Interior train components having low smoke and low heat release, and methods of their manufacture

Patent metadata

Field	Value
Publication number	US-9365720-B2
Application number	US-201414154583-A
Country	US
Kind code	B2
Filing date	Jan 14, 2014
Priority date	Jan 14, 2014
Publication date	Jun 14, 2016
Grant date	Jun 14, 2016

Abstract

A railway component comprises a polycarbonate composition comprising: a first polycarbonate selected from a linear polycarbonate homopolymer, a branched polycarbonate, a poly(carbonate-bisphenol arylate ester), a poly(aliphatic ester-carbonate), or a combination thereof; a second polymer different from the first polycarbonate, the second polymer comprising a poly(carbonate-siloxane) copolymer, a polydialkylsiloxane, a silicone graft copolymer, or a combination thereof, wherein siloxane units in the second polymer are present in an amount of 0.3 to 3 wt. %, based on the total weight of the composition; and 10 to 40 wt. % of glass fiber, based on the total weight of the polycarbonate composition.

First claim

What is claimed is:

1. A railway component,
wherein the component is a molded or extruded interior train component comprising a polycarbonate composition comprising:
a first polycarbonate selected from a linear polycarbonate homopolymer, a branched polycarbonate, a poly(carbonate-bisphenol arylate ester), a poly(aliphatic ester-carbonate), or a combination comprising at least one of the foregoing;
a second polymer different from the first polycarbonate, the second polymer comprising a poly(carbonate-siloxane) copolymer, a polydialkylsiloxane, a silicone graft copolymer, or a combination comprising at least one of the foregoing, wherein siloxane units in the second polymer are present in the polycarbonate composition in an amount of 0.3 to 3 wt. %, based on the total weight of the polycarbonate composition; and
10 to 50 wt. % of glass fiber, based on the total weight of the polycarbonate composition;
wherein a sample of the polycarbonate composition has:
a smoke density after 4 minutes (DS-4) of less than or equal to 300 determined according to ISO 5659-2 on a 3 mm thick plaque at 50 kW/m 2 , and
a maximum average heat release (MAHRE) of equal to or less than 90 kW/m 2 measured according to ISO 5660-1 on a 3 mm thick plaque at 50 kW/m 2 ,
wherein the component is free of a polyetherimide.

2. The railway component of claim 1 , wherein a sample of the polycarbonate composition has:
a smoke density after 4 minutes (DS-4) of less than or equal to 150 determined according to ISO 5659-2 on a 3 mm thick plaque at 50 kW/m 2 , and
a maximum average heat release (MAHRE) of equal to or less than 60 kW/m 2 measured according to ISO 5660-1 on a 3 mm thick plaque at 50 kW/m 2 .

3. The railway component of claim 1 , wherein the first polycarbonate comprises linear polycarbonate homopolymer comprising repeating units of the formula

wherein
R a and R b are each independently a C 1-12 alkyl group, C 1-12 alkenyl, C 3-8 cycloalkyl, or C 1-12 alkoxy,
p and q are each independently integers of 0 to 4, and
X a is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, a C 1-11 alkylidene of formula —C(R c )(R d )— wherein R c and R d are each independently hydrogen or C 1-10 alkyl, or a group of the formula —C(═R e )— wherein R e is a divalent C 1-10 hydrocarbon group.

4. The railway component of claim 1 , wherein the linear polycarbonate homopolymer comprises bisphenol A carbonate units.

5. The railway component of claim 1 , wherein the linear polycarbonate has an average molecular weight of 18,000 to 25,000 g/mol; and wherein the composition has a melt volume flow rate of about 8 to about 25 cc/10 min, measured at 300° C./1.2 Kg at 360 second dwell according to ISO 1133.

6. The railway component of claim 1 , wherein the first polycarbonate comprises a branched polycarbonate comprising repeating carbonate units of the formula:

wherein R a and R b are each independently C 1-12 alkyl, C 1-12 alkenyl, C 3-8 cycloalkyl, or C 1-12 alkoxy, p and q are each independently 0 to 4, and X a is a bridging group between the two arylene groups, and is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, a C 1-11 alkylidene of the formula —C(R c )(R d )— wherein R c and R d are each independently hydrogen or C 1-10 alkyl, or a group of the formula —C(═R e )— wherein R e is a divalent C 1-10 hydrocarbon group, and
greater than or equal to 0.2 mole %, based on the total moles of the branched polycarbonate, of moieties derived from a branching agent.

