Interior aircraft components and methods of manufacture

Patent metadata

Field	Value
Publication number	US-9718956-B2
Application number	US-201414154737-A
Country	US
Kind code	B2
Filing date	Jan 14, 2014
Priority date	Jan 14, 2014
Publication date	Aug 1, 2017
Grant date	Aug 1, 2017

Abstract

A aircraft component comprises a polycarbonate composition comprising: a first polycarbonate selected from a polycarbonate homopolymer, 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 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.

First claim

What is claimed is:

1. An aircraft component,
wherein the component is a molded or extruded interior aircraft component comprising a polycarbonate composition comprising:
a first polycarbonate selected from a polycarbonate homopolymer, 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:
an ASTM E662 smoke test Ds-1.5 value of less than 100 and Ds-4 value of less than 200 when measured at a thickness of 3 mm,
a flame time of less than 15 seconds, a burn length of less than 152 mm, and a drip extinguishing time of less than 5 seconds, each measured using the method of FAR F25.5, in accordance with FAR 25.853(a) at a thickness of 3 mm.

2. The aircraft 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.

3. The aircraft component of claim 2 , wherein the linear polycarbonate homopolymer comprises bisphenol A carbonate units.

4. The aircraft component of claim 2 , 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.

5. The aircraft 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.

6. The aircraft 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.

7. The aircraft component of claim 6 , wherein the second repeating units are siloxane units of the formulas

or a combination comprising at least one of the foregoing, wherein
R is each independently a C 1-13 monovalent hydrocarbon group,
Ar is each independently a C 6-30 aromatic group,
R 2 is each independently a C 2-8 alkylene group, and
E has an average value of 2 to 200.

8. The aircraft component of claim 7 , wherein the siloxane units are of the formula

or a combination comprising at least one of the foregoing, wherein E has an average value of 2 to 200.

9. The aircraft component of claim 7 , wherein the siloxane units are of the formula

wherein
R is each independently a C 1-13 monovalent hydrocarbon group,
R 3 is independently a divalent C 2-8 aliphatic group,
M is each independently a halogen, cyano, nitro, C 1-8 alkylthio, C 1-8 alkyl, C 1-8 alkoxy, C 2-8 alkenyl, C 2-8 alkenyloxy group, C 3-8 cycloalkyl, C 3-8 cycloalkoxy, C 6-10 aryl, C 6-10 aryloxy, C 7-12 arylalkyl, C 7-12 arylalkoxy, C 7-12 alkylaryl, or C 7-12 alkylaryloxy, or a combination comprising at least one of the foregoing,
n is each independently 0, 1, 2, 3, or 4, and
E has an average value of 2 to 200.

10. The aircraft component of claim 7 , wherein the siloxane units are siloxane units of the formula

or a combination comprising at least one of the foregoing, wherein E has an average value of 2 to 200.

11. The aircraft component of claim 10 , wherein E has an average value of 5 to 120.

12. The aircraft component of claim 1 , wherein the second polymer is a polydialkylsiloxane having a viscosity from 10 to 100,000,000 mPa-s at 25° C., and wherein the alkyl groups each independently comprises 1 to 10 carbon atoms.

13. The aircraft component of claim 12 , wherein the polydialkylsiloxane is a polydimethylsiloxane having a viscosity from 50 to 1,000 mPa-s at 25° C.

14. The aircraft component of claim 1 , wherein the second polymer is a silicone graft copolymer comprising a core comprising a polydiorganosiloxane and a vinyl-based monomer graft copolymerized with the core to form a shell.

15. The aircraft component of claim 1 , wherein glass fiber has a length of about 1 to about 10 millimeters and a diameter of about 5 to about 20 micrometers.

16. The aircraft component of claim 1 , wherein glass fiber is bonding glass fiber that bounds with a polycarbonate, a polyphenylene ether or a polyamide.

17. The aircraft component of claim 1 , wherein the glass fiber is present in an amount of 10 to 20 wt. %, based on the total weight of the composition; and wherein the component has:
a tensile modulus of equal to or higher than 3400 MPa, measured according to ISO 527 at 5 mm/min and at 23° C.,
a tensile strength of equal to or higher than 50 MPa measured according to ISO 527 at 5 mm/min and at 23° C.,
an IZOD notched impact of equal to or higher than 5 kJ/m 2 measured according to ISO 180 at 5.5 J and at 23° C. on a 3 mm thick sample, and
a density of equal to or lower than 1.36 g/cm 3 measured according to ISO 1183.

18. The aircraft component of claim 1 , wherein the glass fiber is present in an amount of 20 to 30 wt. %, based on the total weight of the composition; and wherein the com

Assignees

• Sabic Global Technologies Bv

Inventors

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

Classifications

• C08G77/04

  Polysiloxanes · CPC title

• C08L69/00 Primary

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

• C08L51/085

  on to polysiloxanes · CPC title

• C08L69/005

  Polyester-carbonates · CPC title

• C08F283/124

  on to polysiloxanes having carbon-to-carbon double bonds · CPC title