-steps or multiple stages. These sub-steps or stages are not necessarily completed at the same time, but can be executed at different times. Their execution order is not necessarily sequential, but can be executed in turn or alternately with at least some of other steps or other sub-steps or stages.

[0134] It is understandable that, by weight, the raw materials for preparing polycarbonate composite materials include: 5-20 parts of imitation flocking masterbatch, 80-95 parts of the first PC resin, 0-1 part of the first antioxidant, 0-4 parts of the first lubricant, 0-2 parts of the first flame retardant, 1-3 parts of the first white masterbatch, and 0.001-0.01 parts of color powder. Similarly, the first PC resin, first antioxidant, first lubricant, first flame retardant, first white particles, and color powder are first mixed to prepare a resin base, which is then mixed with the imitation flocking masterbatch and injection molded. The specific process is as described above and will not be repeated here.

[0135] A third aspect of this application provides the application of the above-described polycarbonate composite material or the polycarbonate composite material prepared by the above-described preparation method in the fields of electronics and electrical engineering, security monitoring, household appliance casings, or consumer products.

[0136] For example, polycarbonate composites are used in the manufacture of electronic and electrical products, security monitoring products, appliance housings, or consumer products.

[0137] The fourth aspect of this application also provides a method for preparing a flocking-inspired masterbatch, comprising the following steps:

[0138] The following raw materials are obtained by weight percentage: 65.3%~90% second PC resin, 5.3%~30% fluff, and 1.4%~4.7% additives;

[0139] Mix the fluff and part of the second PC resin at a speed of 50 rpm to 80 rpm, then add the remaining second PC resin and additives and continue mixing.

[0140] The resulting mixture was extruded and granulated to prepare a flocking-like masterbatch.

[0141] By using the above preparation method, the lighter fibers are fully mixed with a portion of the second PC resin powder before extrusion to form a certain coating, so that the color and size of the fibers are well maintained during the extrusion granulation process.

[0142] In some embodiments, a portion of the second PC resin accounts for 40% to 60% of the total second PC resin by mass.

[0143] In some embodiments, the total mixing time is 40 s to 100 s before the resulting mixture is extruded and granulated. For example, the total mixing time may be, but is not limited to, 40 s, 50 s, 60 s, 70 s, 80 s, 90 s, 100 s or any combination of these values.

[0144] In some embodiments, during the extrusion granulation step, the extrusion temperature is 270°C to 300°C, and the screw speed is 200 rpm to 1000 rpm. Specifically, in the extrusion granulation step, the temperature is segmented from the feed port to the die head as follows: the feed port temperature is 245°C to 265°C, and segments one through seven are each independently set at 275°C to 290°C. It is understood that the temperatures of segments one through seven can be the same or different. Optionally, in one example, the temperature of segments one through six is ​​285°C, and the temperature of segment seven is 280°C.

[0145] In one embodiment, during the extrusion granulation step, the vacuum level of the twin-screw metering section vacuum device is controlled to be less than -0.8 bar, and the temperature of the cooling water tank is 30°C to 80°C.

[0146] The fifth aspect of this application also provides a flocking-inspired masterbatch, which is prepared by the preparation method described in the fourth aspect above.

[0147] To make the objectives and advantages of this application clearer, the following detailed description of the polycarbonate composite material and its effects, in conjunction with specific embodiments, is provided. It should be understood that the specific embodiments described herein are for illustrative purposes only and should not be construed as limiting the scope of this application. Unless otherwise specified, the following embodiments do not include components other than unavoidable impurities. Unless otherwise specified, the drugs and instruments used in the embodiments are conventionally selected in the art. Experimental methods not specifying specific conditions in the embodiments were implemented under conventional conditions, such as those described in literature, books, or methods recommended by the manufacturer.

