A pc / ppsu composite material and a preparation method and application thereof

Abstract

The application discloses a PC / PPSU composite material and a preparation method and application thereof, and relates to the technical field of plastics. The PC / PPSU composite material comprises the following components in parts by weight: PC resin 24-91 parts; PPSU resin 29-82 parts; reinforcing agent 1.3-6 parts; and compatibility agent 0.4-6 parts. The reinforcing agent comprises at least one of carbon black and activated carbon, the specific surface area of the carbon black is 80-230 m 2 / g, and the iodine adsorption value of the activated carbon is not less than 700 mg / g. The PC / PPSU composite material has excellent heat resistance, welding line strength and leakage resistance.

Description

Technical Field

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

[0002] Polycarbonate (PC) possesses excellent properties such as high strength, high toughness, high heat resistance, good dimensional stability, and electrical insulation, leading to its widespread application in home appliances, medical devices, and electronics. However, polycarbonate's glass transition temperature is only 149℃, and its heat distortion temperature is relatively low (1.80MPa, 130~135℃), which limits the expansion of its application areas. Researching and developing high-temperature-resistant modified PC materials has long been a key research direction in the field of polymer materials.

[0003] Existing technologies utilize interfacial polycondensation of bisphenol monomers with phosgene (carbonyl chloride) to produce high-temperature resistant PCs, achieving heat distortion temperatures exceeding 150°C. However, this copolymerization method suffers from long development cycles, complex production processes, and high costs. Preparing plastic alloys through physical or chemical blending of two or more different plastics is the simplest, most economical, and effective method for modifying engineering plastics, enabling complementary or even synergistic performance effects. For example, existing technologies disclose that PC / ABS or PC / PS alloys can improve the processing fluidity of PC; PC / PBT alloys can improve the solvent resistance and reduce internal stress of PC. However, these PC alloys all come at the cost of sacrificing the heat resistance of PC. Therefore, researching and developing high-performance, high-heat-resistant PC alloy materials is a shared challenge for both academia and industry.

[0004] Polyphenylene sulfone (PPSU) is a high-performance engineering plastic containing sulfone (-SO2-) and aryl groups in its molecular backbone. It boasts a glass transition temperature as high as 220℃ and a heat resistance temperature exceeding 180℃. Furthermore, PPSU exhibits good tensile strength and impact toughness. Blending polycarbonate with PPSU holds promise for preparing high-heat-resistant PC alloy materials. However, PPSU is typically synthesized via a nucleophilic reaction of 4,4'-dichlorodiphenyl sulfone and biphenylhydrazine. The reaction generally uses sulfolane as a solvent, anhydrous potassium / sodium carbonate as a salt-forming agent, and toluene as a dehydrating agent, employing a two-step reaction of "salt formation" and "polymerization." This results in the presence of residual sodium chloride or potassium chloride in the synthesized PPSU, which is difficult to remove. These residual sodium chloride or potassium chloride tends to precipitate and accumulate at the weld lines of injection-molded samples, leading to a decrease in the strength of the weld lines. Meanwhile, sodium chloride and potassium chloride, as ionic impurities, can cause residual and localized precipitation, making it easy for materials to form ionic conductive pathways in humid and electrically charged environments. This can induce surface leakage and tracking failure, significantly deteriorating the electrical insulation performance and long-term reliability of the material, and thus reducing the material's relative tracking index (CTI). Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a PC / PPSU composite material, its preparation method, and its applications. The PC / PPSU composite material of this invention possesses excellent heat resistance, weld line strength, and leakage current resistance.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: In a first aspect, the present invention provides a PC / PPSU composite material comprising the following components in parts by weight: 24-91 parts PC resin; 29-82 parts PPSU resin (polyphenyl sulfone resin); 1.3-6 parts reinforcing agent; 0.4-6 parts compatibilizer; The reinforcing agent includes at least one of carbon black and activated carbon, wherein the carbon black has a specific surface area of ​​80-230 m². 2 / g, wherein the iodine adsorption value of the activated carbon is not less than 700 mg / g.

