Method and system for processing polymer compositions

Abstract

The present invention provides a method for processing a polymer composition comprising polycarbonate and at least one polymer and / or at least one additive with high quality, simplicity, and flexibility. [Solution] A method and processing system (1) for processing a polymer composition (C), wherein at least one polymer (P) and / or at least one additive (A) are supplied from a first supply opening (40), and a polycarbonate molten material (S) is processed. PC ) is supplied to the screw machine (2) from the second supply opening (46). At least one polymer (P) and / or the at least one additive (A), and polycarbonate molten (S PC The material is homogenized by a screw machine (2) to form a polymer composition (C), which is then discharged from the screw machine (2).

Description

[Technical Field]

[0001] The present invention relates to a method and a processing system for processing a polymer composition comprising polycarbonate and at least one polymer and / or at least one additive. [Background technology]

[0002] A method and apparatus for continuously producing a thermoplastic polymer blend is known from Patent Document 1. This polymer blend comprises polycarbonate and at least another blending component (e.g., polybutylene terephthalate). The polycarbonate molten material is transported by a melt pump directly from the system for producing polycarbonate to a static mixing section. The other blending component is processed by a screw machine and mixed with the polycarbonate molten material in the static mixing section. The mixture of the polycarbonate molten material and the molten other blending component is then granulated. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] EP 1 222 231 B1 [Overview of the project] [Problems that the invention aims to solve]

[0004] The object of the present invention is to provide a method that enables high-quality, simple, and flexible processing of a polymer composition comprising polycarbonate and at least one polymer and / or at least one additive. [Means for solving the problem]

[0005] This objective is achieved by a method having the features of claim 1. This method is used to process polymer compositions continuously. In particular, at least one polymer is melted and processed by a screw machine. By supplying a polycarbonate molten material to the screw machine, homogenization of the polycarbonate molten material with at least one polymer and / or at least one additive is simple and effective. This improved homogenization enhances the quality level of the polymer composition. The improved homogenization allows for flexible selection of the ratio of at least one polymer and / or at least one additive to the polycarbonate molten material, as well as the at least one polymer and / or at least one additive itself, without compromising the quality of the polymer composition. Furthermore, since a static mixer is not required, the structure of the processing system is simplified.

[0006] At least one polymer is selected from the group consisting of acrylonitrile butadiene styrene (ABS), styrene acrylonitrile (SAN), polyethylene terephthalate (PET), and polybutylene terephthalate (PBT). At least one polymer is not polycarbonate.

[0007] The ratio of molten polycarbonate to polymer composition w PC In particular, 30% by weight ≤ w PC ≤90% by weight, especially 40% by weight ≤w PC ≤80% by weight, and especially 50% by weight ≤w PC It is ≤70% by weight.

[0008] The proportion of at least one polymer to the polymer composition w P In particular, 10% by weight ≤ w P ≤70% by weight, especially 20% by weight ≤w P ≤60% by weight, and especially ≤30% by weight ≤w P It is ≤50% by weight.

[0009] When using acrylonitrile butadiene styrene (ABS) as a polymer, the proportion of the polycarbonate molten material is wPC is, for example, 30% by weight ≤ w PC ≤ 70% by weight, particularly 40% by weight ≤ w PC ≤ 60% by weight. The proportion w of acrylonitrile-butadiene-styrene ABS is, for example, 30% by weight ≤ w ABS ≤ 70% by weight, particularly 40% by weight ≤ w ABS ≤ 60% by weight.

[0010] The at least one additive is particularly selected from the group consisting of UV stabilizers, thermal stabilizers, oxygen absorbers, mold release agents (Mold Release: MR), dyes and fillers. In particular, fibers such as talc and / or glass fibers and / or carbon fibers are used as fillers.

[0011] When the at least one additive is selected from the group consisting of UV stabilizers, thermal stabilizers, oxygen absorbers, mold release agents (Mold Release: MR) and dyes, the proportion w of the at least one additive relative to the polymer composition A is particularly 0.0001% by weight ≤ w A ≤ 2.5% by weight, particularly 0.0005% by weight ≤ w A ≤ 1.5% by weight, and particularly 0.0005% by weight ≤ w A ≤ 1% by weight.

[0012] When the at least one additive is a filler, the proportion w of the at least one additive relative to the polymer composition A is particularly 1% by weight ≤ w A ≤ 80% by weight, particularly 10% by weight ≤ w A ≤ 70% by weight, and particularly 20% by weight ≤ w A ≤ 40% by weight.

[0013] When the polycarbonate melt is fed into the screw machine through the second feed opening, the temperature of the polycarbonate melt is T PC , where particularly 270°C ≤ T PC ≤ 330°C, particularly 280°C ≤ T PC ≤ 320°C, and particularly 290°C ≤ T PC ≤ 310°C.

[0014] The screw machine comprises at least one processing element shaft. The screw machine is particularly a multi-screw machine, preferably a twin-screw machine. The multi-screw machine, in particular, comprises at least two processing element shafts. The at least two processing element shafts preferably rotate in the same direction.

[0015] This multi-screw machine is characterized by having a housing in which at least two housing bores are formed. A processing element shaft is rotatably or rotatably arranged in each of the at least two housing bores. The at least two processing element shafts preferably rotate in the same direction, i.e., are rotatably drivable in the same direction of rotation. A first supply opening and a second supply opening are formed in the housing and open into at least two housing bores.

[0016] This screw machine defines the conveying direction. The second supply opening is located in the conveying direction, particularly downstream of the first supply opening. The polycarbonate molten material is preferably supplied directly from the manufacturing apparatus to the screw machine through the second supply opening. Once the polymer composition is discharged from the screw machine, it is filtered and / or granulated.

