Reinforced flame retardant polycarbonate composition and molded article comprising same

Patent metadata

Field	Value
Publication number	US-10030139-B2
Application number	US-201715651950-A
Country	US
Kind code	B2
Filing date	Jul 17, 2017
Priority date	Nov 1, 2013
Publication date	Jul 24, 2018
Grant date	Jul 24, 2018

Abstract

A polymer composition includes: about 20 wt % to about 80 wt % of a polycarbonate polymer; about 1 wt % to about 20 wt % of a polycarbonate-siloxane copolymer; about 15 wt % to about 35 wt % of a reinforcing filler having a tensile modulus of at least about 150 GPa; and about 4 wt % to about 20 wt % of a flame retardant comprising phosphorous. The polymer composition demonstrates a flexural modulus in an amount equal to or greater than about 10 GPa. Methods of forming a polymer composition and blended thermoplastic compositions are also described.

First claim

We claim:

1. A polymer composition comprising:
a polycarbonate polymer present in an amount of about 20 weight % to about 80 weight % relative to the total weight of the polymer composition;
a polycarbonate-siloxane copolymer present in an amount of about 1 weight % to about 20 weight % relative to the total weight of the polymer composition;
a reinforcing filler having a tensile modulus of at least about 150 GPa, the reinforcing filler present in an amount of about 15 weight % to about 35 weight % relative to the total weight of the polymer composition; and
a flame retardant present in an amount of about 4 weight % to about 20 weight % relative to the total weight of the polymer composition, wherein the flame retardant comprises phosphorus,

wherein the polymer composition demonstrates a flexural modulus in an amount equal to or greater than about 10 GPa.

2. The polymer composition of claim 1 , wherein the polycarbonate polymer comprises an aromatic polycarbonate, a polycarbonate-sebacic acid copolymer, or a branched polycarbonate, or a combination thereof, in an amount of about 5 weight % to about 30 weight % relative to the total weight of the polymer composition.

3. The polymer composition of claim 1 , wherein the reinforcing filler comprises a chopped carbon fiber, a long carbon fiber, a ceramic fiber, or a combination thereof; and, optionally, glass fiber.

4. The polymer composition of claim 1 , wherein the flame retardant comprises phosphazene, aryl phosphate, bisphenol A disphosphate, resorcinol bis-diphenylphosphate, bisphenol A diphenyl phosphate, or resorcinol diphosphate, or a combination thereof.

5. The polymer composition of claim 1 , further comprising talc present in an amount of about 0.1 weight % to about 5 weight % relative to the total weight of the polymer composition.

6. The polymer composition of claim 1 , wherein the polymer composition demonstrates a flexural modulus in an amount equal to or greater than about 14 GPa.

7. The polymer composition of claim 1 , having a notched Izod impact strength of greater than or equal to 60 J/m.

8. The polymer composition of claim 1 , being capable of achieving UL94 V0 rating at a thickness of about 0.8 mm to about 1.0 mm.

9. The polymer composition of claim 1 , wherein the polymer composition demonstrates a higher flexural modulus than a substantially similar reference polymer composition in the absence of the flame retardant comprising phosphorous.

10. The polymer composition of claim 1 , wherein the polymer composition demonstrates a higher flexural strength than a substantially similar reference polymer composition in the absence of the flame retardant comprising phosphorous.

11. A method comprising:
forming a polymer composition, wherein the polymer composition comprises:
a polycarbonate polymer present in an amount of about 20 weight % to about 80 weight % relative to the total weight of the polymer composition;
a polycarbonate-siloxane copolymer present in an amount of about 1 weight % to about 20 weight % relative to the total weight of the polymer composition;
a reinforcing filler having a tensile modulus of at least about 150 GPa, the reinforcing filler present in an amount of about 15 weight % to about 35 weight % relative to the total weight of the polymer composition; and
a flame retardant present in an amount of about 4 weight % to about 20 weight % relative to the total weight of the polymer composition, wherein the flame retardant comprises phosphorus,

wherein the polymer composition demonstrates a flexural modulus in an amount equal to or greater than about 10 GPa.

12. The method of claim 11 , wherein the polycarbonate polymer comprises an aromatic polycarbonate, a polycarbonate-sebacic acid copolymer, or a branched polycarbonate, or a combination thereof, in an amount of about 5 weight % to about 30 weight % relative to the total weight of the polymer composition.

13. The method of claim 11 , wherein the reinforcing filler comprises a chopped carbon fiber, a long carbon fiber, a ceramic fiber, or a combination thereof; and, optionally, glass fiber.

14. The method of claim 11 , wherein the flame retardant comprises phosphazene, aryl phosphate, bisphenol A disphosphate, resorcinol bis-diphenylphosphate, bisphenol A diphenyl phosphate, or resorcinol diphosphate, or a combination thereof.

15. A blended thermoplastic composition comprising:
about 30 wt % to about 75 wt % of a polycarbonate component;
greater than 0 wt % to about 10 wt % of an impact modifier component;
about 15 wt % to about 40 wt % of a filler component having a tensile modulus of at least about 150 GPa;
about 5 wt % to about 20 wt % of a flame retardant component; and
about 0.5 wt % to about 10 wt % of a surface enhancer component;

wherein the blended thermoplastic composition demonstrates a flexural modulus in an amount equal to or greater than about 10 GPa.

16. The blended thermoplastic composition of claim 15 , comprising: about 30 wt % to about 75 wt % of a polycarbonate component; greater than 0 wt % to about 10 wt % of an impact modifier component; about 15 wt % to about 40 wt % of a filler component; about 5 wt % to about 20 wt % of a flame retardant component; and about 0.5 wt % to about 10 wt % of a surface enhancer component.

17. The blended thermoplastic composition of claim 15 , wherein the blended thermoplastic composition has a notched Izod impact strength greater than or equal to about 60 J/m when tested in accordance with ASTM D256.

18. The blended thermoplastic composition of claim 15 , wherein a molded sample comprising the blended thermoplastic composition is capable of achieving UL94 V0 rating at a thickness of 1.0 mm (±10%).

19. The blended thermoplastic composition of claim 15 , wherein a molded sample comprising the blended thermoplastic composition is capable of achieving UL94 V0 rating at a thickness of 1.5 mm (±10%).

20. The blended thermoplastic composition of claim 15 , wherein a molded sample comprising the blended thermoplastic composition has a flexural modulus greater than or equal to about 10 GPa when tested in accordance with ASTM D790 and having a melt flow rate (MFR) of greater than or equal to about 8 g/10 min when tested in accordance with ASTM D1238 at 260° C. under a load of 2.16 kg.

Assignees

• Sabic Global Technologies Bv

Inventors

• Atkinson Paul Michael
• Sun Xiaoyu
• Li Ying
• Sun Pei
• Shen Dake
• Wang Huanbing
• Shi Hongtao

Classifications

• C08L2205/06

  having improved processability or containing aids for moulding methods · CPC title

• C08L69/005

  Polyester-carbonates · CPC title

• C08L2201/02

  Flame or fire retardant/resistant · CPC title

• C08L69/00 Primary

  Compositions of polycarbonates; Compositions of derivatives of polycarbonates · CPC title

• C08L2205/02

  containing two or more polymers of the same C08L -group · CPC title