FLAME RETARDANT, OPTICALLY CLEAR THERMOPLASTIC MOLDING COMPOSITION
The present invention relates to a flame-retardant, optically clear thermoplastic molding composition. The composition contains a A) about 60 pbw to about 97 pbw of a polycarbonate, B) about 1 pbw to about 20 pbw of bromine-substituted oligocarbonate, C) about 1 pbw to about 20 pbw of a phosphorus-containing compound and D) about 0.01 pbw to about 1 pbw of at least one alkali or alkaline-earth salt of perfluoroalkane sulfonic acid and optionally E) about 0.01 to about 1 pbw of a phosphite antioxidant/stabilizer. In accordance with UL-94 standard the flame-retardant, optically clear thermoplastic molding composition is rated 5VA at 3.00 mm and V-0 at 2.3 mm, more preferably V-0 at 1.5 mm according to UL-94.
1 . A flame-retardant, optically clear thermoplastic molding composition comprising:
A) about 60 pbw to about 97 pbw of a polycarbonate;
B) about 1 pbw to about 20 pbw of bromine-substituted oligocarbonate;
C) about 1 pbw to about 20 pbw of a phosphorus-containing compound; and
D) about 0.01 pbw to about 1 pbw of at least one alkali or alkaline-earth salt of perfluoroalkane sulfonic acid,
wherein the flame-retardant, optically clear thermoplastic molding composition is free of fluorinated polyolefin and is rated 5VA at 3.00 mm and V-0 at 2.3 mm according to UL-94.
2 . The flame-retardant, optically clear thermoplastic molding composition according to claim 1 , wherein the polycarbonate is present in an amount of about 70 pbw to about 90 pbw.
3 . The flame-retardant, optically clear thermoplastic molding composition according to claim 1 , wherein the polycarbonate is present in an amount of about 80 pbw to about 85 pbw.
4 . The flame-retardant, optically clear thermoplastic molding composition according to claim 1 , wherein the bromine-substituted oligocarbonate is present in an amount of about 5 pbw to about 15 pbw.
5 . The flame-retardant, optically clear thermoplastic molding composition according to claim 1 , wherein the bromine-substituted oligocarbonate is present in an amount of about 8 pbw to about 12 pbw.
6 . The flame-retardant, optically clear thermoplastic molding composition according to claim 1 , wherein said bromine-substituted oligocarbonate conforms structurally to formula (IV),
where R 1 , R 2 , R 3 and R 4 independently denote H, Br or CH 3 with the proviso that at least one of R 1 , R 2 , R 3 , R 4 denotes Br, and where R 5 denotes an aryl, alkylaryl or alkyl radicals, and n is 1-100.
7 . The flame-retardant, optically clear thermoplastic molding composition according to claim 1 , wherein said bromine-substituted oligocarbonate conforms structurally to formula (IVa),
and having a bromine content greater than 40 percent relative to its weight.
8 . The flame-retardant, optically clear thermoplastic molding composition according to claim 1 , wherein the phosphorus-containing compound is present in an amount of about 2 pbw to about 7 pbw.
9 . The flame-retardant, optically clear thermoplastic molding composition according to claim 1 , wherein the phosphorus-containing compound is present in an amount of about 3 pbw to about 10 pbw.
10 . The flame-retardant, optically clear thermoplastic molding composition according to claim 1 , wherein the phosphorus-containing compound conforms structurally to formula (V),
wherein
R 1 , R 2 , R 3 and R 4 independently represents C 1 -C 8 -alkyl, or C 5 -C 6 -cycloalkyl, C 6 -C 20 -aryl or C 7 -C 12 -aralkyl,
n independently denotes 0 or 1,
q denotes 0.5 to 30, and
X is a mono- or poly-nuclear aromatic radical having from 6 to 30 carbon atoms, or an aliphatic radical having from 2 to 30 carbon atoms.
11 . The flame-retardant, optically clear thermoplastic molding composition according to claim 1 , wherein the phosphorus-containing compound conforms structurally to formula (VII),
12 . The flame-retardant, optically clear thermoplastic molding composition according to claim 1 , wherein the at least one alkali or alkaline-earth salt of perfluoroalkane sulfonic acid is present in an amount of about 0.02 pbw to about 0.5 pbw.
