Flame retardant thermoplastic polycarbonate compositions
View Patent ↗A flame retardant thermoplastic composition comprising in combination a polycarbonate component; an impact modifier composition, the components of the impact modifier composition comprising a) a bulk polymerized ABS, and b) an impact modifier different from the ABS; an ungrafted rigid copolymer; and a flame retardant. The compositions have an improved balance of physical properties such as impact strength and flow, while at the same time maintaining their good flame performance.
1. A thermoplastic composition comprising in combination
a polycarbonate component;
an impact modifier composition, the components comprising
a) a bulk polymerized ABS;
b) an impact modifier different from the ABS;
an ungrafted rigid copolymer; and
a flame retardant,
wherein b) comprises an elastomeric phase comprising a butadiene rubber, an ethylene-propylene-diene monomer rubber, an elastomeric copolymer of a C 1-8 alkyl (meth)acrylate with butadiene, or a combination comprising at least one of the foregoing elastomers, together with a rigid copolymer phase derived from the copolymerization of a monomer of formula (9):
wherein each X c is independently hydrogen, C 1 -C 12 alkyl, C 3 -C 12 cycloalkyl, C 6 -C 12 aryl, C 7 -C 12 aralkyl, C 7 -C 12 alkaryl, C 1 -C 12 alkoxy, C 3 -C 12 cycloalkoxy, C 6 -C 12 aryloxy, chloro, bromo, or hydroxy, and R is hydrogen, C 1 -C 5 alkyl, bromo, or chloro, with a monomer of the generic formula (10):
wherein R is hydrogen, C 1 -C 5 alkyl, bromo, or chloro, and X c is cyano, C 1 -C 12 alkoxycarbonyl, C 1 -C 12 aryloxycarbonyl, or hydroxycarbonyl.
2. The thermoplastic composition of claim 1 , wherein the elastomer phase comprises polybutadiene and the rigid copolymer phase comprises units derived from the copolymerization of styrene, alpha-methyl styrene, dibromostyrene, vinyltoluene, vinylxylene, butylstyrene, para-hydroxystyrene, methoxystyrene, or a combination comprising at least one of the foregoing styrenes with acrylonitrile, ethacrylonitrile, methacrylonitrile, alpha-chloroacrylonitrile, beta-chloroacrylonitrile, alpha-bromoacrylonitrile, acrylic acid, methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl (meth)acrylate, t-butyl (meth)acrylate, n-propyl (meth)acrylate, isopropyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, or a combination comprising at least one of the foregoing co-monomers.
3. The composition of claim 2 wherein the impact modifier other than bulk polymerized ABS is MBS, MABS or a combination comprising at least one of the foregoing impact modifiers.
4. The thermoplastic composition of claim 1 , further comprising a filler.
5. The thermoplastic composition of claim 1 , comprising about 50 to about 94 wt. % polycarbonate component, about 3 to about 35 wt % of an impact modifier composition, about 1 to about 7 wt. % ungrafted rigid copolymer, and about 2 to about 25 wt. % flame retardant.
6. The thermoplastic composition of claim 1 , wherein the ungrafted rigid copolymer is SAN.
7. The thermoplastic composition of claim 1 , wherein the composition is capable of achieving a UL94 rating of V0 at a thickness of 1.5 mm.
8. The thermoplastic composition of claim 1 , wherein a molded sample of the composition has a notched Izod impact of at least 90 J/m at 23° C. using a 3.2 mm thick bar per ASTM D256.