[0007] Preferably, the specific surface area of ​​the carbon black is 100-200 m². 2 / g, for example, could be 100m 2 / g、110m 2 / g, 120m 2 / g, 130m 2 / g, 140m 2 / g, 150m 2 / g, 160m 2 / g、170m 2 / g、180m 2 / g、190m 2 / g、200m 2 The specific surface area of ​​the carbon black is determined according to GB / T 10722-2021. (The values ​​are within the range of any one or both of the values ​​in g.)

[0008] Preferably, the iodine adsorption value of the activated carbon is 700-1000 mg / g, for example, it can be any one or a range of two of 700 mg / g, 750 mg / g, 800 mg / g, 850 mg / g, 900 mg / g, 950 mg / g, and 1000 mg / g. The test method for the iodine adsorption value of the activated carbon is determined according to GB / T 12496.8-2015.

[0009] Preferably, the reinforcing agent comprises carbon black and activated carbon, and the mass ratio of carbon black to activated carbon is 1:(1-3), for example, it can be any one or a range of both of 1:1, 1:1.2, 1:1.5, 1:1.8, 1:2, 1:2.2, 1:2.5, 1:2.8, and 1:3.

[0010] Preferably, the PC resin is bisphenol A type polycarbonate.

[0011] Preferably, the melt flow rate of the PC resin under 300°C / 1.2kg load conditions is 5-25 g / 10min, more preferably 10-20 g / 10min, for example, it can be any one or a combination of 10 g / 10min, 11 g / 10min, 12 g / 10min, 13 g / 10min, 14 g / 10min, 15 g / 10min, 16 g / 10min, 17 g / 10min, 18 g / 10min, 19 g / 10min, and 20 g / 10min. The melt flow rate of the PC resin is measured according to ISO 1133-1:2011.

[0012] Preferably, the melt flow rate of the PPSU resin under 365℃ / 5kg load conditions is 10-50 g / 10min, and more preferably 12-45 g / 10min.

[0013] More preferably, the melt flow rate of the PPSU resin under 365°C / 5kg load conditions is 15-24 g / 10min, for example, it can be any one or a range of two of 15 g / 10min, 16 g / 10min, 17 g / 10min, 18 g / 10min, 19 g / 10min, 20 g / 10min, 21 g / 10min, 22 g / 10min, 23 g / 10min, and 24 g / 10min. The melt flow rate of the PPSU resin is measured according to ISO 1133-1:2011.

[0014] Preferably, the PC resin accounts for no less than 20% of the mass percentage of the PC / PPSU composite material.

[0015] Preferably, the PPSU resin accounts for no less than 22% by mass in the PC / PPSU composite material.

[0016] Preferably, the compatibilizer is an epoxy-grafted compatibilizer.

[0017] More preferably, the epoxy-grafted compatibilizer includes at least one of styrene-grafted glycidyl methacrylate, ethylene-methacrylate-glycidyl methacrylate copolymer, ethylene-acrylate-glycidyl methacrylate copolymer, and polyoctene-ethylene-grafted glycidyl methacrylate.

[0018] Preferably, the PC / PPSU composite material comprises the following components in parts by weight: 30-75 parts PC resin; 40-70 parts PPSU resin; 1-4 parts reinforcing agent; 1-3 parts compatibilizer.

[0019] Preferably, the PC / PPSU composite material further includes 0-3 parts of additives.

[0020] Preferably, the additives include at least one of antioxidants and lubricants.

[0021] Preferably, the antioxidant includes at least one of antioxidant 1010, antioxidant 168, and antioxidant 1076; Preferably, the lubricant comprises at least one of pentaerythritol stearate, polyethylene wax, and silicone lubricant.

