High-tenacity polycarbonate modified material, method of making and use thereof

Abstract

The application discloses a high-toughness polycarbonate modified material and a preparation method and application thereof. The high-toughness polycarbonate modified material comprises the following components in parts by weight: polycarbonate 82-110 parts, core-shell impact modifier 4-7 parts, filler 8-15 parts, flame retardant 1-3 parts, antioxidant 0.15-1.5 parts, and lubricant 0.1-0.5 parts. The core-shell impact modifier comprises the following components in parts by weight: emulsifier 43-56 parts, polymerized monomer 90-113 parts, crosslinking monomer 2.5-6 parts, shell monomer 32-45 parts, and initiator 0.1-1 part. The polymerized monomer at least comprises acrylic acid and phenyl acrylate, and the mass ratio of the two is 1:(0.8-1.2). The crosslinking monomer comprises diallyl phthalate and 2-phenylpropyl acrylate, and the mass ratio of the two is 3:(0.5-1). The application can improve the toughness of the carbonate by the position and interaction of benzene rings in the main chain and the branch chain of the molecular structure of the modifier.

Description

Technical Field

[0001] This invention relates to the field of polymer materials technology, and in particular to a high-toughness polycarbonate modified material, its preparation method, and its application. Background Technology

[0002] Polycarbonate is an amorphous thermoplastic, one of the five major engineering plastics. It possesses high rigidity, modulus, good high-temperature resistance, and dimensional stability, while also being impact-resistant. It is used in various industries and products, including electronics, home appliances, office equipment, power tools, and charging stations, through methods such as 3D printing and injection molding. With rapid industrial development, traditional polycarbonate can no longer meet the demands of industrial manufacturing, leading to higher requirements for its toughness, strength, and other properties.

[0003] Products made from polycarbonate materials, especially those without toughening modification, tend to be rigid and brittle. During storage and use, insufficient toughness can lead to breakage, affecting service life and quality. However, conventional toughening can compromise the rigidity of the material. Summary of the Invention

[0004] The purpose of this invention is to provide high-toughness polycarbonate modified materials, their preparation methods, and applications, in order to solve the problems in the prior art.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is: a high-toughness polycarbonate modified material, comprising the following components by weight: 82-110 parts of polycarbonate, 4-7 parts of core-shell type impact modifier, 8-15 parts of filler, 1-3 parts of flame retardant, 0.15-1.5 parts of antioxidant, and 0.1-0.5 parts of lubricant;

[0006] The core-shell type impact modifier comprises the following components by weight: 43-56 parts emulsifier, 90-113 parts polymeric monomer, 2.5-6 parts crosslinking monomer, 32-45 parts shell monomer, and 0.1-1 parts initiator. The polymeric monomer includes at least acrylic acid and phenyl acrylate in a mass ratio of 1:(0.8-1.2). The crosslinking monomer includes diallyl phthalate and 2-phenylpropyl acrylate in a mass ratio of 3:(0.5-1).

[0007] As a further optimization, the shell monomer comprises styrene and methyl methacrylate; the mass ratio of styrene to methyl methacrylate is 1:(1-1.2).

[0008] As a further optimization, the emulsifier is sodium dodecyl sulfate or sodium dodecylbenzene sulfonate; the initiator is potassium persulfate or azobisisobutyronitrile.

[0009] As a further optimization, the preparation method of the core-shell type impact modifier includes the following steps:

[0010] S101) The polymerizing monomer and crosslinking monomer are added to the emulsifier solution to prepare the reaction solution;

[0011] S102) The initiator is added to the reaction solution and reacted at 70-80℃ for 2-4 hours to obtain the core layer liquid;

[0012] S103) Add shell monomer and initiator dropwise to the core layer liquid and react at 70-90℃ for 3-5 hours to obtain core-shell polymer liquid;

[0013] S104) The polymerization solution was washed and dried to obtain a core-shell type impact modifier.

[0014] As a further optimization, the filler is hollow glass microspheres, and the particle size of the hollow glass microspheres is 50-200μm, preferably 80μm.

[0015] As a further optimization, the flame retardant is one or more of sulfonate flame retardants, phosphate flame retardants, and halogen-free flame retardants, with halogen-free flame retardants, such as silicone polymer SFR-1000, being preferred.

