POLYCARBONATE COMPOSITIONS CONTAINING POLYETHERCARBONATE POLYOLS
Patent Information
- Application Number
- DE502021008087
- Authority / Receiving Office
- DE · DE
- Patent Type
- Patents
- Current Assignee / Owner
- Priority Date
- 2020-05-26
- Filing Date
- 2021-05-20
- Publication Date
- 2025-08-14
- Estimated Expiration
- 2041-05-20
AI Technical Summary
Existing polycarbonate compositions used in injection molding for components like diffuser sheets in ultrabooks and automotive headlight covers face challenges with heat resistance, optical properties, flowability, and demolding issues, with Bisphenol A diphosphate improving flow but reducing heat resistance, and isosorbide esters causing volatile deposits.
Incorporating polyethercarbonate polyols into polycarbonate compositions to enhance heat resistance, optical properties, and flowability while maintaining demolding efficiency, achieved through a catalytic reaction of alkylene oxides and carbon dioxide with H-functional starter compounds.
The compositions exhibit improved optical transmission, reduced yellowness, and enhanced melt stability with higher melt volume flow rates, maintaining heat resistance and facilitating better demolding and processing.
Description
[0001] The invention relates to compositions containing aromatic polycarbonate and polyether carbonate polyols, as well as molded parts obtainable therefrom. The compositions exhibit improved rheological and optical properties as well as improved demolding and processing behavior in injection molding.
[0002] Particularly for thin-walled, transparent (housing) parts, such as diffuser sheets in ultrabooks, smartphones, or smartbooks, a low melt viscosity is required to produce components with uniform wall thickness. Other application areas requiring good flow properties include the automotive sector (e.g., headlight covers, bezels, lighting control systems) and the electrical / electronics sector (lighting components, housing parts, covers, smart meter applications).
[0003] Bisphenol A diphosphate (BDP) is traditionally used to improve flow, in amounts of up to more than 10 wt.% to achieve the desired effect. However, this significantly reduces heat resistance. This effect is described, for example, in WO 2015 / 135958 A1.
[0004] Furthermore, there is a need, especially for the aforementioned components, to further improve the transmission in order to utilize the energy used for the respective application as effectively as possible. Other optical properties, such as the yellowness index (YI) and the opacity of the material, should also be improved if possible. Heat resistance should not be significantly impaired, but Vicat temperatures should preferably remain at least 135.0°C.
[0005] JP S62 36457 A and EP 0 004 020 A1 describe transparent thermoplastic compositions comprising aromatic polycarbonate and a polyether carbonate.
[0006] One prior art solution, described in WO 2017 / 178583 A1, involves adding isosorbide esters to polycarbonate compositions. A disadvantage of this solution is the relatively high volatility of the isosorbide esters, which can lead to undesirable deposit formation during injection molding.
[0007] The object was therefore to provide polycarbonate-based compositions which still have good heat resistance, ie Vicat temperatures of at least 135°C, preferably at least 140°C, which have improved optical properties, ie a higher transmission Ty, a lower yellowness index (YI) and the lowest possible turbidity, and at the same time have improved flowability, and if possible also with improved demolding and processing behavior.
[0008] Surprisingly, it was found that polycarbonate compositions exhibit improved optical properties—i.e., higher transmission in the VIS range and a lower yellowness index—compared to compositions without the corresponding additives when polyethercarbonate polyols are added. The heat distortion temperature, determined by the Vicat temperature, remains almost unchanged at moderate amounts of the additive, and remains at an acceptable level at higher concentrations of polyethercarbonate polyols. At the same time, the coefficients of sliding and static friction are reduced, resulting in improved demolding and processing behavior in injection molding.
[0009] Polyethercarbonate polyols are generally known. Polyethercarbonate polyols are typically produced by catalytic reaction of alkylene oxides (epoxides) and carbon dioxide in the presence of H-functional starter compounds ("starters"). This reaction is schematically depicted in Scheme (I), where R represents an organic radical such as alkyl, alkylaryl, or aryl, each of which may also contain heteroatoms such as O, S, Si, etc., and where e, f, and g represent an integer. The product shown here in Scheme (I) for the polyethercarbonate polyol should be understood merely to mean that blocks with the structure shown can, in principle, be found in the resulting polyethercarbonate polyol, but the order, number, and length of the blocks, as well as the OH functionality of the starter, can vary and is not limited to the polyethercarbonate polyol shown in Scheme (I).This reaction (see Scheme (I)) is ecologically very advantageous, as it represents the conversion of a greenhouse gas such as CO2 into a polymer. Another product, actually a by-product, is the cyclic carbonate shown in Scheme (1) (for example, for R = CH3, propylene carbonate, also referred to as cPC below, or for R = H, ethylene carbonate, also referred to as cEC below).
[0010] A process for producing polyethercarbonate polyols is described, for example, in EP 2 530 101 A1, EP 3 027 673 B1, or European patent application No. 19189265.2. European patent application No. 19189265.2 describes a process for producing polyethercarbonate polyols with a very low cyclic polycarbonate content, so that the production of polyethercarbonate polyols for compositions according to the invention by this process is preferred. The use of polyethercarbonate polyols together with isocyanates for producing polyurethane foams is known and is described, for example, in WO 2012 / 130760 A1, EP 0 222 453 A2, or WO 2018 / 219893 A1. However, the use as an additive for polycarbonate compositions is not described.
[0011] The polycarbonate compositions according to the invention containing polyethercarbonate polyols exhibit improved optical properties, measurable by a higher optical transmission (transmission in the VIS range, Ty, illuminant D65), determined according to ISO 13468-2:2006 at 4 mm thickness, preferably also a lower yellowness index (YI), determined according to ASTM E 313-15 (observer 10° / illuminant: D65) on sample plates with a layer thickness of 4 mm, compared to corresponding compositions which otherwise contain the same components in addition to polycarbonate in the same amounts except for the polyethercarbonate polyols. In addition, the compositions exhibit good melt stabilities with improved rheological properties, namely a higher melt volume flow rate (MVR), determined according to DIN EN ISO 1133:2012-3 (at a test temperature of 300 °C, mass 1.2 kg), an improved melt viscosity, determined according to ISO 11443:2005, and good demolding properties.
[0012] The present invention therefore relates to transparent thermoplastic compositions containing A) aromatic polycarbonate and B) polyethercarbonate polyol.
[0013] "Transparent" in the sense of the invention means that the compositions have a visual transmission Ty (D65 in 10° observation) of at least 84%, preferably of at least 88%, particularly preferably of at least 88.5%, very particularly preferably of at least 89.0%, determined according to ISO 13468-2:2006 at a thickness of 4 mm, and a turbidity < 5%, preferably < 2%, particularly preferably < 1.5%, very particularly preferably < 1.0%, determined according to ASTM D1003:2013 at a layer thickness of 4 mm.
[0014] The compositions preferably contain A) 70.0 wt% to 99.95 wt% aromatic polycarbonate and B) 0.05 wt% to 2.0 wt% polyethercarbonate polyol.
[0015] The compositions according to the invention further preferably contain A) 80.0 wt.% to 99.9 wt.% aromatic polycarbonate and B) 0.1 wt.% to 1.2 wt.% polyethercarbonate polyol, C) 0 to 1.0 wt.% of at least one thermal stabilizer and / or transesterification stabilizer, D) 0 to 1.0 wt.% of at least one UV absorber and E) optionally one or more further additives other than components B, C and D.
[0016] Particularly preferably, such compositions consist of A) 95.0 wt.% to 99.9 wt.% aromatic polycarbonate and B) 0.1 wt.% to 1.2 wt.% polyethercarbonate polyol, C) 0 to 1.0 wt.% of at least one thermal stabilizer and / or transesterification stabilizer, D) 0 to 1.0 wt.% of at least one UV absorber and E) optionally one or more further additives, wherein the further additives are selected from the group consisting of antioxidants, mold release agents, flame retardants, IR absorbers, antistatic agents, optical brighteners, colorants such as organic dyes and / or additives for laser marking and F) optionally blend partners.
[0017] C 1 - to C 4 -alkyl in the following description of the invention stands, for example, for methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, tert-butyl, C 1 - to C 6 -alkyl and furthermore for example for n-pentyl, 1-methylbutyl, 2-methylbutyl, 3-methylbutyl, neo-pentyl, 1-ethylpropyl, cyclohexyl, cyclopentyl, n-hexyl, 1,1-dimethylpropyl, 1,2-dimethylpropyl, 1,2-dimethylpropyl, 1-methylpentyl, 2-methylpentyl, 3-methylpentyl, 4-methylpentyl, 1,1-dimethylbutyl, 1,2-dimethylbutyl, 1,3-dimethylbutyl, 2,2-dimethylbutyl, 2,3-dimethylbutyl, 3,3-Dimethylbutyl, 1-Ethylbutyl, 2-Ethylbutyl, 1,1,2-Trimethylpropyl, 1,2,2-Trimethylpropyl, 1-Ethyl-1-methylpropyl, 1-Ethyl-2-methylpropyl, or 1-Ethyl-2-methylpropyl. C1- to C10-Alkyl also represents, for example, n-heptyl and n-octyl, pinyl, adamantyl, the isomeric menthyls, n-nonyl, and n-decyl.C1 to C34 alkyl also represents, for example, n-dodecyl, n-tridecyl, n-tetradecyl, n-hexadecyl, or n-octadecyl. The same applies to the corresponding alkyl radical, for example, in aralkyl or alkylaryl, alkylphenyl, or alkylcarbonyl radicals. Alkylene radicals in the corresponding hydroxyalkyl, aralkyl, or alkylaryl radicals represent, for example, the alkylene radicals corresponding to the preceding alkyl radicals.