[0017] The method according to claim 2 enables the simple and flexible processing of polymer compositions at a high quality level. The bulk material consists of solid particles, particularly granules and / or powders. The presence of at least one polymer as bulk material allows the at least one polymer to be simply and flexibly supplied to a screw machine and melted within the screw machine. For this purpose, the screw machine sequentially forms a supply zone for supplying the at least one polymer and a melting zone for melting the at least one polymer in the conveying direction. The at least one polymer is melted by the screw machine to form a polymer melt. The polycarbonate melt is supplied particularly to at least one polymer that has been at least partially melted. When the polycarbonate melt is supplied, at least 30% by weight, particularly at least 50% by weight, and particularly at least 70% by weight of a portion of the at least one polymer is preferably melted. When the polycarbonate melt is supplied, 95% by weight or less, particularly 85% by weight or less, and particularly 75% by weight or less of a portion of the at least one polymer is preferably melted. As a result, at least one polymer can be melted by utilizing at least partially the thermal energy of the polycarbonate molten material. Alternatively, at least one polymer can be completely melted when the polycarbonate molten material is supplied.

[0018] The method according to claim 3 enables the simple and flexible processing of polymer compositions at a high quality level. At least one polymer and / or at least one additive can be simply, accurately, and reliably supplied into a screw machine by a first supply device. The first supply device preferably comprises at least one feeder and / or a supply screw machine. The first supply device preferably has at least one first feeder for supplying at least one polymer and / or at least one second feeder for supplying at least one additive. If multiple polymers are supplied, the first supply device has a feeder in particular for each polymer being supplied. If multiple additives are supplied, the first supply device has a feeder in particular for each additive being supplied. At least one feeder is gravimetric and / or volumetric. At least one feeder preferably weighs and supplies at least one polymer and / or at least one additive to a supply screw machine that transports them into the screw machine. The feed screw machine is equipped with two conveying screw shafts (i.e., a two-part structure), and the feed screw machine is preferably configured as a side feed machine connected to the screw machine housing from the side.

[0019] The method according to claim 4 enables the simple and flexible processing of polymer compositions at a high quality level. The polycarbonate molten material can be simply, accurately, and reliably supplied into the screw machine by a second supply device. The second supply device particularly comprises a melt pump and / or a supply screw machine. Preferably, the polycarbonate molten material is supplied from the manufacturing apparatus via a conveyor line and through a second supply opening to the screw machine by a melt pump.

[0020] The method according to claim 5 enables the simple and flexible processing of polymer compositions at a high quality level. The processing system comprises a manufacturing apparatus for producing a polycarbonate melt. The manufacturing apparatus particularly comprises at least one reactor for producing a polycarbonate melt. This is particularly by a phosgene-free transesterification method by transesterification of a carbonate ester with a dihydroxy compound. The polycarbonate melt is supplied to a screw machine via a supply line, particularly by a second supply apparatus, directly from the manufacturing apparatus. The screw machine forms a supply zone for supplying the polycarbonate melt, which is located downstream of a supply zone for supplying at least one polymer and / or at least one additive in the transport direction, and optionally via a melting zone for melting at least one polymer.

[0021] The method according to claim 6 enables the simple and flexible processing of polymer compositions at a high quality level. Unwanted volatile components can be removed from at least one partially molten polymer and / or polycarbonate molten material by degassing. The screw machine preferably has at least one degassing opening. At least one degassing opening is formed in the housing of the screw machine. The screw machine particularly forms a homogenization zone located in the conveying direction downstream of a supply zone for supplying at least one polymer and / or at least one additive. The homogenization zone is preferably located downstream of the molten zone for melting at least one polymer and the supply zone for supplying the polycarbonate molten material in the conveying direction. At least one degassing opening is particularly located within the homogenization zone. Degassing is carried out particularly during homogenization. The at least partially homogenized polymer composition is preferably degassed. At least one degassing opening is particularly located downstream of a second supply opening in the conveying direction. At least one degassing opening is particularly connected to a degassing device. The degassing device preferably generates a vacuum for degassing. Degassing preferably occurs after the entrainer (separating agent) has been supplied. For example, water is used as the entrainer. The screw machine, in particular, has an entrainer supply opening formed in the housing of the screw machine. The entrainer supply opening is located upstream of at least one degassing opening in the conveying direction. The entrainer supply opening is preferably located between a second supply opening for supplying the polycarbonate molten material and at least one degassing opening. Degassing can reduce the ratio of diphenylcarbazide (DPC) and / or acetonitrile (ACN) to less than 100 ppm, particularly less than 50 ppm, and particularly less than 10 ppm. The unit ppm (parts per million) refers to the total amount of diphenylcarbazide (DPC) and / or acetonitrile (ACN) molecules or monomers contained in the entire polymer composition.

[0022] The method according to claim 7 enables the simple and flexible processing of polymer compositions at a high quality level. At least a portion of at least one additive is supplied into the screw machine by a third feeding device. The third feeding device opens into a third feeding opening of the screw machine. The third feeding opening is located upstream or downstream of the second feeding opening in the conveying direction of the screw machine. The third feeding device comprises at least one feeder and / or one feeding screw machine. If multiple additives are supplied, the third feeding device preferably comprises a feeder for each additive. At least one feeder weighs and supplies at least one additive in particular to the feeding screw machine, which then conveys the additive into the screw machine. At least one feeder is particularly gravimetric and / or volumetric. The feeding screw machine comprises particularly two conveying screw shafts (i.e., a two-part structure). The feeding screw machine is preferably designed as a lateral feeding machine and is connected laterally to the housing of the screw machine. The third supply opening is located in the supply direction, particularly downstream of the first supply opening and / or the second supply opening, and / or upstream of at least one degassing opening. The third supply opening is preferably formed laterally in the housing of the screw machine.