[0016] As a further optimization, the antioxidant is antioxidant 1010 or antioxidant 168.

[0017] As a further optimization, the lubricant is pentaerythritol stearate.

[0018] This invention also provides a method for preparing a high-toughness polycarbonate modified material, comprising the following steps:

[0019] S10) to prepare core-shell type impact modifier;

[0020] S20) After mixing polycarbonate, core-shell type impact modifier, filler, flame retardant, antioxidant and lubricant evenly according to the mass parts, a premix is ​​obtained;

[0021] S30) The premixed material is placed in a twin-screw extruder, the temperature range is set to 220-270℃, the speed is set to 300-500rpm, and the material is extruded, cooled, and granulated to obtain a high-toughness polycarbonate modified material.

[0022] This invention also provides an application of a high-toughness polycarbonate modified material, which is used for electronic and electrical appliance housings. For some conventional parts, it can be prepared by injection molding, but for small-batch sample parts or housing structures that are not easily molded, it can be prepared by 3D printing, such as processing polycarbonate into powder and then forming it layer by layer by sintering.

[0023] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0024] 1. By forming benzene ring structures in the main chain and the resulting branches, the main chain benzene rings can impart high strength to the material, while the branched benzene rings can further form a cross-linked three-dimensional structure, which can improve the toughness of the material. Moreover, the interaction force between the main chain benzene rings and the branched benzene rings can cause the branched benzene rings to be adsorbed near the main chain benzene rings. Even if the branches bend or spiral relative to the main chain, this morphology can also avoid a loose three-dimensional structure, making the overall structure have higher toughness.

[0025] 2. 2-Phenylacetyl acrylate has a physical cross-linking effect. Its propyl side chains increase the rigidity of the chain segments, reduce the chain entanglement density, form a locally ordered structure, enhance the toughness of the material, and can also assist in chemical cross-linking. For example, when 2-phenylpropionyl acrylate is added to the cross-linking monomer diallyl phthalate, the benzene ring in 2-phenylpropionyl acrylate can adjust the distribution of the spatial three-dimensional structure, avoid the brittleness caused by excessive cross-linking, and make the spatial distribution have better toughness. Detailed Implementation

[0026] The following are specific embodiments of the present invention, which further describe the technical solution of the present invention, but the present invention is not limited to these embodiments.

[0027] Example 1:

[0028] A high-toughness polycarbonate modified material comprises the following components by weight: 92 parts polycarbonate, 7 parts core-shell type impact modifier, 14 parts hollow glass microspheres, 2.2 parts halogen-free flame retardant, 1.5 parts antioxidant 1010, and 0.3 parts pentaerythritol stearate.

[0029] The core-shell type impact modifier comprises the following components by weight: 100 parts water, 52 parts sodium dodecyl sulfate, 95 parts polymeric monomer, 6 parts crosslinking monomer, 36 parts shell monomer, and 0.5 parts potassium persulfate. The polymeric monomer includes 46 parts acrylic acid and 49 parts phenyl acrylate. The crosslinking monomer includes 4.5 parts diallyl phthalate and 1.5 parts 2-phenylpropyl acrylate. The shell monomer includes 18 parts styrene and 18 parts methyl methacrylate. The preparation method of the impact modifier includes the following steps: S101) Add the polymerizing monomer and crosslinking monomer to a sodium dodecyl sulfate solution to obtain a reaction solution; S102) Add potassium persulfate to the reaction solution and react at 70-80℃ for 2-4 hours to obtain a core layer liquid; S103) Add the shell layer monomer and potassium persulfate dropwise to the core layer liquid and react at 70-90℃ for 3-5 hours to obtain a core-shell polymer liquid; S104) Wash and dry the polymer liquid to obtain a core-shell type impact modifier.

[0030] A method for preparing a high-toughness polycarbonate modified material includes the following steps:

[0031] S10) Prepare a core-shell type impact modifier according to the above method;

[0032] S20) Polycarbonate, core-shell type impact modifier, hollow glass microspheres, halogen-free flame retardant, antioxidant 1010 and pentaerythritol stearate are mixed evenly according to the mass parts to obtain a premix.

[0033] S30) The premixed material is placed in a twin-screw extruder, the temperature range is set to 250-270℃, the speed is 450rpm, and the material is extruded, cooled, and granulated to obtain a high-toughness polycarbonate modified material.

