Thermoplastic composition having high metal adhesion for NMT applications

Abstract

The thermoplastic composition comprises from about 10 wt% to about 80 wt% of a chemical recycling polyester component, from about 10 wt% to about 60 wt% of a reinforcing filler, and from about 5 wt% to about 20 wt% of a polycarbonate component. The thermoplastic composition has improved metal adhesion strength as compared to a comparative composition comprising a virgin polyester component instead of the chemical recycling polyester component. A method for forming the thermoplastic composition is also described.

Description

Technical Field

[0001] The present disclosure relates to a thermoplastic composition comprising a chemically recycled polyester component having improved metal adhesion properties.

Background Art

[0002] Polybutylene terephthalate (PBT) is an easily processable thermoplastic polymer that provides high chemical resistance and excellent dimensional stability characteristics. PBT is widely used in nano molding technology (NMT) applications. Unfortunately, after being molded into the nano holes of a metal substrate, the adhesion strength of PBT decreases. As a result, in NMT applications, it is necessary to add an accelerator additive to the PBT composition. The accelerator additive may have an adverse effect on other properties. Also, with the increase in environmental standards and agreements (such as the Paris Agreement), the demand for more sustainable solutions is increasing.

Summary of the Invention

Problems to be Solved by the Invention

[0003] Aspects of the present disclosure address these and other drawbacks.

Means for Solving the Problems

[0004] Aspects of the present disclosure relate to a thermoplastic composition comprising from about 10 wt% (weight percent) to about 80 wt% of a chemically recycled polyester component, from about 10 wt% to about 60 wt% of a reinforcing filler, and from about 5 wt% to about 20 wt% of a polycarbonate component. The thermoplastic composition has improved metal adhesion strength compared to a comparative composition comprising a virgin polyester component instead of the chemically recycled polyester component.

[0005] Aspects of the present disclosure relate to a method for forming a thermoplastic composition, the method comprising combining a chemical recycling polyester component of from about 10 wt% to about 80 wt%, a reinforcing filler of from about 10 wt% to about 60 wt%, and a polycarbonate component of from about 5 wt% to about 20 wt% to form a mixture, and forming the thermoplastic composition by injection molding, extrusion molding, rotational molding, blow molding, or thermoforming the mixture. The thermoplastic composition has improved metal adhesion strength compared to a comparative composition comprising a virgin polyester component instead of the chemical recycling polyester component. The combined weight percentage values of all components do not exceed 100 wt%, and all weight percentage values are based on the total weight of the composition.

DETAILED DESCRIPTION OF THE INVENTION

[0006] Before disclosing and describing the compounds, compositions, articles, systems, devices, and / or methods, it should be understood that they can be various, since they are not limited to specific synthesis methods, unless otherwise specified, or to specific reagents, unless otherwise specified. It should also be understood that the terms used herein are merely for the purpose of describing particular aspects and are not intended to be limiting.

[0007] The present disclosure encompasses combinations of various elements of the present disclosure, such as combinations of elements from dependent claims that depend on the same independent claim.

[0008] Also, unless otherwise specified, it should be understood that no method described in this specification is ever intended to be construed as requiring that its steps be performed in a particular order. Thus, in a method claim, if the order in which the steps are to be followed is not actually recited, or if the steps are not particularly specified as being limited to a particular order in the claims or the description, in no way is any order to be implied. This applies to any possible non-explicit interpretation, including logical matters regarding the arrangement or operation flow of steps, plain meaning derived from grammatical construction or punctuation, and the number or type of aspects described in the specification.

[0009] All publications mentioned in this specification are hereby incorporated by reference into this specification to disclose and explain the methods and / or materials to which the publications are relevant.

[0010] <Definition> It should also be understood that the terms used in this specification are merely for the purpose of describing particular aspects and are not intended to be limiting. As used in the specification and the claims, the term "comprising" may include aspects of "consisting of" and "consisting essentially of". Unless otherwise defined, all technical and scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. Many terms to be defined in this specification are referred to in this specification and the following claims.

[0011] As used in the specification and the appended claims, the singular forms "a", "an", and "the" include the plural forms as well, unless the context clearly dictates otherwise. Thus, for example, a reference to "a reinforcing filler" includes a mixture of two or more reinforcing fillers.

[0012] As used in this specification, the term "combination" includes blends, mixtures, alloys, reaction products, and the like.