[0023] Another object of the present invention is to provide a processing system for processing polymer compositions comprising polycarbonate and at least one polymer and / or at least one additive in a simple and flexible manner at a high quality level.

[0024] This objective is achieved by a processing system having the features of claim 8. This processing system is used to continuously process a polymer composition comprising polycarbonate and at least one polymer and / or at least one additive. At least one polymer and / or at least one additive is supplied to a first supply zone of the screw machine through a first supply opening. The polycarbonate molten material is supplied to a second supply zone of the screw machine through a second supply opening. The second supply opening is preferably located downstream of the first supply opening in the conveying direction of the screw machine, or the second supply zone is located downstream of the first supply zone in the conveying direction. In the homogenization zone, at least one polymer and / or at least one additive and the polycarbonate molten material are homogenized to form a polymer composition. The homogenization zone is located downstream of the first and second supply openings, or downstream of the first and second supply zones, in the conveying direction. The screw machine preferably comprises a first supply zone, a melting zone, a second supply zone, a homogenization zone, and a discharge zone in sequence in the conveying direction.

[0025] The screw machine comprises at least one processing element shaft. In the homogenization zone, the at least one processing element shaft comprises at least one kneading element and / or at least one mixing element. The at least one kneading element is specifically designed as a kneading disc and / or kneading block and comprises a plurality of kneading discs integrally connected to one another. The at least one mixing element is specifically a toothed mixing element and / or a turbine mixing element. The at least one mixing element can be designed to transport and / or be neutral with respect to transport. The at least one mixing element is used specifically for dispersion mixing. The at least one mixing element is specifically designed to avoid high shear forces. The homogenization zone begins with a first kneading element or first mixing element located downstream of the supply zone for supplying the polycarbonate molten material and ends with the last kneading element or last mixing element of the at least one processing element shaft.

[0026] At least one processing element shaft has an outer diameter D. The length of the homogenization zone is L. H In particular, 4 ≤ L H / D ≤ 16, especially 5 ≤ L H / D ≤ 15, and especially 6 ≤ L H / D ≤ 14.

[0027] The screw machine is a multi-screw machine, and more preferably a twin-screw machine. The multi-screw machine is particularly equipped with at least two processing element shafts. The at least two processing element shafts preferably rotate in the same direction.

[0028] The multi-screw machine comprises, in particular, a housing in which at least two housing bores are formed. A processing element shaft is rotatably or rotatably driven in each of the at least two housing bores. Preferably, the at least two processing element shafts rotate in the same direction, i.e., are rotatably driven in the same direction of rotation. A first and second supply opening are formed in the housing and open into at least two housing bores.

[0029] The processing system includes, in particular, a filtering device and / or a granulating device located downstream of the screw machine in the conveying direction. The filtering device for filtering the polymer composition and the granulating device for producing granules from the filtered polymer composition are preferably located downstream of the screw machine.

[0030] The advantages of the processing system according to the present invention correspond to the advantages of the method according to the present invention that have already been described. The processing system can be further developed in particular by at least one feature described in relation to the method according to the present invention.

[0031] The processing system described in claim 9 enables the simple and flexible processing of polymer compositions at a high quality level. In the melting zone, at least one polymer supplied as bulk material is at least partially melted. The melting zone is located upstream of the second supply opening or the second supply zone in the conveying direction of the screw machine. As a result, the polycarbonate molten material is supplied to at least one polymer that has been at least partially melted.

[0032] In the melting zone, at least one processing element shaft comprises at least one mixing element. The at least one mixing element comprises a plurality of mixing discs integrally connected to each other, particularly configured as mixing discs and / or mixing blocks. The melting zone begins at the first mixing element of at least one processing element shaft and ends at the nearest supply opening located downstream, for example, a second supply opening for supplying molten polycarbonate or a third supply opening for supplying at least one additive. The at least one processing element shaft has an outer diameter D. The length of the melting zone in the conveying direction is L. A In particular, 4 ≤ L A / D≦12, especially 5≦L A / D≦11, and especially 6≦L A / D ≤ 10.

[0033] The processing system described in claim 10 enables the simple and flexible processing of polymer compositions at a high quality level. Undesirable volatile components generated during the processing of the polymer composition can be removed from the screw machine by a degasser. Degassing can be carried out under atmospheric pressure or by a generated vacuum. The degasser preferably comprises a vacuum generator. The degasser is connected to at least one degassing opening formed in the housing of the screw machine. The at least one degassing opening is located particularly in the molten zone and / or the supply zone for supplying the polycarbonate molten material and / or the homogenization zone. The at least one degassing opening is located downstream of the first supply opening and / or the second supply opening, particularly in the conveying direction.

[0034] The screw machine preferably includes an entrainer supply device for supplying the entrainer. The entrainer supply device is connected to an entrainer supply opening formed in the housing of the screw machine, in particular. The entrainer supply opening is located in particular upstream of at least one degassing opening in the conveying direction. The entrainer supply opening is located in particular downstream of a first supply opening and / or a second supply opening in the conveying direction.