[0034] Example 2:

[0035] A high-toughness polycarbonate modified material comprises the following components by weight: 96 parts polycarbonate, 7 parts core-shell type impact modifier, 10 parts hollow glass microspheres, 2.2 parts halogen-free flame retardant, 1.5 parts antioxidant 1010, and 0.3 parts pentaerythritol stearate.

[0036] The core-shell type impact modifier comprises the following components by weight: 100 parts water, 52 parts sodium dodecyl sulfate, 95 parts polymeric monomer, 6 parts crosslinking monomer, 36 parts shell monomer, and 0.5 parts potassium persulfate. The polymeric monomer includes 50 parts acrylic acid and 45 parts phenyl acrylate. The crosslinking monomer includes 5 parts diallyl phthalate and 1 part 2-phenylpropyl acrylate. The shell monomer includes 18 parts styrene and 18 parts methyl methacrylate. (Core-shell type impact modifier) The preparation method of the modifier includes the following steps: S101) Add the polymerizing monomer and the crosslinking monomer to a sodium dodecyl sulfate solution to obtain a reaction solution; S102) Add potassium persulfate to the reaction solution and react at 70-80℃ for 2-4 hours to obtain a core layer liquid; S103) Add the shell layer monomer and potassium persulfate dropwise to the core layer liquid and react at 70-90℃ for 3-5 hours to obtain a core-shell polymer solution; S104) Wash and dry the polymer solution to obtain a core-shell type impact modifier.

[0037] A method for preparing a high-toughness polycarbonate modified material includes the following steps:

[0038] S10) Prepare a core-shell type impact modifier according to the above method;

[0039] S20) Polycarbonate, core-shell type impact modifier, hollow glass microspheres, halogen-free flame retardant, antioxidant 1010 and pentaerythritol stearate are mixed evenly according to the mass parts to obtain a premix.

[0040] S30) The premixed material is placed in a twin-screw extruder, the temperature range is set to 250-270℃, the speed is 450rpm, and the material is extruded, cooled, and granulated to obtain a high-toughness polycarbonate modified material.

[0041] Example 3:

[0042] A high-toughness polycarbonate modified material comprises the following components by weight: 92 parts polycarbonate, 4 parts core-shell type impact modifier, 15 parts hollow glass microspheres, 2.5 parts halogen-free flame retardant, 1 part antioxidant 168, and 0.5 parts pentaerythritol stearate.

[0043] The core-shell type impact modifier comprises the following components by weight: 100 parts water, 50 parts sodium dodecyl sulfate, 100 parts polymeric monomer, 6 parts crosslinking monomer, 32 parts shell monomer, and 0.5 parts potassium persulfate. The polymeric monomer includes 50 parts acrylic acid and 50 parts phenyl acrylate. The crosslinking monomer includes 4.7 parts diallyl phthalate and 1.3 parts 2-phenylpropyl acrylate. The shell monomer includes 16 parts styrene and 16 parts methyl methacrylate. The preparation method of the impact modifier includes the following steps: S101) Add the polymerizing monomer and the crosslinking monomer to a sodium dodecyl sulfate solution to obtain a reaction solution; S102) Add potassium persulfate to the reaction solution and react at 70-80℃ for 2-4 hours to obtain a core layer liquid; S103) Add the shell layer monomer and potassium persulfate dropwise to the core layer liquid and react at 70-90℃ for 3-5 hours to obtain a core-shell polymer liquid; S104) Wash and dry the polymer liquid to obtain a core-shell type impact modifier.

[0044] A method for preparing a high-toughness polycarbonate modified material includes the following steps:

[0045] S10) Prepare a core-shell type impact modifier according to the above method;

[0046] S20) Polycarbonate, core-shell type impact modifier, hollow glass microspheres, halogen-free flame retardant, antioxidant 168 and pentaerythritol stearate are mixed evenly according to the mass parts to obtain a premix.

[0047] S30) The premixed material is placed in a twin-screw extruder, the temperature range is set to 250-270℃, the speed is 450rpm, and the material is extruded, cooled, and granulated to obtain a high-toughness polycarbonate modified material.