[0018] Aryl stands for a carbocyclic aromatic radical with 6 to 34 backbone carbon atoms. The same applies to the aromatic part of an arylalkyl radical, also called an aralkyl radical, as well as to aryl components of more complex groups, such as arylcarbonyl radicals.
[0019] Examples of C6 to C34 aryl are phenyl, o-, p-, m-tolyl, naphthyl, phenanthrenyl, anthracenyl or fluorenyl.
[0020] Arylalkyl or aralkyl each independently means a straight-chain, cyclic, branched or unbranched alkyl radical as defined above, which may be mono-, poly- or fully substituted by aryl radicals as defined above.
[0021] In the context of the present invention, the stated % by weight of components A, B, C, D and E - unless explicitly stated otherwise - each relate to the total weight of the composition. In addition to components A, B, C and D, the composition may contain further components - further additives according to component E and / or blend partners. In a preferred embodiment, the composition contains no further components, but the aforementioned components, more preferably components A, B and optionally C, optionally D and optionally E, particularly preferably components A to D, add up to 100 % by weight; ie the composition consists of these components.
[0022] The compositions according to the invention are preferably used for producing molded parts. The compositions preferably have a melt volume flow rate (MVR) of 2 to 75 cm 3 / (10 min), more preferably of 3 to 65 cm 3 / (10 min), and particularly preferably of 6 to 35 cm 3 / (10 min), determined according to ISO 1133:2012-3 (test temperature 300°C, mass 1.2 kg).
[0023] The individual components of the compositions according to the invention are explained in more detail below: Component A
[0024] "Polycarbonate" in the context of the invention refers to both homopolycarbonates and copolycarbonates. The polycarbonates can be linear or branched in a known manner. Mixtures of polycarbonates can also be used according to the invention.
[0025] The composition according to the invention preferably contains, as component A, from 20.0% by weight to 99.95% by weight, preferably up to 99.9% by weight, in particular up to 99.8% by weight, of aromatic polycarbonate. The amount of aromatic polycarbonate in the composition is preferably at least 70% by weight, more preferably at least 75% by weight, and even more preferably at least 80% by weight, particularly preferably at least 87% by weight, and most preferably at least 95.0% by weight, wherein a single polycarbonate or a mixture of several polycarbonates may be present. The thermoplastic composition is thus preferably "based" on aromatic polycarbonate, with the above definitions from "at least 70% by weight polycarbonate" meaning "polycarbonate-based."
[0026] The polycarbonates contained in the compositions are prepared in a known manner from dihydroxyaryl compounds, carbonic acid derivatives, optionally chain terminators and branching agents.
[0027] Details of the production of polycarbonates have been documented in numerous patents for approximately 40 years. Examples include Schnell, "Chemistry and Physics of Polycarbonates," Polymer Reviews, Volume 9, Interscience Publishers, New York, London, Sydney 1964; D. Freitag, U. Grigo, PR Müller, H. Nouvertné, BAYER AG, "Polycarbonates" in Encyclopedia of Polymer Science and Engineering, Volume 11, Second Edition, 1988, pages 648-718; and finally, U. Grigo, K. Kirchner, and PR Müller, "Polycarbonates" in Becker / Braun, Kunststoff-Handbuch, Volume 3 / 1, Polycarbonates, Polyacetals, Polyesters, Cellulose Esters, Carl Hanser Verlag Munich, Vienna 1992, pages 117 to 299.
[0028] Aromatic polycarbonates are produced, for example, by reacting dihydroxyaryl compounds with carbonic acid halides, preferably phosgene, and / or with aromatic dicarboxylic acid dihalides, preferably benzenedicarboxylic acid dihalides, by the interfacial process, optionally using chain terminators and optionally using trifunctional or more than trifunctional branching agents. Production via a melt polymerization process is also possible by reacting dihydroxyaryl compounds with, for example, diphenyl carbonate.
[0029] Dihydroxyaryl compounds suitable for the production of polycarbonates are, for example, hydroquinone, resorcinol, dihydroxydiphenyls, bis-(hydroxyphenyl)-alkanes, bis-(hydroxyphenyl)-cycloalkanes, bis-(hydroxyphenyl)-sulfides, bis-(hydroxyphenyl)-ethers, bis-(hydroxyphenyl)-ketones, bis-(hydroxyphenyl)-sulfones, bis-(hydroxyphenyl)-sulfoxides, α-α'-bis-(hydroxyphenyl)-diisopropylbenzenes, phthalimidines derived from isatin or phenolphthalein derivatives, as well as their nuclear alkylated, nuclear arylated and nuclear halogenated compounds.
[0030] Preferred dihydroxyaryl compounds are 4,4'-dihydroxydiphenyl, 2,2-bis-(4-hydroxyphenyl)-propane (bisphenol A), 2,4-bis-(4-hydroxyphenyl)-2-methylbutane, 1,1-bis-(4-hydroxyphenyl)-p-diisopropylbenzene, 2,2-bis-(3-methyl-4-hydroxyphenyl)-propane, dimethyl bisphenol A, bis-(3,5-dimethyl-4-hydroxyphenyl)-methane, 2,2-bis-(3,5-dimethyl-4-hydroxyphenyl)-propane, bis-(3,5-dimethyl-4-hydroxyphenyl)-sulfone, 2,4-bis-(3,5-dimethyl-4-hydroxyphenyl)-2-methylbutane, 1,1-Bis-(3,5-dimethyl-4-hydroxyphenyl)-p-diisopropylbenzene and 1,1-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, as well as the bisphenols (I) to (III) in which R' is each C 1 to C 4 alkyl, aralkyl or aryl, preferably methyl or phenyl, most preferably methyl.
[0031] Particularly preferred bisphenols are 2,2-bis-(4-hydroxyphenyl)-propane (bisphenol A), 2,2-bis-(3,5-dimethyl-4-hydroxyphenyl)-propane, 1,1-bis-(4-hydroxyphenyl)-cyclohexane, 1,1-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 4,4'-dihydroxydiphenyl and dimethyl-bisphenol A as well as the bisphenols of the formulas (I), (II) and (III).
[0032] These and other suitable dihydroxyaryl compounds are described, for example, in US 3 028 635 A, US 2 999 825 A, US 3 148 172 A, US 2 991 273 A, US 3 271 367 A, US 4 982 014 A and US 2 999 846 A, in DE 1 570 703 A, DE 2063 050 A, DE 2 036 052 A, DE 2 211 956 A and DE 3 832 396 A, in FR 1 561 518 A, in the monograph "H. Schnell, Chemistry and Physics of Polycarbonates, Interscience Publishers, New York 1964" and in JP 62039 / 1986 A, JP 62040 / 1986 A and JP 105550 / 1986 A.
[0033] In the case of homopolycarbonates, only one dihydroxyaryl compound is used; in the case of copolycarbonates, several dihydroxyaryl compounds are used.
[0034] Suitable carbonic acid derivatives include phosgene or diphenyl carbonate.
[0035] Suitable chain terminators that can be used in the production of polycarbonates are monophenols. Suitable monophenols include phenol itself, alkylphenols such as cresols, p-tert-butylphenol, cumylphenol, and mixtures thereof.
[0036] Preferred chain terminators are phenols which are mono- or polysubstituted by C1 to C30 alkyl radicals, linear or branched, preferably unsubstituted, or by tert-butyl. Particularly preferred chain terminators are phenol, cumylphenol, and / or p-tert-butylphenol.
[0037] The amount of chain terminator to be used is preferably 0.1 to 5 mol%, based on the moles of diphenols used. The chain terminators can be added before, during, or after the reaction with a carbonic acid derivative.
[0038] Suitable branching agents are the tri- or more than trifunctional compounds known in polycarbonate chemistry, in particular those with three or more than three phenolic OH groups.
[0039] Suitable branching agents are, for example, 1,3,5-tri-(4-hydroxyphenyl)benzene, 1,1,1-tri-(4-hydroxyphenyl)ethane, tri-(4-hydroxyphenyl)phenylmethane, 2,4-bis-(4-hydroxyphenylisopropyl)phenol, 2,6-bis-(2-hydroxy-5'-methylbenzyl)-4-methylphenol, 2-(4-hydroxyphenyl)-2-(2,4-dihydroxyphenyl)propane, tetra-(4-hydroxyphenyl)methane, tetra-(4-(4-hydroxyphenylisopropyl)phenoxy)methane and 1,4-bis-((4',4"-dihydroxytriphenyl)methyl)benzene and 3,3-bis-(3-methyl-4-hydroxyphenyl)-2-oxo-2,3-dihydroindole.