[0022] The PC / PPSU composite material of the present invention may further include at least one of mineral powder, colorant, antistatic agent, and ultraviolet light absorber.

[0023] The PC / PPSU composite material of the present invention may include 0-1 parts of mineral powder, and suitable mineral powders include, but are not limited to, calcium carbonate, mica, kaolin, magnesium hydroxide, boehmite and combinations thereof.

[0024] The PC / PPSU composite material of the present invention may include 0-1 parts of colorant, and suitable colorants include, but are not limited to, titanium dioxide, zinc sulfide, iron oxide red, titanium yellow and combinations thereof.

[0025] The PC / PPSU composite material of the present invention may include 0-1 parts of antistatic agent, and suitable antistatic agents include, but are not limited to, zinc oxide, manganese dioxide, chromium trioxide and combinations thereof.

[0026] The PC / PPSU composite material of the present invention may include 0-1 parts of ultraviolet light absorber. Suitable ultraviolet light absorbers include, but are not limited to, hydroxybenzophenones, benzotriazoles, hydroxybenzotriazines, cyanoacrylates, nanoscale inorganic materials (e.g., titanium oxide, cerium oxide, and zinc oxide) and combinations thereof.

[0027] Secondly, this invention also discloses a method for preparing a PC / PPSU composite material, comprising the following steps: The components are mixed and added to a twin-screw extruder, and after granulation and cooling, PC / PPSU composite material is obtained.

[0028] Preferably, the temperature of the twin-screw extruder is 250-300 ℃ and the screw speed is 300 rpm.

[0029] Thirdly, the present invention also discloses the application of PC / PPSU composite material in the manufacture of automotive parts. In particular, the PC / PPSU composite material can be used to manufacture parts with high heat resistance and weld line strength, and is especially suitable for manufacturing lamp covers, transformer assemblies and fuse boxes.

[0030] Compared with the prior art, the beneficial effects of the present invention are as follows: This invention, by adding specific reinforcing agents to the PC / PPSU alloy system, endows the PC / PPSU composite material with excellent heat resistance and high weld line strength. Furthermore, by controlling the specific surface area of ​​carbon black and the iodine adsorption value of activated carbon, this invention improves the dispersibility of carbon black and activated carbon in the resin matrix and effectively adsorbs residual metal chlorides in the polyphenylene sulfone resin during melt extrusion processing. This prevents the precipitation and accumulation of metal chlorides at the weld lines of the injection-molded parts, thereby significantly improving the weld line strength and heat resistance of the PC / PPSU composite material. Moreover, it helps to avoid the formation of ionic conductive pathways in humid or electrically charged environments, leading to surface leakage and tracking failure, thus improving the electrical insulation performance and long-term reliability of the material, and ultimately enhancing the leakage resistance of the PC / PPSU composite material. Detailed Implementation

[0031] To better illustrate the purpose, technical solution, and advantages of the present invention, the present invention will be further described below in conjunction with specific embodiments, but the scope of protection and implementation of the present invention are not limited thereto.

[0032] Unless otherwise specified, the materials and reagents used in the following examples are commercially available.

[0033] Examples 1-14 Examples of the PC / PPSU composite material and its preparation method according to the present invention are shown in Table 1.

[0034] The preparation method of the PC / PPSU composite material includes the following steps: (1) The PC resin, PPSU resin, reinforcing agent, compatibilizer and additives are mixed evenly to obtain a premix; (2) The above premix is ​​fed into a twin-screw extruder, melt-mixed and extruded and granulated in the twin-screw extruder (screw length-to-diameter ratio is 45:1, screw barrel temperature is 250-300 ℃, screw speed is 300 rpm) to obtain the PC / PPSU composite material.

[0035] Comparative Examples 1-8 The only difference between the comparative examples and the embodiments is the type and ratio of components, as shown in Table 2.