[0048] Example 4:

[0049] A high-toughness polycarbonate modified material comprises the following components by weight: 92 parts polycarbonate, 7 parts core-shell type impact modifier, 14 parts hollow glass microspheres, 2 parts halogen-free flame retardant, 1.5 parts antioxidant 1010, and 0.5 parts pentaerythritol stearate.

[0050] The core-shell type impact modifier comprises the following components by weight: 100 parts water, 50 parts sodium dodecylbenzenesulfonate, 100 parts polymeric monomer, 3 parts crosslinking monomer, 36 parts shell monomer, and 0.5 parts potassium persulfate. The polymeric monomer includes 50 parts acrylic acid and phenyl acrylate. The crosslinking monomer includes 2.5 parts diallyl phthalate and 0.5 parts 2-phenylpropyl acrylate. The shell monomer includes 18 parts styrene and 18 parts methyl methacrylate. The preparation method of the impact modifier includes the following steps: S101) Add the polymerizing monomer and crosslinking monomer to a sodium dodecylbenzenesulfonate solution to obtain a reaction solution; S102) Add potassium persulfate to the reaction solution and react at 70-80℃ for 2-4 hours to obtain a core layer liquid; S103) Add the shell layer monomer and potassium persulfate dropwise to the core layer liquid and react at 70-90℃ for 3-5 hours to obtain a core-shell polymer liquid; S104) Wash and dry the polymer liquid to obtain a core-shell type impact modifier.

[0051] A method for preparing a high-toughness polycarbonate modified material includes the following steps:

[0052] S10) Prepare a core-shell type impact modifier according to the above method;

[0053] S20) Polycarbonate, core-shell type impact modifier, hollow glass microspheres, halogen-free flame retardant, antioxidant 1010 and pentaerythritol stearate are mixed evenly according to the mass parts to obtain a premix.

[0054] S30) The premixed material is placed in a twin-screw extruder, the temperature range is set to 250-270℃, the speed is 450rpm, and the material is extruded, cooled, and granulated to obtain a high-toughness polycarbonate modified material.

[0055] Example 5:

[0056] A high-toughness polycarbonate modified material comprises the following components by weight: 90 parts polycarbonate, 7 parts core-shell type impact modifier, 15 parts hollow glass microspheres, 1.5 parts halogen-free flame retardant, 1.5 parts antioxidant 168, and 0.5 parts pentaerythritol stearate.

[0057] The core-shell type impact modifier comprises the following components by weight: 110 parts water, 40 parts sodium dodecylbenzenesulfonate, 90 parts polymeric monomer, 6 parts crosslinking monomer, 36 parts shell monomer, and 0.5 parts potassium persulfate. The polymeric monomer includes 45 parts acrylic acid and 45 parts phenyl acrylate. The crosslinking monomer includes 4.5 parts diallyl phthalate and 1.5 parts 2-phenylpropyl acrylate. The shell monomer includes 36 parts styrene and 36 parts methyl methacrylate. The core-shell type impact modifier... The preparation method of the impact modifier includes the following steps: S101) Add the polymerizing monomer and crosslinking monomer to a sodium dodecylbenzenesulfonate solution to obtain a reaction solution; S102) Add potassium persulfate to the reaction solution and react at 70-80℃ for 2-4 hours to obtain a core layer liquid; S103) Add the shell layer monomer and potassium persulfate dropwise to the core layer liquid and react at 70-90℃ for 3-5 hours to obtain a core-shell polymer liquid; S104) Wash and dry the polymer liquid to obtain a core-shell type impact modifier.

[0058] A method for preparing a high-toughness polycarbonate modified material includes the following steps:

[0059] S10) Prepare a core-shell type impact modifier according to the above method;

[0060] S20) Polycarbonate, core-shell type impact modifier, hollow glass microspheres, halogen-free flame retardant, antioxidant 168 and pentaerythritol stearate are mixed evenly according to the mass parts to obtain a premix.

[0061] S30) The premixed material is placed in a twin-screw extruder, the temperature range is set to 250-270℃, the speed is 450rpm, and the material is extruded, cooled, and granulated to obtain a high-toughness polycarbonate modified material.

