Flame retardant thermoplastic composition and articles formed therefrom
View Patent ↗A thermoplastic composition can comprise: polycarbonate, aromatic sulphone sulphonate, aromatic sulphonate, and brominated polycarbonate. In an embodiment, when the composition is formed into a 3 mm thick extruded sheet, the sheet can have a smoke density of less than 200 at an exposure period of 240 seconds in accordance with the smoke density test as set forth in ASTM E662-06, and a burn length of less than 150 mm, a drip flame time of less than 3 seconds, and an overall flame time of less than 15 seconds in accordance with the flammability test as set forth in 14 C.F.R. 25.853, Appendix F, Part I(a)(1)(ii).
1. A thermoplastic resin composition, comprising:
a transparent polycarbonate resin;
an aromatic sulphonate;
an aromatic sulphone sulphonate different from the aromatic sulphonate; and
a brominated polycarbonate resin;
wherein the composition, when in the form of a 3 mm thick extruded sheet, is transparent and has a smoke density of less than 200 at an exposure period of 240 seconds in accordance with the smoke density test as set forth in ASTM E662-06, and a burn length of less than 150 mm, a drip flame time of less than 3 seconds, and an overall flame time of less than 15 seconds in accordance with the flammability test as set forth in 14 C.F.R. 25.853, Appendix F, Part I(a)(1)(ii); and
wherein the composition, when in the form of a 5 mm thick extruded sheet, has a haze of 0% to 6% as measured in accordance with ASTM D1003-00, Procedure A, illuminant C.
2. The composition of claim 1 , wherein the aromatic sulphone sulphonate is present in an amount of 0.01 wt % to 0.6 wt %, based on the total weight of the composition.
3. The composition of claim 2 , wherein the aromatic sulphone sulphonate is present in an amount of 0.1 wt % to 0.4 wt %, based on the total weight of the composition.
4. The composition of claim 1 , wherein the aromatic sulphonate is present in an amount of 0.01 wt % to 0.1 wt %, based on the total weight of the composition.
5. The composition of claim 4 , wherein the aromatic sulphonate is present in an amount of 0.02 wt % to 0.06 wt %, based on the total weight of the composition.
6. The composition of claim 1 , wherein the brominated polycarbonate comprises 24 wt % to 28 wt % bromine, based on the total weight of the brominated polycarbonate.
7. The composition of claim 6 , wherein the brominated polycarbonate is present in an amount of 1 wt % to 10 wt %, based on the total weight of the composition.
8. The composition of claim 7 , wherein the brominated polycarbonate is present in an amount of 2 wt % to 8 wt %, based on the total weight of the polycarbonate resin.
9. The composition of claim 1 , wherein the aromatic sulphone sulphonate comprises an alkali metal diphenyl sulphone sulphonate and the aromatic sulphonate comprises an alkali metal salt of toluene sulfonic acid.
10. The composition of claim 1 , wherein the aromatic sulphonate comprises a sodium salt of toluene sulfonic acid.
11. The composition of claim 1 , wherein the aromatic sulphone sulphonate comprises potassium diphenyl sulphone sulphonate.
12. A thermoplastic composition, comprising:
0.01 wt % to 0.1 wt % sodium toluene sulphonic acid;
0.01 wt % to 0.6 wt % potassium diphenyl sulphon-3-sulphonate;
a brominated polycarbonate resin, in an amount such that the composition comprises 0.26 wt % to 2.6 wt % bromine; and
a polycarbonate resin;
wherein when the composition is formed into a 3 mm thick extruded sheet, the sheet has a smoke density of less than 200 at an exposure period of 240 seconds in accordance with the smoke density test as set forth in ASTM E662-06, and a burn length of less than 150 mm, a drip flame time of less than 3 seconds, and an overall flame time of less than 15 seconds in accordance with the flammability test as set forth in 14 C.F.R. 25.853, Appendix F, Part I(a)(1)(ii);
wherein the thermoplastic composition, when in the form of a 5 mm thick extruded sheet, has a haze of 0% to 6% as measured in accordance with ASTM D1003-00, Procedure A, illuminant C.