[0148] The sources of the main raw materials in the following embodiments and comparative examples are shown in Table 1 below:

[0149] Table 1 Raw Material Source Information

[0150]

[0151] Among them, the average fiber diameter of pile 1205 (denoted as 1#) is 0.015mm and the average fiber length is 1.5mm; the average fiber diameter of pile 3002 (denoted as 2#) is 0.015mm and the average fiber length is 1mm; the average fiber diameter of pile 9C-0.5 (denoted as 3#) is 0.03mm and the average fiber length is 0.5mm.

[0152] The processing equipment used in the following embodiments and comparative examples is as follows:

[0153] The twin-screw extruder is a KraussMaffei ZE28 x40D BP, with a screw length-to-diameter ratio of 40, a screw diameter of 28cm, and a screw speed of 0~1200rpm.

[0154] Example 1

[0155] This embodiment provides a composite material, which, by weight, comprises: 97.1062 parts of resin base and 5 parts of flocking masterbatch (i.e., the weight percentages of resin base and flocking masterbatch are 95% and 5%, respectively). Specifically, the resin base comprises: 95 parts of PC resin, 0.2 parts of antioxidant, 0.2 parts of lubricant, 0.7 parts of flame retardant, 0.0062 parts of colorant, and 1 part of white masterbatch, totaling 97.1062 parts. The flocking masterbatch, by weight percentage, comprises: 66.9% PC resin, 30% flocking material, 0.7% flame retardant, 2% white masterbatch, 0.2% antioxidant, and 0.2% lubricant. The flocking material is a mixture of flocking material #1, flocking material #2, and flocking material #3 in a weight ratio of 1:0.5:1. The PC resin, antioxidant, lubricant, flame retardant, and white masterbatch in the resin base are the same as those in the flocking masterbatch. The PC resin has been dried before use to ensure that its moisture content is less than 0.3%. The specific raw materials are shown in Table 2 below.

[0156] The preparation steps of the polycarbonate composite material in this embodiment are as follows:

[0157] (1) Preparation of resin base material: First, the color powder and white masterbatch are stirred and mixed, then PC resin, antioxidant, lubricant and flame retardant are added and stirred and mixed again. The resulting material is extruded and granulated by a twin-screw extruder to obtain the resin base material. The twin-screw extrusion temperature is set as follows: the temperature from the feed port to the die head is set as follows: 285℃ for sections one to six, 280℃ for section seven, the screw speed is 200rpm~1000rpm, the vacuum degree of the vacuum device in the twin-screw metering section is less than -0.8bar, and the cooling water tank temperature is 30~80℃.

[0158] (2) Preparation of flocking-like masterbatch: After mixing the flock and 50% of PC resin, feed the mixture through the side feed port. Then, mix the remaining 50% of PC resin with antioxidants, lubricants, flame retardants, and white masterbatch. Mixing is done using a low-speed mixer with a mixing speed of 50 rpm to 80 rpm and a total mixing time of 40 s to 100 s. The resulting material is melt-extruded and granulated using a twin-screw extruder to obtain the flocking-like masterbatch. The twin-screw extrusion temperature is set as follows: the temperature from the feed port to the die head is set in sections of 285℃ for sections one to six and 280℃ for section seven. The screw speed is 200 rpm to 1000 rpm. The vacuum degree of the vacuum device in the twin-screw metering section is less than -0.8 bar, and the cooling water tank temperature is 30 to 80℃.

[0159] (3) Material mixing: The resin base material and the imitation flocking masterbatch are mixed in a high-speed mixer, wherein the mixing speed is 100rpm~200rpm and the mixing time is 30s~90s to obtain the mixture.

[0160] (4) Injection molding: The mixture is injection molded to obtain polycarbonate composite material. The injection temperature is 290℃~310℃, the injection pressure is 50MPa~65MPa, and the speed of the injection molding machine is 200rpm~500rpm.

