Reinforced polycarbonate compositions

Patent metadata

Field	Value
Publication number	US-10240039-B2
Application number	US-201515539080-A
Country	US
Kind code	B2
Filing date	Dec 21, 2015
Priority date	Dec 23, 2014
Publication date	Mar 26, 2019
Grant date	Mar 26, 2019

Abstract

The disclosure concerns blended thermoplastic compositions comprising (a) from about 50 wt % to about 80 wt % of a polycarbonate component; (b) from greater than 0 wt % to about 12 wt % of an impact modifier component; (c) from about 10 wt % to about 40 wt % of a filler; and (d) from about 5 wt % to about 15 wt % of a flame retardant component comprising an oligomeric phosphate ester, wherein the oligomeric phosphate ester is a free flowing powder at 23° C.; wherein the blended thermoplastic composition has a ductility of 100% at 10° C. when measured by a Notched Izod Impact test performed according to ASTM D256; wherein the combined weight percent value of all components does not exceed 100 wt %; and wherein all weight percent values are based on the total weight of the composition.

First claim

What is claimed:

1. A blended thermoplastic composition comprising:
a) from about 50 wt % to about 80 wt % of a polycarbonate component;
b) from greater than 0 wt % to about 12 wt % of an impact modifier component;
c) from about 10 wt % to about 40 wt % of a filler;
d) from about 5 wt % to about 15 wt % of a flame retardant component comprising an oligomeric phosphate ester, wherein the oligomeric phosphate ester is a free flowing powder at 23° C.; and
e) from about 1 wt % to about 10 wt % of a second flame retardant component that is a phosphate ester that is a liquid at 23° C.,
wherein the combined weight percent value of all components does not exceed 100 wt %, and
wherein all weight percent values are based on the total weight of the composition.

2. The composition of claim 1 , wherein the blended thermoplastic composition has a ductility of 100% at 10° C. when measured by a Notched Izod Impact test performed according to ASTM D256.

3. The composition of claim 1 , wherein the polycarbonate component comprises at least one bisphenol A polycarbonate and at least one polycarbonate-polysiloxane copolymer.

4. The composition of claim 1 , wherein the polycarbonate component comprises a polycarbonate having a weight average molecular weight from about 18,000 to about 40,000 grams/mole, as measured by gel permeation chromatography using BPA polycarbonate standards.

5. The composition of claim 1 , wherein the polycarbonate component comprises a blend of at least two polycarbonate polymers including a first polycarbonate polymer component and a second polycarbonate polymer component.

6. The composition of claim 5 , wherein the first polycarbonate polymer component is a polycarbonate having a melt flow rate (MFR) from about 20 g/10 min to about 30 g/10 min when measured at 300° C. and under a load of 1.2 kg according to ASTM D1238, and wherein the second polycarbonate polymer component is a polycarbonate having a MFR from about 4.0 g/10 min to about 10.0 g/10 min when measured at 300° C. and under a load of 1.2 kg according to ASTM D1238.

7. The composition of claim 5 , wherein the first polycarbonate component is present in an amount from about 20 wt % to about 70 wt %; and wherein the second polycarbonate component is present in an amount from about 5 wt % to about 40 wt % based on the total weight of the composition.

8. The composition of claim 5 , further comprising a third polycarbonate polymer component.

9. The composition of claim 8 , wherein the third polycarbonate polymer component is a polycarbonate-polysiloxane copolymer.

10. The composition of claim 1 , wherein the composition is capable of achieving a UL 94 V0 rating at a thickness of 1.5 mm or less.

11. The composition of claim 1 , wherein the impact modifier component comprises at least one of acrylonitrile-butadiene-styrene (ABS), polymer methyl methacrylate-butadiene-styrene (MBS), methyl methacrylate-butadiene (MB) polymer, and silicone-acrylic-based rubber.

12. The composition of claim 11 , wherein the impact modifier is present in an amount from about 1 wt % to about 8 wt %.

13. An article comprising the composition of claim 1 .

14. A method of preparing a composition, comprising the step of combining:
a) from about 50 wt % to about 80 wt % of a polycarbonate component;
b) from greater than 0 wt % to about 12 wt % of an impact modifier component;
c) from about 10 wt % to about 40 wt % of a filler;
d) from about 5 wt % to about 15 wt % of a flame retardant component comprising an oligomeric phosphate ester, wherein the oligomeric phosphate ester is a free flowing powder at 23° C.; and
e) from about 1 wt % to about 10 wt % of a second flame retardant component that is a phosphate ester that is a liquid at 23° C.,
wherein the combined weight percent value of all components does not exceed 100 wt %; and
wherein all weight percent values are based on the total weight of the composition.

15. The method of claim 14 , wherein the composition has a ductility of 100% at 10° C. when measured by a Notched Izod Impact test performed according to ASTM D256.

16. The method of claim 14 , wherein the polycarbonate component comprises at least one bisphenol A polycarbonate and at least one polycarbonate-polysiloxane copolymer.

17. The method of claim 14 , wherein the combining comprises extrusion blending.

18. The method of claim 14 , further comprising molding the composition into a molded article.

Assignees

• Sabic Global Technologies Bv

Inventors

• Li Ying
• Wang Huanbing
• Sun Pei Helen
• Shi Hontao
• Shen Dake

Classifications

• C08L55/02

  ABS [Acrylonitrile-Butadiene-Styrene] polymers · CPC title

• C08K5/523

  with hydroxyaryl compounds · CPC title

• C08G64/04

  Aromatic polycarbonates · CPC title

• C08K3/013

  Fillers, pigments or reinforcing additives · CPC title

• C08L83/10

  Block- or graft-copolymers containing polysiloxane sequences (obtained by polymerising a compound having a carbon-to-carbon double bond on to a polysiloxane C08L51/08, C08L53/00) · CPC title