[0040] The amount of branching agents to be used optionally is preferably 0.05 mol% to 2.00 mol%, based on moles of dihydroxyaryl compounds used.
[0041] The branching agents can either be added together with the dihydroxyaryl compounds and the chain terminators in the aqueous alkaline phase or dissolved in an organic solvent prior to phosgenation. In the case of the transesterification process, the branching agents are used together with the dihydroxyaryl compounds.
[0042] Particularly preferred polycarbonates are the homopolycarbonate based on bisphenol A, the homopolycarbonate based on 1,1-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane and the copolycarbonates based on the two monomers bisphenol A and 1,1-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, as well as the dihydroxyaryl compounds of the formulas (I), (II) and (III) in which R' is each C 1 - to C 4 -alkyl, aralkyl or aryl, preferably methyl or phenyl, most preferably methyl, derived homo- or copolycarbonates.
[0043] For the incorporation of additives, component A is preferably used in the form of powders, granules or mixtures of powders and granules.
[0044] A mixture of different polycarbonates can also be used as the polycarbonate, e.g. of the polycarbonates A1 and A2: The amount of aromatic polycarbonate A1 is, based on the total amount of polycarbonate, preferably 80.0 to 94.0 wt.%, more preferably 83.0 to 93.5 wt.%, particularly preferably 84.0 to 93.2 wt.%, wherein this aromatic polycarbonate is based on bisphenol A with a preferred melt volume flow rate MVR of 7 to 15 cm 3 < / (10 min), more preferably with a melt volume flow rate MVR of 8 to 12 cm 3 < / (10 min) and particularly preferably with a melt volume flow rate MVR of 8 to 11 cm 3 < / (10 min), determined according to ISO 1133 (test temperature 300°C, mass 1.2 kg).
[0045] The amount of powdered aromatic polycarbonate A2 is, based on the total amount of polycarbonate, preferably 6.0 to 20.0 wt. %, more preferably 6.5 to 17.0 wt. %, particularly preferably 6.8 to 16.0 wt. %, wherein this aromatic polycarbonate is preferably based on bisphenol A with a preferred melt volume flow rate MVR of 4 to 24 cm 3 / (10 min), more preferably with a melt volume flow rate MVR of 5 to 22 cm 3 / (10 min), and particularly preferably with a melt volume flow rate MVR of 6 to 20 cm 3 / (10 min), determined according to ISO 1133 (test temperature 300°C, mass 1.2 kg). Component B
[0046] Component B in the compositions according to the invention is one or more polyether carbonate polyols.
[0047] Component B preferably comprises a polyether carbonate polyol having a hydroxyl number (OH number) according to DIN 53240-1:2013-06 of ≥ 20 mg KOH / g to ≤ 120 mg KOH / g, more preferably of ≥ 20 mg KOH / g to ≤ 100 mg KOH / g, particularly preferably of ≥ 25 mg KOH / g to ≤ 90 mg KOH / g, which is obtainable in particular by copolymerization of carbon dioxide and one or more alkylene oxides in the presence of one or more H-functional starter molecules, wherein the polyether carbonate polyol preferably has a CO 2 content of 10 to 25 wt.%, more preferably 12 to 20 wt.%, even more preferably up to 19 wt.%.
[0048] Component B preferably comprises a polyethercarbonate polyol obtainable by copolymerizing ≥ 2 wt.% to ≤ 30 wt.% carbon dioxide and ≥ 70 wt.% to ≤ 98 wt.% of one or more alkylene oxides in the presence of one or more H-functional starter molecules. The polyethercarbonate polyols have, for example, an average functionality of 1 to 8, preferably ≥ 1 to ≤ 6, more preferably ≥ 1 to ≤ 4, particularly preferably ≥ 2 to ≤ 3. For the purposes of the invention, "H-functional" refers to a starter compound that has H atoms that are active toward alkoxylation.
[0049] Preferably, the copolymerization of carbon dioxide and one or more alkylene oxides takes place in the presence of at least one DMC catalyst (double metal cyanide catalyst).
[0050] The polyethercarbonate polyols used according to the invention preferably also have ether groups between the carbonate groups, which is shown schematically in formula (IV). In the scheme according to formula (IV), R represents an organic radical such as alkyl, alkylaryl or aryl, which may each also contain heteroatoms such as, for example, O, S, Si, etc., and e and f represent an integer. The polyethercarbonate polyol shown in the scheme according to formula (IV) should merely be understood to mean that blocks with the structure shown can in principle be found in the polyethercarbonate polyol, but the order, number and length of the blocks can vary and is not limited to the polyethercarbonate polyol shown in formula (IV). With regard to formula (IV), this means that the ratio of e / f is preferably from 2:1 to 1:20, particularly preferably from 1.5:1 to 1:10.
[0051] The proportion of incorporated CO2 ("carbon dioxide-derived units"; "CO2 content") in a polyethercarbonate polyol can be determined from the evaluation of characteristic signals in the 1< H NMR spectrum. The following example illustrates the determination of the proportion of carbon dioxide-derived units in a CO2 / propylene oxide polyethercarbonate polyol initiated on 1,8-octanediol.
[0052] The proportion of incorporated CO2 in a polyethercarbonate polyol as well as the ratio of propylene carbonate to polyethercarbonate polyol can be determined by 1< H-NMR (a suitable instrument is from Bruker, DPX 400, 400 MHz; pulse program zg30, waiting time d1: 10s, 64 scans). The sample is dissolved in deuterated chloroform. The relevant resonances in 1< H-NMR (relative to TMS = 0 ppm) are as follows: cyclic propylene carbonate (which was formed as a by-product) with resonance at 4.5 ppm; carbonate resulting from carbon dioxide incorporated in the polyethercarbonate polyol with resonances at 5.1 to 4.8 ppm; unreacted propylene oxide (PO) with resonance at 2.4 ppm; polyether polyol (i.e. without incorporated carbon dioxide) with resonances at 1.2 to 1.0 ppm; the 1,8 octanediol incorporated as starter molecule (if present) with a resonance at 1.6 to 1.52 ppm.
[0053] The weight fraction (in wt.%) of the carbonate bound in the polyether carbonate polyol (LC') in the reaction mixture was calculated according to formula (V), LC ′ = F 5 , 1 − 4 , 8 − F 4 5 ∗ 102 N ∗ 100 % where the value for N ("denominator" N) is calculated according to formula (VI): N = F 5 , 1 − 4 , 8 − F 4 5 ∗ 102 + F 4 5 ∗ 102 + F 2 4 ∗ 58 + 0 , 33 ∗ F 1 , 2 − 1 , 0 ∗ 58 + 0 , 25 ∗ F 1 , 6 − 1 , 52 ∗ 146
[0054] The following abbreviations apply: F(4.5) = area of resonance at 4.5 ppm for cyclic carbonate (corresponding to one H atom); F(5.1-4.8) = area of resonance at 5.1-4.8 ppm for polyethercarbonate polyol and one H atom for cyclic carbonate; F(2.4) = area of resonance at 2.4 ppm for free, unreacted PO; F(1.2-1.0) = area of resonance at 1.2-1.0 ppm for polyetherpolyol; F(1.6-1.52) = area of resonance at 1.6 to 1.52 ppm for 1,8-octanediol (starter), if present.
[0055] The factor 102 results from the sum of the molar masses of CO2 (molar mass 44 g / mol) and that of propylene oxide (molar mass 58 g / mol), the factor 58 results from the molar mass of propylene oxide and the factor 146 results from the molar mass of the starter 1,8-octanediol used (if present).
[0056] The weight fraction (in wt.%) of cyclic carbonate (CC') in the reaction mixture can be calculated according to formula (VII), CC ′ = F 4 5 ∗ 102 N ∗ 100 % where the value for N is calculated according to formula (VI).
[0057] In order to calculate the composition based on the polymer content (consisting of polyether polyol, which was synthesized from starter and propylene oxide during the activation steps taking place under CO2-free conditions, and polyether carbonate polyol, synthesized from starter, propylene oxide and carbon dioxide during the activation steps taking place in the presence of CO2 and during copolymerization) from the composition values of the reaction mixture, the non-polymer components of the reaction mixture, i.e. cyclic propylene carbonate and any unreacted propylene oxide present, were mathematically eliminated. The weight fraction of the carbonate repeat units in the polyether carbonate polyol was converted into a weight fraction of carbon dioxide using the factor F = 44 / (44+58), where 44 g / mol is the molar mass of carbon dioxide and 58 g / mol is the molar mass of propylene oxide.The CO 2 content in the polyethercarbonate polyol is standardised to the proportion of the polyethercarbonate polyol molecule formed during the copolymerisation and, where applicable, the activation steps in the presence of CO 2, i.e. the proportion of the polyethercarbonate polyol molecule resulting from the starter - 1,8-octanediol, if present - and from the reaction of the starter with epoxide added under CO 2 -free conditions was not taken into account.
