Process for improving carbon black dispersion

Abstract

A masterbatch comprising pigment and demolding agent is provided. The demolding agent is selected from the group comprising low molecular weight polyolefin oils, low molecular weight polyolefin waxes, montan waxes and aliphatic or aromatic carboxylic acid esters of fatty acids and/or fatty alcohols, wherein the pigment content of the masterbatch is from 3 to 70 wt. %, based on the total weight of the masterbatch. The masterbatch is suitable for preparation of a polymer composition having improved pigment dispersion.

The invention claimed is: 
     
       1. An injection molded article produced by a process comprising preparing injection molding a coloured polymer composition by melt-mixing,  wherein the coloured polymer composition comprises a melt-mixed coloured polycarbonate composition, comprising:
 a) from 40 to 99.96 wt. % of at least one thermoplastic polymer (a), wherein polymer (a) is at least one selected from the group consisting of aromatic polycarbonates and aromatic polyester carbonates, wherein the polymer (a) has a weight average molecular weight of 15,000 to 80,000 g/mol, and wherein the polymer (a) is a homopolycarbonate or copolycarbonate containing bisphenol A; 
 b) from 0.1 to 3 wt. % of at least one pigment component (b); 
 c) from 0.1 to 3 wt. % of at least one demoulding agent (c) selected from the group consisting of pentaerythritol tetrastearate, glycerol monostearate, and stearyl stearate; 
 d) from 0 to 60 wt. % of one or more thermoplastic polyesters (d); 
 e) from 0 to 40 wt. % of one or more elastomers (e) other than component f; 
 f) from 0 to 40 wt. % of one or more optionally rubber-modified vinyl (co)polymers (f); and 
 g) from 0 to 10 wt. % one or more further additives;  
 the process comprising using a masterbatch, wherein the melt-mixed coloured polycarbonate composition comprises a masterbatch consists consisting of the at least one pigment (b) and the at least one demoulding agent (c) in compounding prepared using a shear and mixing unit in a single-shaft extruder, a multi-shaft extruder, an internal mixer, a co-kneader, or a shear roller device, 
 wherein the demoulding agent is at least one selected from the group consisting of pentaerythritol tetrastearate, glycerol monostearate and stearyl stearate, 
 wherein the at least one pigment is (b) comprises a carbon-based pigment and the content of pigment in the masterbatch is from 40 to 60 wt. %, based on the total weight of the masterbatch, 
 wherein the carbon-based pigment is selected from the group consisting of: a) carbon black; b) graphite; c) fullerene; d) graphene; e) activated charcoal; and f) carbon nanotubes, and  
 wherein the process additionally comprises preparing the masterbatch by using a shear and mixing unit in a single-shaft extruder, multi-shaft extruder, internal mixer, co-kneader or a shear roller device, 
 wherein the pigment is homogeneously distributed and present in finely dispersed form in the polymer composition, 
 wherein the produced coloured polymer composition is a polycarbonate composition comprising 
 a) from 40 to 99.96 wt. % of at least one thermoplastic polymer (a), wherein polymer (a) is at least one selected from the group consisting of aromatic polycarbonates and aromatic polyester carbonates, wherein the polymer has a weight average molecular weight of 15,000 to 80,000 g/mol and is a homopolycarbonate or copolycarbonate containing bisphenol A 
 b) from 0.1 to 3 wt. % of at least one pigment component (b), 
 c) from 0.1 to 3 wt. % of at least one demoulding agent (c) selected from the group consisting of pentaerythritol tetrastearate, glycerol monostearate and stearyl stearate, 
 d) from 0 to 60 wt. % of one or more thermoplastic polyesters (d), 
 e) from 0 to 40 wt. % of one or more elastomers (e) other than component f, 
 f) from 0 to 40 wt. % of one or more optionally rubber-modified vinyl (co)polymers (f), and 
 g) from 0 to 10 wt. % one or more further additives. 
 
     
     
       2. An injection molded article according to  claim 1 , wherein the pigment is carbon black. 
     
     
       3. An injection molded article according to  claim 1 , wherein the masterbatch is prepared by a process comprises comprising:
 a) metering said demoulding agent and said pigment into said shear and mixing unit, 
 b) melt-mixing the pigment in the demoulding agent and thereby dispersing the pigment in the demoulding agent to form a melt mixture, 
 c) optionally filtering the melt mixture, 
 d) forming melt strands, 
 e) cooling and granulating the melt strands, and 
 f) when using underwater or water-ring granulation in step e), drying granules. 
 
     
     
       4. The injection molded article according to  claim 3 , wherein the granulating is carried out by underwater granulation or hot-face water-ring granulation. 
     
     
       5. An injection molded article according to  claim 1  wherein said pigment is not in powder form. 
     
     
       6. An injection molded article according to  claim 1  wherein said pigment is in the form of a pigment concentrate. 
     
     
       7. An injection molded article according to  claim 1 , wherein said masterbatch comprises a concentrate of carbon black in said demoulding agent and said demoulding agent is pentaerythritol tetrastearate. 
     
     
       8. The injection molded article according to  claim 1 , wherein the coloured polymer composition is a polycarbonate composition comprising comprises: 
 a) from 50 to 75 wt. % of at least one thermoplastic polymer (a), 
 b) from 0.1 to 1.5 wt. % of at least one pigment component (b), 
 c) from 0.1 to 1.5 wt. % of at least one demoulding agent (c), 
 d) from 20 to 60 wt. % of one or more thermoplastic polyesters (d), 
 e) from 2 to 20 wt. % of one or more elastomers (e) other than component f, 
 f) from 3 to 40 wt. % of one or more optionally rubber-modified vinyl (co)polymers (f), and 
 g) from 0.2 to 10 wt. % one or more further additives. 
 
     
     
       9. The injection molded article according to  claim 8 , wherein the demoulding agent is pentaerythritol tetrastearate. 
     
     
       10. An injection molded article according to  claim 1 , wherein the demoulding agent is pentaerythitol tetrastearate. 
     
     
       11. An injection molded article according to  claim 1 , wherein the masterbatch is used in the form of comprises granules or pellets of 1 to 5 mm in length. 
     
     
       12. An injection molded article according to  claim 1 , wherein the masterbatch is used in the form of comprises powder having a diameter of 0.1 to 0.5 mm. 
     
     
       13. An injection molded article according to  claim 1 , wherein the pigment is used in the preparation of the coloured polymer composition is provided solely in the form of the masterbatch consisting of pigment and demoulding agent.