7. The railway component of claim 6 , wherein the branching agent comprises trimellitic trichloride, 1,1,1-tris(4-hydroxyphenyl)ethane or a combination of trimellitic trichloride and 1,1,1-tris(4-hydroxyphenyl)ethane.

8. The railway component of claim 6 , wherein the branched polycarbonate comprises end-capping groups derived from an end-capping agent selected from phenol, p-t-butylphenol, p-methoxyphenol, p-cyanophenol, p-cumylphenol, or a combination comprising at least one of the foregoing.

9. The railway component of claim 1 , wherein the first polycarbonate comprises a poly(carbonate-bisphenol arylate ester) comprising bisphenol A carbonate units as the first repeating units and arylate ester units as the second repeating units, wherein the second repeating units are of the formula

wherein
R a and R b are each independently C 1-12 alkyl, C 1-12 alkenyl, C 3-8 cycloalkyl, or C 1-12 alkoxy,
p and q are each independently 0 to 4, and
X a is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, a C 1-11 alkylidene of the formula —C(R c )(R d )— wherein R c and R d are each independently hydrogen or C 1-10 alkyl, or a group of the formula —C(═R e )— wherein R e is a divalent C 1-10 hydrocarbon group.

10. The railway component of claim 9 , wherein
R a and R b are each independently a C 1-3 alkyl,
p and q are each independently 0 or 1,
X a is alkylidene of formula —C(R c )(R d )— wherein R c and R d are each C 1-6 alkyl, and
the ratio of the weight percent of the ester units to the carbonate units in the poly(carbonate-bisphenol arylate ester) is 50:50 to 99:1.

11. The railway component of claim 10 , wherein the poly(carbonate-bisphenol arylate ester) is a poly(bisphenol A carbonate)-co-(bisphenol phthalate ester) comprising 55 to 65 wt. % of the ester units, wherein the ester units have a molar ratio of isophthalate to terephthalate of 45:55 to 55:45.

12. The railway component of claim 10 , wherein the poly(carbonate-bisphenol arylate ester) is a poly(bisphenol A carbonate)-co-(bisphenol phthalate ester) comprising 75 to 85 wt. % of the ester units, wherein the ester units have a molar ratio of isophthalate to terephthalate of 98:2 to 88:12.

13. The railway component of claim 1 , wherein the first polycarbonate comprises a poly(aliphatic ester-carbonate), and the poly(aliphatic ester-carbonate) comprises bisphenol A sebacate ester units and bisphenol A carbonate units in a molar ratio of 2:98 to 8:92.

14. The railway component of claim 1 , wherein the second polymer comprises a poly(carbonate-siloxane) copolymer comprising first repeating units and second repeating units, wherein
the first repeating units are bisphenol carbonate units of the formula

wherein
R a and R b are each independently C 1-12 alkyl, C 1-12 alkenyl, C 3-8 cycloalkyl, or C 1-12 alkoxy,
p and q are each independently 0 to 4, and
X a is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, a C 1-11 alkylidene of formula —C(R c )(R d )— wherein R c and R d are each independently hydrogen or C 1-10 alkyl, or a group of the formula —C(═R e )— wherein R e is a divalent C 1-10 hydrocarbon group; and
the second repeating units are polysiloxane units of the formula

wherein
R is each independently a C 1-13 monovalent hydrocarbon group, and
E has an average value of 2 to 200.

15. The railway component of claim 14 , wherein the second repeating units are siloxane units of the formulas

Assignees

• Sabic Innovative Plastics Ip
• Sabic Global Technologies Bv

Inventors

• Van Der Mee Mark Adrianus Johannes
• Wirtz Remco
• Assink Roland Sebastian
• Van De Grampel Robert Dirk

Classifications

• C08L2201/02

  Flame or fire retardant/resistant · CPC title

• C08L2205/02

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

• C08L81/00

  Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen or carbon only; Compositions of polysulfones; Compositions of derivatives of such polymers · CPC title

• C08L51/085

  on to polysiloxanes · CPC title

• C08L2205/025

  containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure · CPC title