[0161] Example 2

[0162] This embodiment provides a composite material, which, by weight, comprises: 93.1062 parts of resin base and 10 parts of flocking-simulated masterbatch (i.e., the weight percentages of resin base and flocking-simulated masterbatch are 90% and 10%, respectively). The resin base comprises, by weight, 90 parts of PC resin, 0.2 parts of antioxidant, 0.2 parts of lubricant, 0.7 parts of flame retardant, 0.0062 parts of colorant, and 2 parts of white masterbatch, totaling 93.1062 parts. The flocking-simulated masterbatch comprises: 66.9% PC resin, 30% flocking material, 0.7% flame retardant, 2% white masterbatch, 0.2% antioxidant, and 0.2% lubricant. The flocking material is a mixture of flocking material #1, flocking material #2, and flocking material #3 in a weight ratio of 1:0.5:1. The PC resin, antioxidant, lubricant, flame retardant, and white masterbatch in the resin base are the same as those in the flocking masterbatch. The PC resin has been dried before use to ensure that its moisture content is less than 0.3%. The specific raw materials are shown in Table 2 below.

[0163] The preparation steps of the composite material in this embodiment are the same as those in Example 1, and will not be repeated here.

[0164] Example 3

[0165] This embodiment provides a composite material, which, by weight, comprises: 80% resin base and 20 parts imitation flocking masterbatch (i.e., the weight percentages of resin base and imitation flocking masterbatch are 81% and 19%, respectively). The base includes, by weight, 80 parts PC resin, 0.2 parts antioxidant, 0.2 parts lubricant, 1 part flame retardant, 0.0062 parts colorant, and 3 parts white masterbatch. The imitation flocking masterbatch comprises, by weight percentage, 66.9% PC resin, 30% flocking, 0.7% flame retardant, 2% white masterbatch, 0.2% antioxidant, and 0.2% lubricant. The flocking is a mixture of flocking #1, flocking #2, and flocking #3 in a weight ratio of 1:0.5:1. The PC resin, antioxidant, lubricant, flame retardant, and white masterbatch in the resin base are the same as those in the flocking masterbatch. The PC resin has been dried before use to ensure that its moisture content is less than 0.3%. The specific raw materials are shown in Table 2 below.

[0166] The preparation steps of the composite material in this embodiment are the same as those in Example 1, and will not be repeated here.

[0167] Example 4

[0168] This embodiment provides a composite material, which, by weight, comprises: 84.4062 parts of resin base and 20 parts of flocking-simulated masterbatch (i.e., the weight percentages of resin base and flocking-simulated masterbatch are 81% and 19%, respectively). The resin base, by weight, comprises: 80 parts of PC resin, 0.2 parts of antioxidant, 0.2 parts of lubricant, 1 part of flame retardant, 0.0062 parts of colorant, and 3 parts of white masterbatch. The flocking-simulated masterbatch, by weight percentage, comprises: 90% PC resin, 6.9% flocking, 0.7% flame retardant, 2% white masterbatch, 0.2% antioxidant, and 0.2% lubricant. The flocking is a mixture of flocking #1, flocking #2, and flocking #3 in a weight ratio of 1:1.5:0.5. The PC resin, antioxidant, lubricant, flame retardant, and white masterbatch in the resin base are the same as those in the flocking masterbatch. The PC resin has been dried before use to ensure that its moisture content is less than 0.3%. The specific raw materials are shown in Table 2 below.

[0169] Example 5

[0170] This embodiment provides a composite material, which, by weight, comprises: 84.4062 parts of resin base and 20 parts of flocking-simulated masterbatch (i.e., the weight percentages of resin base and flocking-simulated masterbatch are 81% and 19%, respectively). Specifically, the base includes, by weight, 80 parts of PC resin, 0.2 parts of antioxidant, 0.2 parts of lubricant, 1 part of flame retardant, 0.0062 parts of colorant, and 3 parts of white masterbatch. The flocking-simulated masterbatch, by weight percentage, comprises: 80% PC resin, 16.9% flocking, 0.7% flame retardant, 2% white masterbatch, 0.2% antioxidant, and 0.2% lubricant. The flocking is a mixture of flocking #1, flocking #2, and flocking #3 in a weight ratio of 1:1:0.75. The PC resin, antioxidant, lubricant, flame retardant, and white masterbatch in the resin base are the same as those in the flocking masterbatch. The PC resin has been dried before use to ensure that its moisture content is less than 0.3%. The specific raw materials are shown in Table 2 below.