[0058] The polyethercarbonate polyol preferably comprises a polyethercarbonate polyol with a CO2 content of 10 wt.% to 25 wt.%.
[0059] The production of polyether carbonate polyols according to component B is carried out, for example, by: (α) an H-functional starter compound or a mixture of at least two H-functional starter compounds is initially introduced and, if appropriate, water and / or other highly volatile compounds are removed by elevated temperature and / or reduced pressure ("drying"), the DMC catalyst being added to the H-functional starter compound or to the mixture of at least two H-functional starter compounds before or after drying, (β) for activation, a portion (based on the total amount of alkylene oxides used in the activation and copolymerization) of one or more alkylene oxides is added to the mixture resulting from step (α), this addition of a portion of alkylene oxide optionally being carried out in the presence of CO2, and then the temperature peak ("hotspot") occurring due to the subsequent exothermic chemical reaction and / or a pressure drop in the reactor are each awaited,and wherein the activation step (β) can also be carried out several times, (γ) one or more of the alkylene oxides and carbon dioxide are added to the mixture resulting from step (β), wherein the alkylene oxides used in step (β) can be the same as or different from the alkylene oxides used in step (γ).
[0060] In general, alkylene oxides (epoxides) with 2 to 24 carbon atoms can be used to produce polyether carbonate polyols. The alkylene oxides having 2 to 24 carbon atoms are, for example, one or more compounds selected from the group consisting of ethylene oxide, propylene oxide, 1-butene oxide, 2,3-butene oxide, 2-methyl-1,2-propene oxide (isobutene oxide), 1-pentene oxide, 2,3-pentene oxide, 2-methyl-1,2-butene oxide, 3-methyl-1,2-butene oxide, 1-hexene oxide, 2,3-hexene oxide, 3,4-hexene oxide, 2-methyl-1,2-pentene oxide, 4-methyl-1,2-pentene oxide, 2-ethyl-1,2-butene oxide, 1-heptene oxide, 1-octene oxide, 1-nonene oxide, 1-decene oxide, 1-undecene oxide, 1-Dodecene oxide, 4-methyl-1,2-pentene oxide, butadiene monoxide, isoprene monoxide, cyclopentene oxide, cyclohexene oxide, cycloheptene oxide, cyclooctene oxide, styrene oxide, methylstyrene oxide, pinene oxide, mono- or polyepoxidized fats as mono-, di- and triglycerides, epoxidized fatty acids, C1-C24 esters of epoxidized fatty acids, epichlorohydrin, glycidol,and derivatives of glycidol, such as methyl glycidyl ether, ethyl glycidyl ether, 2-ethylhexyl glycidyl ether, allyl glycidyl ether, glycidyl methacrylate, and epoxy-functional alkoxysilanes, such as 3-glycidyloxypropyltrimethoxysilane, 3-glycidyloxypropyltriethoxysilane, 3-glycidyloxypropyltripropoxysilane, 3-glycidyloxypropylmethyldimethoxysilane, 3-glycidyloxypropylethyldiethoxysilane, and 3-glycidyloxypropyltriisopropoxysilane. Preferably, ethylene oxide and / or propylene oxide and / or 1,2-butylene oxide are used as alkylene oxides, particularly preferably propylene oxide.
[0061] In a preferred embodiment of the invention, the proportion of ethylene oxide in the total amount of propylene oxide and ethylene oxide used is ≥ 0 and ≤ 90 wt.%, preferably ≥ 0 and ≤ 50 wt.%, and particularly preferably no ethylene oxide is used.
[0062] Compounds with H atoms active for alkoxylation can be used as suitable H-functional starting compounds. Examples of groups with active H atoms active for alkoxylation are -OH, -NH 2 (primary amines), -NH- (secondary amines), -SH, and -CO 2 H. -OH and -NH 2 are preferred, and -OH is particularly preferred. As H-functional starter compound, for example, one or more compounds are selected from the group consisting of water, mono- or polyhydric alcohols, polyhydric amines, polyhydric thiols, amino alcohols, thioalcohols, hydroxyesters, polyether polyols, polyester polyols, polyester ether polyols, polyether carbonate polyols, polycarbonate polyols, polycarbonates, polyethyleneimines, polyetheramines (e.g. so-called Jeffamine ®< from Huntsman, such as D-230, D-400, D-2000, T-403, T-3000, T-5000 or corresponding products from BASF, such as Polyetheramine D230, D400, D200, T403, T5000), polytetrahydrofurans (e.g.PolyTHF ®< from BASF, such as PolyTHF ®< 250, 650S, 1000, 1000S, 1400, 1800, 2000), polytetrahydrofuranamines (BASF product Polytetrahydrofuranamine 1700), polyetherthiols, polyacrylate polyols, castor oil, the mono- or diglyceride of ricinoleic acid, monoglycerides of fatty acids, chemically modified mono-, di- and / or triglycerides of fatty acids, and C 1 - to C 24 -alkyl fatty acid esters which contain on average at least 2 OH groups per molecule. For example, the C 1 to C 24 alkyl fatty acid esters, which contain on average at least 2 OH groups per molecule, are commercial products such as Lupranol Balance ®< (BASF AG), Merginol ®< types (Hobum Oleochemicals GmbH), Sovermol ®< types (Cognis Deutschland GmbH & Co. KG) and Soyol ®< TM types (USSC Co.).
[0063] Alcohols, amines, thiols and carboxylic acids can be used as monofunctional starter compounds. The following monofunctional alcohols can be used: methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, t-butanol, 3-buten-1-ol, 3-butyn-1-ol, 2-methyl-3-buten-2-ol, 2-methyl-3-butyn-2-ol, propyl alcohol, 2-Methyl-2-propanol, 1-t-butoxy-2-propanol., 1-pentanol, 2-pentanol, 3-pentanol, 1-hexanol, 2-hexanol, 3-hexanol, 1-heptanol, 2-heptanol, 3-heptanol, 1-octanol, 2-octanol, 3-octanol, 4-octanol, phenol, 2-Hydroxybiphenyl, 3-hydroxybiphenyl, 4-hydroxybiphenyl, 2-hydroxypyridine, 3-hydroxypyridine, 4-hydroxypyridine. Monofunctional amines include: butylamine, t-butylamine, pentylamine, hexylamine, aniline, aziridine, pyrrolidine, piperidine, and morpholine. Monofunctional thiols include: ethanethiol, 1-propanethiol, 2-propanethiol, 1-butanethiol, 3-methyl-1-butanethiol, 2-butene-1-thiol, and thiophenol.Monofunctional carboxylic acids include: formic acid, acetic acid, propionic acid, butyric acid, fatty acids such as stearic acid, palmitic acid, oleic acid, linoleic acid, linolenic acid, benzoic acid, acrylic acid.
[0064] Polyhydric alcohols suitable as H-functional starter compounds are, for example, dihydric alcohols (such as ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,3-propanediol, 1,4-butanediol, 1,4-butenediol, 1,4-butynediol, neopentyl glycol, 1,5-pentanediol, methylpentanediols (such as 3-methyl-1,5-pentanediol), 1,6-hexanediol; 1,8-octanediol, 1,10-decanediol, 1,12-dodecanediol, bis-(hydroxymethyl)-cyclohexanes (such as 1,4-bis-(hydroxymethyl)cyclohexane), triethylene glycol, tetraethylene glycol, polyethylene glycols, dipropylene glycol, tripropylene glycol, polypropylene glycols, dibutylene glycol and polybutylene glycols); trihydric alcohols (such as trimethylolpropane, glycerin, trishydroxyethyl isocyanurate, castor oil), tetrahydric alcohols (such as pentaerythritol);Polyalcohols (such as sorbitol, hexitol, sucrose, starch, starch hydrolysates, cellulose, cellulose hydrolysates, hydroxy-functionalized fats and oils, especially castor oil), as well as all modification products of these aforementioned alcohols with varying amounts of ε-caprolactone. Trihydric alcohols such as trimethylolpropane, glycerol, trishydroxyethyl isocyanurate, and castor oil can also be used in mixtures of H-functional starters.