[0062] Comparative Example 1:

[0063] A high-toughness polycarbonate modified material comprises the following components by weight: 92 parts polycarbonate, 7 parts core-shell type impact modifier, 14 parts hollow glass microspheres, 2.2 parts halogen-free flame retardant, 1.5 parts antioxidant 1010, and 0.3 parts pentaerythritol stearate.

[0064] The core-shell type impact modifier comprises the following components by weight: 100 parts water, 52 parts sodium dodecyl sulfate, 95 parts polymeric monomer, 6 parts crosslinking monomer, 36 parts shell monomer, and 0.5 parts potassium persulfate. The polymeric monomer includes 46 parts acrylic acid and 49 parts butyl acrylate. The crosslinking monomer includes 4.5 parts diallyl phthalate and 1.5 parts 2-phenylpropyl acrylate. The shell monomer includes 18 parts styrene and 18 parts methyl methacrylate. The preparation method of the impact modifier includes the following steps: S101) Add the polymerizing monomer and crosslinking monomer to a sodium dodecyl sulfate solution to obtain a reaction solution; S102) Add potassium persulfate to the reaction solution and react at 70-80℃ for 2-4 hours to obtain a core layer liquid; S103) Add the shell layer monomer and potassium persulfate dropwise to the core layer liquid and react at 70-90℃ for 3-5 hours to obtain a core-shell polymer liquid; S104) Wash and dry the polymer liquid to obtain a core-shell type impact modifier.

[0065] A method for preparing a high-toughness polycarbonate modified material includes the following steps:

[0066] S10) Prepare a core-shell type impact modifier according to the above method;

[0067] S20) Polycarbonate, core-shell type impact modifier, hollow glass microspheres, halogen-free flame retardant, antioxidant 168 and pentaerythritol stearate are mixed evenly according to the mass parts to obtain a premix.

[0068] S30) The premixed material is placed in a twin-screw extruder, the temperature range is set to 250-270℃, the speed is 450rpm, and the material is extruded, cooled, and granulated to obtain a high-toughness polycarbonate modified material.

[0069] Comparative Example 2:

[0070] A high-toughness polycarbonate modified material comprises the following components by weight: 92 parts polycarbonate, 7 parts core-shell type impact modifier, 14 parts hollow glass microspheres, 2.2 parts halogen-free flame retardant, 1.5 parts antioxidant 1010, and 0.3 parts pentaerythritol stearate.

[0071] The core-shell type impact modifier comprises the following components by weight: 100 parts water, 52 parts sodium dodecyl sulfate, 95 parts polymeric monomer, 6 parts crosslinking monomer, 36 parts shell monomer, and 0.5 parts potassium persulfate. The polymeric monomer includes 46 parts acrylic acid and 49 parts phenyl acrylate, the crosslinking monomer is ethylene glycol dimethacrylate, and the shell monomer includes 18 parts styrene and 18 parts methyl methacrylate. The preparation method of the core-shell type impact modifier includes the following steps: S101) Add the polymeric monomer and crosslinking monomer to a sodium dodecyl sulfate solution to obtain a reaction solution; S102) Add potassium persulfate to the reaction solution and react at 70-80℃ for 2-4 hours to obtain a core layer solution; S103) Add the shell monomer and potassium persulfate dropwise to the core layer solution and react at 70-90℃ for 3-5 hours to obtain a core-shell polymer solution; S104) Wash and dry the polymer solution to obtain the core-shell type impact modifier.

[0072] A method for preparing a high-toughness polycarbonate modified material includes the following steps:

[0073] S10) Prepare a core-shell type impact modifier according to the above method;

[0074] S20) Polycarbonate, core-shell type impact modifier, hollow glass microspheres, halogen-free flame retardant, antioxidant 1010 and pentaerythritol stearate are mixed evenly according to the mass parts to obtain a premix.

[0075] S30) The premixed material is placed in a twin-screw extruder, the temperature range is set to 250-270℃, the speed is 450rpm, and the material is extruded, cooled, and granulated to obtain a high-toughness polycarbonate modified material.

[0076] Comparative Example 3:

[0077] A high-toughness polycarbonate modified material comprises the following components by weight: 92 parts polycarbonate, 7 parts core-shell type impact modifier, 14 parts hollow glass microspheres, 2.2 parts halogen-free flame retardant, 1.5 parts antioxidant 1010, and 0.3 parts pentaerythritol stearate.

