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Patent Analysis of

Ionizing radiation resistant polycarbonate resin composition and article comprising the same

Updated Time 12 June 2019

Patent Registration Data

Publication Number

US10150864

Application Number

US15/195058

Application Date

28 June 2016

Publication Date

11 December 2018

Current Assignee

LOTTE ADVANCED MATERIALS CO., LTD.

Original Assignee (Applicant)

SAMSUNG SDI CO., LTD.

International Classification

C08L69/00,C08K5/00

Cooperative Classification

C08L69/00,C08K5/0041,C08L71/02,C08K5/08

Inventor

JANG, HYUN HYE,CHEI, WOO SUK,HUR, JONG CHAN,KWON, O SUNG,CHI, JUN HO

Patent Images

This patent contains figures and images illustrating the invention and its embodiment.

US10150864 Ionizing radiation resistant polycarbonate resin 1 US10150864 Ionizing radiation resistant polycarbonate resin 2 US10150864 Ionizing radiation resistant polycarbonate resin 3
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Abstract

Disclosed herein is a polycarbonate resin composition. The polycarbonate resin composition includes: a polycarbonate resin; a polyalkylene glycol compound; and an anthraquinone colorant, wherein the polycarbonate resin composition has a yellow index (YI) of about −2 to about 2, as measured in accordance with ASTM D1925 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for 7 days and has an a* value of about −2 to about 2 and a b* value of −2 to about 2 as measured in accordance with ASTM D2244 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for 7 days. The polycarbonate resin composition can exhibit excellent properties in terms of color, transparency, and impact resistance after being irradiated with ionizing radiation.

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Claims

1. A polycarbonate resin composition comprising:

a polycarbonate resin; a polyalkylene glycol compound; and an anthraquinone colorant comprising a red anthraquinone colorant and a violet anthraquinone colorant in a weight ratio of from 1:1.30 to 1:1.72, wherein the polycarbonate resin composition has a yellow index (YI) of about −2 to about 2, as measured in accordance with ASTM D1925 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for 7 days and has an a* value of about −2 to about 2 and a b* value of −2 to about 2 as measured in accordance with ASTM D2244 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for 7 days.

2. The polycarbonate resin composition according to claim 1, comprising the polyalkylene glycol compound in an amount of about 0.4 parts by weight to about 1 parts by weight based on about 100 parts by weight of the polycarbonate resin, and the anthraquinone colorant in an amount of about 0.0001 parts by weight to about 0.002 parts by weight based on about 100 parts by weight of the polycarbonate resin.

3. The polycarbonate resin composition according to claim 1, further comprising: an epoxy ester compound represent by Formula 1: wherein R1 and R3 are the same or different and are each independently a C1 to C10 hydrocarbon group; R2 and R4 are the same or different and are each independently a hydrogen atom or a C1 to C10 hydrocarbon group, wherein R1 and R2 are optionally connected to one another to form a ring and/or R3 and R4 are optionally connected to one another to form a ring; m and n are the same or different and are each independently 0 or 1; and m+n is 1 or 2.

4. The polycarbonate resin composition according to claim 3, comprising the epoxy ester compound in an amount of about 0.001 parts by weight to about 3 parts by weight based on about 100 parts by weight of the polycarbonate resin.

5. The polycarbonate resin composition according to claim 1, wherein the polycarbonate resin composition has a transmittance of about 80% or higher, as measured in accordance with ASTM D1003 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for about 7 days.

6. The polycarbonate resin composition according to claim 1, wherein the polycarbonate resin composition has an Izod impact strength of about 90 kgf cm/cm or higher, as measured in accordance with ASTM D256 after irradiating an about 3.2 mm thick Izod specimen with γ-rays at about 25 kGy and leaving the specimen for about 7 days.

7. A molded article formed of the polycarbonate resin composition according to claim 1.

8. The molded article according to claim 7, wherein the molded article is an ionizing radiation resistant medical supply article.