[0065] The H-functional starter compounds can also be selected from the class of polyether polyols, in particular those with a molecular weight M n in the range from 100 to 4000 g / mol, preferably 250 to 2000 g / mol. Preference is given to polyether polyols composed of repeating ethylene oxide and propylene oxide units, preferably with a proportion of 35 to 100% propylene oxide units, particularly preferably with a proportion of 50 to 100% by weight propylene oxide units. These can be random copolymers, gradient copolymers, alternating or block copolymers of ethylene oxide and propylene oxide. Suitable polyether polyols, composed of repeating propylene oxide and / or ethylene oxide units are, for example, the Desmophen ®< -, Acclaim ®< -, Arcol ®< -, Baycoll ®< -, Bayfille-, Bayflex ®< -Baygale-, PET ®< - and polyether polyols from Covestro Deutschland AG (such asDesmophen ®< 3600Z, Desmophen ®< 1900U, Acclaim ®< Polyol 2200, Acclaim ®< Polyol 4000I, Arcol ®< Polyol 1004, Arcol ®< Polyol 1010, Arcol ®< Polyol 1030, Arcol ®< Polyol 1070, Baycoll ®< BD 1110, Bayfill ®< VPPU 0789, Baygal ®< K55, PET ®< 1004, Polyether ®< S180). Other suitable homo-polyethylene oxides are, for example, the Pluriol ®< E brands from BASF SE, suitable homo-polypropylene oxides are, for example, the Pluriol ®< P brands from BASF SE, suitable mixed copolymers of ethylene oxide and propylene oxide are, for example, the Pluronic ®< PE or Pluriol ®< RPE brands from BASF SE.
[0066] The H-functional starter compounds can also be selected from the substance class of polyester polyols, in particular those with a molecular weight M n in the range from 200 to 4500 g / mol, preferably 400 to 2500 g / mol. At least difunctional polyesters are used as polyester polyols. Polyester polyols preferably consist of alternating acid and alcohol units. Examples of acid components used are succinic acid, maleic acid, maleic anhydride, adipic acid, phthalic anhydride, phthalic acid, isophthalic acid, terephthalic acid, tetrahydrophthalic acid, tetrahydrophthalic anhydride, hexahydrophthalic anhydride or mixtures of the stated acids and / or anhydrides. Examples of alcohol components used areEthanediol, 1,2-propanediol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, neopentyl glycol, 1,6-hexanediol, 1,4-bis(hydroxymethyl)cyclohexane, diethylene glycol, dipropylene glycol, trimethylolpropane, glycerol, pentaerythritol, or mixtures of the above-mentioned alcohols are used. If dihydric or polyhydric polyether polyols are used as the alcohol component, polyester ether polyols are obtained, which can also serve as starter compounds for the preparation of the polyether carbonate polyols. If polyether polyols are used to prepare the polyester ether polyols, polyether polyols with a number-average molecular weight M n of 150 to 2000 g / mol are preferred.
[0067] Furthermore, polycarbonate polyols (such as polycarbonatediols) can be used as H-functional starter compounds, in particular those with a molecular weight M n in the range from 150 to 4500 g / mol, preferably 500 to 2500 g / mol, which are prepared, for example, by reacting phosgene, dimethyl carbonate, diethyl carbonate, or diphenyl carbonate with di- and / or polyfunctional alcohols or polyester polyols or polyether polyols. Examples of polycarbonate polyols can be found, for example, in EP 1359177 A1. For example, the Desmophen®< C grades from Covestro Deutschland AG, such as Desmophen®< C 1100 or Desmophen®< C 2200, can be used as polycarbonate diols.
[0068] Polyethercarbonate polyols can also be used as H-functional starter compounds. In particular, polyethercarbonate polyols prepared according to the process described above are used. These polyethercarbonate polyols used as H-functional starter compounds are prepared beforehand in a separate reaction step.
[0069] Preferred H-functional starter compounds are alcohols of the general formula (VIII), HO-(CH 2 ) x -OH (VIII), where x is a number from 1 to 20, preferably an even number from 2 to 20. Examples of alcohols according to formula (VIII) are ethylene glycol, 1,4-butanediol, 1,6-hexanediol, 1,8-octanediol, 1,10-decanediol and 1,12-dodecanediol. Further preferred H-functional starter compounds are neopentyl glycol, trimethylolpropane, glycerol, pentaerythritol, reaction products of the alcohols according to formula (VIII) with ε-caprolactone, e.g. reaction products of trimethylolpropane with ε-caprolactone, reaction products of glycerol with ε-caprolactone, and reaction products of pentaerythritol with ε-caprolactone. Further preferred H-functional starting compounds are water, diethylene glycol, dipropylene glycol, castor oil, sorbitol and polyether polyols composed of repeating polyalkylene oxide units.
[0070] The H-functional starter compounds are particularly preferably one or more compounds selected from the group consisting of ethylene glycol, propylene glycol, 1,3-propanediol, 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 2-methylpropane-1,3-diol, neopentyl glycol, 1,6-hexanediol, diethylene glycol, dipropylene glycol, glycerol, trimethylolpropane, di- and trifunctional polyether polyols, wherein the polyether polyol is composed of a di- or tri-H-functional starter substance and propylene oxide or a di- or tri-H-functional starter substance, propylene oxide and ethylene oxide. The polyether polyols preferably have a number-average molecular weight M n in the range from 62 to 4500 g / mol, and in particular a number-average molecular weight M n in the range from 62 to 3000 g / mol, very particularly preferably a molecular weight of 62 to 1500 g / mol. The polyether polyols preferably have a functionality of ≥ 2 to ≤ 3.
[0071] In a preferred embodiment of the invention, the polyether carbonate polyol is obtainable by addition of carbon dioxide and alkylene oxides to H-functional starter compounds using multimetal cyanide catalysts (DMC catalysts). The preparation of polyether carbonate polyols by addition of alkylene oxides and CO2 to H-functional starter compounds using DMC catalysts is known, for example, from EP-A 0222453, WO-A 2008 / 013731, and EP-A 2115032.
[0072] DMC catalysts are known in principle from the prior art for the homopolymerization of epoxides (see, for example, US-A 3,404,109, US-A 3,829,505, US-A 3,941,849, and US-A 5,158,922). DMC catalysts, which are described, for example, in US-A 5,470,813, EP-A 700,949, EP-A 743,093, EP-A 761,708, WO-A 97 / 40086, WO-A 98 / 16310, and WO-A 00 / 47649, possess very high activity in the homopolymerization of epoxides and enable the preparation of polyether polyols and / or polyether carbonate polyols at very low catalyst concentrations (25 ppm or less). A typical example are the highly active DMC catalysts described in EP-A 700 949, which contain, in addition to a double metal cyanide compound (e.g. zinc hexacyanocobaltate(III)) and an organic complex ligand (e.g. t-butanol), a polyether with a number-average molecular weight M n greater than 500 g / mol.
[0073] The DMC catalyst is usually used in an amount of ≤ 1 wt.%, preferably in an amount of ≤ 0.5 wt.%, particularly preferably in an amount of ≤ 500 ppm and in particular in an amount of ≤ 300 ppm, in each case based on the weight of the polyether carbonate polyol.
[0074] For the thermal reduction of the volatile constituents, methods generally known to the person skilled in the art from the prior art can be used. For example, the thermal reduction of the volatile constituents can be achieved by means of thin-film evaporation, short-path evaporation or falling-film evaporation, this preferably taking place under reduced pressure (vacuum). In addition, conventional distillation processes can also be used in which the polyether carbonate polyol is heated, for example, in a flask or stirred tank to a temperature of 80 to 200°C, and the volatile constituents are distilled off overhead. To increase the efficiency of the distillation, it is possible to work under reduced pressure and / or use an inert stripping gas (e.g. nitrogen) and / or use an entraining agent (e.g. water or an inert organic solvent).In addition, the reduction of the volatile components can also be carried out by vacuum stripping in a packed column, with steam or nitrogen usually being used as the stripping gas.
[0075] Preferably, the polyether carbonate polyol has a content of carbonate groups ("units derived from carbon dioxide"), calculated as CO 2 , of ≥ 2.0 wt.% and ≤ 30.0 wt.%, preferably of ≥ 5.0 wt.% and ≤ 28.0 wt.% and particularly preferably of ≥ 10.0 wt.% and ≤ 25.0 wt.%.
[0076] The polyether carbonate polyol(s) preferably have a hydroxyl number of ≥ 20 mg KOH / g to ≤ 250 mg KOH / g and are obtainable by copolymerization of ≥ 2.0 wt.% to ≤ 30.0 wt.% carbon dioxide and ≥ 70 wt.% to ≤ 98 wt.% propylene oxide in the presence of a hydroxy-functional starter molecule, such as trimethylolpropane and / or glycerol and / or propylene glycol and / or sorbitol. The hydroxyl number can be determined according to DIN 53240-1:2013-06.
[0077] Preferred polyether carbonate polyols have a molecular weight M n of 400 to 10,000 g / mol, particularly preferably of 500 to 6,000 g / mol.
[0078] The number-average molecular weight M n and weight-average molecular weight M w , as well as the polydispersity (M w / M n ), of the products were determined by gel permeation chromatography (GPC). The procedure was according to DIN 55672-1 (March 2016): "Gel Permeation Chromatography, Part 1 - Tetrahydrofuran as Eluent" (SECurity GPC system from PSS Polymer Service, flow rate 1.0 ml / min; columns: 2×PSS SDV linear M, 8×300 mm, 5 µm; RID detector). Polystyrene samples of known molecular weight were used for calibration.