[0013] In this specification, a range can be expressed as from one value (the first value) to another value (the second value). When such a range is expressed, the range includes, in some embodiments, one or both of the first value and the second value. Similarly, when a value is expressed as an approximate value, it is understood that the use of the preamble "about" causes a particular value to form another embodiment. It is further understood that each endpoint of a range is important with respect to the other endpoint and is independent of the other endpoint. It is also understood that a number of values are disclosed in this specification, and each value is disclosed in this specification as "about" that particular value in addition to the value itself. For example, if the value "10" is disclosed, "about 10" is also disclosed. It is also understood that each unit between two specific units is also disclosed. For example, if 10-15 is disclosed, 11, 12, 13, and 14 are also disclosed.

[0014] As used herein, the terms "about" and "at or about" mean that the quantity or value is the specified value, approximately the specified value, or approximately the same as the specified value. As used herein, unless otherwise indicated or implied, it is generally understood that it is a nominal value and shows a variation of ±10%. The term is intended to convey that similar values promote equivalent results or effects described in the claims. That is, quantities, sizes, compounding methods, parameters, and other quantities and characteristics need not be exact and need not be exact, but may, if necessary, be approximate and / or larger or smaller, reflecting allowable values, conversion factors, rounding, measurement errors, etc., and other factors known to those skilled in the art. Generally, a quantity, size, compounding method, parameter, or other quantity or characteristic is "about" or "substantially" whether or not so specified. When "about" is used before a quantitative value, it is understood that the parameter includes the particular quantitative value itself unless otherwise specified.

[0015] Disclosed are the components used in the preparation of the compositions of the present disclosure and the compositions themselves used in the methods disclosed herein. Also disclosed herein are these materials and other materials, and where combinations, subsets, interactions, groups, etc. of these materials are disclosed, specific references to the various individual and collective combinations and permutations of these compounds cannot be explicitly disclosed, but it is understood that each is specifically contemplated and described herein. For example, if a particular compound is disclosed and considered, and numerous modifications that can be made to a number of molecules containing the compound are considered, then every possible combination and permutation of the compound, and possible modifications, are specifically considered, unless specifically indicated to the contrary. Thus, if a class of molecules A, B, and C are disclosed, and a class of molecules D, E, and F and an example of a combination molecule A-D are disclosed, then each is considered individually and collectively, i.e., combinations of A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are considered to be disclosed, even if each is not individually described. Similarly, any subset or combination of these is also disclosed. Thus, for example, subgroups of A-E, B-F, and C-E are considered to be disclosed. This concept applies to all aspects of this application, including but not limited to the steps in the methods of forming and using the compositions of the present disclosure. Thus, if there are various additional executable steps, it is understood that each of these additional steps can be performed in any particular aspect or combination of aspects of the methods of the present disclosure.

[0016] References in the specification and concluding patent claims to the parts by weight of a particular element or component in a composition or article mean the weight relationship between that element or component and any other element or component in the composition or article in which the parts by weight are expressed. Thus, in a compound containing 2 parts by weight of component X and 5 parts by weight of component Y, X and Y are present in a weight ratio of 2:5, and this ratio exists regardless of whether additional components are contained in the compound.

[0017] Unless otherwise stated, the weight percentages of the components are based on the total weight of the formulation or composition in which the component is included.

[0018] As used herein, "polycarbonate" refers to an oligomer or polymer containing residues of one or more dihydroxy compounds, such as dihydroxy aromatic compounds, joined by carbonate linkages, and includes homopolycarbonates, copolycarbonates, and (co)polyester carbonates.

[0019] The terms "residue" and "structural unit" used with respect to the components of a polymer are synonymous throughout this specification.

[0020] As used herein, the terms "weight percent," "wt%," and "wt.%" which are used interchangeably, indicate the weight percent of a given component based on the total weight of the composition, unless otherwise specified. That is, unless otherwise specified, all wt% values are based on the total weight of the composition. It should be understood that the sum of the wt% values of all components in the disclosed composition or formulation is equal to 100.

[0021] Unless otherwise indicated herein, all test standards are the latest standards in effect at the time of filing of this application.

[0022] Each of the materials disclosed herein is commercially available and / or the methods for its production are known to those skilled in the art.

[0023] It is understood that the compositions disclosed herein have specific functions. Specific structural requirements for performing the disclosed functions are disclosed herein, and there are various structures that can perform the same functions related to the disclosed structures, and it is understood that these structures typically achieve the same results.

[0024] <Thermoplastic composition> Aspects of the present disclosure relate to a composition comprising from about 10 wt% (weight percent) to about 80 wt% of a chemically recycled polyester component, from about 10 wt% to about 60 wt% of a reinforcing filler, and from about 5 wt% to about 20 wt% of a polycarbonate component. The thermoplastic composition has improved metal adhesion strength compared to a comparative composition comprising a virgin polyester component instead of the chemically recycled polyester component. The combined weight percentage values of all components do not exceed 100 wt%, and all weight percentage values are based on the total weight of the composition.