[0171] Comparative Example 1

[0172] Comparative Example 1 provides a composite material, which, by mass parts, comprises the following raw materials: 90 parts PC resin, 0.2 parts lubricant, 0.7 parts flame retardant, 0.2 parts antioxidant, 1 part white masterbatch, 0.0062 parts color powder, and 10 parts of fluff 3#. The specific raw materials are shown in Table 2 below.

[0173] The preparation steps of the composite material in Comparative Example 1 are as follows:

[0174] (1) Preparation of mixed granules: The fluff, color powder and white masterbatch are stirred and mixed, and then PC resin (the weight ratio of powder to granules in PC resin = 85:5), antioxidant, lubricant and flame retardant are added and stirred and mixed. The resulting mixture is extruded and granulated by a twin-screw extruder to obtain mixed granules. In the mixing step, the speed is 100rpm~200rpm and the time is 30s~90s. In the extrusion and granulation step, the twin-screw extrusion temperature is set as follows: the temperature from the feed port to the die head is set as follows: 285℃ for the first to sixth sections and 280℃ for the seventh section. The screw speed is 200rpm~1000rpm. The vacuum degree of the vacuum device in the twin-screw metering section is less than -0.8bar. The cooling water tank temperature is 30-80℃.

[0175] (2) Injection molding: The mixed granules are injection molded to obtain polycarbonate composite material. The injection temperature is 290℃~310℃, the injection pressure is 50MPa~65MPa, and the speed of the injection molding machine is 200rpm~500rpm.

[0176] Comparative Example 2

[0177] Comparative Example 2 provides a composite material, which, by mass parts, comprises the following raw materials: 90 parts PC resin, 0.2 parts lubricant, 0.7 parts flame retardant, 0.2 parts antioxidant, 2 parts white masterbatch, 0.0062 parts color powder, 5 parts of fluff #2 and 5 parts of fluff #3. The specific raw materials are shown in Table 2 below.

[0178] The preparation steps of the composite material in Comparative Example 2 are the same as those in Comparative Example 1, and will not be repeated here.

[0179] Comparative Example 3

[0180] Comparative Example 3 provides a composite material, the raw materials of which, by mass dispersion, include: 90 parts PC resin, 0.2 parts lubricant, 0.7 parts flame retardant, 0.2 parts antioxidant, 3 parts white masterbatch, 0.0062 parts color powder, 8 parts of fluff 1# and 2 parts of fluff 3#. The specific raw materials are shown in Table 2 below.

[0181] The preparation steps of the composite material in Comparative Example 3 are the same as those in Comparative Example 1, and will not be repeated here.

[0182] The types and amounts of raw materials used in the above embodiments and comparative examples are shown in Table 2 below.

[0183] Table 2. Types and amounts of raw materials used in Examples 1-5 and Comparative Examples 1-3 (unit: parts by mass)

[0184]

[0185] In the above embodiments and comparative examples, the performance testing methods for the composite materials are as follows:

[0186] Melt flow index (PC): Tested according to ASTM D1238 standard, under test conditions of 300℃ / 1.2kg;

[0187] Notched impact strength of cantilever beam: Tested according to ISO 180 standard, at 23℃;

[0188] Glow wire flammability index: According to UL94-2018 test standard, the test conditions are GWFI-1.1mm.