[0078] The core-shell type impact modifier comprises the following components by weight: 100 parts water, 52 parts sodium dodecyl sulfate, 95 parts polymeric monomer, 6 parts crosslinking monomer, 36 parts shell monomer, and 0.5 parts potassium persulfate. The polymeric monomer includes 46 parts acrylic acid and 49 parts phenyl acrylate, the crosslinking monomer is diallyl phthalate, and the shell monomer includes 18 parts styrene and 18 parts methyl methacrylate. The preparation method of the core-shell type impact modifier includes the following steps: S101) Add the polymeric monomer and crosslinking monomer to a sodium dodecyl sulfate solution to obtain a reaction solution; S102) Add potassium persulfate to the reaction solution and react at 70-80℃ for 2-4 hours to obtain a core layer solution; S103) Add the shell monomer and potassium persulfate dropwise to the core layer solution and react at 70-90℃ for 3-5 hours to obtain a core-shell polymer solution; S104) Wash and dry the polymer solution to obtain the core-shell type impact modifier.

[0079] A method for preparing a high-toughness polycarbonate modified material includes the following steps:

[0080] S10) Prepare a core-shell type impact modifier according to the above method;

[0081] S20) Polycarbonate, core-shell type impact modifier, hollow glass microspheres, halogen-free flame retardant, antioxidant 1010 and pentaerythritol stearate are mixed evenly according to the mass parts to obtain a premix.

[0082] S30) The premixed material is placed in a twin-screw extruder, the temperature range is set to 250-270℃, the speed is 450rpm, and the material is extruded, cooled, and granulated to obtain a high-toughness polycarbonate modified material.

[0083] Comparative Example 4:

[0084] A high-toughness polycarbonate modified material comprises the following components by weight: 92 parts polycarbonate, 7 parts core-shell type impact modifier, 14 parts hollow glass microspheres, 2.2 parts halogen-free flame retardant, 1.5 parts antioxidant 1010, and 0.3 parts pentaerythritol stearate.

[0085] The core-shell type impact modifier comprises the following components by weight: 100 parts water, 52 parts sodium dodecyl sulfate, 95 parts polymeric monomer, 6 parts crosslinking monomer, 36 parts shell monomer, and 0.5 parts potassium persulfate. The polymeric monomer includes 46 parts acrylic acid and 49 parts phenyl acrylate. The crosslinking monomer includes 4.5 parts diallyl phthalate and 1.5 parts ethylene glycol dimethacrylate. The shell monomer includes 18 parts styrene and 18 parts methyl methacrylate. The preparation method of the impact modifier includes the following steps: S101) Add the polymerizing monomer and crosslinking monomer to a sodium dodecyl sulfate solution to obtain a reaction solution; S102) Add potassium persulfate to the reaction solution and react at 70-80℃ for 2-4 hours to obtain a core layer liquid; S103) Add the shell layer monomer and potassium persulfate dropwise to the core layer liquid and react at 70-90℃ for 3-5 hours to obtain a core-shell polymer liquid; S104) Wash and dry the polymer liquid to obtain a core-shell type impact modifier.

[0086] A method for preparing a high-toughness polycarbonate modified material includes the following steps:

[0087] S10) Prepare a core-shell type impact modifier according to the above method;

[0088] S20) Polycarbonate, core-shell type impact modifier, hollow glass microspheres, halogen-free flame retardant, antioxidant 1010 and pentaerythritol stearate are mixed evenly according to the mass parts to obtain a premix.

[0089] S30) The premixed material is placed in a twin-screw extruder, the temperature range is set to 250-270℃, the speed is 450rpm, and the material is extruded, cooled, and granulated to obtain a high-toughness polycarbonate modified material.