[0025] In some aspects, the chemically recycled polyester component comprises polybutylene terephthalate (PBT). The chemically recycled PBT is a copolymer containing 1 to 20% of comonomers such as ethylene glycol, isophthalic acid (IPA), and diethylene glycol (DEG) described below.

[0026]

Chemical formula

[0027] In certain aspects, the polymer component is a chemically recycled poly(butylene terephthalate) named iQ PBT, derived from chemically upcycled (or post-consumer recycled) PET. Fibers formed from iQ PBT provide environmentally friendly advantages that offer desirable modulus, breaking stress, and elongation at break.

[0028] Commercial examples of upcycled PBT include those sold under the trade name ELCRIN(™) iQ Resin, manufactured by SABIC(™). PBT can be obtained from poly(ethylene terephthalate) components by any method including depolymerization of the poly(ethylene terephthalate) component to provide PET-derived PBT and polymerization of the depolymerized poly(ethylene terephthalate) component with 1,4-butanediol. For example, the PET-derived poly(butylene terephthalate) component is obtained by depolymerizing poly(ethylene terephthalate) and / or poly(ethylene terephthalate) copolymers with a 1,4-butanediol component at 180°C to 230°C, with stirring, in the presence of a catalyst component, at a pressure of at least atmospheric pressure, at high temperature, in an inert atmosphere, to produce a molten mixture containing oligomers containing ethylene terephthalate moieties, oligomers containing ethylene isophthalate moieties, oligomers containing diethylene terephthalate moieties, oligomers containing diethylene isophthalate moieties, oligomers containing butylene terephthalate moieties, oligomers containing butylene isophthalate moieties, covalently bonded oligomeric moieties containing at least two of the above moieties, 1,4-butanediol, ethylene glycol, or combinations thereof; stirring the molten mixture at near atmospheric pressure and raising the temperature of the molten mixture to a high temperature under conditions sufficient to form PET-derived PBT containing at least one residue derived from the poly(ethylene terephthalate) component.

[0029] In certain embodiments, PBT comprises terephthalic acid (TPA) derived from 48 wt% to 59.4 wt% recycled polyethylene terephthalate (rPET), 12 wt% to 40.6 wt% butanediol (BDO), and 1 wt% to 20 wt% additional monomers. The additional monomers can include, but are not limited to, ethylene glycol (EG), isophthalic acid (IPA), diethylene glycol (DEG), or combinations thereof.

[0030] The polycarbonate component may include a polycarbonate homopolymer, a polycarbonate copolymer, or a combination thereof. In certain embodiments, the polycarbonate component includes a polycarbonate copolymer.

[0031] The polycarbonate copolymer may include a copolyester carbonate in some embodiments. The copolyester carbonate copolymer may include ester units of the following formula: [Chemical formula] wherein D is a divalent group derived from a dihydroxy compound, for example, a C 2-30 alkylene group, a C 3-30 cycloaliphatic group, a C 6-30 aromatic group, or a polyoxyalkylene group having 2 to 6 carbon atoms, specifically 2, 3, or 4 carbon atoms, in which the alkylene group may be an alkylene group, T is a divalent group derived from a dicarboxylic acid, for example, a C 2-30 alkylene group, a C 6-30 cycloaliphatic group, a C 6-30 alkyl aromatic group, or a C 6-30 aromatic group.

[0032] Examples of the aromatic dicarboxylic acid from which the T group in the ester is derived include isophthalic acid or terephthalic acid, 1,2-di(p-carboxyphenyl)ethane, 4,4'-dicarboxydiphenyl ether, 4,4'-bisbenzoic acid, and combinations including at least one of the above acids. Acids containing a condensed ring may also be present, such as 1,4-, 1,5-, or 2,6-naphthalenedicarboxylic acid. Specific dicarboxylic acids are terephthalic acid, isophthalic acid, naphthalenedicarboxylic acid, cyclohexanedicarboxylic acid, or combinations thereof. Specific dicarboxylic acids include a combination of isophthalic acid and terephthalic acid, where the weight ratio of isophthalic acid to terephthalic acid is from 99:1 to 1:99. In one embodiment, D is C 2-6is an alkylene group, and T is p-phenylene, m-phenylene, naphthalene, a divalent alicyclic group, or a combination thereof. Polyesters of this class include poly(alkylene terephthalate).

