Composite polycarbonate material, preparation method, and lamp

Abstract

The present application discloses a composite polycarbonate material, a preparation method, and a lamp. The composite polycarbonate material is prepared from the following raw materials in parts by weight: 80.5-85.2 parts of polycarbonate; 5-10 parts of an acrylonitrile-styrene-acrylate copolymer; 5-9 parts of carbon nanotube masterbatches; 0.5-1 part of a dispersant; 0.1-0.3 parts of an antioxidant; and 0.1-0.3 parts of an anti-aging additive. The composite polycarbonate material has lower sheet resistance, better dust adsorption resistance, higher fluidity, a faster forming cycle and more excellent photooxidative aging performance; and said material, when being applied to a housing or a reflector of a lamp, can greatly reduce dust adsorption on the lamp and can also significantly reduce the glare of the lamp.

Description

Composite polycarbonate material, preparation method and lamp

[0001] This application claims priority to a Chinese patent application filed on December 29, 2023, with application number 202311862044.0 and invention name “Composite polycarbonate materials, preparation methods and lamps”. The entire contents of this patent application are incorporated by reference into this application. Technical Field

[0002] The present application relates to the fields of materials and lighting, and in particular to a composite polycarbonate material, a preparation method and a lamp. Background Art

[0003] As our requirements for quality of life improve, people's requirements for lighting fixtures are also getting higher and higher. In addition to having more and stronger functions, the LED lamps on the market now have higher and higher requirements on the appearance of the lamps.

[0004] The aesthetics of a lamp primarily depends on its housing, and the material used is crucial to its performance and aesthetics. Over time, many lamps tend to accumulate dust on their housings. Lamps are often hung high up, making cleaning difficult. Over time, this can negatively impact the lamp's aesthetics.

[0005] We urgently need a new material to address the dust absorption problem. It can achieve anti-static properties and reduce reflector glare without affecting product function and quality, thus promoting technological upgrades for various types of lighting fixtures, including spotlights, downlights, and grille lights. This can effectively address customers' changing needs and meet their lighting quality requirements.

[0006] In view of this, it is indeed necessary to provide a composite polycarbonate material, a preparation method and a lamp to solve the above problems. Summary of the Invention

[0007] The purpose of this application is to provide a composite polycarbonate material that has good dust resistance.

[0008] To achieve the above-mentioned purpose, the present application provides a polycarbonate material for use in lamps, wherein the raw materials thereof include the following components by weight:

[0009] Optionally, when the melt flow rate of the polycarbonate is 300° C. / 1.2 kg, the melt index of the polycarbonate is in the range of 10-15 g / 10 min, and the molecular weight of the polycarbonate is between 22,000 and 25,000 DA.

[0010] Optionally, the concentration of the single-walled carbon nanotubes in the carbon nanotube masterbatch is 20%, and the diameter of the single-walled carbon nanotubes is 2 to 25 nm.

[0011] Optionally, the monomer copolymerization ratio of the acrylonitrile-styrene-acrylate copolymer is acrylonitrile:styrene:acrylate=2:7:1, and the melt index of the acrylonitrile-styrene-acrylate copolymer is 20-25 g / 10 min.

[0012] Optionally, the antioxidant includes a hindered phenol antioxidant or a phosphite antioxidant.

[0013] Optionally, the anti-aging agent includes at least one of a benzotriazole anti-aging agent, a hindered phenol anti-aging agent, and a phosphite compound anti-aging agent.

[0014] Optionally, the acid value of the dispersant is 9 to 16 mg KOH / g.

[0015] Another object of the present application is to provide a method for preparing the above-mentioned composite polycarbonate material.

[0016] To achieve the above objectives, the present application provides a preparation method for preparing the above composite polycarbonate material, comprising:

[0017] Put polycarbonate, acrylonitrile-styrene-acrylate copolymer, carbon nanotube masterbatch, dispersant, antioxidant, and anti-aging additive into a low-speed mixer and stir for 5 minutes to mix them evenly to obtain a primary material;

[0018] The primary material is extruded into granules using a twin-screw extruder. The processing temperature of the twin-screw extruder is 250-270° C., the head temperature is 270° C., and the screw speed is 300 rpm.

[0019] Another object of the present application is to provide a lamp using the above-mentioned composite polycarbonate material.

[0020] To achieve the above-mentioned objectives, the present application provides a lamp, which includes a housing and / or a reflector, and the housing and / or the reflector are made of the above-mentioned composite polycarbonate material.

[0021] Optionally, the lamp includes one of a downlight, a ceiling lamp, a kitchen and bathroom lamp, a decorative lamp and a table lamp.