[0090] Comparative Example 5:

[0091] A high-toughness polycarbonate modified material comprises the following components by weight: 105 parts polycarbonate, 7 parts core-shell type impact modifier, 2.2 parts halogen-free flame retardant, 1.5 parts antioxidant 1010, and 0.3 parts pentaerythritol stearate;

[0092] The core-shell type impact modifier comprises the following components by weight: 100 parts water, 52 parts sodium dodecyl sulfate, 95 parts polymeric monomer, 6 parts crosslinking monomer, 36 parts shell monomer, and 0.5 parts potassium persulfate. The polymeric monomer includes 46 parts acrylic acid and 49 parts phenyl acrylate. The crosslinking monomer includes 4.5 parts diallyl phthalate and 1.5 parts 2-phenylpropyl acrylate. The shell monomer includes 18 parts styrene and 18 parts methyl methacrylate. The preparation method of the impact modifier includes the following steps: S101) Add the polymerizing monomer and crosslinking monomer to a sodium dodecyl sulfate solution to obtain a reaction solution; S102) Add potassium persulfate to the reaction solution and react at 70-80℃ for 2-4 hours to obtain a core layer liquid; S103) Add the shell layer monomer and potassium persulfate dropwise to the core layer liquid and react at 70-90℃ for 3-5 hours to obtain a core-shell polymer liquid; S104) Wash and dry the polymer liquid to obtain a core-shell type impact modifier.

[0093] A method for preparing a high-toughness polycarbonate modified material includes the following steps:

[0094] S10) Prepare a core-shell type impact modifier according to the above method;

[0095] S20) Polycarbonate, core-shell type impact modifier, hollow glass microspheres, halogen-free flame retardant, antioxidant 1010 and pentaerythritol stearate are mixed evenly according to the mass parts to obtain a premix.

[0096] S30) The premixed material is placed in a twin-screw extruder, the temperature range is set to 250-270℃, the speed is 450rpm, and the material is extruded, cooled, and granulated to obtain a high-toughness polycarbonate modified material.

[0097] Comparative Example 6:

[0098] A high-toughness polycarbonate modified material comprises the following components by weight: 92 parts polycarbonate, 7 parts core-shell type impact modifier, 14 parts hollow glass microspheres, 2.2 parts halogen-free flame retardant, 1.5 parts antioxidant 1010, and 0.3 parts pentaerythritol stearate.

[0099] The core-shell type impact modifier comprises the following components by weight: 100 parts water, 52 parts sodium dodecyl sulfate, 95 parts polymeric monomer, 6 parts crosslinking monomer, 36 parts shell monomer, and 0.5 parts potassium persulfate. The polymeric monomer includes 46 parts acrylic acid and 49 parts butyl acrylate, the crosslinking monomer includes ethylene glycol dimethacrylate, and the shell monomer includes 18 parts styrene and 18 parts methyl methacrylate. The preparation method of the core-shell type impact modifier includes the following steps: S101) Add the polymeric monomer and crosslinking monomer to a sodium dodecyl sulfate solution to obtain a reaction solution; S102) Add potassium persulfate to the reaction solution and react at 70-80℃ for 2-4 hours to obtain a core layer solution; S103) Add the shell monomer and potassium persulfate dropwise to the core layer solution and react at 70-90℃ for 3-5 hours to obtain a core-shell polymer solution; S104) Wash and dry the polymer solution to obtain the core-shell type impact modifier.

[0100] A method for preparing a high-toughness polycarbonate modified material includes the following steps:

[0101] S10) Prepare a core-shell type impact modifier according to the above method;

[0102] S20) Polycarbonate, core-shell type impact modifier, hollow glass microspheres, halogen-free flame retardant, antioxidant 168 and pentaerythritol stearate are mixed evenly according to the mass parts to obtain a premix.

[0103] S30) The premixed material is placed in a twin-screw extruder, the temperature range is set to 250-270℃, the speed is 450rpm, and the material is extruded, cooled, and granulated to obtain a high-toughness polycarbonate modified material.

[0104] Application Examples:

[0105] The granular high-toughness polycarbonate modified materials prepared in Examples 1 to 5 and Comparative Examples 1 to 6 were tested as test blocks under the same conditions (injection molding or 3D printing) according to ASTM standards. The test conditions and test results are shown in the table below.