[0033] In one aspect, the ester units of the polyester or polyester block include allylated ester units derived from the reaction product of 1 equivalent of an isophthalic acid derivative and / or terephthalic acid derivative having resorcinol of the following formula, [Chemical formula] wherein each R f is independently C 1-12 alkyl, or halogen, and u is from 0 to 4. It is understood that when u is 0, R f is hydrogen. Typically, the halogen can be chlorine or bromine. In one aspect, compounds in which the -OH groups are meta-substituted with respect to each other and R f and u are as described above are also generally referred to herein as resorcinol. Examples of compounds that can be represented by this formula are resorcinol (where u is 0), substituted resorcinol compounds such as 5-methylresorcinol, 5-ethylresorcinol, 5-propylresorcinol, 5-butylresorcinol, 5-t-butylresorcinol, 5-phenylresorcinol, 5-cumylresorcinol, 2,4,5,6-tetrafluororesorcinol, or 2,4,5,6-tetrabromoresorcinol, catechol, hydroquinone, substituted hydroquinones such as 2-methylhydroquinone, 2-ethylhydroquinone, 2-propylhydroquinone, 2-butylhydroquinone, 2-t-butylhydroquinone, 2-phenylhydroquinone, 2-cumylhydroquinone, 2,3,5,6-tetramethylhydroquinone, 2,3,5,6-tetra-t-butylhydroquinone, 2,3,5,6-tetrafluorohydroquinone, or 2,3,5,6-tetrabromohydroquinone, or combinations containing at least one of the above compounds.

[0034] Such allylated ester units are also referred to herein as isophthalate - terephthalate - resorcinol ester units and are sometimes referred to by abbreviations such as ITR ester units. As used herein, isophthalate - terephthalate - resorcinol ester units include a combination of isophthalate esters, terephthalate esters, and resorcinol esters. In certain embodiments, the isophthalate - terephthalate - resorcinol ester units include a combination of isophthalate - resorcinol ester units and terephthalate - resorcinol ester units, where the molar ratio of the isophthalate - resorcinol ester units to the terephthalate - resorcinol ester units is from 99:1 to 1:99, or from 95:5 to 5:95, or from 90:10 to 10:90, or from 80:20 to 20:80. In certain embodiments, when u is 0, the allylated ester units include isophthalate - terephthalate - resorcinol ester units where resorcinol is 1,3 - dihydroxybenzene. Exemplary aromatic polyester blocks include poly(isophthalate - terephthalate - resorcinol) ester, poly(isophthalate - terephthalate - bisphenol - A) ester, poly[(isophthalate - terephthalate - resorcinol) ester - co - (isophthalate - terephthalate - bisphenol - A)] ester, or combinations including at least one of these. In one embodiment, a useful allylated polyester block is poly(isophthalate - terephthalate - resorcinol) ester. In certain embodiments, the copolyester carbonate copolymer includes an ITR block and a polycarbonate block as shown in the following formula, [Chemical formula] wherein x is the mole % of the ITR ester block and y is the mole % of the polycarbonate block. An exemplary copolyester carbonate copolymer is the SLX90 / 10 resin available from SABIC. SLX90 / 10 includes 90 mole % of the ITR block and 10 mole % of the PC block.

[0035] In yet another aspect, the copolyester carbonate copolymer has a ratio of ITR ester units to polycarbonate monomer units of 20:80 to 95:5, or 85:15 to 95:5, or 88:12 to 92:8, or about 90:10.

[0036] The reinforcing filler may, in some aspects, include glass fibers, silica (SiO 2 ) microparticles, carbon fibers, or combinations thereof. In certain aspects, the reinforcing filler includes glass fibers, such as, but not limited to, flat glass fibers.

[0037] The thermoplastic composition may, in some aspects, include at least one additional additive. The at least one additional additive may include, but is not limited to, an impact modifier, an organic filler, an acid scavenger, a stabilizer, a drip inhibitor, an antioxidant, an antistatic agent, a chain extender, a colorant, a release agent, a flow promoter, a lubricant, a plasticizer, a quenching coolant, a flame retardant, a UV reflective additive, a foaming agent, a reinforcing agent, or combinations thereof.

[0038] In certain aspects, the at least one additional additive includes an epoxy-based impact modifier present in an amount of about 0.01 wt% to a maximum of 4 wt%. An exemplary epoxy-based impact modifier is Lotader® AX8900 available from Arkema.

[0039] The thermoplastic compositions according to aspects of the present disclosure have improved properties compared to conventional compositions. In one aspect, the composition has a metal adhesion strength that is at least 3% higher than a comparative composition that includes a virgin polyester component instead of the chemical recycle polyester component. In a further aspect, the composition has a metal adhesion strength that is at least 5% higher, at least 8% higher, at least 10% higher, at least 12% higher, at least 15% higher, 3 to 30% higher, 3 to 25% higher, or 3 to 20% higher than a comparative composition that includes a virgin polyester component instead of the chemical recycle polyester component.