[0035] The processing system described in claim 11 enables the simple and flexible processing of polymer compositions at a high quality level. At least one polymer and / or at least one additive can be simply, accurately, and reliably supplied into a screw machine by a first supply device. The first supply device preferably comprises at least one feeder and / or a supply screw machine. The first supply device preferably has at least one first feeder for supplying at least one polymer and / or at least one second feeder for supplying at least one additive. When multiple polymers are supplied, the first supply device has a feeder in particular for each polymer supplied. When multiple additives are supplied, the first supply device has a feeder in particular for each additive supplied. At least one feeder is gravimetric and / or volumetric. At least one feeder preferably weighs and supplies at least one polymer and / or at least one additive to a supply screw machine that transports them into the screw machine. The supply screw machine comprises, in particular, two transport screw shafts (i.e., a two-part structure). The feed screw machine is preferably configured as a side feed machine and is connected to the screw machine housing from the side.

[0036] The processing system described in claim 12 enables the simple and flexible processing of polymer compositions at a high quality level. The polycarbonate molten material can be simply, accurately, and reliably supplied into the screw machine by a second supply device. The second supply device particularly comprises a melt pump and / or a supply screw machine. Preferably, the polycarbonate molten material is supplied from the manufacturing apparatus via a conveyor line and through the second supply opening to the screw machine by the melt pump.

[0037] The processing system described in claim 13 enables the simple and flexible processing of polymer compositions at a high quality level. The processing system comprises a manufacturing apparatus for producing a polycarbonate melt. The manufacturing apparatus particularly comprises at least one reactor for producing a polycarbonate melt. This is particularly by a phosgene-free transesterification method by transesterification of a carbonate ester with a dihydroxy compound. The polycarbonate melt is supplied by a second supply apparatus, particularly directly from the manufacturing apparatus into a screw machine. The screw machine forms a supply zone for supplying the polycarbonate melt, which is located downstream of a supply zone for supplying at least one polymer and / or at least one additive in the conveying direction, and optionally via a melting zone for melting at least one polymer.

[0038] The processing system described in claim 14 enables the simple and flexible processing of polymer compositions at a high quality level. At least a portion of at least one additive is supplied to a screw machine by a third feeding device. The third feeding device opens into a third feeding opening of the screw machine. The third feeding opening is located upstream or downstream of the second feeding opening in the conveying direction of the screw machine. The third feeding device comprises at least one feeder and / or one feeding screw machine. If multiple additives are supplied, it is preferable that the third feeding device comprises a feeder for each additive. At least one feeder particularly weighs and / or supplies at least one additive to a feeding screw machine, which conveys the additive into the screw machine. At least one feeder is particularly gravimetric and / or volumetric. The feeding screw machine particularly comprises two conveying screw shafts (i.e., a two-part structure). The feeding screw machine is preferably configured as a lateral feeding machine and is connected laterally to the housing of the screw machine. The third supply opening is located in the conveying direction, particularly downstream of the first supply opening and / or the second supply opening, and / or upstream of at least one degassing opening. The third supply opening is preferably formed laterally in the housing of the screw machine.

[0039] The processing system described in claim 15 enables the simple and flexible processing of polymer compositions at a high quality level. The ratio L / D allows at least one polymer and / or at least one additive to be homogenized with the supplied polycarbonate molten material by the screw machine. In particular, the ratio L / D allows at least one polymer to be melted by the screw machine. Furthermore, the ratio L / D allows for the degassing of at least one molten polymer and / or polycarbonate molten material.

[0040] Further features, advantages, and details of the present invention will become apparent from the following description of embodiments. [Brief explanation of the drawing]

[0041] [Figure 1] This is a partial cross-sectional side view of a processing system for processing a polymer composition comprising polycarbonate and at least one polymer and / or at least one additive. [Figure 2] Figure 1 is a partial cross-sectional top view of the processing system shown. [Modes for carrying out the invention]

[0042] The processing system 1 shown in Figures 1 and 2 is used to continuously process a polymer composition C comprising polycarbonate and at least one polymer P and / or at least one additive A. The at least one polymer P is selected from the group consisting of acrylonitrile butadiene styrene (ABS), styrene acrylonitrile (SAN), polyethylene terephthalate (PET), and polybutylene terephthalate (PBT). The at least one polymer P is not polycarbonate.

[0043] Processing system 1 includes a multi-screw machine 2, a first supply device 3 for supplying at least one polymer P and / or at least one additive A, and polycarbonate molten material S. PC A second supply device 4 for supplying, a third supply device 5 for supplying at least a portion of at least one type of additive A, and polycarbonate molten S PC The system includes a manufacturing apparatus 6, a pressurizing apparatus 7, a filtering apparatus 8, a granulation apparatus 9, and a control device 10 for manufacturing [the product].

[0044] The multi-screw machine 2 uses at least one polymer P and a polycarbonate molten material S. PCIt is used to continuously process a polymer composition C from at least one additive A. The multi-screw machine 2 is configured as a co-rotating twin-screw machine. The multi-screw machine 2 comprises a housing 11, which consists of a plurality of housing sections 13-23 that are arranged in a continuous manner along the conveying direction 12 and connected to one another. The last housing section 23 is closed by a discharge plate 24. The discharge plate 24 forms a discharge opening 25. The housing 11 has two parallel housing bores 26, 27 that penetrate each other. The housing bores 26, 27 have a horizontal figure-eight shape in cross-section.

[0045] Two processing element shafts 28 and 29 are arranged within housing bores 26 and 27 and are capable of rotational drive in the same direction around associated rotating shafts 30 and 31. To rotate these, the multi-axis screw machine 2 is equipped with a drive motor 32 and a power split transmission 33, with a coupling 34 positioned between them. The processing element shafts 28 and 29 are rotationally driven by the drive motor 32 via the power split transmission 33, around the rotating shafts 30 and 31 in the same direction.