9. An article comprising the thermoplastic composition of claim 1 .
10. A method of manufacture of an article comprising molding, extruding, or shaping the composition of claim 1 .
11. A thermoplastic composition comprising in combination
from about 60 wt. % to about 89 wt. % a polycarbonate component;
an impact modifier composition, the components comprising
a) from about 4 wt. % to about 20 wt. % of a bulk polymerized ABS;
b) from about 1 wt. % to about 10 wt. % of an impact modifier different
from the BABS, based on the total weight of the thermoplastic composition;
from 1 wt. % about 7 wt. % of an ungrafted rigid copolymer; and
from about 5 wt. % to about 20 wt. % a flame retardant,
wherein b) comprises an elastomeric phase comprising a butadiene rubber, an ethylene-propylene-diene monomer rubber, an elastomeric copolymer of a C 1-8 alkyl (meth)acrylate with butadiene or a combination comprising at least one of the foregoing elastomers, together with a rigid copolymer phase derived from the copolymerization of a monomer of formula (9):
wherein each X c is independently hydrogen, C 1 -C 12 alkyl, C 3 -C 12 cycloalkyl, C 6 -C 12 aryl, C 7 -C 12 aralkyl, C 7 -C 12 alkaryl, C 1 -C 12 alkoxy, C 3 -C 12 cycloalkoxy, C 6 -C 12 aryloxy, chloro, bromo, or hydroxy, and R is hydrogen, C 1 -C 5 alkyl, bromo, or chloro, with a monomer of the generic formula (10):
wherein R is hydrogen, C 1 -C 5 alkyl, bromo, or chloro, and X c is cyano, C 1 -C 12 alkoxycarbonyl, C 1 -C 12 aryloxycarbonyl, or hydroxycarbonyl.
12. The thermoplastic composition of claim 11 , wherein the elastomer-modified impact modifier different from bulk polymerized ABS is MBS and comprises at least about 2 wt. % of the total composition.
13. The thermoplastic composition of claim 11 , wherein a molded sample of the composition has a notched Izod impact of at least 90 J/m at 23° C. using a 3.2 mm thick bar per ASTM D256.
14. The thermoplastic composition of claim 11 , wherein the ungrafted rigid copolymer comprises SAN.
15. The thermoplastic composition of claim 11 , wherein composition is capable of achieving a UL94 rating of VO at a thickness of 1.5 mm.
16. A thermoplastic composition comprising in combination
from about 60 wt. % to about 89 wt. % a polycarbonate component;
from about 5 to about 35 wt. % of an impact modifier composition, the components comprising
a) a bulk polymerized ABS;
b) MBS;
from about 1 wt. % to about 7 wt. % of SAN; and
from about 5 wt. % to about 20 wt. % a flame retardant,
wherein a molded sample of the composition has a notched Izod impact of at least 90 J/m at 23° C. when measured according to ASTM D256.
17. The thermoplastic composition of claim 16 , wherein the flame retardant is a phosphorous-containing flame retardant.
18. The thermoplastic composition of claim 16 , wherein composition is capable of achieving a UL94 rating of V0 at a thickness of 1.5 mm.
19. An article comprising the thermoplastic composition of claim 16 .
20. A thermoplastic composition comprising in combination
a polycarbonate component;
an impact modifier composition, the components comprising
a) a bulk polymerized ABS;
b) an impact modifier different from the ABS,
wherein b) comprises an elastomeric phase comprising a butadiene rubber, an ethylene-propylene-diene monomer rubber, an elastomeric copolymer of a C 1-8 alkyl (meth)acrylate with butadiene or a combination comprising at least one of the foregoing elastomers, together with a rigid copolymer phase derived from the copolymerization of a monomer of formula (9):
wherein each X c is independently hydrogen, C 1 -C 12 alkyl, C 3 -C 12 cycloalkyl, C 6 -C 12 aryl, C 7 -C 12 aralkyl, C 7 -C 12 alkaryl, C 1 -C 12 alkoxy, C 3 -C 12 cycloalkoxy, C 6 -C 12 aryloxy, chloro, bromo, or hydroxy, and R is hydrogen, C 1 -C 5 alkyl, bromo, or chloro, with a monomer of the generic formula (10):
wherein R is hydrogen, C 1 -C 5 alkyl, bromo, or chloro, and X c is cyano, C 1 -C 12 alkoxycarbonyl, C 1 -C 12 aryloxycarbonyl, or hydroxycarbonyl;
an ungrafted rigid copolymer; and
a flame retardant,
wherein the thermoplastic has a notched Izod impact strength of at least 95 J/m, determined at 23° C. using a 3.2 mm thick bar per ASTM D256, and wherein composition is capable of achieving a UL94 rating of V0 at a thickness of 1.5 mm.