[0040] The metal bonding strength can be determined according to metal surface treatment and the Nano Molding Technology (NMT) method. These treatments are conventional methods for determining metal bonding strength known to those skilled in the art. Currently, two main processes, namely, the T (Tai sei plas) treatment and the TRI (Technology Rising from IWATE) treatment, are used for metal surface treatment. These methods were developed by different Japanese companies. When comparing these two treatment methods, TRI typically provides higher strength obtained from both the physical fixation of plastic within the metal nano - holes and the chemical reaction between the chemical film on the metal surface and the plastic. In contrast, the T treatment mainly relies on physical fixation.

[0041] The metal bonding strength is used for the evaluation of NMT performance. In the NMT process, the plastic resin is injected onto the metal surface treated with a special chemical solution. This NMT process is developed from the technology of fusing metal and plastic. It enables the manufacture of specific parts of consumer products and replaces the conventional insert molding or die - casting process.

[0042] <Manufacturing method>

[0043] One or any of the above - described components described herein are first dry - blended with each other or with any combination of the above - described components, and then supplied to an extruder from one or more feeders, or may be supplied separately to the extruder from one or more feeders. The filler used in the present disclosure may also be first processed into a masterbatch and then supplied to the extruder. The components may be supplied to the extruder from a throat hopper or any side feeder.

[0044] The extruders used in the present disclosure may have a single screw, multiple screws, meshing co-rotating or counter-rotating screws, non-meshing co-rotating or counter-rotating screws, reciprocating screws, pin screws, screen screws, pin barrels, rolls, rams, helical rotors, co-kneaders, disk pack processors, various other types of extrusion equipment, or combinations including at least one of the above.

[0045] The components may be mixed together and then melt-blended to form a thermoplastic composition. The melt-blending of the components involves the use of shear forces, extensional forces, compressive forces, ultrasonic energy, electromagnetic energy, thermal energy, or combinations including at least one of the above forces or energy forms.

[0046] The barrel temperature on the extruder during compounding may be set to a temperature at which at least a part of the polymer has reached about the melting temperature when the resin is a semi-crystalline organic polymer, or may be set to the flow point (e.g., glass transition temperature) when the resin is an amorphous resin.

[0047] The mixture containing the components mentioned above may be subjected to a plurality of blending and forming steps as necessary. For example, the thermoplastic composition may first be extruded and formed into pellets. Then, the pellets may be supplied to a molding machine that can form the pellets into any desired shape or product. Alternatively, the thermoplastic composition exiting from a single melt blender may be formed into a sheet or strand and subjected to post-extrusion processes such as uniaxial or biaxial orientation.

[0048] In some embodiments, to avoid excessive thermal degradation of the components, the melting temperature in the process may be maintained as low as possible. In certain embodiments, the melting temperature is maintained at about 230°C to about 350°C, although higher temperatures can be used provided that the residence time of the resin within the processing equipment is relatively short. In some embodiments, the melt-processed composition exits the processing equipment, such as an extruder, through small outlet holes of a die. The resulting strands of molten resin may be cooled by passing them through a water bath. The cooled strands may be cut into pellets for packaging and further handling.

[0049] Aspects of the present disclosure are directed to a method of forming a thermoplastic composition, the method comprising combining a chemical recycling polyester component in an amount of about 10 wt% to about 80 wt%, a reinforcing filler in an amount of about 10 wt% to about 60 wt%, and a polycarbonate component in an amount of about 5 wt% to about 20 wt% to form a mixture, and forming the thermoplastic composition by injection molding, extrusion molding, rotational molding, blow molding, or thermoforming the mixture. The thermoplastic composition has improved metal adhesion strength compared to a comparative composition that includes a virgin polyester component instead of the chemical recycling polyester component. The combined weight percentage values of all components do not exceed 100 wt%, and all weight percentage values are based on the total weight of the composition.

[0050] A thermoplastic composition formed according to the methods described herein may include any of the components described herein in the amounts described herein and may have any of the properties described herein.

[0051] <Manufactured article> In certain embodiments, the present disclosure relates to shaped articles, formed articles, or molded articles that include a thermoplastic composition. The thermoplastic composition can be formed into useful shaped articles by various means such as injection molding, extrusion molding, rotational molding, blow molding, and thermoforming to form articles and structural components of personal or commercial electronic devices including, but not limited to, mobile phones, tablet computers, personal computers, notebooks and portable computers, and other similar devices, medical applications, RFID applications, automotive applications, etc. In a further embodiment, the article is extrusion molded. In yet another embodiment, the article is injection molded. In certain embodiments, the article is a nano molding technology component.

[0052] The present disclosure encompasses combinations of various elements of the present disclosure, such as combinations of elements from dependent claims that depend on the same independent claim.