[0079] In a further embodiment, a polyether carbonate polyol is used containing blocks according to formula (IV), wherein the ratio e / f is from 2:1 to 1:20.
[0080] Polyether carbonate polyols with a hydroxyl number according to DIN 53240-1:2013-06 of ≥ 20 mg KOH / g to ≤ 120 mg KOH / g are particularly preferred.
[0081] Most preferably, the polyether carbonate polyol also has a CO2 content of 10 to 20 wt.%. Component C
[0082] The compositions according to the invention optionally contain one or more thermal and / or transesterification stabilizers.
[0083] Preferred thermal stabilizers are triphenylphosphine, tris-(2,4-di-tert-butylphenyl)phosphite (Irgafos ®< 168), tetrakis-(2,4-di-tert-butylphenyl)-[1,1-biphenyl]-4,4'-diylbisphosphonite, octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionate (Irganox ®< 1076), bis-(2,4-dicumylphenyl)-pentaerythritol diphosphite (Doverphos ®< S-9228 PC), bis-(2,6-di-tert-butyl-4-methylphenyl)-pentaerythritol diphosphite (ADK STAB PEP-36). They are used alone or in a mixture (e.g. Irganox ®< B900 (mixture of Irgafos ®< 168 and Irganox ®< 1076 in a ratio of 4:1) or Doverphos ®< S-9228 PC with Irganox ®< B900 or Irganox ®< 1076).
[0084] Phosphates or sulfonic acid esters are preferably included as transesterification stabilizers. Triisooctyl phosphate is preferably included as transesterification stabilizer.
[0085] The thermal stabilizers and / or transesterification stabilizers are preferably used in an amount of up to 1.0 wt.%, particularly preferably in a total amount of 0.005 wt.% to 0.5 wt.%, very particularly preferably 0.01 wt.% to 0.2 wt.%. Component D
[0086] The compositions according to the invention preferably contain at least one UV absorber as an additive. The UV absorbers have the lowest possible transmission below 400 nm and the highest possible transmission above 400 nm. Ultraviolet absorbers particularly suitable for use in the composition according to the invention are benzotriazoles, triazines, benzophenones, and / or arylated cyanoacrylates.
[0087] Particularly suitable ultraviolet absorbers are hydroxybenzotriazoles, such as 2-(3',5'-bis-(1,1-dimethylbenzyl)-2'-hydroxy-phenyl)-benzotriazole (Tinuvin ®< 234, BASF SE, Ludwigshafen), 2-(2'-hydroxy-5'-(tert.-octyl)-phenyl)-benzotriazole (Tinuvin ®< 329, BASF SE, Ludwigshafen), bis-(3-(2H-benzotriazolyl)-2-hydroxy-5-tert.-octyl)methane (Tinuvin ®< 360, BASF SE, Ludwigshafen), 2-(4,6-Diphenyl-1,3,5-triazin-2-yl)-5-(hexyloxy)-phenol (Tinuvin ®< 1577, BASF SE, Ludwigshafen), as well as benzophenones such as 2,4-Dihydroxybenzophenone (Chimasorb ®< 22, BASF SE, Ludwigshafen) and 2-Hydroxy-4-(octyloxy)-benzophenone (Chimassorb ®< 81, BASF SE, Ludwigshafen), 2,2-Bis[[(2-cyano-1-oxo-3,3-diphenyl-2-propenyl)oxy]-methyl]-1,3-propanediyl ester (9CI) (Uvinul ®< 3030, BASF SE, Ludwigshafen), 2-[2-Hydroxy-4-(2-ethylhexyl)oxy]phenyl-4,6-di(4-phenyl)phenyl-1,3,5-triazine (Tinuvin ®< 1600, BASF SE, Ludwigshafen), tetraethyl 2,2'-(1,4-phenylenedimethylidene)bismalonate (Hostavin ®< B-Cap, Clariant AG) or N-(2-ethoxyphenyl)-N'-(2-ethylphenyl)-et-handiamide (Tinuvin ®< 312, CAS No. 23949-66-8, BASF SE, Ludwigshafen).
[0088] Particularly preferred special UV stabilizers are Tinuvin ®< 360, Tinuvin ®< 329, Tinuvin ®< 312, Tinuvin ®< 326 and / or Tinuvin ®< 1600, most particularly preferred are Tinuvin ®< 329, Tinuvin ®< 326 and / or Tinuvin ®< 360.
[0089] Mixtures of the ultraviolet absorbers mentioned can also be used.
[0090] If UV absorbers are included, the composition preferably contains ultraviolet absorbers in an amount of up to 1.0 wt.%, more preferably up to 0.8 wt.%, particularly preferably 0.05 wt.% to 0.5 wt.%, very particularly preferably 0.08 wt.% to 0.4 wt.%, extremely preferably 0.1 wt.% to 0.3 wt.%, based on the total composition. Component E
[0091] In addition, other customary additives ("further additives") are optionally present, preferably up to 10.0 wt. %, more preferably 0.1 wt. % to 6.0 wt. %, particularly preferably 0.1 wt. % to 3.0 wt. %, very particularly preferably 0.2 wt. % to 1.0 wt. %, in particular up to 0.5 wt. % of other customary additives ("further additives"). The group of further additives does not include any thermal stabilizers and / or transesterification stabilizers or UV absorbers, since these are already described as components C and D. It is understood that component E also does not include any polyether carbonate polyol, since this is already described as component B.
[0092] Such additives, as are typically added to polycarbonates, are described, for example, in EP-A 0 839 623, WO-A 96 / 15102, EP-A 0 500 496, or "Plastics Additives Handbook," Hans Zweifel, 5th Edition 2000, Hanser Verlag, Munich. The other additives are preferably selected from the group of antioxidants, mold-release agents, flame retardants, other stabilizers, IR absorbers, antistatic agents, optical brighteners, colorants such as organic dyes, and / or additives for laser marking. These are preferably used in the amounts customary for polycarbonate. These additives can be added individually or as a mixture.
[0093] The composition may be free of mold release agents, e.g. (glycerol monostearate) GMS and pentaerythritol tetrastearate (PETS).
[0094] The compositions according to the invention particularly preferably contain at least one thermal stabilizer and / or transesterification stabilizer (component C) and / or a UV absorber.
[0095] It is understood that the components used may contain common impurities, for example, resulting from their manufacturing processes. It is preferable to use components that are as pure as possible. It is further understood that these impurities may also be present in a closed formulation of the composition. The impurities are part of the total weight of the respective component.
[0096] The compositions according to the invention, containing components A and B, and optionally C and / or optionally D and / or optionally E, are prepared using conventional incorporation methods by combining, mixing, and homogenizing the individual components, with homogenization preferably taking place in the melt under the action of shear forces. Optionally, the combining and mixing takes place before melt homogenization using powder premixes.
[0097] Premixes of granules or granules and powders with components B to E can also be used.
[0098] Premixes prepared from solutions of the mixture components in suitable solvents may also be used, with homogenization in solution if necessary and the solvent subsequently removed.
[0099] In particular, components B to E of the composition according to the invention can be introduced into the polycarbonate by known methods or as a masterbatch.
[0100] The use of masterbatches is preferred for incorporating components B to E, individually or in a mixture.
[0101] In this context, the composition according to the invention can be combined, mixed, homogenized, and then extruded in conventional devices such as screw extruders (e.g., twin-screw extruders, ZSK), kneaders, Brabender or Banbury mills. After extrusion, the extrudate can be cooled and comminuted. Individual components can also be premixed, and then the remaining starting materials can be added individually and / or in a mixed form.
[0102] The merging and mixing of a premix in the melt can also take place in the plasticizing unit of an injection molding machine. In this case, the melt is transferred directly into a molded body in the subsequent step.
[0103] The compositions according to the invention can be processed in the usual way on conventional machines, for example on extruders or injection molding machines, to form any desired shaped articles, such as films, sheets or bottles.
[0104] The molded parts are preferably manufactured by injection molding, extrusion or from solution in a casting process.
[0105] The compositions according to the invention are suitable for producing multilayer systems. Here, the polycarbonate composition is applied in one or more layers to a molded article made of a plastic. Application can occur simultaneously with or immediately after the molding of the molded article, for example, by back-injection molding of a film, coextrusion, or multi-component injection molding. However, application can also occur on the finished molded base body, for example, by lamination with a film, overmolding of an existing molded article, or by coating from a solution.
[0106] The compositions according to the invention are suitable for the production of components in the automotive sector, for example for panels, headlight covers or parts thereof, or frames, lenses and collimators or light guides, as well as for the production of transparent frame components in the EE (electrical / electronic) and IT sectors, in particular also parts of lighting units, especially for applications that place high demands on flowability (thin-film applications). Such applications include, for example, components for screens or housings, for example for ultrabooks or frames for LED display technologies, e.g., OLED displays or LCD displays, or even for e-ink devices. Further fields of application include transparent housing or cover parts of mobile communication devices, such as smartphones, tablets, ultrabooks, notebooks or laptops, but also navigation devices, smartwatches or heart rate monitors, as well as electrical applications in thin-walled versions, e.g.,Home and industrial networking units and smart meter housing components.