[0189] Appearance: The polycarbonate composite materials prepared in the above embodiments and comparative examples were injection molded into 90mm×55mm×3mm fine leather texture color plates and observed under D65 light. The changes in the base color and the length, quantity, and obviousness of the fluff were rated respectively. The best was grade V and the worst was grade I. Grade V is characterized by long fluff, uniform distribution, large quantity, and a very obvious three-dimensional effect. Grade I is characterized by almost invisible fluff, too short or too few fluff, or severe changes in the base color.

[0190] The test results of Examples 1-5 and Comparative Examples 1-3 are shown in Table 3.

[0191] Table 3. Performance and appearance of the products from Examples 1-5 and Comparative Examples 1-3

[0192]

[0193] The appearance of the polycarbonate composite material prepared in Example 1 is as follows: Figure 2 As shown. The appearance of the polycarbonate composite material prepared in Example 3 is as follows. Figure 3 As shown. The appearance of the polycarbonate composite material prepared in Comparative Example 1 is as follows. Figure 4 As shown. The appearance of the polycarbonate composite material prepared in Comparative Example 2 is as follows. Figure 5 As shown.

[0194] Based on the performance test results in Table 3 and Figures 2-5As can be seen from the appearance, the paint-free polycarbonate composite materials of each embodiment of this application can achieve a good paint-free flocking effect in twin-screw extrusion shearing and injection molding, with appearance ratings of III or above, and some embodiments reaching IV or even V. They possess an elegant texture, a simulated three-dimensional fiber feel, and a soft, skin-friendly visual effect, resembling plastic flocking. Furthermore, their flame retardant properties are relatively good, all above V1, with some embodiments reaching V0. In contrast, the comparative examples, using traditional extrusion processes, suffer from poor shear resistance of the flocking fibers, making it difficult to achieve a good appearance. Although increasing the amount of flocking fibers can improve the flocking effect to some extent, the flame retardancy and impact resistance are significantly poor, limiting its application. In some embodiments of this application, by designing appropriate extrusion and injection molding processes and the proportions of each component, the shear resistance and heat resistance of the system can be effectively improved, resulting in better uniformity of flocking color, size, and appearance.

[0195] Furthermore, as can be seen from the embodiments of this application, by optimizing the proportions of each component, the prepared polycarbonate composite material can have better paint-free flocking effect, mechanical properties, and flame retardant properties.

[0196] Therefore, the polycarbonate composite materials and their preparation methods provided in some embodiments of this application have at least the following advantages compared to conventional technologies:

[0197] (1) Traditional polycarbonate systems have the problem of high gloss of the parts. The polycarbonate composite materials provided in some embodiments of this application can achieve an elegant texture, simulated three-dimensional fiber feel and soft and skin-friendly visual plastic flocking effect in the polycarbonate system.

[0198] (2) The traditional method of using pile has poor shear resistance and will significantly affect the mechanical properties and flame retardant properties of the material. In some embodiments of this application, by designing appropriate combinations of components and optimizing the preparation method, the shear resistance and heat resistance of the pile system are improved, so that the uniformity of pile color, size and appearance is maintained. At the same time, the composite material of some embodiments of this application also has excellent flame retardant properties and mechanical properties.

[0199] (3) Some embodiments of this application provide a flame-retardant PC coating-free composite material with a flocking effect that can be injection molded in one step without the need for post-coating treatment. It is energy-saving and environmentally friendly, with a short production cycle, which greatly improves production efficiency and significantly reduces the overall cost of industrialization. At the same time, it can give the product surface a rich aesthetic appearance and is widely used in fields with stringent performance requirements such as electronics, security monitoring, and consumer products.

[0200] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0201] The embodiments described above are merely illustrative of several implementation methods of this application, intended to facilitate a detailed understanding of the technical solutions of this application, but should not be construed as limiting the scope of protection of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the scope of protection of this application. It should be understood that technical solutions obtained by those skilled in the art based on the technical solutions provided in this application through logical analysis, reasoning, or limited experimentation are all within the scope of protection of the appended claims. Therefore, the scope of protection of this patent application should be determined by the content of the appended claims, and the specification and drawings can be used to interpret the content of the claims.