[0053] <Aspects of the present disclosure> In various embodiments, the present disclosure relates to and includes at least the following embodiments.

[0054] <Embodiment 1> A thermoplastic composition comprising, consisting of, or consisting essentially of from about 10 wt% to about 80 wt% of a chemically recycled polyester component, from about 10 wt% to about 60 wt% of a reinforcing filler, from about 5 wt% to about 20 wt% of a polycarbonate component, wherein the thermoplastic composition has improved metal adhesion strength compared to a comparative composition comprising a virgin polyester component in place of the chemically recycled polyester component, the combined weight percentage values of all components do not exceed 100 wt%, and all weight percentage values are based on the total weight of the composition.

[0055] <Embodiment 2> The thermoplastic composition according to Embodiment 1, wherein the chemically recycled polyester component comprises polybutylene terephthalate (PBT).

[0056] <Aspect 3> The PBT is the thermoplastic composition according to Embodiment 2, comprising terephthalic acid (TPA) derived from 48 wt% to 59.4 wt% recycled polyethylene terephthalate (rPET), 12 wt% to 40.6 wt% butanediol (BDO), and 1 wt% to 20 wt% additional monomers.

[0057] <Aspect 4> The polycarbonate component is the thermoplastic composition according to any one of Embodiments 1 to 3, comprising a polycarbonate homopolymer, a polycarbonate copolymer, or a combination thereof.

[0058] <Aspect 5> The polycarbonate component is the thermoplastic composition according to Embodiment 4, comprising a polycarbonate copolymer.

[0059] <Aspect 6> The polycarbonate copolymer is the thermoplastic composition according to Embodiment 5, comprising an isophthalate - terephthalate - resorcinol (ITR) block and a polycarbonate block.

[0060] <Aspect 6A> The polycarbonate copolymer is the thermoplastic composition according to Embodiment 6, wherein the ratio of the ITR block to the polycarbonate block is 20:80 to 95:5.

[0061] <Aspect 7> The polycarbonate copolymer is the thermoplastic composition according to Embodiment 6, comprising 90 mol% of the ITR block and 10 mol% of the polycarbonate block.

[0062] <Aspect 8> The reinforcing filler is the thermoplastic composition according to any one of Embodiments 1 to 7, comprising glass fiber, silica (SiO 2 ) microparticles, carbon fiber, or a combination thereof.

[0063] <Aspect 9> The reinforcing filler-containing thermoplastic composition according to aspect 8, which contains flat glass fibers.

[0064] <Aspect 10> The thermoplastic composition according to any one of aspects 1 to 9, wherein the composition contains at least one additional additive.

[0065] <Aspect 11> The thermoplastic composition according to aspect 10, wherein the at least one additional additive includes an impact modifier, an organic filler, an acid scavenger, a stabilizer, a dropping inhibitor, an antioxidant, an antistatic agent, a chain extender, a colorant, a release agent, a flow promoter, a lubricant, a plasticizer, a quenching coolant, a flame retardant, a UV reflection additive, a foaming agent, a reinforcing agent, or a combination thereof.

[0066] <Aspect 12> The thermoplastic composition according to aspect 11, wherein the at least one additional additive includes an epoxy-based impact modifier present in an amount of about 0.01 wt% to a maximum of 4 wt%.

[0067] <Aspect 13> The thermoplastic composition according to any one of aspects 1 to 12, which has a metal adhesion strength that is at least 3% higher compared to a comparative composition containing a virgin polyester component instead of the chemical recycle polyester component.

[0068] <Aspect 14> An article comprising the thermoplastic composition according to any one of aspects 1 to 13, wherein the article is a nanoforming technology component.

[0069] <Aspect 15> A method for forming a thermoplastic composition, forming a mixture by combining about 10 wt% to about 80 wt% of a chemical recycle polyester component, about 10 wt% to about 60 wt% of a reinforcing filler, and about 5 wt% to about 20 wt% of a polycarbonate component; Forming the thermoplastic composition by injection molding, extrusion molding, rotational molding, blow molding, or thermoforming the mixture, which comprises, consists of, or consists essentially of, The thermoplastic composition has improved metal adhesion strength compared to a comparative composition containing a virgin polyester component instead of the chemical recycling polyester component, A method wherein the combined weight percentage values of all components do not exceed 100 wt%, and all weight percentage values are based on the total weight of the composition.

[0070] <Aspect 16> The thermoplastic composition, article or method according to any one of Aspects 1 to 15, wherein the metal adhesion strength is determined by a metal surface treatment and a nano molding technology (NMT) method.

[0071] <Aspect 17> The thermoplastic composition, article or method according to Aspect 16, wherein the metal surface treatment is a T (Taiseiplas) treatment or a TRI (Technology Rising from IWATE) treatment.