13. A sheet comprising:
a transparent thermoplastic composition, comprising:
0.01 wt % to 0.1 wt % aromatic sulphonate;
0.01 wt % to 0.6 wt % aromatic sulphone sulphonate;
a brominated polycarbonate resin, in an amount such that the composition comprises 0.26 wt % to 2.6 wt % bromine; and
a polycarbonate resin;
wherein the thermoplastic composition is in the form of a transparent sheet;
wherein when the composition is formed into a 3 mm thick extruded sheet, the sheet has a smoke density of less than 200 at an exposure period of 240 seconds in accordance with the smoke density test as set forth in ASTM E662-06, and a burn length of less than 150 mm, a drip flame time of less than 3 seconds, and an overall flame time of less than 15 seconds in accordance with the flammability test as set forth in 14 C.F.R. 25.853, Appendix F, Part I(a)(1)(ii); and
wherein the composition, when in the form of a 5 mm thick extruded sheet, has a haze of 0% to 6% as measured in accordance with ASTM D1003-00, Procedure A, illuminant C.
14. The sheet of claim 13 , wherein the aromatic sulphone sulphonate comprises potassium diphenyl sulphone sulphonate in an amount of 0.1 wt % to 0.4 wt %, and the aromatic sulphonate comprises a sodium salt of toluene sulfonic acid in an amount of 0.01 wt % to 0.1 wt %, based on the total weight of the composition.
15. The sheet of claim 13 , wherein the aromatic sulphonate is present in an amount of 0.02 wt % to 0.06 wt % based on the total weight of the composition, and the composition comprises 0.52 wt % to 2.08 wt % bromine.
16. An aircraft interior component comprising the sheet of claim 13 .
17. The sheet of claim 13 , wherein the sheet has a haze level of less than or equal to 4% as measured in accordance with ASTM D1003-00, Procedure A, illuminant C.
18. A sheet comprising:
transparent thermoplastic resin composition, comprising:
a polycarbonate resin;
an aromatic sulphonate;
an aromatic sulphone sulphonate; and
a brominated polycarbonate resin;
wherein when the composition is formed into a 3 mm thick extruded sheet, the sheet has a smoke density of less than 200 at an exposure period of 240 seconds in accordance with the smoke density test as set forth in ASTM E662-06, and a burn length of less than 150 mm, a drip flame time of less than 3 seconds, and an overall flame time of less than 15 seconds in accordance with the flammability test as set forth in 14 C.F.R. 25.853, Appendix F, Part I(a)(1)(ii); and
wherein the composition, when in the form of a 5 mm thick extruded sheet, has a haze of 0% to 6% as measured in accordance with ASTM D1003-00, Procedure A, illuminant C.
19. The sheet of claim 18 , wherein the sheet has a haze level of less than or equal to 4% as measured in accordance with ASTM D1003-00, Procedure A, illuminant C.
20. The sheet of claim 18 , wherein the aromatic sulphone sulphonate comprises potassium diphenyl sulphone sulphonate and the aromatic sulphonate comprises a sodium salt of toluene sulfonic acid.
21. The composition of claim 1 , wherein, the haze is less than or equal to 4%.
22. The composition of claim 21 , wherein the haze is 0.5% to 4%.
23. The sheet of claim 18 , wherein the haze is less than or equal to 4%.
24. The composition of claim 1 , wherein, when in the form of a 5.0 mm sheet, has a transparency of greater than or equal to 60%, as measured in accordance with ASTM D1003-00, Procedure A, illuminant C.
25. The composition of claim 24 , wherein the transparency is greater than or equal to 75%.
26. The composition of claim 24 , wherein the transparency is greater than or equal to 90%.
27. The composition of claim 1 , wherein the aromatic sulphonate comprises a sodium salt of toluene sulfonic acid in an amount of 0.02 wt % to 0.06wt %, the aromatic sulphone sulphonate comprises potassium diphenyl sulphone sulphonate in an amount of 0.1 wt % to 0.4wt %, and 0.25wt % to 2.5 wt % bromine, all based on the total weight of the composition.
28. The composition of claim 1 , wherein the aromatic sulphonate comprises a sodium salt of toluene sulfonic acid in an amount of 0.01 wt % to 0.1wt %, the aromatic sulphone sulphonate comprises potassium diphenyl sulphone sulphonate in an amount of 0.lwt % to 0.4wt %, and 0.25wt % to 2.5wt % bromine, all based on the total weight of the composition.
29. The composition of claim 1 , wherein the composition comprises 1.04 to 1.56 wt % bromine.