Claims

1. A polycarbonate composite material, characterized in that, The raw materials for preparing the polycarbonate composite material, by weight percentage, include: 80%~95% resin base and 5%~20% flocking masterbatch; The resin base material contains a first PC resin; based on the total mass percentage of the simulated flocking masterbatch as 100%, the simulated flocking masterbatch comprises: 65.3%~90% second PC resin, 5.3%~30% flocking fibers, and 1.4%~4.7% additives; The first PC resin and the second PC resin each independently include one or more of aromatic polycarbonate, aliphatic polycarbonate and aromatic-aliphatic polycarbonate. Under test conditions of 300°C and a load of 1.2 kg, the melt flow index of the first PC resin and the second PC resin are each independently 3 g / 10 min to 65 g / 10 min.

2. The polycarbonate composite material according to claim 1, characterized in that, One or more of the following conditions must be met: (1) In the simulated flocking masterbatch, the mass percentage of the flock is 10%~25%; (2) In the flocking masterbatch, the mass percentage of the second PC resin is 72%~87%; (3) By mass percentage, the raw materials for preparing the polycarbonate composite material include: 80%~90% resin base and 10%~20% imitation flocking masterbatch; (4) The additives include a second antioxidant of 0.1% to 0.3% by mass of the imitation flocking masterbatch, a second lubricant of 0.1% to 0.4% by mass of the second flame retardant, and a second white masterbatch of 1% to 3% by mass of the second antioxidant masterbatch.

3. The polycarbonate composite material according to claim 1, characterized in that, Under test conditions of 300℃ and a load of 1.2kg, the melt flow index of the first PC resin and the second PC resin were independently 5g / 10min to 40g / 10min.

4. The polycarbonate composite material according to claim 3, characterized in that, Under test conditions of 300℃ and a load of 1.2kg, the melt flow index of the first PC resin and the second PC resin were independently 7g / 10min to 30g / 10min.

5. The polycarbonate composite material according to any one of claims 1 to 4, characterized in that, The downy fibers satisfy one or more of the following conditions: (1) The pile includes one or more of fiber filaments, marble filaments and injection-molded fiber pile; (2) The average fiber diameter of the down is 0.015mm~0.15mm, and the average fiber length is 0.5mm~1.5mm; (3) The down includes a mixture of down with different average fiber lengths and / or average fiber diameters.

6. The polycarbonate composite material according to any one of claims 1 to 4, characterized in that, The down includes a first down, a second down, and a third down in a mass ratio of 1:(0.5~1.5):(0.5~1), wherein the average fiber diameter of the first down is less than the average fiber diameter of the second down and the average fiber diameter of the third down, and the average fiber length of the first down is greater than the average fiber length of the second down and the average fiber length of the third down.

7. The polycarbonate composite material according to any one of claims 1 to 4, characterized in that, The resin base material comprises, by weight parts: 80 to 95 parts of first PC resin, 0 to 1 part of first antioxidant, 0 to 4 parts of first lubricant, 0 to 2 parts of first flame retardant, 1 to 3 parts of first white masterbatch, and 0.001 to 0.01 parts of color powder.

8. The polycarbonate composite material according to claim 7, characterized in that, The resin base material comprises, by weight, 80 to 90 parts of first PC resin, 0.1 to 0.3 parts of first antioxidant, 0.1 to 0.4 parts of first lubricant, 0.2 to 1 part of first flame retardant, 1 to 3 parts of first white masterbatch, and 0.001 to 0.01 parts of color powder.

9. The polycarbonate composite material according to claim 8, characterized in that, The resin base material comprises, by weight, 80 to 90 parts of first PC resin, 0.1 to 0.3 parts of first antioxidant, 0.1 to 0.4 parts of first lubricant, 0.7 to 1 part of first flame retardant, 2 to 3 parts of first white masterbatch, and 0.005 to 0.01 parts of color powder.