[0036] In the components described in each embodiment and comparative example: The PC resin 1 is bisphenol A type, with a melt flow rate of 10 g / 10 min, PC 1300-10 NP, manufactured by LG Chem Ltd., South Korea. The PC resin 2 is bisphenol A type, with a melt flow rate of 22 g / 10 min, PC 1300-22 NP, LG Chem.

[0037] The PPSU resin 1 has a melt flow rate of 15g / 10min, is KFSU12, and is manufactured by Kingfa Science & Technology Co., Ltd. The PPSU resin 2 has a melt flow rate of 24 g / 10 min, is COLORCOMP 9X02695H, and is manufactured by SABIC. The PPSU resin 3 has a melt flow rate of 45 g / 10 min, is KFSU10, and is manufactured by Kingfa Science & Technology Co., Ltd. The PPSU resin 4 has a melt flow rate of 12 g / 10 min, is PARYLS® PPSU F1150, and is manufactured by Jiangmen Youju.

[0038] The reinforcing agent 1 is carbon black, BLACK PEARLS 700, with a BET value of 200m.2 / g; The reinforcing agent 2 is carbon black, Longxing Chemical N330, with a BET value of 80m. 2 / g; The reinforcing agent 3 is carbon black, Cabot M900, with a BET value of 230m. 2 / g; The reinforcing agent 4 is carbon black, BLACK PEARLS 130, with a BET value of 25m. 2 / g; The reinforcing agent 5 is carbon black, BLACK PEARLS 1300, with a BET value of 560m. 2 / g; The reinforcing agent 6 is activated carbon, JPWT-325, with an iodine adsorption value of 1000 mg / g; The reinforcing agent 7 is activated carbon, JPKL-35, with an iodine adsorption value of 700 mg / g; The reinforcing agent 8 is activated carbon, JPKL-90, with an iodine adsorption value of 400 mg / g.

[0039] The reinforcing agent 9 is talc, T109494, Aladdin.

[0040] The compatibilizer 1 is: ethylene-acrylate-glycidyl methacrylate (GMA) copolymer, LOTADERAX 8900, Arkema; Compatibilizer 2: Polyoctene vinyl grafted glycidyl methacrylate, SOG-03, Jia Yi Rong. Antioxidant: Antioxidant 1010, Sanfeng Chemical Co., Ltd.

[0041] Unless otherwise specified, all components and raw materials used in the embodiments and comparative examples of this invention are commercially available, and the same type of components and raw materials are used in each parallel experiment.

[0042] Table 1 Table 2 To verify the performance of the PC / PPSU composite material described in this invention, the PC / PPSU composite materials prepared in each embodiment and comparative example were injection molded into specimens for testing the following properties.

[0043] Performance testing methods: (1) Weld line strength: Tensile test was conducted according to ISO 527-2-2012, with a span of 115 mm, a tensile rate of 50 mm / min, and a test temperature of 23 °C. The test sample was a tensile sample obtained by injection molding and with a weld line formed in the middle (the melt enters the sample from both ends).

[0044] (2) Heat distortion temperature: The heat distortion temperature was tested in accordance with ISO75-1-2013, and the test load was 1.8MPa.

[0045] (3) Tracking resistance index (CTI) of weld line: The CTI performance test is carried out in accordance with the relevant provisions in the standard ASTM D3638-2021. The unit is V. The test sample is a tensile sample obtained by injection molding with a weld line in the middle (the melt enters the sample from both ends of the sample). The test position is located at the weld line.

[0046] The performance parameters obtained from the above tests are shown in Table 3.

[0047] Table 3 As can be seen from Examples 1-14, the weld line strength of the PC / PPSU composite material of the present invention can reach more than 55 MPa, the heat distortion temperature can reach more than 145°C, and the tracking resistance index of the weld line can reach more than 190V. This shows that the PC / PPSU composite material of the present invention has excellent heat resistance, weld line strength, and leakage resistance.