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Claim Tree

  • 1
    1. A polycarbonate resin composition comprising:
    • a polycarbonate resin
    • a polyalkylene glycol compound
    • and an anthraquinone colorant comprising a red anthraquinone colorant and a violet anthraquinone colorant in a weight ratio of from 1:1.30 to 1:1.72, wherein the polycarbonate resin composition has a yellow index (YI) of about −2 to about 2, as measured in accordance with ASTM D1925 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for 7 days and has an a* value of about −2 to about 2 and a b* value of −2 to about 2 as measured in accordance with ASTM D2244 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for 7 days.
    • 2. The polycarbonate resin composition according to claim 1, comprising
      • the polyalkylene glycol compound in an amount of about 0.4 parts by weight to about 1 parts by weight based on about 100 parts by weight of the polycarbonate resin, and the anthraquinone colorant in an amount of about 0.0001 parts by weight to about 0.002 parts by weight based on about 100 parts by weight of the polycarbonate resin.
    • 3. The polycarbonate resin composition according to claim 1, further comprising:
      • an epoxy ester compound represent by Formula 1: wherein R1 and R3 are the same or different and are each independently a C1 to C10 hydrocarbon group
      • R2 and R4 are the same or different and are each independently a hydrogen atom or a C1 to C10 hydrocarbon group, wherein R1 and R2 are optionally connected to one another to form a ring and/or R3 and R4 are optionally connected to one another to form a ring
      • m and n are the same or different and are each independently 0 or 1
      • and m+n is 1 or 2.
    • 5. The polycarbonate resin composition according to claim 1, wherein
      • the polycarbonate resin composition has a transmittance of about 80% or higher, as measured in accordance with ASTM D1003 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for about 7 days.
    • 6. The polycarbonate resin composition according to claim 1, wherein
      • the polycarbonate resin composition has an Izod impact strength of about 90 kgf cm/cm or higher, as measured in accordance with ASTM D256 after irradiating an about 3.2 mm thick Izod specimen with γ-rays at about 25 kGy and leaving the specimen for about 7 days.
    • 7. A molded article formed of the polycarbonate resin composition according to claim 1.
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Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 USC Section 119 to and the benefit of Korean Patent Application No. 10-2015-0093812, filed on Jun. 30, 2015, and Korean Patent Application No. 10-2016-0064374, filed on May 25, 2016, the entire disclosure of each of which is incorporated herein by reference.

FIELD

The present invention relates to an ionizing radiation resistant polycarbonate resin composition and a molded article including the same.

BACKGROUND

Polycarbonate resins have good mechanical and thermal properties and are thus used in a variety of applications. Particularly, polycarbonate resins can exhibit excellent properties in terms of transparency, hygiene, stiffness, and heat resistance and are thus widely used as a material for medical supplies such as medical devices, surgical instruments, and surgical appliances.

Such medical supplies require sterilization. Sterilization methods include contact treatment using sterilization gases such as ethylene oxide, heat treatment in an autoclave, and irradiation treatment using ionizing radiation such as γ-rays, electron beams, and X-rays.

Ethylene oxide used in contact treatment, however, is toxic and unstable and thus there can be environmental problems with the disposal thereof. Heat treatment in an autoclave can cause degradation of a resin during high temperature treatment and requires high energy costs and a drying process for removing residual moisture from treated components. Thus, irradiation treatment using ionizing radiation, which allows treatment at low temperature and is relatively economical, is generally used for sterilization.

Generally, polycarbonate resins suffer from yellowing and deterioration in physical properties when irradiated with ionizing radiation. To overcome these problems, there have been proposed a method of blending a polycarbonate resin with other polymers, a method of adding various additives to a polycarbonate resin, and a method of copolymerizing a polycarbonate resin. See for example Korean Patent Publication No. 10-2012-0077665.

However, these methods have failed to completely solve problems such as yellowing and deterioration in physical properties.

Therefore, there is a need for a polycarbonate resin composition which exhibits excellent properties in terms of color, transparency, and impact resistance after being irradiated with ionizing radiation such that liquid level or color of contents such as chemicals or blood in a molded article can be easily distinguished.

SUMMARY OF THE INVENTION

Embodiments provide a polycarbonate resin composition that can exhibit excellent properties in terms of color, transparency, and impact resistance after irradiation with ionizing radiation, and a molded article including the same.