[0046] The multi-screw machine 2 forms a first supply zone 35, a melting zone 36, a second supply zone 37, a homogenization zone 38, and a discharge zone 39 in this order along the conveying direction 12.

[0047] In the first supply zone 35, a first supply opening 40 is formed in the housing 11. The first supply opening 40 is formed, for example, in the first housing section 13. The first supply opening 40 is located on the upper side of the housing 11 and opens from above into the housing bores 26, 27. In the first supply zone 35, the processing element shafts 28, 29 are equipped with transport elements 41, 41'.

[0048] The first supply device 3 is used to supply a first portion of at least one polymer P and at least one additive A to the first supply zone 35. The first supply device 3 includes a first feeder 42, which is either gravimetric or volumetric. The first feeder 42 opens into a supply hopper 43, which then opens into a first supply opening 40. The first portion of at least one polymer P and at least one additive A can be pre-mixed and supplied by the first feeder 42. Alternatively, at least one polymer P can be supplied by the first feeder 42, and the first portion of at least one additive A can be supplied by at least another feeder.

[0049] The melting zone 36 is used to melt at least one polymer P. The melted at least one polymer P is used to form a polymer molten product S. P This forms the molten zone 36. In the molten zone 36, the processing element shafts 28, 29 include kneading elements 44, 44' and conveying elements 45, 45'. The kneading elements 44, 44' include, in particular, a kneading block and / or individual kneading discs having a plurality of kneading discs integrally connected to one another. The molten zone 36 begins with the first kneading elements 44, 44' in the conveying direction 12 and ends with the third supply opening 47. The third supply opening 47 will be described in detail below.

[0050] The processing element shafts 28 and 29 have an outer diameter D. The outer diameter D is specifically the maximum outer diameter. The processing element shafts 28 and 29 have a length L in the melting zone 36. A It has L A The ratio of / D is 4 ≤ L A / D≦12, especially 5≦L A / D≦11, and especially 6≦L A / D ≤ 10.

[0051] The multi-screw machine 2 has a second supply opening 46 and a third supply opening 47 in the second supply zone 37. The second supply opening 46 and the third supply opening 47 are located downstream of the first supply opening 40 in the conveying direction 12. The second supply opening 46 is located downstream of the third supply opening 47 in the conveying direction 12. Alternatively, the second supply opening 46 may be located upstream of the third supply opening 47 in the conveying direction 12. In the second supply zone 37, the processing element shafts 28 and 29 have conveying elements 64 and 64'.

[0052] The second supply device 4 supplies molten polycarbonate S PC It is used to supply to a multi-screw machine 2. For this purpose, the second supply device 4 opens into a second supply opening 46. This second supply opening 46 is formed in the housing 11, for example, in the housing section 18. The second supply opening 46 opens into the housing bores 26, 27. The second supply opening 46 is formed, for example, on the upper side of the housing 11.

[0053] The second supply device 4 comprises a melt pump 48 and a supply line 49. The melt pump 48 supplies molten polycarbonate S PC From the manufacturing apparatus 6 in which the polycarbonate molten material S is produced, PC The contents are transported to the second supply opening 46 via the supply line 49.

[0054] Manufacturing apparatus 6 processes molten polycarbonate S PC Used to manufacture: Molten polycarbonate S PC It is produced, in particular, by a phosgene-free transesterification method (in which a transesterification reaction occurs between carbonate esters and dihydroxy compounds). In a phosgene-free, direct, and continuous transesterification method, the raw materials are first continuously mixed in a predetermined molar ratio to form a raw material molten product. The raw material molten product passes through multiple transesterification reactors, where the raw materials are converted into monomer molten products in multiple transesterification stages. In a pre-condensation reactor, a prepolymer is produced from the monomer molten product. Polycarbonate molten product S PCIt is produced from a prepolymer to the desired degree of polymerization using multiple polycondensation reactors. Polycarbonate molten S PC The manufacturing method is known and common.

[0055] The third supply device 5 is used to supply a second portion of at least one type of additive A to the multi-screw machine 2. For this purpose, the third supply device 5 opens into a third supply opening 47. The third supply opening 47 is formed on the side of the housing 11, for example in the housing section 17, and opens into the housing bores 26, 27.

[0056] The third feeding device 5 comprises a second feeder 50 and a feeding screw machine 51. The second feeder 50 is either gravimetric or positive displacement. The feeding screw machine 51 is specifically designed as a twin-screw lateral feeding machine. The feeding screw machine 51 comprises a housing 52, which has two housing bores 53 and 54. Two conveying element shafts 55 and 56 are positioned within the housing bores 53 and 54 and are rotatable in the same direction around associated rotating shafts 57 and 58. To drive these shafts, the feeding screw machine 51 comprises a drive motor 59 and a power split transmission 60. The conveying element shafts 55 and 56 are driven by the drive motor 59 via the power split transmission 60 in the same direction of rotation around the rotating shafts 57 and 58. A feeding opening 61 is formed in the housing 52, into which a feeding hopper 62 opens. The second feeder 50 opens into the feeding hopper 62. The housing 52 is not closed and forms a supply port 63. This supply port 63 opens into a third supply opening 47. For this purpose, the housing 52 is connected to the housing 11 of the multi-screw machine 2. The conveying element shafts 55 and 56 protrude from the housing 52 and extend into the third supply opening 47.