[0048] Comparing Comparative Examples 1-3 with Example 1, it can be seen that if the specific surface area of ​​carbon black is too low or too high, the weld line strength of the PC / PPSU composite material decreases significantly, and the heat distortion temperature and the tracking resistance index of the weld line also decrease. If the iodine adsorption value of activated carbon is too low, the weld line strength, heat distortion temperature, and tracking resistance index of the PC / PPSU composite material all decrease. This indicates that controlling the specific surface area of ​​carbon black and / or the iodine adsorption value of activated carbon within the range defined by this invention is beneficial to improving the weld line strength, heat resistance, and tracking resistance of the PC / PPSU composite material.

[0049] Comparing Comparative Examples 4-5 with Example 1, it can be seen that in Comparative Example 4, no reinforcing agent was added, and the weld line strength of the PC / PPSU composite material was significantly reduced, as were the heat distortion temperature and the tracking resistance index of the weld line. In Comparative Example 5, the reinforcing agent content was too high, and the weld line strength of the PC / PPSU composite material was significantly reduced. Furthermore, the heat distortion temperature and the tracking resistance index of the weld line were also reduced. This indicates that the present invention can improve the weld line strength, heat resistance, and leakage resistance of the composite material by adding a specific amount of reinforcing agent.

[0050] A comparison of Comparative Examples 6-7 with Example 1 shows that if the content of PC resin and PPSU resin is outside the range defined in this invention, it will affect the weld line strength, heat resistance, and leakage current resistance of the PC / PPSU composite material. Therefore, by controlling the content of PC resin and PPSU resin within the range defined in this invention, the PC / PPSU composite material can simultaneously possess excellent heat resistance, weld line strength, and leakage current resistance.

[0051] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the essence and scope of the technical solutions of the present invention.

Claims

1. A PC / PPSU composite material, characterized in that, Includes the following components in parts by weight: 24-91 parts PC resin; 29-82 parts PPSU resin; 1.3-6 parts reinforcing agent; 0.4-6 parts compatibilizer; The reinforcing agent includes at least one of carbon black and activated carbon, wherein the carbon black has a specific surface area of ​​80-230 m². 2 / g, wherein the iodine adsorption value of the activated carbon is not less than 700 mg / g.

2. The PC / PPSU composite material as described in claim 1, characterized in that, The specific surface area of ​​the carbon black is 100-200 m². 2 / g, wherein the iodine adsorption value of the activated carbon is 700-1000 mg / g.

3. The PC / PPSU composite material as described in claim 1, characterized in that, The reinforcing agent includes carbon black and activated carbon, and the mass ratio of carbon black to activated carbon is 1:(1-3).

4. The PC / PPSU composite material as described in claim 1, characterized in that, The melt flow rate of the PC resin under the conditions of 300℃ / 1.2kg load is 5-25 g / 10min.

5. The PC / PPSU composite material as described in claim 1, characterized in that, The melt flow rate of the PPSU resin under 365℃ / 5kg load conditions is 10-50 g / 10min.

6. The PC / PPSU composite material as described in claim 5, characterized in that, The melt flow rate of the PPSU resin under 365℃ / 5kg load conditions is 15-24 g / 10min.

7. The PC / PPSU composite material as described in claim 1, characterized in that, The compatibilizer includes at least one of styrene-grafted glycidyl methacrylate, ethylene-methacrylate-glycidyl methacrylate copolymer, ethylene-acrylate-glycidyl methacrylate copolymer, and polyoctene-ethylene-grafted glycidyl methacrylate.

8. The PC / PPSU composite material as described in claim 1, characterized in that, The PC / PPSU composite material also includes 0-3 parts of additives.

9. A method for preparing the PC / PPSU composite material according to any one of claims 1-8, characterized in that, Includes the following steps: The components are mixed and added to a twin-screw extruder, and after granulation and cooling, PC / PPSU composite material is obtained.

10. The application of the PC / PPSU composite material as described in any one of claims 1-8 in the manufacture of automotive parts.

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