In exemplary embodiments, the polycarbonate resin composition includes: a polycarbonate resin; a polyalkylene glycol compound; and an anthraquinone colorant, wherein the polycarbonate resin composition has a yellow index (YI) of about −2 to about 2, as measured in accordance with ASTM D1925 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for 7 days and has an a* value of about −2 to about 2 and a b* value of −2 to about 2 as measured in accordance with ASTM D2244 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for 7 days.

In exemplary embodiments, the polyalkylene glycol compound may be present in an amount of about 0.4 parts by weight to about 1 parts by weight based on about 100 parts by weight of the polycarbonate resin, and the anthraquinone colorant may be present in an amount of about 0.0001 parts by weight to about 0.002 parts by weight based on about 100 parts by weight of the polycarbonate resin.

In exemplary embodiments, the anthraquinone colorant may include a red anthraquinone colorant and a violet anthraquinone colorant in a weight ratio of about 1:about 1 to about 1:about 2.

In exemplary embodiments, the polycarbonate resin composition may further include an epoxy ester compound represent by Formula 1:

wherein R1 and R3 are the same or different and are each independently a C1 to C10 hydrocarbon group; R2 and R4 are the same or different and are each independently a hydrogen atom or a C1 to C10 hydrocarbon group, wherein R1 and R2 are optionally connected to one another to form a ring (that is, R1 and R2 may or may not be connected to one another to form a ring) and/or wherein R3 and R4 are optionally connected to one another to form a ring (that is, R3 and R4 may or may not be connected to one another to form a ring); m and n are the same or different and are each independently 0 or 1; and m+n is 1 or 2.

In exemplary embodiments, the epoxy ester compound may be present in an amount of about 0.001 parts by weight to about 3 parts by weight based on about 100 parts by weight of the polycarbonate resin.

In exemplary embodiments, the polycarbonate resin composition may have a transmittance of about 80% or higher, as measured in accordance with ASTM D1003 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for about 7 days.

In exemplary embodiments, the polycarbonate resin composition may have an Izod impact strength of about 90 kgf·cm/cm or higher, as measured in accordance with ASTM D256 after irradiating an about 3.2 mm thick Izod specimen with γ-rays at about 25 kGy and leaving the specimen for about 7 days.

Other embodiments relate to a molded article formed of the polycarbonate resin composition as set forth above.

In exemplary embodiments, the molded article may be an ionizing radiation resistant medical supply article.

DETAILED DESCRIPTION

Exemplary embodiments now will be described more fully hereinafter in the following detailed description, in which some, but not all embodiments of the invention are described. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

A polycarbonate resin composition according to the present invention can have ionizing radiation resistance and includes: a polycarbonate resin; a polyalkylene glycol compound; and an anthraquinone colorant, wherein the polycarbonate resin composition has a yellow index (YI) of about −2 to about 2, as measured in accordance with ASTM D1925 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for 7 days and has an a* value of about −2 to about 2 and a b* value of −2 to about 2 as measured in accordance with ASTM D2244 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for 7 days.

The polycarbonate resin may include any suitable polycarbonate resin such as an aromatic polycarbonate resin used in a typical polycarbonate resin composition. The polycarbonate resin may be prepared by a typical method, for example, by reacting a dihydric phenol compound with phosgene in the presence of a molecular weight regulator and a catalyst, or through transesterification of a dihydric phenol compound and a carbonate precursor such as diphenyl carbonate.

In preparation of the polycarbonate resin, the dihydric phenol compound may be a bisphenol compound, for example, 2,2-bis(4-hydroxyphenyl)propane (hereinafter, “bisphenol A”). Here, the bisphenol A may be partially or completely replaced by one or more other dihydric phenol compounds. Examples of other dihydric phenol compounds may include without limitation hydroquinone, 4,4′-biphenol, bis(4-hydroxyphenyl)methane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 2,2-bis(3,5-dimethyl-4-hydroxyphenyl)propane, 2,2-bis(3-methyl-4-hydroxyphenyl)propane, bis(4-hydroxyphenyl)sulfide, bis(4-hydroxyphenyl)sulfone, bis(4-hydroxyphenyl)sulfoxide, bis(4-hydroxyphenyl)ketone, halogenated bisphenol, such as bis(4-hydroxyphenyl)ether or 2,2-bis(3,5-dibromo-4-hydroxyphenyl)propane, and the like, and mixtures thereof. However, the dihydric phenol compound that can be used for preparation of the polycarbonate resin is not limited thereto, and the polycarbonate resin may be prepared using any suitable dihydric phenol compound.