10. The polycarbonate composite material according to any one of claims 1 to 4, characterized in that, The resin base material includes a first PC resin, a first antioxidant, a first lubricant, a first flame retardant, a first white masterbatch, and color powder; by mass parts, the raw materials for preparing the polycarbonate composite material include: 5 to 20 parts of flocked imitation masterbatch, 80 to 95 parts of the first PC resin, 0 to 1 part of the first antioxidant, 0 to 4 parts of the first lubricant, 0 to 2 parts of the first flame retardant, 1 to 3 parts of the first white masterbatch, and 0.001 to 0.01 parts of color powder.

11. The polycarbonate composite material according to claim 10, characterized in that, The raw materials for preparing the polycarbonate composite material, by weight, include: 10 to 20 parts of flocked masterbatch, 80 to 90 parts of first PC resin, 0.1 to 0.3 parts of first antioxidant, 0.1 to 0.4 parts of first lubricant, 0.2 to 1 part of first flame retardant, 1 to 3 parts of first white masterbatch, and 0.001 to 0.01 parts of color powder.

12. The polycarbonate composite material according to claim 11, characterized in that, The raw materials for preparing the polycarbonate composite material, by weight, include: 10-20 parts of flocked masterbatch, 80-90 parts of first PC resin, 0.1-0.3 parts of first antioxidant, 0.1-0.4 parts of first lubricant, 0.7-1 part of first flame retardant, 2-3 parts of first white masterbatch, and 0.005-0.01 parts of color powder.

13. A method for preparing a polycarbonate composite material according to any one of claims 1 to 12, characterized in that, Includes the following steps: The following raw materials are obtained by weight percentage: 80%~95% resin base and 5%~20% imitation flocking masterbatch; wherein, the resin base contains a first PC resin; and based on the total weight percentage of the imitation flocking masterbatch as 100%, the imitation flocking masterbatch comprises: 65.3%~90% second PC resin, 5.3%~30% flocking fibers, and 1.4%~4.7% additives; The composite material is prepared by mixing the flocking masterbatch and the resin base and injection molding.

14. The method for preparing the polycarbonate composite material according to claim 13, characterized in that, One or more of the following conditions must be met: (1) The preparation steps of the simulated flocking masterbatch include: At a first rotation speed, the fluff and a portion of the second PC resin are mixed, and the remaining second PC resin and the additives are added and the mixture is continued. The resulting mixture was extruded and granulated to prepare the flocking-like masterbatch; Wherein, the first rotation speed is less than the second rotation speed, and the second rotation speed is the rotation speed in the step of mixing the imitation flocking masterbatch and the resin base material; (2) In the injection molding process, the injection temperature is 290℃~310℃, the injection pressure is 50MPa~65MPa, and the speed of the injection molding machine is 200rpm~500rpm.

15. The method for preparing the polycarbonate composite material according to claim 14, characterized in that, The first speed is 50 rpm to 80 rpm, and the second speed is 100 rpm to 200 rpm.

16. The method for preparing the polycarbonate composite material according to claim 14, characterized in that, The second PC resin accounts for 40% to 60% of the total mass of the second PC resin.

17. The method for preparing the polycarbonate composite material according to claim 14, characterized in that, In the extrusion granulation step, the extrusion temperature is 270℃~300℃ and the screw speed is 200rpm~1000rpm.

18. The application of the polycarbonate composite material according to any one of claims 1 to 12 or the polycarbonate composite material prepared by the preparation method according to any one of claims 13 to 17 in the fields of electronics and electrical engineering, security monitoring, household appliance housings or consumer products.

19. The use of the polycarbonate composite material according to any one of claims 1 to 12 or the polycarbonate composite material prepared by the preparation method according to any one of claims 13 to 17 in the preparation of electronic and electrical products, security monitoring products, appliance housings or consumer products.

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