Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – From phenol – phenol ether – or inorganic phenolate
Reexamination Certificate
2001-12-04
2002-11-12
Boykin, Terressa M. (Department: 1711)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
From phenol, phenol ether, or inorganic phenolate
C528S198000
Reexamination Certificate
active
06479616
ABSTRACT:
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is based upon and claims priority to Japanese Application No. 2000-395578, with a filing date of Dec. 26, 2000, which is hereby incorporated by reference.
BACKGROUND OF INVENTION
This disclosure relates to modified polycarbonate resins, and in particular to the manufacture of modified polycarbonate resins having good moldability and high heat resistance.
Polycarbonate resins can yield molded articles with excellent transparency, heat resistance, and mechanical strength, and are therefore used in a variety of applications, such as in electrical/electronic components and in components for the interiors and exteriors of automobiles and other vehicles. Polycarbonate resins have a heat deformation temperature of about 130° C. when measured under a load of 18.6 kg; however, even higher heat resistance is sometimes required in applications involving automobile headlights and the like.
SUMMARY OF INVENTION
A method for manufacturing a modified polycarbonate resin comprises reacting an anthracene compound and a polycarbonate resin, wherein the resin is preferably in the melt phase, to produce a modified polycarbonate resin comprising structural units of formula [I-1] or [I-2] as follows:
wherein Y is a C
1
-C
20
bivalent hydrocarbon group; R is a C
1
-C
20
hydrocarbon; R
a
is a hydrogen atom or a C
1
-C
20
hydrocarbon; n is an integer from 0 to 4; each X
1
, which may be the same or different, is a C
1
-C
20
hydrocarbon group or a halogen atom; each X
2
, which may be the same or different, is a hydrogen atom, a C
1
-C
20
hydrocarbon group, or a halogen atom; and a plurality of X
1
and X
2
may combine together to form a ring structure.
The above-described and other features are exemplified by the following detailed description.
DETAILED DESCRIPTION
A transparent modified polycarbonate resin having excellent moldability and high heat resistance is advantageously formed by reacting a polycarbonate resin, preferably in the melt phase, with a reactive anthracene compound.
The polycarbonate resin comprises a main chain and structural units in which the structural units are copolymerization components and/or molecule ends, i.e., the structural units may be attached to along the chain or represent terminal groups to the main chain. Although a number of possible structural units exist, particularly useful structural units include [i-1] or [i-2]:
wherein Y is a C
1
-C
20
bivalent hydrocarbon group such as methylene (—CH
2
—), ethylene (—C
2
H
4
—), propylene (—C
3
H
6
—), or another aliphatic hydrocarbon group, an aromatic hydrocarbon group such as:
or an alicyclic hydrocarbon group; R is a C
1
-C
20
hydrocarbon group such as methyl or ethyl; R
a
is a hydrogen atom or a C
1
-C
20
hydrocarbon group such as methyl or ethyl; and n is an integer from 0 to 4. In formula [i-2], the R and the vinyl-containing group may attach to any position on the benzene ring (ortho, meta, or para).
The polycarbonate resin may contain either one or both of the structural units expressed by formulas [i-1] and [i-2].
The amount in which the structural units expressed by formulas [i-1] and [i-2] above are contained in the polycarbonate resin, although not subject to any particular limitations, can be less than or equal to 0.2 mol, with less than or equal to about 0.1 mol preferred. Also preferred is an amount of greater than or equal to 0.001 mol, with greater than or equal to about 0.002 mol more preferred, where mol is measured as mol per mole of the structural units derived from the aromatic dihydroxy compound the main chain.
The polycarbonate resin disclosed herein commonly has a glass transition temperature of about 148° C. It may be prepared in a solution comprising methyl chloride at a temperature of 25° C. The intrinsic viscosity of the polycarbonate in methyl chloride at 25° C. is not subject to any particular limitations and is appropriately selected with consideration for the intended application and moldability.
The intrinsic viscosity is commonly 0.26 dL/g or greater, preferably 0.30-0.98 dL/g, and more preferably 0.34-0.64 dL/g. Expressed as viscosity-average molecular weight, this value is commonly 10,000 or greater, preferably 12,000-50,000, and more preferably 14,000-30,000. A mixture of polycarbonate resins having different intrinsic viscosities can also be used.