In addition, the polycarbonate resin may be a homopolymer using one dihydric phenol compound, a copolymer using at least two dihydric phenol compounds, or a mixture thereof.

Generally, a polycarbonate resin may be a linear polycarbonate resin, a branched polycarbonate resin, and/or a polyester carbonate copolymer resin. The polycarbonate resin included in the polycarbonate resin composition is not particularly limited and may include such linear polycarbonate resins, branched polycarbonate resins, and/or polyester carbonate copolymer resins.

For example, the linear polycarbonate resin may be a bisphenol A polycarbonate resin, and the branched polycarbonate resin may be prepared by, for example, reacting a polyfunctional aromatic compound such as trimellitic anhydride or trimellitic acid with a dihydric phenol compound and a carbonate precursor. The polyester carbonate copolymer resin may be prepared by, for example, reacting a bifunctional carboxylic acid with a dihydric phenol and a carbonate precursor. In addition, the polycarbonate resin may include typical linear polycarbonate resins, branched polycarbonate resins, and/or polyester carbonate copolymer resins without limitation.

In exemplary embodiments, the polycarbonate resin may include a terminal modified polycarbonate resin having a tert-butylphenoxy group at a terminal thereof. The terminal modified polycarbonate resin may be prepared by a typical method for preparing a polycarbonate resin except that tert-butylphenol is added during the preparation of a polycarbonate resin. When the terminal modified polycarbonate resin is included in the composition, the tert-butylphenoxy group may be present in an amount of about 0.1 mole % to about 80 mole %, for example, about 20 mole % to about 60 mole %, in the polycarbonate resin. Within this range, the polycarbonate resin composition can exhibit further enhanced properties in terms of ionizing radiation resistance, impact resistance, and the like.

In exemplary embodiments, the polycarbonate resin may have a weight average molecular weight (Mw) of about 10,000 g/mol to about 200,000 g/mol, for example, about 15,000 g/mol to about 80,000 g/mol, as measured by gel permeation chromatography (GPC), without being limited thereto.

In addition, the polycarbonate resin may have a melt flow index (MI) of about 3 g/10 min to about 35 g/10 min, as measured in accordance with ISO 1133 (at about 300° C. under a load of about 1.2 kg), without being limited thereto.

The polyalkylene glycol compound may include polyalkylene glycol, ethers of polyalkylene glycol, and/or esters of polyalkylene glycol. The polyalkylene glycol compound may include any polyols used in a typical ionizing radiation resistant composition. Examples of the polyols may include polyethylene glycol, polyethylene glycol methyl ether, polyethylene glycol dimethyl ether, polyethylene glycol dodecyl ether, polyethylene glycol benzyl ether, polyethylene glycol dibenzyl ether, polyethylene glycol-4-nonylphenyl ether, polypropylene glycol, polypropylene glycol methyl ether, polypropylene glycol dimethyl ether, polypropylene glycol dodecyl ether, polypropylene glycol benzyl ether, polypropylene glycol dibenzyl ether, polypropylene glycol-4-nonylphenyl ether, polytetramethylene glycol, polyethylene glycol diacetate ester, polyethylene glycol acetate propionate ester, polyethylene glycol dibutyrate ester, polyethylene glycol distearate ester, polyethylene glycol dibenzoate ester, polyethylene glycol di-2,6-dimethyl benzoate ester, polyethylene glycol di-p-tert-butyl benzoate ester, polyethylene glycol dicaprylate ester, polypropylene glycol diacetate ester, polypropylene glycol acetate propionate ester, polypropylene glycol dibutyrate ester, polypropylene glycol distearate ester, polypropylene glycol dibenzoate ester, polypropylene glycol di-2,6-dimethyl benzoate ester, polypropylene glycol di-p-tert-butyl benzoate ester, polypropylene glycol dicaprylate ester, and the like, without being limited thereto. These may be used alone or as a mixture thereof.