[0057] The homogenization zone 38 contains at least one polymer P or polymer melt S. P , polycarbonate molten material S PCand is used to mix and homogenize with at least one additive A. In this homogenization zone 38, the processing element shafts 28, 29 are provided in the order of kneading elements 65, 65', conveying elements 66, 66', and mixing elements 67, 67' along the conveying direction 12. The kneading elements 65, 65' particularly include kneading blocks and / or individual kneading discs having a plurality of kneading discs integrally connected to each other. The mixing elements 67, 67' particularly include toothed mixing elements and / or turbine mixing elements. The mixing elements 67, 67' are used for dispersion mixing and, with respect to conveying, can be conveyable and / or neutral. The homogenization zone 38 extends from the second supply zone 37 to the discharge zone 39. The homogenization zone 38 begins with the first kneading elements 65, 65' located downstream of the second supply opening 46 in the conveying direction 12 and ends with the last mixing elements 67, 67'. The homogenization zone 38 has a length L in the conveying direction 12. H It has L H The ratio of / D is 4 ≤ L H / D ≤ 16, especially 5 ≤ L H / D ≤ 15, and especially 6 ≤ L H / D ≤ 14.

[0058] Homogenization zone 38 further contains polymer molten material S P and molten polycarbonate S PC Alternatively, it is also used for degassing polymer compositions C produced therefrom. For this purpose, the multi-screw machine 2 has an entrainer supply opening 68 and an associated entrainer supply device 69. The entrainer supply opening 68 is formed downstream of the second supply opening 46 in the conveying direction 12, in the homogenization zone 38 within the housing 11, for example, within the housing section 19. The entrainer supply opening 68 opens into the housing bores 26, 27. The entrainer supply device 69 is connected to the entrainer S M It is connected to an entrainer supply opening 68 for supplying the following. The entrainer supply device 69 includes a container 70 connected to the entrainer supply opening 68 via a pump 71 and a supply line 72.

[0059] For degassing, the multi-screw machine 2 is equipped with a degassing opening 73 and an associated degassing device 74. The degassing opening 73 is formed in the housing 11 downstream of the entrainer supply opening 68 in the conveying direction 12. The degassing opening 73 is formed on the side of the housing 11, for example in the housing section 20. The degassing device 74 is connected to the degassing opening 73.

[0060] The degassing device 74 comprises a degassing screw machine 75 and a vacuum generator 76. The degassing screw machine 75 is specifically designed as a twin-screw side degassing screw machine. The degassing screw machine 75 comprises a housing 77 in which two housing bores 78, 79 are formed, penetrating each other. The housing bores 78, 79 have a figure-eight shape with a horizontal cross-section. Two transport element shafts 80, 81 are located within the housing bores 78, 79 and are rotatable in the same direction around associated rotation axes 82, 83. To drive these, the degassing screw machine 75 comprises a drive motor 84 and a power split transmission 85. The transport element shafts 80, 81 are rotatably driven by the drive motor 84 via the power split transmission 85 around rotation axes 82, 83 in the same direction. A suction opening 86 is formed in the housing 77. The vacuum generator 76 is connected to the suction opening 86. The housing 77 is not closed and forms a connection opening 87. The connection opening 87 opens into a degassing opening 73. For this purpose, the housing 77 is connected to the housing 11 of the multi-screw machine 2. The conveying element shafts 80 and 81 extend through the connection opening 87 into the degassing opening 73.

[0061] At the end of the homogenization zone 38, the polymer melt S P , molten polycarbonate S PC The polymer composition C is formed by mixing and homogenizing the mixture with at least one additive A.

[0062] The discharge zone 39 is used to discharge the generated polymer composition C. In the discharge zone 39, the processing element shafts 28, 29 are equipped with transport elements 88, 88'. The transport elements 88, 88' are used to discharge the polymer composition C through the discharge opening 25.

[0063] The processing element shafts 28 and 29 have a total length L in the conveying direction 12. The ratio L / D is particularly 10 ≤ L / D ≤ ​​52, particularly 14 ≤ L / D ≤ ​​40, and particularly 16 ≤ L / D ≤ ​​36.

[0064] Downstream of the multi-screw machine 2, a pressurizing device 7, a filtering device 8, and a granulating device 9 are arranged sequentially along the conveying direction 12. The pressurizing device 7 is used to increase the pressure of the polymer composition C, making it possible to convey the polymer composition C through the filtering device 8. The pressurizing device 7 includes, for example, a melt pump. The filtering device 8 includes at least one filter element 89 for filtering the molten polymer composition C. Preferably, the filtering device 8 is configured as a switching device with at least two filter elements. In the granulating device 9, the filtered polymer composition C is granulated into granules G. The structure of the granulating device 9 is well known and conventional.

[0065] The control device 10 is used to control the processing system 1 and is in particular connected via signal communication to the multi-screw machine 2, feeding devices 3-5, pressurizing device 7, filtering device 8, and granulation device 9.

[0066] Processing system 1 operates as follows:

[0067] The first supply device 3 weighs and supplies a first portion of at least one polymer P and at least one additive A to the supply hopper 43. The first portion of at least one polymer P and at least one additive A reaches the first supply zone 35 of the multi-screw machine 2 through the first supply opening 40. The at least one polymer P is supplied to the multi-screw machine 2 as bulk material, i.e., granules and / or powder.

[0068] At least one polymer P is selected from the group consisting of acrylonitrile butadiene styrene (ABS), styrene acrylonitrile (SAN), polyethylene terephthalate (PET), and polybutylene terephthalate (PBT). At least one polymer P is not polycarbonate.

[0069] The ratio w of at least one polymer P to the polymer composition C P In particular, 10% by weight ≤ w P ≤70% by weight, especially 20% by weight ≤w P ≤60% by weight, and especially ≤30% by weight ≤w P It is ≤50% by weight.