[0022] Compared with the existing technology, the technical solution of the present application has the following beneficial effects: compared with the shell and / or reflector of the lamp using traditional polycarbonate materials, the shell and / or reflector of the lamp using the composite polycarbonate material of the present application has similar glossiness, lower surface resistivity, higher anti-static effect, can effectively prevent dust adhesion, and at the same time, has better light-oxidation aging performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG1 is a flow chart of the preparation method of the present application.

[0024] Figure 2 is a test comparison diagram of a reflector made of a composite polycarbonate material in a preferred embodiment of the present application and a reflector made of a traditional polycarbonate material in a dusty environment, wherein Figure 2(a) is a reflector made of an ordinary polycarbonate material prepared in Comparative Example 2, and Figure 2(b) is a reflector made of the composite polycarbonate material of the present application. DETAILED DESCRIPTION

[0025] In order to make the objectives, technical solutions and advantages of this application clearer, this application is described in detail below with reference to the accompanying drawings and specific embodiments.

[0026] It should be noted here that in order to avoid obscuring the present application due to unnecessary details, only the structures and / or processing steps closely related to the scheme of the present application are shown in the accompanying drawings, while other details that are not closely related to the present application are omitted.

[0027] In addition, it should be noted that the terms "comprises", "includes" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or apparatus that includes a series of elements includes not only those elements, but also includes other elements not explicitly listed, or also includes elements inherent to such process, method, article or apparatus.

[0028] The technical solutions provided by this application are described in detail below with reference to specific embodiments.

[0029] This embodiment discloses a composite polycarbonate material, which is mainly used in lamps and reflectors. The raw materials of the material include the following components by weight:

[0030] Polycarbonate is the primary raw material of this material. The polycarbonate melt index in this embodiment is in the range of 10-20 g / 10 min. This melt index is measured under the conditions specified by national standards: a temperature of 300°C, a weight of 1.2 kg, and a molecular weight of 22,000 to 25,000 DA.

[0031] In this embodiment, acrylonitrile-styrene-acrylate copolymer is the primary raw material for adjusting processing fluidity, significantly impacting the molding and appearance yield of thin-walled, large parts. The monomer copolymerization ratio of acrylonitrile-styrene-acrylate copolymer is 2:7:1 acrylonitrile:styrene:acrylate, and the melt index of acrylonitrile-styrene-acrylate copolymer is 20-25 g / 10 min.

[0032] The carbon nanotube masterbatch is the only conductive filler in the material that reduces the surface resistivity. The carbon nanotube masterbatch includes single-walled carbon nanotubes with a diameter of 2 to 25 nm. The concentration of carbon nanotubes in the carbon nanotube masterbatch is 20%.

[0033] In this embodiment, the function of the dispersant is to increase the dispersibility of the carbon nanotubes in the material and prevent the nanomaterial from agglomerating during mixing and granulation, thereby preventing uneven dispersion.

[0034] In this embodiment, the antioxidant includes at least one of a hindered phenol antioxidant and a phosphite antioxidant, and the antioxidant has the property of being resistant to high-temperature hydrolysis.

[0035] In this embodiment, the anti-aging agent includes one of a benzotriazole anti-aging agent, a hindered phenol anti-aging agent, and a phosphite compound anti-aging agent.

[0036] The performance of the materials provided in this application is further illustrated below through experimental examples and comparative examples.

[0037] Experimental example:

[0038] The raw materials of each experimental example and comparative example are shown in Table 1:

[0039] Table 1 Raw materials

[0040] (Note: The polycarbonate (PC) in Comparative Example 2 is Covestro PC-2805)

[0041] Each component was placed in a low-speed mixer and stirred for 5 minutes to mix evenly, discharged, and then extruded into granules using a twin-screw extruder; the processing temperature of the screw extruder was 250-270°C, the specific temperature settings are shown in Table 2, the head temperature was 270°C, and the screw speed was 300 rpm.

[0042] Table 2 Screw temperature setting values

[0043] The pellets formed in each experimental example and comparative example were tested for various properties according to national standards. The test results are shown in Table 3.

[0044] Table 3 Performance test results

[0045] (Note: The lower the reflector surface resistivity, the lower the surface brightness, the better the surface anti-glare effect, and the lower the dust absorption)

[0046] As shown in Table 3, the composite polycarbonate materials obtained in Experimental Examples 1-4 surpass the performance of the polycarbonate material obtained in Comparative Example 2 in terms of material fluidity and injection molding cycle. Furthermore, the composite polycarbonate materials obtained in Experimental Examples 1-4 exhibit significantly higher fluidity than existing polycarbonate materials, resulting in a faster molding cycle for products of the same volume. The surface resistivity of the materials obtained in Experimental Examples 1-4 is significantly lower than that of the existing polycarbonate material obtained in Comparative Example 2. Lower resistivity indicates better surface anti-glare and dust resistance. Furthermore, the photo-oxidation aging performance of Experimental Examples 2-3 is significantly superior to that of the polycarbonate materials obtained in Comparative Examples 1 and 2, resulting in a longer service life.