In exemplary embodiments, the polyalkylene glycol compound may have a number average molecular weight (Mn) of about 1,000 g/mol to about 5,000 g/mol, for example, about 1,500 g/mol to about 3,000 g/mol, as measured by gel permeation chromatography (GPC). Within this range, the polycarbonate resin composition can exhibit excellent properties in terms of impact resistance, discoloration resistance, and the like after being irradiated with ionizing radiation.

In exemplary embodiments, the polycarbonate resin composition can include the polyalkylene glycol compound in an amount of about 0.4 parts by weight to about 1 part by weight, for example, about 0.5 parts by weight to about 0.95 parts by weight, based on about 100 parts by weight of the polycarbonate resin. In some embodiments, the polycarbonate resin composition can include the polyalkylene glycol compound in an amount of about 0.4, 0.45, 0.5, 0.55, 0.6, 0.65, 0.7, 0.75, 0.8, 0.85, 0.9, 0.95, or 1 part by weight. Further, according to some embodiments, the amount of the polyalkylene glycol compound can be in a range from about any of the foregoing amounts to about any other of the foregoing amounts.

Within this range, the polycarbonate resin composition can exhibit excellent properties in terms of impact resistance, discoloration resistance, and the like after being irradiated with ionizing radiation.

The anthraquinone colorant allows the polycarbonate resin composition (or a molded article including the resin composition) to be nearly colorless after being irradiated with ionizing radiation and thus can reduce deterioration in transparency.

In exemplary embodiments, the anthraquinone colorant may include a red anthraquinone colorant and a violet anthraquinone colorant in a weight ratio of about 1:about 1 to about 1:about 2, for example, about 1:about 1.3 to about 1:about 1.7. Within this range of weight ratio, the polycarbonate resin composition can exhibit excellent properties in terms of color, transparency, and the like after being irradiated with ionizing radiation.

Examples of the red anthraquinone colorant may include without limitation solvent red 195 of the following structure below

pigment red 177 of the following structure below

1-(methylamino)anthraquinone, and the like, and mixtures thereof.

Examples of the violet anthraquinone colorant may include without limitation disperse violet 26 of the following structure below

acid violet 34 of the following structure below

a compound of the following structure below

wherein each R is the same or different and each is independently a hydrogen atom, a methyl group, a tert-butyl group, or an isooctyl group, and each R′ is the same or different and each is independently a hydrogen atom or —SO3Na,

and the like, and mixtures thereof.

In exemplary embodiments, the polycarbonate resin composition can include the anthraquinone colorant in an amount of about 0.0001 parts by weight to about 0.002 parts by weight, for example, about 0.0005 parts by weight to about 0.0015 parts by weight, and as another example about 0.0007 parts by weight to about 0.0011 parts by weight, based on about 100 parts by weight of the polycarbonate resin. In some embodiments, the polycarbonate resin composition can include the anthraquinone colorant in an amount of about 0.0001, 0.0002, 0.0003, 0.0004, 0.0005, 0.0006, 0.0007, 0.0008, 0.0009, 0.001, or 0.002 parts by weight. Further, according to some embodiments, the amount of the anthraquinone colorant can be in a range from about any of the foregoing amounts to about any other of the foregoing amounts.

Within this range, the polycarbonate resin composition can exhibit excellent properties in terms of color, transparency, and the like after being irradiated with ionizing radiation.

The polycarbonate resin composition according to exemplary embodiments of the present invention may further include an epoxy ester compound including an ester group and an epoxy group.

In exemplary embodiments, the epoxy ester compound can improve ionizing radiation resistance with minimal or no deterioration in hydrolysis resistance and may include, for example, a compound represented by the following Formula 1:

wherein in Formula 1, R1 and R3 are the same or different and are each independently a C1 to C10 hydrocarbon group; R2 and R4 are the same or different and are each independently a hydrogen atom or a C1 to C10 hydrocarbon group; R1 and R2 are optionally connected to one another to form a ring (that is, R1 and R2 may or may not be connected to one another to form a ring) and/or R3 and R4 are optionally connected to one another to form a ring (that is, R3 and R4 may or may not be connected to one another to form a ring); m and n are the same or different and are each independently 0 or 1; and m+n is 1 or 2.