One type of useful main chain is an aromatic homopolycarbonate wherein the repeating structural units are expressed by formula (1) below:
wherein A is a divalent group derived from an aromatic dihydroxy compound.
The aromatic homopolycarbonate can be obtained by reacting a carbonate precursor with an aromatic dihydroxy compound. A single aromatic dihydroxy compound may be used, or two or more such compounds may be used together. The aromatic dihydroxy compound may include monocyclic and polycyclic aromatic compounds having two hydroxy groups as its functional groups, with each of the hydroxy groups directly attached to a carbon atom of the aromatic ring. Specific examples of aromatic dihydroxy compounds include those compounds as expressed by formulas (2) and (3) below:
wherein R
a
and R
b,
which may be the same or different, are halogen atoms or monovalent hydrocarbon groups; m and n comprise integers from 0 to 4; X is
R
c
and R
d
are hydrogen atoms or monovalent hydrocarbon groups (the R
c
and R
d
may also form ring structures); and R
e
is a bivalent hydrocarbon group; and
wherein R
f
is a C
1
-C
10
hydrocarbon group, a halogenated hydrocarbon group in which one or more of the hydrocarbon groups may be substituted by halogen atoms, or a halogen atom; and p is an integer from 0 to 4.
Preferably, the aromatic dihydroxy compounds expressed by formula (2) include but are not limited to bis(4-hydroxyphenyl)methane, 1,1-bis(4-hydroxyphenyl) ethane, 2,2-bis(4-hydroxyphenyl)propane (“bisphenol A”), 2,2-bis(4-hydroxyphenyl) butane, 2,2-bis(4-hydroxyphenyl)octane, bis(4-hydroxyphenyl)phenylmethane, 2,2-bis(4-hydroxy-1-methylphenyl)propane, 1,1-bis(4-hydroxy-t-butylphenyl)propane, 2,2-bis(4-hydroxy-3-bromophenyl)propane, 2,2-(4-hydroxy-3,5-dibromophenyl) propane, and other bis(hydroxyaryl)alkanes; 1,1-bis(4-hydroxyphenyl)cyclopentane, 1,1-(4-hydroxyphenyl)cyclohexane, and other bis(hydroxyaryl)cycloalkanes; 4,4′-dihydroxydiphenyl ether, 4,4′-dihydroxy-3,3′-dimethylphenyl ether, and other dihydroxyaryl ethers; 4,4′-dihydroxydiphenyl sulfide, 4,4′-dihydroxy-3,3′-dimethylphenyl sulfide, and other dihydroxydiaryl sulfides; 4,4′-dihydroxydiphenyl sulfoxide, 4,4′-dihydroxy-3,3′-dimethyldiphenyl sulfoxide, and other dihydroxydiaryl sulfoxides; and 4,4′-dihydroxydiphenyl sulfone, 4,4′-dihydroxy-3,3′-dimethyldiphenyl sulfone, and other dihydroxydiaryl sulfones. Of these, bisphenol A is particularly preferred.
The aromatic dihydroxy compounds expressed by formula (3) may also be used in addition to the aromaic dihdyroxy compounds expressed by formula (2) above. Dihydroxy compounds represented by formula (3) include but are not limited to resorcin; 3-methylresorcin, 3-ethylresorcin, 3-propylresorcin, 3-butylresorcin, 3-t-butylresorcin, 3-phenylresorcin, 3-cumylresorcin, 2,3,4,6-tetrafluororesorcin, 2,3,4,6-tetrabromoresorcin, and other substituted resorcins; catechol; hydroquinone; and substituted hydroquinones such as 3-methylhydroquinone, 3-ethylhydroquinone, 3-propylhydroquinone, 3-butylhydroquinone, 3-t-butylhydroquinone, 3-phenylhydroquinone, 3-cumylhydroquinone, 2,3,5,6-tetramethylhydroquinone, 2,3,5,6-tetra-t-butylhydroquinone, 2,3,5,6-tetrafluorohydroquinone, and 2,3,5,6-tetrabromohydroquinone.
Also useful as an aromatic dihydroxy compound is 2,2,2′,2′-tetrahydro-3,3,3′,3′-tetramethyl-1,1 ′-spirobi-[1 H-indene]-7,7′-diol expressed by formula (4).
The main chain may be comprised of a linear or branched polycarbonate. A blend of linear and branched polycarbona
Boykin Terressa M.
General Electric Company
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