[0107] The molded articles and extrudates made from the compositions according to the invention as well as molded parts, extrudates and multilayer systems containing the compositions according to the invention are also the subject of this application.
[0108] The compositions according to the invention are particularly distinguished by the fact that, due to their polyether carbonate polyol content, they possess excellent rheological and optical properties as well as reduced coefficients of sliding and static friction. A further advantage of the compositions according to the invention is that an additional mold release agent, such as PETS (pentaerythritol tetrastearate), can be dispensed with. These additives often reduce the thermal properties. Therefore, the composition according to the invention preferably does not comprise pentaerythritol tetrastearate.The present invention also further relates to the use of polyether carbonate polyol, in particular one or more of those described above, for improving the transmission Ty and / or for reducing the sliding and static friction coefficients of compositions comprising aromatic polycarbonate (component A), optionally a thermal stabilizer and / or transesterification stabilizer (component C) and optionally further additives (component D), wherein the transmission Ty can be determined, for example, according to ISO 13468-2:2006 at a thickness of 4 mm and the sliding and static friction coefficients on injection-molded discs can be determined according to the method described in EP 1 377 812 B1.
[0109] The embodiments described above for the compositions according to the invention also apply - where applicable - to the uses according to the invention.
[0110] The following examples are intended to illustrate the invention without, however, limiting it. Examples 1. Description of raw materials and test methods
[0111] The polycarbonate compositions described in the following examples were produced by compounding on a Berstorff ZE 25 extruder with a throughput of 10 kg / h. The melt temperature was 275 °C.
[0112] Component A-1: Linear polycarbonate based on bisphenol A with a melt volume flow rate MVR of 9.0 cm 3 < / (10 min) (according to ISO 1133:2012-03, at a test temperature of 300°C and a load of 1.2 kg).
[0113] Component A-2: Linear polycarbonate based on bisphenol A in powder form with a melt volume flow rate MVR of 6.0 cm 3 < / (10 min) (according to ISO 1133:2012-03, at a test temperature of 300°C and a load of 1.2 kg).
[0114] Component B-1:Polyether carbonate polyol, functionality: 2.82; hydroxyl number according to DIN 53240-1:2013-06: 54 mg KOH / g, 14 wt.% CO2 content; produced by copolymerization of propylene oxide and carbon dioxide with glycerol and propylene glycol as H-functional starter compounds in the presence of a double metal cyanide catalyst.
[0115] Component B-2: Polyether carbonate polyol, functionality: 2.0; hydroxyl number according to DIN 53240-1:2013-06: 56 mg KOH / g, 19 wt.% CO2 content, produced by copolymerization of propylene oxide and carbon dioxide with propylene glycol as H-functional starter compound in the presence of a double metal cyanide catalyst.
[0116] Component B-3:Polyether carbonate polyol, functionality: 2.82; hydroxyl number according to DIN 53240-1:2013-06: 170 mg KOH / g; 12 wt.% CO2 content, produced by copolymerization of propylene oxide and carbon dioxide with glycerol and propylene glycol as H-functional starter compound in the presence of a double metal cyanide catalyst.
[0117] Component C-1: Thermal stabilizer triphenylphosphine from BASF.
[0118] Component C-2: Transesterification inhibitor triisooctyl phosphate (TOF) from Lanxess AG.
[0119] Component D: UV absorber Tinuvin 329 from BASF. CO 2 content in polyether carbonate polyol:
[0120] The proportion of incorporated CO2 in the resulting polyethercarbonate polyol was determined by 1< H-NMR (Bruker, DPX 400, 400 MHz; pulse program zg30, waiting time d1: 10s, 64 scans) as described in the general description.
[0121] The Vicat softening temperature VST / B50As a measure of the heat distortion temperature, it was determined in accordance with ISO 306:2013 on test specimens measuring 80 mm x 10 mm x 4 mm with a stamp load of 50 N and a heating rate of 50°C / h or 120 °C / h using the Coesfeld Eco 2920 device from Coesfeld Materialtest.
[0122] The determination of the Melt volume flow rate (MVR) The test was carried out according to ISO 1133:2012-03 (at a test temperature of 300 °C, mass 1.2 kg and 2.16 kg, respectively) using the Zwick 4106 device from Zwick Roell. Additionally, the MVR was measured after 20 minutes of preheating (IMVR20'). This is a measure of melt stability under increased thermal stress.
[0123] The Yellowness Index (YI) was determined according to ASTM E 313-10 (observer: 10° / illuminant: D65) on sample plates with a layer thickness of 4 mm.
[0124] The transmission Ty in the VIS range of the spectrum (visual transmission, D65, 10° observation) was determined according to ISO 13468-2:2006 on sample plates with a layer thickness of 4 mm and 12 mm.
[0125] The turbidity was determined according to ASTM D1003:2013 on sample plates with a layer thickness of 4 mm or 12 mm.
[0126] The Sliding and static friction coefficients were determined using a modified Arburg 370S-800-150 injection molding machine. The method is described in EP 1 377 812 B1. Static friction is the friction coefficient derived from the force required to set relatively stationary bodies (punch / test specimen) in motion (threshold value). Sliding friction is derived accordingly from the constant force required to continue the movement smoothly.
[0127] The friction coefficient is defined as follows: FR = µ x FN or, rearranged to µ, µ = FR / FN (FN= normal force, FR= friction force, µ = friction coefficient).
[0128] For circular motion the following relationship applies: FR = Md / rm (Md = torque, rm = mean radius of the friction surface (ring surface)) and Md / rm= µ x FN and, rearranged for µ, µ= Md / (rm x FN).
[0129] A disc-shaped test specimen with an outer diameter of 92 mm and a thickness of 2.6 mm was manufactured in a friction coefficient tool. It had a 5 mm high and 3 mm wide ridge on the outer edge, which contained shallow recesses similar to a timing belt pulley, through which the torque is transferred from the tool to the test specimen.
[0130] It allows the direct determination of the coefficient of static friction and the coefficient of sliding friction on a disc-shaped test specimen immediately before demolding. The relationship here is that the friction force is proportional to the torque. When the mold is opened, a punch connected to a torque transducer moves against the molded part (friction partner) with a defined normal force FN. The test specimen is held on the other side of the molded part and rotated. The coefficient of static friction and the coefficient of sliding friction between the punch and the test specimen are determined using the torque measured on the punch. Since friction is caused by the unevenness of the surfaces sliding against each other (jamming), the punch was designed with an average surface roughness Ra = 0.05 µm.
[0131] The materials were melted on an injection molding machine and injected at a melt temperature of 300 °C into a closed friction coefficient mold with a mold wall temperature of 90 °C. The mold was held at a holding pressure of 400 bar for 15 seconds. After a residual cooling time of 17 seconds, the mold was opened slightly, and the static and dynamic friction coefficients were determined.