As used herein, the term C1 to C10 hydrocarbon group refers to substituted or unsubstituted C1 to C10 alkyl group, C3 to C10 cycloalkyl group, C5 to C10 aryl group, C1 to C10 alkylene group, C3 to C10 cycloalkylene group, and/or C5 to C10 arylene group. Also as used herein, the term “substituted” refers to one or more hydrogen atoms substituted with a substituent such as a halogen group, a C1 to C30 alkyl group, a C1 to C30 haloalkyl group, a C6 to C30 aryl group, a C2 to C30 heteroaryl group, a C1 to C20 alkoxy group, or a combination thereof, and the term “hetero” refers to one or more of N, S, O and/or P atoms in place of a hydrogen atom.

Examples of the epoxy ester compound including an ester group and an epoxy group may include one or more compounds represented by Formulas 1a to 1c, without being limited thereto:

In exemplary embodiments, when present, the polycarbonate resin composition can include the epoxy ester compound including an ester group and an epoxy group in an amount of about 0.001 parts by weight to about 3 parts by weight, for example, about 0.01 parts by weight to about 2 parts by weight, based on about 100 parts by weight of the polycarbonate resin. In some embodiments, the polycarbonate resin composition can include the epoxy ester compound in an amount of about 0.001, 0.002, 0.003, 0.004, 0.005, 0.006, 0.007, 0.008, 0.009, 0.01, 0.02, 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, or 3 parts by weight. Further, according to some embodiments, the amount of the epoxy ester compound can be in a range from about any of the foregoing amounts to about any other of the foregoing amounts.

Within this range, the polycarbonate resin composition can exhibit excellent properties in terms of discoloration resistance with minimal or no deterioration in hydrolysis resistance and thermal stability after being irradiated with ionizing radiation.

The polycarbonate resin composition according to one embodiment may further include one or more other resins without altering advantageous effects of the present invention. For example, the polycarbonate resin composition may further include polyethylene terephthalate, polybutylene terephthalate, and/or polyester polycarbonate, without being limited thereto.

When other resins are used, such other resins may be present in an amount of about 50 parts by weight or less, for example, about 1 part by weight to about 15 parts by weight, based on about 100 parts by weight of the polycarbonate resin, without being limited thereto. In some embodiments, the polycarbonate resin composition can include the other resin in an amount of about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50 parts by weight. Further, according to some embodiments, the amount of the other resin can be in a range from about any of the foregoing amounts to about any other of the foregoing amounts.

In addition, the polycarbonate resin composition may further optionally include one or more of any suitable additives generally used in a resin composition. Examples of the additives may include fillers, reinforcing agents, stabilizers, colorants, antioxidants, antistatic agents, flow enhancers, release agents, and/or nucleating agents, without being limited thereto. When the additives are used, the additives may be present in an amount of about 25 parts by weight or less, for example, about 10 parts by weight or less, based on about 100 parts by weight of the polycarbonate resin, without being limited thereto.

The polycarbonate resin composition may be prepared by any known method for preparing a thermoplastic resin composition. For example, the polycarbonate resin composition may be prepared in pellet form by mixing the above components and optionally other additives by a typical method, followed by melt extrusion using a twin screw extruder or the like. The prepared pellets may be formed into various molded articles through various molding methods, such as injection molding, extrusion molding, vacuum molding, cast molding, and the like.

The polycarbonate resin composition may have a yellow index (YI) of about −2 to about 2, for example, about −1 to about 1, and as another example about 0, as measured in accordance with ASTM D1925 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for 7 days. The polycarbonate resin composition may have an a* value of about −2 to about 2, for example, about −1 to about 1, and as another example about 0 and a b* value of −2 to about 2, for example, about −1 to about 1, and as another example about 0, as measured in accordance with ASTM D2244 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for 7 days. If the yellow index (YI) and the a* and b* values exceed about 2 or are below about −2, this can make it difficult to distinguish liquid level or color of contents such as chemicals and blood in a molded article produced using the polycarbonate resin composition while causing the molded article to exhibit poor appearance characteristics.

In exemplary embodiments, the polycarbonate resin composition may have a transmittance of about 80% or higher, for example, about 80% to about 95%, as measured in accordance with ASTM D1003 after irradiating an about 3.2 mm thick specimen with γ-rays at about 25 kGy and leaving the specimen for about 7 days. Within this range of transmittance, liquid level or color of contents such as chemicals and blood in the molded article can be easily distinguished.

