Thermoplastic Compositions Containing Nanoscale-Sized Particle Additives For Laser Direct Structuring And Methods For The Manufacture And Use Thereof

Abstract

This invention relates generally to a thermoplastic compositions and, more particularly, to compositions comprising a polymer matrix and comprising a filler composition. To that end, according to the aspects of the invention, a thermoplastic composition is disclosed that generally comprises a polymer matrix and at least one filler composition. The polymer matrix generally comprises at least one polycarbonate or polyamide. The filler composition generally comprises at least one laser direct structuring additive with a mean particle size of less than 1 μm and may additionally optionally comprise flame retardants, stabilizers and process aids.

What is claimed is: 
     
         1 . A polymer composition comprising:
 a) a first polycarbonate polymer; and   b) a laser direct structuring additive,   wherein the laser direct structuring additive comprises a mean particle size of equal to or less than 1 μm.   
     
     
         2 . The polymer composition according to  claim 1 , wherein the polymer composition further comprises a polycarbonate-polysiloxane copolymer. 
     
     
         3 . The polymer composition according to any one of  claims 1 - 2 , wherein the polymer composition further comprises a second polycarbonate polymer. 
     
     
         4 . The polymer composition according to  claim 3 , wherein the second polycarbonate polymer comprises a branched polycarbonate. 
     
     
         5 . The polymer composition according to any one of  claims 1 - 4 , wherein the polymer composition further comprises a supporting material. 
     
     
         6 . The polymer composition according to  claim 5 , wherein the supporting material acts as a carrier or improves the performance of the polymer composition, or a combination thereof. 
     
     
         7 . The polymer composition according to any one of  claims 1 - 6 , wherein the polymer composition further comprises a flame retardant additive. 
     
     
         8 . The polymer composition according to  claim 7 , wherein the flame retardant additive comprises BPADP or phosphazene, or a combination thereof. 
     
     
         9 . The polymer composition according to any one of  claims 1 - 8 , wherein the polymer composition further comprises a reinforcing filler. 
     
     
         10 . The polymer composition according to  claim 9 , wherein the reinforcing filler comprises a glass fiber, a carbon fiber, or a mineral filler, or a combination thereof. 
     
     
         11 . The polymer composition according to any one of  claims 1 - 10 , wherein the polymer composition is capable of being activated by a laser. 
     
     
         12 . The polymer composition according to any one of  claims 1 - 11 , wherein the polymer composition is capable of being molded into an article. 
     
     
         13 . The polymer composition according to any one of  claims 1 - 12 , wherein the polymer composition demonstrates a flexural modulus in an amount equal to or greater than 3 GPa. 
     
     
         14 . The polymer composition according to any one of  claims 1 - 13 , wherein the polymer composition demonstrates a tensile modulus in an amount equal to or greater than 3 GPa. 
     
     
         15 . The polymer composition according to any one of  claims 1 - 14 , further comprising an impact modifier component. 
     
     
         16 . The polymer composition according to  claim 15 , wherein the impact modifier component is present in an amount from about 10 wt % to about 25 wt %. 
     
     
         17 . The polymer composition according to any of  claims 15 - 16 , wherein the impact modifier component comprises one or more of an acrylonitrile butadiene styrene (“ABS”) copolymer, a methacrylate butadiene styrene (“MBS”) copolymer, and a bulk polymerized ABS (“BABS”) copolymer. 
     
     
         18 . The polymer composition according to any of  claims 15 - 17 , wherein the impact modifier component is a bulk polymerized ABS copolymer. 
     
     
         19 . The polymer composition according to any of  claims 15 - 18 , wherein the bulk polymerized ABS copolymer is present in an amount from about 10 wt % to about 25 wt %. 
     
     
         20 . The polymer composition according to any of  claims 15 - 19 , wherein the bulk polymerized ABS copolymer has a butadiene content of from about 13 wt % to about 18 wt %. 
     
     
         21 . The polymer composition according to any of  claims 15 - 20 , wherein the impact modifier component is a methacrylate butadiene styrene copolymer. 
     
     
         22 . The polymer composition according to any of  claims 15 - 21 , wherein the impact modifier component is an acrylonitrile butadiene styrene copolymer. 
     
     
         23 . A polymer composition comprising:
 a) a polyamide polymer; and   b) a laser direct structuring additive;   wherein the laser direct structuring additive comprises a mean particle size of equal to or less than 1 μm.   
     