[0132] The sample plates were each manufactured by injection molding at a melt temperature of 300 °C and a mold wall temperature of 90 °C. Table 1 Table 1 V1 2 3 4 5 6 7 8 9 10 11 12 A1 85 85 85 85 85 85 85 85 85 85 85 85 A2 15 14,9 14,6 14,35 14,9 14,8 14,6 14,35 14,9 14,8 14,6 14,35 B1 0,1 0,4 0,65 B2 0,1 0,2 0,4 0,65 B3 0,1 0,2 0,4 0,65 Test MVR 300°C / 1.2kg 9,2 9,5 9,7 10,6 9,4 9,4 9,4 10,9 9,4 9,6 10,4 11,0 IMVR20' 300°C / 1.2kg 9,2 10,2 10,9 14,1 9,9 9,9 10,2 12,6 10,1 10,6 12,0 14,1 DMVR / IMVR20' 0,0 0,7 1,2 3,5 0,5 0,5 0,8 1,7 0,7 1,0 1,6 3,1 Vicat VST B50 145,3 144,4 142,9 141,3 145,0 144,9 143,4 140,7 144,8 143,8 142,8 140,4 IZOD notched impact strength ISO7391 / 180A 3mm 23°C 73z 72z 72z 70z 71z 71z 70z 68z 70z 72z 70z 71z Optical data 300°C / 80°C transmission 88,8 89,1 89,2 89,5 88,9 89,0 89,1 89,2 89,0 89,1 89,3 89,4 Yellowness Index 3,8 3,3 3,1 2,2 3,9 3,5 3,7 2,9 3,8 3,1 2,8 2,6 turbidity 0,9 0,5 0,4 0,4 0,4 0,4 0,3 0,5 0,4 0,4 0,4 0,3 Friction coefficient Static friction 0,60 0,46 0,3 0,26 0,52 0,54 0,43 0,32 0,61 0,52 0,44 0,34 Sliding friction 0,62 0,49 0,36 0,32 0,55 0,55 0,49 0,39 0,59 0,55 0,51 0,42
[0133] With increasing proportion of polyethercarbonate polyol, the inventive compositions exhibit increasingly higher transmittance (Comparative Example C1, compared with inventive examples 2 to 4, 5 to 8, and 9 to 12). At the same time, the yellowness index and turbidity are reduced. It can also be observed that the friction coefficients (static friction, sliding friction) are also reduced by the addition of polyethercarbonate polyol, thus improving demolding behavior. Furthermore, the polyethercarbonate polyols improve flowability. The heat distortion temperature of the above compositions remains virtually unchanged despite the addition of polyethercarbonate polyol. Table 2 V13 14 15 16 17 18 19 A1 [Wt.%] 85 85 85 85 85 85 85 A2 [Wt.%] 15 14,2 13,8 14,2 13,8 14,2 13,8 B1 [Wt.%] 0,8 1,2 B2 [Wt.%] 0,8 1,2 B3 [Wt.%] 0,8 1,2 Test MVR 300°C / 1.2kg [cm3 / (10 min)] 9,1 10,5 11,5 10,6 12,2 11,5 12,6 IMVR20' 300°C / 1.2kg [cm3 / (10 min)] 9,3 12,8 12,9 15,5 15,9 14,3 14,8 DMVR / IMVR20' 0,2 2,3 1,4 4,9 3,7 2,8 2,2 Vicat VST B50 [°C] 144,5 139,7 137,1 139,6 137,1 139,0 136,8 Optical data 300°C / 80°C transmission [%] 88,74 89,07 89,12 89,29 89,47 89,45 89,5 Yellowness Index 3,68 2,17 2,14 2,71 2,29 2,48 2,33 turbidity [%] 1,72 1,71 1,6 1,29 0,69 0,48 0,49
[0134] Larger amounts of polyethercarbonate polyol gradually reduce heat resistance; however, at 1.2 wt.% polyethercarbonate polyol, heat resistance is still sufficient. Compared to comparative experiment C13, it can be seen that the addition of polyethercarbonate polyol to the compositions according to the invention improves flowability, increases transmittance, and reduces the YI value and turbidity. Table 3 V20 V21 22 V23 24 25 A1 [Wt.%] 93 93 93 93 93 93 A2 [Wt.%] 7 6,975 6,575 6,99 6,79 6,59 B2 [Wt.%] 0,4 0,2 0,4 C1 [Wt.%] 0,025 0,025 C2 [Wt.%] 0,01 0,01 0,01 Test MVR [cm3 / (10 min)] 9,4 9,4 10,3 9,3 9,9 10,0 IMVR20' 300°C / 1.2 kg [cm3 / (10 min)] 9,5 9,6 12,0 9,5 10,3 12,0 DMVR / IMVR20' 0,1 0,2 1,7 0,2 0,4 2,0 Vicat VST B50 [°C] 146,2 145,2 143,7 146,0 144,6 143,6 Optical data Sample thickness (ro) 4 4 4 4 4 4 L * (ro) 95,63 95,8 95,83 95,6 95,72 95,75 a* (ro) -0,27 -0,07 -0,09 -0,27 -0,22 -0,23 b* (ro) 1,81 0,88 0,85 1,85 1,47 1,47 Transmission (ro) [%] 89,12 89,52 89,59 89,05 89,34 89,41 Yellowness Index (ro) 3,23 1,6 1,53 3,3 2,62 2,61 Turbidity (ro) [%] 0,46 0,57 0,43 0,5 0,43 0,4
[0135] The above-mentioned effects are also observed for compositions containing thermal stabilizer or transesterification stabilizer (component C1 or component C2). Table 4 V26 V27 28 29 A1 [Wt.%] 93,0 93,0 93,0 93,0 A2 [Wt%] 7,0 6,8 6,6 6,4 B3 [Wt.%] 0,2 0,4 D [Wt.%] 0,2 0,2 0,2 Test MVR [cm3 / (10 min)] 9,4 9,9 10,3 12,6 IMVR20' 300°C / 1.2kg [cm3 / (10 min)] 9,5 10 11,1 14,5 DMVR / IMVR20' 0,1 0,1 0,8 1,9 Vicat VST B50 [°C] 146,3 145 143,9 140,2 Optical data Sample thickness (ro) 4 4 4 4 L* (ro) 95,6 95,37 95,65 95,58 a* (ro) -0,25 -0,41 -0,39 -0,43 b* (ro) 1,78 2,32 1,97 2,03 Transmission (ro) [%] 89,04 88,51 89,16 89,00 Yellowness Index (ro) 3,17 4,08 3,42 3,52 Turbidity (ro) [%] 0,49 1,19 0,44 0,69
[0136] As expected, the addition of UV absorbers increases the YI value due to their inherent color. However, the YI value can also be reduced by adding polyether carbonate polyol.
Claims
1. Transparent thermoplastic composition containing A) aromatic polycarbonate and B) polyether carbonate polyol, C) optionally at least one heat stabilizer and / or transesterification stabilizer, D) optionally at least one UV absorber and E) optionally one or more further additives distinct from components B, C and D, wherein "transparent" means a visual transmittance Ty (D65 observed at 10°) of at least 84%, determined according to ISO 13468-2:2006 at a thickness of 4 mm, and a haze of < 5%, determined according to ASTM D1003:2013 at a layer thickness of 4 mm.
2. Transparent thermoplastic composition according to Claim 1 containing A) 70.0% by weight to 99.95% by weight of aromatic polycarbonate and B) 0.05% by weight to 2.0% by weight of polyether carbonate polyol.
3. Transparent thermoplastic composition according to Claim 1, wherein the composition contains A) 80.0% by weight to 99.9% by weight of aromatic polycarbonate and B) 0.1% by weight to 1.2% by weight of polyether carbonate polyol, C) 0% to 1.0% by weight of at least one heat stabilizer and / or transesterification stabilizer, D) 0% to 1.0% by weight of at least one UV absorber and E) optionally one or more further additives distinct from components B, C and D.
4. Transparent thermoplastic composition according to any of the preceding claims, wherein the composition contains at least 0.2% by weight of polyether carbonate polyol.
5. Transparent thermoplastic composition according to any of the preceding claims, containing at least one UV absorber as component D.
6. Transparent thermoplastic composition according to any of the preceding claims, consisting of the components A, B, optionally C, optionally D, optionally E and optionally blend partners.
7. Transparent thermoplastic composition according to any of the preceding claims, consisting of A) 95.0% by weight to 99.9% by weight of aromatic polycarbonate and B) 0.1% by weight to 1.2% by weight of polyether carbonate polyol, C) 0% to 1.0% by weight of at least one heat stabilizer and / or transesterification stabilizer, D) 0% to 1.0% by weight of at least one UV absorber and E) optionally one or more further additives, wherein the further additives are selected from the group consisting of antioxidants, demoulding agents, flame retardants, IR absorbers, antistats, optical brighteners, colorants such as organic dyes and / or additives for laser marking.
8. Transparent thermoplastic composition according to any of the preceding claims, wherein the polyether carbonate polyol present has a hydroxyl number (OH number) according to DIN 53240-1:2013-06 of ≥ 20 mg KOH / g to ≤ 120 mg KOH / g.
9. Transparent thermoplastic composition according to any of the preceding claims, wherein the polyether carbonate polyol present is exclusively one having a hydroxyl number according to DIN 53240-1:2013-06 of ≥ 20 mg KOH / g to ≤ 120 mg KOH / g and / or a CO2 content of 10% to 25% by weight.
10. Transparent thermoplastic composition according to any of the preceding claims, wherein the polyether carbonate polyol has a hydroxyl number of ≥ 20 mg KOH / g to ≤ 250 mg KOH / g determined according to DIN 53240-1:2013-06 and is obtainable by copolymerization of ≥ 2.0% by weight to ≤ 30.0% by weight of carbon dioxide and ≥ 70% by weight to ≤ 98% by weight of propylene oxide in the presence of a hydroxy-functional starter molecule.
11. Transparent thermoplastic composition according to any of the preceding claims, wherein the polyether carbonate polyol contains blocks according to formula (IV), wherein the ratio e / f is from 2 : 1 to 1 :
20.
12. Moulding produced from a transparent thermoplastic composition according to any of the preceding claims.
13. Moulding according to Claim 12, wherein the moulding is part of a headlight cover or a headlight cover, part of a display, part of a lighting unit or a lens.
14. Use of polyether carbonate polyol to improve the transmittance in the VIS range of a transparent thermoplastic composition based on aromatic polycarbonate.
15. Use according to Claim 14, wherein the polyether carbonate polyol has a hydroxyl number according to DIN 53240-1:2013-06 of ≥ 20 mg KOH / g to ≤ 120 mg KOH / g and / or a CO2 content of 10% by weight to 25% by weight.