13 . The flame-retardant, optically clear thermoplastic molding composition according to claim 1 , wherein the polycarbonate is branched.
14 . The flame-retardant, optically clear thermoplastic molding composition according to claim 1 , wherein the flame-retardant, optically clear thermoplastic molding composition is free of fluorinated polyolefin and is rated 5VA at 3.00 mm and V-0 at 1.5 mm according to UL-94.
15 . The flame-retardant, optically clear thermoplastic molding composition according to claim 1 , wherein the salt of perfluoroalkane sulfonic acid is a perfluoroalkane sulfonate salt of at least one member selected from the group consisting of alkali metal, alkaline earth metal, C 1-6 -alkylammonium, and ammonium.
16 . The flame-retardant, optically clear thermoplastic molding composition according to claim 1 , wherein the salt is at least one member selected from the group consisting of sodium perfluoromethylbutane sulphonate, potassium perfluoromethylbutane sulphonate, tetraethyl ammonium perfluoromethylbutane sulphonate; sodium perfluoromethane sulphonate, potassium perfluoromethane sulphonate, tetraethyl ammonium perfluoromethane sulphonate; sodium perfluoroethane sulphonate, potassium perfluoroethane sulphonate, tetraethyl ammonium perfluoroethane sulphonate; sodium perfluoropropane sulphonate, potassium perfluoropropane sulphonate, tetraethyl ammonium perfluoropropane sulphonate; sodium perfluorohexane sulphonate, potassium perfluorohexane sulphonate, tetraethyl ammonium perfluorohexane sulphonate; sodium perfluoroheptane sulphonate, potassium perfluoroheptane sulphonate, tetraethyl ammonium perfluoroheptane sulphonate; sodium perfluoroctanesulphonate, potassium perfluoroctanesulphonate, tetraethyl ammonium perfluoroctane-sulphonate; sodium perfluorobutane sulfonate, potassium perfluorobutane sulfonate, tetraethyl ammonium perfluorobutane sulfonate; sodium diphenylsulfone-sulphonate, potassium diphenylsulfone-sulphonate, and tetraethyl ammonium diphenylsulfone-sulphonate.
17 . A flame-retardant, optically clear thermoplastic molding composition comprising:
A) about 60 to about 97 pbw of an aromatic polycarbonate;
B) about 1 to about 20 pbw of bromine-substituted oligocarbonate;
C) about 1 to about 20 pbw of a phosphorus-containing compound;
D) about 0.01 to about 1 pbw of at least one alkali or alkaline-earth salt of perfluoroalkane sulfonic acid; and
E) about 0.01 to about 1 pbw of a phosphite antioxidant/stabilizer,
wherein the flame-retardant, optically clear thermoplastic molding composition is free of fluorinated polyolefin and is rated 5VA at 3.00 mm and V-0 at 1.5 mm according to UL-94.
18 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein the polycarbonate is present in an amount of about 70 pbw to about 90 pbw.
19 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein the polycarbonate is present in an amount of about 80 pbw to about 85 pbw.
20 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein the bromine-substituted oligocarbonate is present in an amount of about 5 pbw to about 15 pbw.
21 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein the bromine-substituted oligocarbonate is present in an amount of about 8 pbw to about 12 pbw.
22 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein said bromine-substituted oligocarbonate conforms structurally to formula (IV),
where R 1 , R 2 , R 3 and R 4 independently denote H, Br or CH 3 with the proviso that at least one of R 1 , R 2 , R 3 , R 4 denotes Br, and where R 5 denotes an aryl, alkylaryl or alkyl radicals, and n is 1-100.
23 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein said bromine-substituted oligocarbonate conforms structurally to formula (IVa),
and having a bromine content greater than 40 percent relative to its weight.
24 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein the phosphorus-containing compound is present in an amount of about 2 pbw to about 7 pbw.
25 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein the phosphorus-containing compound is present in an amount of about 3 pbw to about 10 pbw.