[0047] In addition, as can be seen from Table 3, although Comparative Example 1 and Experimental Example 3 use the same main raw material, polycarbonate, Comparative Example 1 lacks acrylonitrile-styrene-acrylate, so the material obtained in Comparative Example 1 has low fluidity and a long processing cycle. In addition, acrylonitrile-styrene-acrylate has better aging resistance than polycarbonate, so Experimental Example 3 has better photo-oxidation aging resistance. It can also be seen that Experimental Example 4 uses the same main raw materials, polycarbonate and ASA, as in Experimental Example 3. In Experimental Example 4, conductive carbon black is used as the conductive agent, which reduces the overall impact strength, and the reflector surface brightness is high and the resistivity is high, thus failing to achieve the dust resistance performance of Experimental Example 3 using carbon nanotubes as the conductive agent.

[0048] In summary, the composite polycarbonate material provided in the embodiments of the present application has impact strength similar to that of traditional polycarbonate materials, lower surface resistivity, better resistance to dust adsorption, higher fluidity, faster molding cycle and better photo-oxidation aging performance.

[0049] The composite polycarbonate material provided in this application can be applied to the housing and reflector of lamps, including but not limited to downlights, ceiling lamps, kitchen and bathroom lamps, decorative lamps, table lamps, etc., and can significantly reduce the dust adsorption problem of lamps while significantly reducing the glare problem of lamps. It should also be noted that although the composite polycarbonate material provided in this embodiment is generally used to form the housing and / or reflector of lamps, it does not exclude its application in forming other lamp components with similar working conditions as the housing and / or reflector, and it can even be applied to components of other electrical products with similar working conditions, and this application does not impose any restrictions on this.

[0050] The above embodiments are only used to illustrate the technical solutions of the present application and are not intended to limit the present application. Although the present application has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that the technical solutions of the present application may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present application.

Claims

1. A composite polycarbonate material, applied to lamps, wherein, By weight, its raw materials include the following components:

2. The composite polycarbonate material according to claim 1, wherein When the melt flow rate of the polycarbonate is at 300 °C / 1.2 kg, the melt index range of the polycarbonate is 10 - 15 g / 10 min, and the molecular weight of the polycarbonate is between 22,000 and 25,000 DA.

3. The composite polycarbonate material according to claim 1, wherein, The concentration of single-walled carbon nanotubes in the carbon nanotube masterbatch is 20%, and the diameter of the single-walled carbon nanotubes is 2 - 25 nm.

4. The composite polycarbonate material according to claim 1, wherein, The monomer copolymerization ratio of the acrylonitrile-styrene-acrylate copolymer is acrylonitrile:styrene:acrylate = 2:7:1, and the melt index of the acrylonitrile-styrene-acrylate copolymer is 20 - 25 g / 10 min.

5. The composite polycarbonate material according to claim 1, wherein The antioxidant includes a hindered phenol antioxidant or a phosphite antioxidant.

6. The composite polycarbonate material according to claim 1, wherein, The anti-aging aid includes at least one of a benzotriazole anti-aging aid, a hindered phenol anti-aging aid, and a phosphite compound anti-aging aid.

7. The composite polycarbonate material according to claim 1, wherein, The acid value of the dispersant is 9 - 16 mg KOH / g.

8. A preparation method for preparing the composite polycarbonate material according to any one of claims 1 to 7, wherein, Comprising: Put the polycarbonate, acrylonitrile-styrene-acrylate copolymer, carbon nanotube masterbatch, dispersant, antioxidant, and anti-aging aid into a low-speed mixer and stir for 5 minutes to mix them evenly to obtain a primary material; Extrude and pelletize the primary material with a twin-screw extruder. The processing temperature of the twin-screw extruder is 250 - 270 °C, the head temperature is 270 °C, and the rotation speed of the screw is 300 rpm.

9. A lighting fixture, wherein, The lamp includes a housing and / or a reflector, and the housing and / or the reflector are made of the composite polycarbonate material according to any one of claims 1 - 7.

10. The luminaire according to claim 9, wherein, The lamp includes one of a downlight, a ceiling lamp, a kitchen and bathroom lamp, a decorative lamp, and a table lamp.

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