[0106]

[0107]

[0108] The experimental data above show that the materials prepared using Examples 1 to 5 and Comparative Examples 1 to 6 have similar tensile strengths, but the materials prepared using Examples 1 to 5 show significantly improved elongation at break and notched impact strength, demonstrating superior performance in improving elongation at break and impact toughness. Specifically, comparing Comparative Examples 1 to 6 with Example 1 reveals that: the material formed in Comparative Example 1 does not contain benzene ring structures in the main chain of the core-shell impact modifier; the material formed in Comparative Example 2 does not contain benzene ring structures in the side chains of the core-shell impact modifier; the material formed in Comparative Example 3 contains benzene rings in the side chains of the core-shell impact modifier but not auxiliary crosslinking structures; the material formed in Comparative Example 4 contains benzene rings and other chemical crosslinking structures in the side chains of the core-shell impact modifier; the material formed in Comparative Example 5 does not contain hollow glass microspheres; and the material formed in Comparative Example 6 exhibits superior performance in core-shell impact modifier... Neither the main chain nor the branches of the modifier contain benzene ring structures. Based on the differences in molecular chains and structures in the modifier, it can be shown that, given the good strength of both the main chain and branch benzene ring structures, the interaction between these structures alters the spatial structure, resulting in excellent elasticity and toughness. Furthermore, given that the addition of hollow glass microspheres can make polycarbonate materials lighter overall, data from Example 1 and Comparative Example 5 show that the spatial structure of the main chain (containing benzene rings) and branches (containing benzene rings) of the core-shell impact modifier can ensure that the strength of polycarbonate is not affected, or is minimally affected.

[0109] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A high-toughness polycarbonate modified material, characterized in that, The product comprises the following components by weight: 82-110 parts polycarbonate, 4-7 parts core-shell impact modifier, 8-15 parts filler, 1-3 parts flame retardant, 0.15-1.5 parts antioxidant, and 0.1-0.5 parts lubricant, wherein the filler is hollow glass microspheres; The core-shell type impact modifier comprises the following components by weight: 43-56 parts emulsifier, 90-113 parts polymeric monomer, 2.5-6 parts crosslinking monomer, 32-45 parts shell monomer, and 0.1-1 parts initiator. The polymeric monomer includes at least acrylic acid and phenyl acrylate in a mass ratio of 1:(0.8-1.2). The crosslinking monomer includes diallyl phthalate and 2-phenylpropyl acrylate in a mass ratio of 3:(0.5-1). The shell monomer includes styrene and methyl methacrylate in a mass ratio of 1:(1-1.2). The polymeric monomer and crosslinking monomer are core monomers.

2. The high-toughness polycarbonate modified material according to claim 1, characterized in that, The emulsifier is sodium dodecyl sulfate or sodium dodecylbenzene sulfonate; the initiator is potassium persulfate or azobisisobutyronitrile.

3. The high-toughness polycarbonate modified material according to claim 1, characterized in that, The preparation method of the core-shell type impact modifier includes the following steps: S101) The polymerizing monomer and crosslinking monomer are added to the emulsifier solution to prepare the reaction solution; S102) The initiator is added to the reaction solution and reacted at 70-80℃ for 2-4 hours to obtain the core layer liquid; S103) Add shell monomer and initiator dropwise to the core layer liquid and react at 70-90℃ for 3-5 hours to obtain core-shell polymer liquid; S104) The polymerization solution was washed and dried to obtain a core-shell type impact modifier.

4. The high-toughness polycarbonate modified material according to claim 1, characterized in that, The hollow glass microspheres have a particle size of 50-200 μm.

5. The high-toughness polycarbonate modified material according to claim 1, characterized in that, The flame retardant is one or more of the following: sulfonate flame retardants, phosphate flame retardants, and halogen-free flame retardants.

6. The high-toughness polycarbonate modified material according to claim 1, characterized in that, The antioxidant is antioxidant 1010 or antioxidant 168.

7. The high-toughness polycarbonate modified material according to claim 1, characterized in that, The lubricant is pentaerythritol stearate.

8. A method for preparing a high-toughness polycarbonate modified material according to any one of claims 1 to 7, characterized in that, Includes the following steps: S10) to prepare core-shell type impact modifier; S20) After mixing polycarbonate, core-shell type impact modifier, filler, flame retardant, antioxidant and lubricant evenly according to the mass parts, a premix is ​​obtained; S30) The premixed material is placed in a twin-screw extruder, the temperature range is set to 220-270℃, the speed is set to 300-500rpm, and the material is extruded, cooled, and granulated to obtain a high-toughness polycarbonate modified material.

9. An application of a high-toughness polycarbonate modified material according to any one of claims 1 to 7, characterized in that, The high-toughness polycarbonate modified material is used for electronic and electrical appliance housings.

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