In exemplary embodiments, the polycarbonate resin composition may have a notched Izod impact strength of about 90 kgf·cm/cm or higher, for example, about 95 kgf·cm/cm to about 110 kgf·cm/cm, as measured in accordance with ASTM D256 after irradiating an about 3.2 mm thick Izod specimen with γ-rays at about 25 kGy and leaving the specimen for about 7 days.

A molded article according to the present invention may be produced (formed) from the ionizing radiation resistant polycarbonate resin composition as set forth above by any known molding method. The molded article can have excellent properties in terms of color, transparency, impact resistance, and the like after being irradiated with ionizing radiation and thus may be used in ionizing radiation resistant medical supplies including without limitation: container shaped packaging means for receiving or packaging syringes, surgical instruments, intravenous injectors, and surgical appliances; components of medical apparatuses, such as artificial lungs, artificial kidneys, anesthesia inhalers, intravenous connectors, hemodialyzers, hemofilters, safety syringes, and accessories thereof; and components of blood centrifuges, surgical instruments, surgical appliances, and intravenous injectors.

Next, the present invention will be described in more detail with reference to the following examples. It should be understood that these examples are provided for illustration only and are not to be in any way construed as limiting the present invention.

In addition, descriptions of details apparent to those skilled in the art will be omitted for clarity.

EXAMPLE

Details of each component used in the following Examples and Comparative Examples are as follows:

(A) Polycarbonate Resin

A bisphenol A-type polycarbonate resin (weight average molecular weight (Mw): 28,000 g/mol, melt flow index (MI): 8 g/10 min (at 300° C. under a load of 1.2 kg)) is used.

(B) Polyalkylene Glycol Compound

Polypropylene glycol (number average molecular weight (Mn): 2,000 g/mol) is used.

(C) Anthraquinone Colorant

(C1) A red anthraquinone colorant, solvent red 195 having the structure below, is used.

(C2) A violet anthraquinone colorant, disperse violet 26 having the structure below, is used.

(D) Colorant

(D1) Solvent Red 179 having the structure below available from Lanxess Corporation is used.

(D2) Pigment violet 29 having the structure below available from BASF SE is used.

(E) Epoxy Ester Compound

A compound represented by Formula 1a is used

Examples 1 to 6 and Comparative Examples 1 to 5: Preparation and Evaluation of Polycarbonate Resin Composition

According to compositions and amounts as listed in Tables 1 and 2, (A) a polycarbonate resin, (B) a polyalkylene glycol compound, (C) an anthraquinone colorant, (D) a colorant, and (E) an epoxy ester compound are mixed, followed by extrusion molding using a twin-screw type extruder (L/D=36, Φ=32 mm) at 260° C. and preparation of a polycarbonate resin composition in pellet form using a pelletizer. The polycarbonate resin composition prepared in pellet form is dried in an oven at 120° C. for 4 hours, followed by injection molding using an injection molding machine (DHC 120WD, Dongshin Hydraulics Co., Ltd.) under conditions of a molding temperature of 270° C. and a mold temperature of 70° C., thereby preparing a specimen. The prepared specimen is evaluated as to the following properties, and results are shown in Tables 1 and 2.

Property Evaluation

(1) Yellow index (YI) and a* and b* after irradiation with γ-rays: Yellow index and a* and b* values are measured on a 3.2 mm thick specimen in accordance with ASTM D1925 and ASTM D2244, respectively, after irradiating the specimen with γ-rays at 25 kGy and leaving the specimen for 7 days.

(2) Transmittance after irradiation with γ-rays (unit: %): Transmittance (total luminous transmittance) is measured on a 3.2 mm thick specimen in accordance with ASTM D1003 after irradiating the specimen with γ-rays at 25 kGy and leaving the specimen for 7 days.

(3) Notched Izod impact strength after irradiation with γ-rays (unit: kgf·cm/cm): Izod impact strength is measured on a 3.2 mm thick Izod specimen in accordance with ASTM D256 after irradiating the specimen with γ-rays at 25 kGy and leaving the specimen for 7 days.