26 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein the phosphorus-containing compound conforms structurally to formula (V),
wherein
R 1 , R 2 , R 3 and R 4 independently represents C 1 -C 8 -alkyl, or C 5 -C 6 -cycloalkyl, C 6 -C 20 -aryl or C 7 -C 12 -aralkyl,
n independently denotes 0 or 1,
q denotes 0.5 to 30, and
X is a mono- or poly-nuclear aromatic radical having from 6 to 30 carbon atoms, or an aliphatic radical having from 2 to 30 carbon atoms.
27 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein the phosphorus-containing compound conforms structurally to formula (VII),
28 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein the at least one alkali or alkaline-earth salt of perfluoroalkane sulfonic acid is present in an amount of about 0.02 pbw to about 0.5 pbw.
29 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein the salt of perfluoroalkane sulfonic acid is a perfluoroalkane sulfonate salt of at least one member selected from the group consisting of alkali metal, alkaline earth metal, C 1-6 -alkylammonium, and ammonium.
30 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein the salt is at least one member selected from the group consisting of sodium perfluoromethylbutane sulphonate, potassium perfluoromethylbutane sulphonate, tetraethyl ammonium perfluoromethylbutane sulphonate; sodium perfluoromethane sulphonate, potassium perfluoromethane sulphonate, tetraethyl ammonium perfluoromethane sulphonate; sodium perfluoroethane sulphonate, potassium perfluoroethane sulphonate, tetraethyl ammonium perfluoroethane sulphonate; sodium perfluoropropane sulphonate, potassium perfluoropropane sulphonate, tetraethyl ammonium perfluoropropane sulphonate; sodium perfluorohexane sulphonate, potassium perfluorohexane sulphonate, tetraethyl ammonium perfluorohexane sulphonate; sodium perfluoroheptane sulphonate, potassium perfluoroheptane sulphonate, tetraethyl ammonium perfluoroheptane sulphonate; sodium perfluoroctanesulphonate, potassium perfluoroctanesulphonate, tetraethyl ammonium perfluoroctanesulphonate; sodium perfluorobutane sulfonate, potassium perfluorobutane sulfonate, tetraethyl ammonium perfluorobutane sulfonate; sodium diphenylsulfone-sulphonate, potassium diphenylsulfone-sulphonate, and tetraethyl ammonium diphenylsulfone-sulphonate.
31 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein the phosphite stabilizer is present in an amount of about 0.02 to about 0.5 pbw.
32 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein the phosphite stabilizer is present in an amount of about 0.04 to about 0.1 pbw.
33 . The flame-retardant, optically clear thermoplastic molding composition according to claim 17 , wherein the phosphite stabilizer is Bis(2,4-dicumylphenyl) pentaerythritol diphosphite.
34 . A process for the production of a flame-retardant, optically clear thermoplastic molding composition comprising reacting:
A) about 60 pbw to about 97 pbw of a polycarbonate;
B) about 1 pbw to about 20 pbw of bromine-substituted oligocarbonate;
C) about 1 pbw to about 20 pbw of a phosphorus-containing compound; and
D) about 0.01 pbw to about 1 pbw of at least one alkali or alkaline-earth salt of perfluoroalkane sulfonic acid,
wherein the flame-retardant, optically clear thermoplastic molding composition is free of fluorinated polyolefin and is rated 5VA at 3.00 mm and V-0 at 2.3 mm according to UL-94.
35 . A process for the production of flame-retardant, optically clear thermoplastic molding composition comprising reacting:
A) about 60 to about 97 pbw of an aromatic polycarbonate;
B) about 1 to about 20 pbw of bromine-substituted oligocarbonate;
C) about 1 to about 20 pbw of a phosphorus-containing compound;
D) about 0.01 to about 1 pbw of at least one alkali or alkaline-earth salt of perfluoroalkane sulfonic acid; and
E) about 0.01 to about 1 pbw of a phosphite antioxidant/stabilizer,
wherein the flame-retardant, optically clear thermoplastic molding composition is free of fluorinated polyolefin and is rated 5VA at 3.00 mm and V-0 at 1.5 mm according to UL-94.