[0072] <Aspect 18> The thermoplastic composition, article or method according to Aspect 16, wherein the metal surface treatment is a TRI treatment.

Examples

[0073] The following examples are presented to provide those skilled in the art with a complete disclosure and description of how the compounds, compositions, articles, devices and / or methods claimed herein are made and evaluated, are purely illustrative in intent, and are not intended to limit the present disclosure. Efforts have been made to ensure accuracy with respect to numerical values (e.g., amounts, temperatures, etc.), but some errors and deviations should be accounted for. Unless otherwise noted, parts are parts by weight, temperature is in °C or ambient temperature, pressure is at or near atmospheric pressure. Unless otherwise noted, percentages regarding compositions are expressed in wt%.

[0074] The reaction conditions have numerous variations and combinations and, for example, include component concentrations, desired solvents, solvent mixtures, temperatures, pressures, and other reaction ranges and conditions that can be used to optimize the purity and yield of products obtained from the described processes. Optimizing such process conditions requires only reasonable and routine experimentation.

[0075] The compounds described herein were compounded into pellets in a twin-screw extruder. All components other than the glass fiber were premixed and fed from the main throat of the feeder. The glass fiber was added downstream. The extruder had conditions of an output of 50 kilograms per hour (kg / hr), a screw speed of 200 revolutions per minute (rpm), a vacuum of -0.08 megapascals (MPa), a torque of 50 - 65%, a barrel temperature of 250 - 260 °C, and a die head temperature of 260 °C.

[0076] The pelletized composition was injection molded under conditions of a drying temperature of about 120 - 140 °C, a processing temperature of 270 - 280 °C, a tool temperature of 140 - 150 °C, an injection speed of 10 millimeters per second (mm / s), a cooling time of 20 - 50 seconds (s), and a maximum pressure of 100 bar. The composition injection molded onto an aluminum alloy pretreated by TRI or NMT treatment was adhered to form nanoholes.

[0077] The adhesive strength was measured at a speed of 5 millimeters per second (mm / s) using an MTS Criterion (registered trademark) Series 40 Electromechanical Universal Testing Machine (Model 44, C44.304). The melt volume flow rate (MVR) was measured with a granular sample dried at 90 °C for 4 hours (hr) according to ASTM D1238. Tensile data was obtained at a test speed of 5 millimeters per minute (mm / min) according to ASTM D638. Flexural data was obtained according to ASTM 790. Notched Izod impact strength (NII) and unnotched Izod impact strength (UNI) data were obtained at room temperature (23 °C) according to ASTM D256 and ASTM D4812, respectively.

[0078] The comparative compositions, the example compositions, and their properties are shown in Table 1.

[0079]

Table 1A

[0080]

Table 1B

[0081] From the results, it was observed that the example compositions E1 and E2 (including iQ PBT resin) had improved adhesion in the TRI treatment compared to the composition C1 containing virgin PBT resin. In addition, the composition E2 containing less impact modifier (Lotader AX8900) also had improved NMT adhesion. This result suggests that the iQ PBT composition has improved adhesion strength compared to the composition containing virgin PBT. The mechanical properties of the compositions E1 and E2 were generally equivalent to those of the comparative composition C1.

[0082] Compositions containing 40 - 42 wt% glass fiber were prepared and tested as shown in Table 2.

[0083]

Table 2A

[0084]

Table 2B

[0085] From the results, it was observed that the example composition E3 containing iQ PBT had slightly improved adhesion compared to the comparative composition C1, and the example composition E4 with a lower content of impact modifier (Lotader) had further improved adhesion compared to the composition C1.

[0086] Comparative compositions C3 and C4 contain virgin PBT instead of iQ PBT. Those skilled in the art will recognize that replacing PBT with iQ PBT generally results in a decrease in the mechanical properties (e.g., metal adhesion strength, NII) of the thermoplastic composition. However, when comparing C1 with E1 and C2 with E3, it has been discovered in the present disclosure that the compositions containing iQ PBT can unexpectedly and counterintuitively achieve improved metal adhesion strength at substantially the same level of NII.

[0087] Furthermore, it can be seen from comparative compositions C3 and C4 that even when the content of the impact modifier is low in the composition containing virgin PBT, it is not helpful for improving the metal adhesion strength of the composition. For example, the TRI adhesion of comparative composition C4 is lower than that of comparative composition C3. In contrast, with respect to example compositions E3 and E4, the compositions containing iQ PBT can have improved metal adhesion strength and substantially the same level of NII while containing less impact modifier.

[0088] From these results, it can be concluded that the glass-filled iQ PBT composition has higher adhesion strength and is therefore more suitable for NMT applications than the comparative compositions containing virgin PBT.