[0070] In the first supply zone 35, the first portion of at least one polymer P and at least one additive A is transported along the transport direction 12 into the melting zone 36. In the melting zone 36, at least one polymer P is melted into a polymer molten product S. P This forms a molten zone 36. At the end of the molten zone 36, for example, at least 30% by weight, particularly at least 50% by weight, and particularly at least 70% by weight of at least one polymer P is melted.

[0071] In the second supply zone 37, the second portion of at least one additive A is first supplied by the third supply device 5 to the multi-screw machine 2 or at least one molten polymer P. For this purpose, the second portion of at least one additive A is supplied into the supply hopper 62 by the second feeder and then supplied into the supply screw machine 51 through the supply opening 61. The second portion of at least one additive A is supplied into the multi-screw machine 2 by the conveying element shafts 55, 56 through the supply port 63 and the third supply opening 47.

[0072] At least one additive A is selected from the group consisting of ultraviolet stabilizers, heat stabilizers, oxygen absorbers, mold release agents (mold release agent: MR), dyes, and fillers. Talc and / or fibers (e.g., glass fibers and / or carbon fibers) are used as fillers.

[0073] If at least one additive A is selected from the group consisting of UV stabilizers, heat stabilizers, oxygen absorbers, mold release agents (MR), and dyes, the ratio of at least one additive A to polymer composition C is w A In particular, 0.0001% by weight ≤ w A ≤2.5% by weight, especially 0.0005% by weight ≤w A ≤1.5% by weight, and especially 0.0005% by weight ≤w A It is ≤1% by weight.

[0074] If at least one additive A is a filler, the ratio of at least one additive A to the polymer composition C is w A In particular, 1% by weight ≤ w A ≤80% by weight, especially ≤10% by weight A ≤70% by weight, and especially ≤20% by weight ≤w A It is ≤40% by weight.

[0075] Furthermore, in the second supply zone 37, molten polycarbonate S PC The molten polycarbonate S is supplied into the multi-screw machine 2 through the second supply opening 46 by the second supply device 4. PC The molten polycarbonate S is continuously supplied to the multi-screw machine 2 by the second supply device 4. PC The temperature is T PC In particular, 270℃≦T PC ≤330℃, especially 280℃ ≤T PC ≤320℃, and especially 290℃ ≤T PC The temperature is ≤310℃. Polycarbonate molten material S PC Temperature T PC This completely melts at least one remaining unmelted polymer P.

[0076] Polycarbonate melt S relative to polymer composition C PC ratio w PC is, in particular, 30% by weight ≤ w PC ≤ 90% by weight, in particular 40% by weight ≤ w PC ≤ 80% by weight, and particularly 50% by weight ≤ w PC ≤ 70% by weight.

[0077] Polycarbonate melt S PC is directly fed from the production apparatus 6 to the multi-screw machine 2 via the melt pump 48 and the supply line 49. Polymer melt S P , polycarbonate melt S PC , and at least one additive A are conveyed by the conveying elements 64, 64' to the homogenization zone 38.

[0078] In the homogenization zone 38, polymer melt S P , polycarbonate melt S PC and at least one additive A are mixed and homogenized. During homogenization, polymer melt S P and polycarbonate melt S PC are degassed. For degassing, in the homogenization zone 38, first, entrainer S M is fed by the entrainer supply device 69 through the entrainer supply opening 68 into the multi-screw machine 2. Entrainer S M is, for example, water. Entrainer S M dissolves the volatile components in polymer melt S P and polycarbonate melt S PC . The volatile components are extracted from the housing bores 26, 27 by the degassing device 74 via the degassing opening 73. The volatile components are extracted via the degassing openings, the housing bores 78, 79, and the suction opening 86. The conveying element shafts 80, 81 ensure that polymer melt S P , polycarbonate melt S PC , and at least one additive A remain in the housing bores 26, 27. At the end of the homogenization zone 38, polymer melt S P , polycarbonate melt SPC The polymer composition C is of high quality when the polymer composition C is homogeneously mixed with at least one additive A and degassed.

[0079] In the discharge zone 39, the polymer composition C is discharged through the discharge opening 25 of the discharge plate 24. The pressure of the polymer composition C is then increased by the pressurizing device 7, and it is pumped and filtered by the filtering device 8. The filtered polymer composition C is then granulated in a conventional manner by the granulating device 9 to form granules G.

[0080] Molten polycarbonate S PC The fact that the polymer molten polymer S is supplied directly from the manufacturing apparatus 6 to the multi-screw machine 2 means that the processing of the polymer composition C is energy-efficient. P and molten polycarbonate S PC Furthermore, homogenization with at least one additive A makes it possible to process high-quality polymer composition C simply and flexibly. By using a multi-screw machine 2, homogenization can be carried out substantially more easily and effectively than with conventional static mixers. In particular, since degassing is performed during homogenization, the quality of polymer composition C can be improved.