TABLE 1
Example
1
2
3
4
5
6
(A) (parts by weight)
100
100
100
100
100
100
(B) (parts by weight)
0.75
0.75
0.75
0.75
0.75
0.75
(C) (parts by
(C1)
0.00039
0.00035
0.00033
0.00028
0.00044
0.00039
weight)
(C2)
0.00051
0.00055
0.00057
0.00042
0.00066
0.00051
(D) (parts by
(D1)
weight)
(D2)
(E) (parts by weight)
0.04
a* after irradiation with γ-rays
−0.8
−0.8
−0.8
−0.6
−0.9
−0.5
b* after irradiation with γ-rays
0.9
0.9
0.9
0.7
1.0
0.3
YI after irradiation with γ-rays
0.6
0.6
0.6
0.5
0.7
−0.1
Transmittance after irradiation
80
80
80
81
80
84
with γ-rays (%)
Izod impact strength after
98
98
98
99
98
99
irradiation with γ-rays
(kgf · cm/cm)


TABLE 2
Comparative Example
1
2
3
4
5
(A) (parts by weight)
100
100
100
100
100
(B) (parts by weight)
0.75
0.75
0.75
0.75
0.75
(C) (parts by weight)
(C1)
0.00035
(C2)
0.00055
(D) (parts by
(D1)
0.00039
0.00035
0.00035
weight)
(D2)
0.00051
0.00055
0.00055
(E) (parts by weight)
a* after irradiation with γ-rays
−8.0
−6.1
−5.8
−3.5
−6.4
b* after irradiation with γ-rays
22.8
15.8
15.3
−1.9
23.0
YI after irradiation with γ-rays
31.1
23.5
21.3
4.3
26.0
Transmittance after irradiation
84
65
68
75
70
with γ-rays (%)
Izod impact strength after
99
99
99
99
98
irradiation with γ-rays
(kgf · cm/cm)

From Tables 1 and 2, it can be seen that the polycarbonate resin compositions according to the present invention (Examples 1 to 6) are nearly colorless and exhibit excellent properties in terms of transparency and impact resistance after being irradiated with ionizing radiation.

Conversely, it can be seen that the polycarbonate resin composition of Comparative Example 1 not including any colorant has poor properties in terms of color (YI, a*, and b*) and ionizing radiation resistance (discoloration resistance) after being irradiated with ionizing radiation, the polycarbonate resin compositions of Comparative Examples 2 and 3 including a typical colorant (D) instead of the anthraquinone colorant (C) according to the present invention have considerably low transparency (transmittance) and exhibit relatively poor properties in terms of color and ionizing radiation resistance (discoloration resistance) after being irradiated with ionizing radiation, as compared with those of Examples, and the polycarbonate resin compositions of Comparative Examples 4 to and 5 including both the anthraquinone colorant (C) and a typical colorant (D) exhibit relatively poor properties in terms of color, ionizing radiation resistance (discoloration resistance), and transparency after being irradiated with ionizing radiation, as compared with those of Examples.

Although some embodiments have been described herein, it should be understood that these embodiments are provided for illustration only and are not to be construed in any way as limiting the present invention, and that various modifications, changes, alterations, and equivalent embodiments can be made by those skilled in the art without departing from the spirit and scope of the invention. Therefore, the scope of the present invention should be defined by the appended claims and equivalents thereof.

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Citation

Patents Cited in This Cited by
Title Current Assignee Application Date Publication Date
Polycarbonate resin composition stabilized against radiation MITSUBISHI ENGINEERING-PLASTICS CORPORATION 06 March 1997 10 September 1997
Use of ring-aromatic sulphonic acid esters to stabilise thermoplastic polycarbonates against gamma radiation BAYER AG 18 September 1992 07 April 1993
Polycarbonate compositions resistant to gamma radiation BAYER AG 04 March 1996 18 September 1996
Polycarbonates stabilized against radiation BAYER AG 11 January 1995 26 July 1995
Ionizing radiation stable thermoplastic composition, method of making, and articles formed therefrom SABIC INNOVATIVE PLASTICS IP B.V. 19 October 2006 28 July 2010
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US10150864 Ionizing radiation resistant polycarbonate resin 1 US10150864 Ionizing radiation resistant polycarbonate resin 2 US10150864 Ionizing radiation resistant polycarbonate resin 3