Polycarbonate compositions with improved flame retardance

Patent metadata

Field	Value
Publication number	US-10597530-B2
Application number	US-201615742933-A
Country	US
Kind code	B2
Filing date	Jun 7, 2016
Priority date	Jul 9, 2015
Publication date	Mar 24, 2020
Grant date	Mar 24, 2020

Abstract

Polycarbonate compositions with high flame retardance are disclosed. The compositions include a polycarbonate having repeating units derived from a monomer with an ester side group, and also include a flame retardant additive. These compositions may be further blended with another polycarbonate. The resulting compositions have high flame retardance and improved anti-drip properties.

First claim

The invention claimed is:

1. A flame retardant composition, comprising:
a first polycarbonate polymer having repeating units derived from a monomer having the structure of Formula (A) or Formula (B):

wherein
R and R′ are C 2 -C 15 alkyl;
m, n, p, and q are each 0 or 1, m+n=1, and p+q=1; and
E is C 1 -C 15 alkyl; and
about 0.05 to about 0.5 wt. % of a flame retardant additive, wherein the flame retardant additive is an alkali metal salt of a perfluorinated C1-C16 alkyl sulfonate, potassium diphenylfone sulfonate, sodium benzene sulfonate, sodium toluene sulfonate, or a cyclic siloxane having the formula [(R″) 2 SiO] y wherein R″ wherein R is a monovalent hydrocarbon or fluorinated hydrocarbon having from 1 to 18 carbon atoms and y is a number from 3 to 12,
wherein the first polycarbonate is un-crosslinked.

2. The flame retardant composition of claim 1 , wherein the first polycarbonate polymer is a copolymer.

3. The flame retardant composition of claim 2 , wherein the monomer is isopropyl diphenolate or ethyl-3,5-dihydroxybenzoate.

4. The flame retardant composition of claim 2 , wherein the first polycarbonate polymer further comprises repeating units derived from bisphenol-A or from a branching agent.

5. The flame retardant composition of claim 2 , wherein the first polycarbonate polymer contains from about 0.25 mole % to about 25 mole % of the repeating units derived from the monomer of Formula (A) or Formula (B).

6. The flame retardant composition of claim 1 , wherein the first polycarbonate polymer has a weight-average molecular weight of from about 10,000 to about 50,000.

7. The flame retardant composition of claim 1 , further comprising a second polycarbonate polymer.

8. The flame retardant composition of claim 7 , wherein the second polycarbonate polymer is a bisphenol-A homopolymer.

9. The flame retardant composition of claim 7 , wherein the second polycarbonate polymer is a copolymer containing repeating units derived from 1,1-bis(4-hydroxyphenyl)-1-phenyl-ethane.

10. The flame retardant composition of claim 9 , wherein the second polycarbonate polymer contains from about 15 wt % to about 30 wt % of bromine.

11. A flame retardant composition, comprising,
a first polycarbonate polymer having repeating units derived from a monomer having the structure of Formula (A) or Formula (B):

wherein
R and R′ are C 2 -C 15 alkyl;
m, n, p, and q are each 0 or 1, m+n=1, and p+q=1; and
E is C 1 -C 15 alkyl;
a second polycarbonate polymer; and
a flame retardant additive,

wherein the second polycarbonate polymer also has repeating units derived from the monomer of Formula (A) or Formula (B), the first polycarbonate polymer having a higher weight-average molecular weight than the second polycarbonate polymer.

12. The flame retardant composition of claim 11 , wherein the weight ratio of the first polycarbonate polymer to the second polycarbonate polymer is from about 15:85 to about 99:1.

13. The flame retardant composition of claim 1 , wherein the repeating units derived from the monomer of Formula (A) or Formula (B) are from about 0.25 mole % to about 5 mole % of the composition.

14. A flame retardant composition, comprising:
a first polycarbonate polymer having repeating units derived from a monomer having the structure of Formula (A) or Formula (B):

wherein
R and R′ are C 2 -C 15 alkyl;
m, n, p, and q are each 0 or 1, m+n=1, and p+q=1; and
E is C 1 -C 15 alkyl;
a flame retardant;
a second polycarbonate polymer which is a bisphenol-A homopolymer; and
a third polycarbonate polymer which is a copolymer containing repeating units derived from bisphenol-A and from tetrabromobisphenol-A.

15. The flame retardant composition of claim 14 , containing
from about 20 parts to about 80 parts by weight of the first polycarbonate polymer;
from about 10 parts to about 60 parts by weight of the second polycarbonate polymer; and
from about 1 part to about 2 parts by weight of the third polycarbonate polymer.

16. The flame retardant composition of claim 11 , wherein the composition contains from about 0.05 wt % to about 0.5 wt % of the flame retardant additive.

17. The flame retardant composition of claim 1 , wherein the flame retardant additive is a salt of diphenylsulfone-3-sulfonic acid or a salt of perfluorobutane sulfonic acid.

18. The flame retardant composition of claim 1 , wherein an article molded from the composition can attain UL94 V0 performance at a thickness of 2.0 mm.

19. The flame retardant composition of claim 1 , wherein an article molded from the composition can attain UL94 V0 performance at a thickness of 1.5 mm.

20. The flame retardant composition of claim 1 , wherein the composition has a melt volume rate (MVR) of from about 3 cm 3 /10 min to about 25 cm 3 /10 min, when measured according to ASTM D1238-10, 6 minute dwell.

21. The flame retardant composition of claim 1 , wherein the first polycarbonate polymer further comprises repeating units derived from bisphenol-A and repeating units derived from a branching agent comprising trishydroxyphenylethane, the branching agent making up from about 0.01 mole % to about 0.5 mole % of the repeating units in the first polycarbonate polymer.

Assignees

• Sabic Global Technologies Bv

Inventors

• Rosenquist Niles Richard
• Hoover James Franklin
• Chellamuthu Manojkumar

Classifications

• C08L2205/03

  containing three or more polymers in a blend · CPC title

• C08L2201/02

  Flame or fire retardant/resistant · CPC title

• C08G64/06

  not containing aliphatic unsaturation · CPC title

• C08L69/00 Primary

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

• C08K5/42

  Sulfonic acids; Derivatives thereof · CPC title