[0081] Manufacturing apparatus 6 processes molten polycarbonate S PC Multiple production lines can be provided for this purpose. Each production line can be assigned a multi-screw machine 2 equipped with feeding devices 3-5, a pressurizing device 7, a filtering device 8, and a granulating device 9. As a result, for example, different polymers P and / or different additives A and / or different polycarbonate melts S can be produced. PC Various polymer compositions C having the following properties can be manufactured. [Explanation of Symbols]

[0082] 1. Processing System 2 Multi-screw machine 3 1st supply device 4 Second supply device 5 Third supply device 6 Manufacturing equipment 7 Pressurizing device 8. Filter device 9 Granulation equipment 10 Control device 11, 52, 77 Housing 12 Conveying direction 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23 Housing Section 24 Discharge Plate 25 Discharge opening 26, 27, 53, 54 Housing bore 28, 29 Processing element shaft 30, 31, 57, 58 Rotation axis 32 Drive motor 33. Power split type transmission 34 Coupling 35. Supply Zone 1 36 Melting Zones 37 Second Supply Zone 38 Homogenization Zone 39 Discharge Zones 40 1st supply opening 41, 41' Conveyor element 42 First Feeder 43 Supply Hopper 44, 44' Mixing elements 45, 45' Conveyor element 46 Second supply opening 47 Third supply opening 48 Melt pump 49 Supply lines 50 Second Feeder 51. Supply Screw Machine 55, 56 Conveyor element shaft 59 Drive motor 60 Power split transmission 61 Supply opening 62 supply hopper 63 supply ports 64, 64' Conveyor element 65, 65' Mixing elements 66, 66' Carrier element 67, 67' mixed element 68 Entrainer supply opening 69 Entrainer supply device 70 containers 71 Pump 72 supply lines 73 Degassing opening 74 Degassing device 75. Degassing screw machine 76 Vacuum Generator 78, 79 Housing bore 80, 81 Conveyor element shaft 82, 83 Rotation axis 84 Drive motor 85 Power split transmission 86 Suction opening 87 Connection opening 88, 88' Carrier element 89 filter elements A additive C polymer composition G Granules P molten polymer S M Entrenner S P Polymer melt S PC Molten polycarbonate

Claims

1. A method for processing a polymer composition comprising polycarbonate and at least one polymer and / or at least one additive, - A step of providing a processing system (1) equipped with a screw machine (2), wherein the screw machine (2) has a first supply opening (40) for supplying the at least one polymer (P) and / or the at least one additive (A), and a polycarbonate molten material (S ＰＣ A step comprising a second supply opening (46) for supplying ) - A step of supplying the at least one polymer (P) and / or the at least one additive (A) to the screw machine (2) through the first supply opening (40), - The molten polycarbonate (S ＰＣ The step of supplying the following to the screw machine (2) through the second supply opening (46): - The at least one polymer (P) and / or the at least one additive (A), and the polycarbonate molten material (S ＰＣ The steps of homogenizing the above using the screw machine (2) to form the polymer composition (C), and - A step of discharging the polymer composition (C) from the screw machine (2), A method that includes this.

2. The method according to claim 1, characterized in that the at least one polymer (P) is supplied to the screw machine (2) as a bulk material and melted within the screw machine (2).

3. The method according to claim 1 or 2, characterized in that the at least one polymer (P) and / or the at least one additive (A) are supplied to the screw machine (2) by a first supply device (3).

4. The aforementioned molten polycarbonate (S ＰＣ The method according to any one of claims 1 to 3, characterized in that the material is supplied to the screw machine (2) by a second supply device (4).

5. The aforementioned molten polycarbonate (S ＰＣ The method according to any one of claims 1 to 4, characterized in that the material is supplied from the manufacturing apparatus (6) to the screw machine (2).

6. At least partially melted at least one polymer (P) and / or the polycarbonate molten material (S) ＰＣ The method according to any one of claims 1 to 5, characterized in that the gas is degassed by the screw machine (2).

7. The method according to any one of claims 1 to 6, characterized in that at least a portion of the at least one additive (A) is supplied to the screw machine (2) through the third supply opening (47).

8. A processing system for processing a polymer composition comprising polycarbonate and at least one polymer and / or at least one additive, - A screw machine (2) having a first supply opening (40) for supplying the at least one polymer (P) and / or the at least one additive (A), The screw machine (2) processes the molten polycarbonate (S ＰＣ It is provided with a second supply opening (46) for supplying ( ), and The screw machine (2) uses the at least one polymer (P) and / or the at least one additive (A) and the polycarbonate molten material (S ＰＣ A processing system characterized by comprising a homogenization zone (38) for homogenizing the above and forming the polymer composition (C).

9. The processing system according to claim 8, characterized in that the screw machine (2) comprises a melting zone (36) for at least partially melting the at least one polymer (P).

10. The screw machine (2) processes the at least one polymer (P) that is at least partially melted and / or the polycarbonate melt (S ＰＣ ), and is characterized by comprising a degassing device (74) for performing degassing, the processing system according to claim 8 or 9.

11. The processing system according to at least one of claims 8 to 10, further comprising a first supply device (3) for supplying the at least one polymer (P) and / or the at least one additive (A) to the screw machine (2) through the first supply opening (40).

12. The aforementioned molten polycarbonate (S ＰＣ The processing system according to at least one of claims 8 to 11, further comprising a second supply device (4) for supplying the ) to the screw machine (2) through the second supply opening (46).

13. The aforementioned molten polycarbonate (S ＰＣ The processing system according to at least one of claims 8 to 12, characterized by comprising a manufacturing apparatus (6) for manufacturing ).

14. The processing system according to at least one of claims 8 to 13, further comprising a third supply device (5) for supplying at least a portion of the at least one additive (A) to the screw machine (2) through a third supply opening (47).

15. The processing system according to at least one of claims 8 to 14, wherein the screw machine (2) comprises at least one processing element shaft (28, 29) having a length L and an outer diameter D, and the ratio L / D is 10 ≤ L / D ≤ ​​52, in particular 14 ≤ L / D ≤ ​​40, and in particular 16 ≤ L / D ≤ ​​36.

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