     
         24 . The polymer composition according to  claim 23 , wherein the polymer composition further comprises a flame retardant additive. 
     
     
         25 . The polymer composition according to  claim 24 , wherein the flame retardant additive comprises Exolit OP. 
     
     
         26 . The polymer composition according to any one of  claims 23 - 25 , wherein the polymer composition further comprises a reinforcing filler. 
     
     
         27 . The polymer composition according to  claim 26 , wherein the reinforcing filler comprises a glass fiber, a carbon fiber, or a mineral filler, or a combination thereof. 
     
     
         28 . The polymer composition according to any one of  claims 23 - 27 , wherein the polymer composition is capable of being activated by a laser. 
     
     
         29 . The polymer composition according to any one of  claims 23 - 28 , wherein the polymer composition is capable of being molded into an article. 
     
     
         30 . The polymer composition according to any one of  claims 23 - 29 , wherein the polymer composition demonstrates a flexural modulus in an amount equal to or greater than 3 GPa. 
     
     
         31 . The polymer composition according to any one of  claims 23 - 30 , wherein the polymer composition demonstrates a tensile modulus in an amount equal to or greater than 3 GPa. 
     
     
         32 . A polymer composition comprising:
 a) a thermoplastic polymer, and   b) a laser direct structuring additive,   wherein the laser direct structuring additive comprises a mean particle size of equal to or less than 1 μm.   
     
     
         33 . A method for the manufacture of a polymer composition comprising the steps of:
 a) providing a first polycarbonate polymer;   b) providing a laser direct structuring additive; and   c) combining the first polycarbonate polymer and laser direct structuring additive to form a polymer composition;   wherein the laser direct structuring additive comprises a mean particle size of equal to or less than 1 μm.   
     
     
         34 . The method according to  claim 33 , wherein the polymer composition further comprises a polycarbonate-polysiloxane copolymer. 
     
     
         35 . The method according to any one of  claims 31 - 34 , wherein the polymer composition further comprises a second polycarbonate polymer. 
     
     
         36 . The method according to  claim 35 , wherein the second polycarbonate polymer comprises a branched polycarbonate. 
     
     
         37 . The method according to any one of  claims 31 - 36 , wherein the polymer composition further comprises a supporting material. 
     
     
         38 . The method according to  claim 37 , wherein the supporting material acts as a carrier or improves the performance of the polymer composition, or a combination thereof. 
     
     
         39 . The method according to any one of  claims 31 - 38 , wherein the polymer composition further comprises a flame retardant additive. 
     
     
         40 . The method according to  claim 39 , wherein the flame retardant additive comprises BPADP or phosphazene, or a combination thereof. 
     
     
         41 . The method according to any one of  claims 31 - 40 , wherein the polymer composition is capable of being activated by a laser. 
     
     
         42 . The method according to any one of  claims 31 - 41 , wherein the polymer composition is capable of being molded into an article. 
     
     
         43 . The method according to any one of  claims 31 - 42 , wherein the polymer composition demonstrates a flexural modulus in an amount equal to or greater than 3 GPa. 
     
     
         44 . The method according to any one of  claims 31 - 43 , wherein the polymer composition demonstrates a tensile modulus in an amount equal to or greater than 3 Gpa. 
     
     
         45 . A method for the manufacture of a polymer composition comprising the steps of:
 a) providing a polymer;   b) providing a laser direct structuring additive; and   c) combining the polyamide polymer and laser direct structuring additive to form a polymer composition;   wherein the laser direct structuring additive comprises a mean particle size of equal to or less than 1 μm.   
     
     
         46 . The method according to  claim 45 , wherein the polymer is a polyamide polymer or a thermoplastic. 
     
     
         47 . The method according to  claim 45 , wherein the polymer composition further comprises a flame retardant additive. 
     
     
         48 . The method according to  claim 47 , wherein the flame retardant additive comprises Exolit OP. 
     
     
         49 . The method according to any one of  claims 45 - 48 , wherein the polymer composition is capable of being activated by a laser. 
     
     
         50 . The method according to any one of  claims 45 - 49 , wherein the polymer composition is capable of being molded into an article. 
     
     
         51 . The method according to any one of  claims 45 - 50 , wherein the polymer composition demonstrates a flexural modulus in an amount equal to or greater than 3 GPa. 
     
     
         52 . The method according to any one of  claims 45 - 51 , wherein the polymer composition demonstrates a tensile modulus in an amount equal to or greater than 3 Gpa.