[0089] The above description is intended to be illustrative and not restrictive. For example, the above-described embodiments (or one or more aspects thereof) may be used in combination with each other. Other aspects may be used by those skilled in the art and the like upon reading the above description. The abstract is provided to enable the reader to quickly ascertain the nature of the technical disclosure in accordance with 37 C.F.R. 1.72(b). It is submitted with the understanding that it is not to be used to interpret or limit the scope or meaning of the claims. Also, in the above summary of the invention, various features may be grouped in order to simplify the disclosure. This should not be construed as intending that any non-claimed disclosure feature is essential to any of the claims. Rather, the subject of the invention may lie in fewer features than all of the features of a particular disclosed aspect. Accordingly, the following claims are intended to be incorporated into the summary of the invention as examples or aspects, while each claim stands on its own as a separate aspect, and such aspects are envisioned to be combinable with each other in various combinations or permutations. The scope of the present disclosure should be determined with reference to the appended claims and the full scope of equivalents to which such claims are entitled.

Claims

1. A thermoplastic composition comprising from about 10 wt% to about 80 wt% of a chemically recycled polyester component, from about 10 wt% to about 60 wt% of a reinforcing filler, and from about 5 wt% to about 20 wt% of a polycarbonate component, wherein the thermoplastic composition has improved metal adhesion strength compared to a comparative composition comprising a virgin polyester component instead of the chemically recycled polyester component, the combined weight percent values of all components do not exceed 100 wt%, and all weight percent values are based on the total weight of the composition.

2. The thermoplastic composition according to claim 1, wherein the chemically recycled polyester component comprises polybutylene terephthalate (PBT).

3. The thermoplastic composition according to claim 2, wherein the PBT comprises terephthalic acid (TPA) derived from 48 wt% to 59.4 wt% of recycled polyethylene terephthalate (rPET), 12 wt% to 40.6 wt% of butanediol (BDO), and 1 wt% to 20 wt% of additional monomers.

4. The thermoplastic composition according to any one of claims 1 to 3, wherein the polycarbonate component comprises a polycarbonate homopolymer, a polycarbonate copolymer, or a combination thereof.

5. The thermoplastic composition according to claim 4, wherein the polycarbonate component comprises a polycarbonate copolymer.

6. The thermoplastic composition according to claim 5, wherein the polycarbonate copolymer comprises an isophthalate - terephthalate - resorcinol (ITR) block and a polycarbonate block.

7. The thermoplastic composition according to claim 6, wherein the ratio of the ITR block to the polycarbonate block of the polycarbonate copolymer is from 20:80 to 95:

5.

8. The thermoplastic composition according to claim 6, wherein the polycarbonate copolymer comprises 90 mol% of the ITR block and 10 mol% of the polycarbonate block.

9. The reinforcing filler is glass fiber, silica (SiO ２ ), fine particles, carbon fiber, or a combination thereof, and the thermoplastic composition according to any one of claims 1 to 8.

10. The thermoplastic composition according to claim 9, wherein the reinforcing filler comprises flat glass fibers.

11. The composition according to any one of claims 1 to 10, comprising at least one additional additive including an impact modifier, an organic filler, an acid scavenger, a stabilizer, a dripping inhibitor, an antioxidant, an antistatic agent, a chain extender, a colorant, a release agent, a flow promoter, a lubricant, a plasticizer, a quenching coolant, a flame retardant, a UV reflection additive, a foaming agent, a reinforcing agent, or a combination thereof.

12. The thermoplastic composition according to claim 11, wherein the at least one additional additive includes an epoxy-based impact modifier present in an amount of about 0.01 wt% to a maximum of 4 wt%.

13. The thermoplastic composition according to any one of claims 1 to 12, having a metal adhesion strength that is at least 3% higher than that of a comparative composition containing a virgin polyester component instead of the chemical recycling polyester component.

14. An article comprising the thermoplastic composition according to any one of claims 1 to 13, wherein the article is a nano-molding technology component.

15. A method for forming a thermoplastic composition, comprising: combining about 10 wt% to about 80 wt% of a chemical recycling polyester component, about 10 wt% to about 60 wt% of a reinforcing filler, and about 5 wt% to about 20 wt% of a polycarbonate component to form a mixture; forming the thermoplastic composition by injection molding, extrusion molding, rotational molding, blow molding, or thermoforming the mixture; and the thermoplastic composition has an improved metal adhesion strength compared to a comparative composition containing a virgin polyester component instead of the chemical recycling polyester component, wherein the combined weight percentage values of all components do not exceed 100 wt%, and all weight percentage values are based on the total weight of the composition.

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