Flame retardant polycarbonate compositions, method of manufacture thereof, and articles therefrom

1. A thermoplastic polycarbonate composition comprising, based on the total weight of the thermoplastic polycarbonate composition:

(a) greater than 10 to less than 30 wt % of a reinforcing mineral filler, wherein the reinforcing mineral filler consists of talc; and

(b) greater than 60 to less than 90 wt. % of a polymer component, comprising, based on the weight of the polymer component,

68 to 99.9 wt. % of an aromatic polycarbonate,

0.1 to 2 wt. % of a fluorinated polymer,

0.1 to 5 wt. % of a silicone oil,

optionally, 0.1 to 25 wt. % of an impact modifier; and

optionally, 0.1 to 5 wt. % of an additive composition comprising an antioxidant, a mold release agent, and a stabilizer;

wherein a molded sample of the thermoplastic polycarbonate composition has

no drips when measured in accordance with NF P 92-505 at a thickness of 1.5 mm,

a smoke density index of less than 10, determined in accordance with the formula:

SDI=( Ds max/100)+( VOF 4/30)

wherein

SDI is the smoke density index;

Ds max is the maximum smoke density; and

VOF4 is the average smoke density measured over the first four minutes, and is calculated in accordance with the formula:

½ Ds 0 +Ds 1 +Ds 2 +Ds 3+½ Ds 4;

wherein

Ds0 is the smoke density at 0 minutes,

Ds1 is the smoke density at 1 minute,

Ds2 is the smoke density at 2 minutes,

Ds3 is the smoke density at 3 minutes, and

Ds4 is the smoke density at 4 minutes; and

Ds max, Ds0, Ds1, Ds2, Ds3, and Ds4 are measured in accordance with NF X 10-702 at a thickness of 3 mm, and

100% ductility in a multi-axial impact test at 23° C., measured in accordance with ISO 6603.

2. The composition of claim 1 , comprising from 15 to less than 30 wt. % of talc, wherein the composition has no drips at a thickness of 3 mm when measured in accordance with NF P 92-505.

3. The composition of claim 1 , further comprising 1 to 8 wt. % of an organic, phosphorus-containing flame retardant.

4. The composition of claim 1 , comprising from 1 to 25 wt. % of a polycarbonate-polysiloxane impact modifier, based on the total weight of the polymer component, wherein a molded sample of the composition has 100% ductility in a multi-axial impact test at 23° C., measured in accordance with ISO 6603.

5. The composition of claim 1 , comprising less than 6 wt. % of free styrene-acrylonitrile, based on the total weight of the polymer component, wherein a molded sample of the composition has 100% ductility in a multi-axial impact test at 23° C., measured in accordance with ISO 6603.

6. The composition of claim 1 , comprising 15 to 22 wt. % of talc as the reinforcing mineral filler, based on the total weight of the composition, wherein molded samples of the composition 4 mm in thickness have an M2 or M1 rating.

7. The composition of claim 6 , further comprising 0.2 to 2 wt. % of a fluorinated polymer, based on the total weight of the polymer component, wherein a molded sample of the composition has 100% ductility in a multi-axial impact test at 23° C. and a thickness of 3.2 mm, an M1 rating at a thickness of 1 mm, and an F1 rating at a thickness of 4 mm.

8. The composition of claim 1 , comprising 15 to 22 wt. % of talc; 88 to 95 wt. % of the polycarbonate; 0.1 to 5 wt. % of bulk acrylonitrile-butadiene styrene; 0.5 to 1.0 wt. % of silicone oil; no halogenated flame retardants; and 3 to 8 wt. % of an aromatic diphosphate flame retardant.

9. The composition of claim 8 , wherein the fluorinated polymer is polytetrafluoroethylene associated with a thermoplastic, fluorinated polymer having a fluorinated backbone.

10. The composition of claim 1 , comprising 0.25 to 2.0 wt % of silicone oil.

11. A method of forming the composition of claim 1 , comprising combining the components of the composition thereof.

12. An article comprising the composition of claim 1 .

13. A method for the manufacture of an article, comprising molding or extruding the composition of claim 1 .

14. A thermoplastic polycarbonate composition comprising, based on the total weight of the thermoplastic polycarbonate composition,

(a) 15 to 22 wt. % of talc;

(b) less than 5 wt. % of clay; and

(c) 78 to 85 wt. % of a polymer component, comprising, based on the weight of the polymer component,

79 to 98.7 wt. % of a polycarbonate comprising units derived from bisphenol A;

0.1 to 2 wt. % of a fluorinated polymer;

1 to 8 wt. % of a phosphorus-containing flame retardant comprising units derived from bisphenol A;

0 to 5 wt. % of a bulk acrylonitrile-butadiene-styrene;

0.1 to 5 wt. % of a silicone oil; and

0.1 to 1 wt. % of an additive composition comprising an antioxidant, a mold release agent, and a stabilizer;

wherein a molded sample of the thermoplastic polycarbonate composition has

no drips when measured in accordance with NF P 92-505;

a smoke density index of less than 10 determined in accordance with the formula:

SDI=( Ds max/100)+( VOF 4/30)

wherein

SDI is the smoke density index;

Ds max is the maximum smoke density; and

VOF4 is the average smoke density measured over the first four minutes, and is calculated in accordance with the formula:

½ Ds 0 +Ds 1 +Ds 2 +Ds 3+½ Ds 4;

wherein

Ds0 is the smoke density at 0 minutes,

Ds1 is the smoke density at 1 minute,

Ds2 is the smoke density at 2 minutes,

Ds3 is the smoke density at 3 minutes, and

Ds4 is the smoke density at 4 minutes; and

Ds max, Ds0, Ds1, Ds2, Ds3, and Ds4 are measured in accordance with NF X 10-702 at a thickness of 3 mm;

100% ductility in a multi-axial impact test at 23° C., measured in accordance with ISO 6603; and an M1 rating at a thickness of 4 mm.

15. The composition of claim 14 , comprising 0.25 to 2.0 wt % of silicone oil.

16. A sheet, comprising:

a thermoplastic polycarbonate composition comprising, based on the total weight of the thermoplastic polycarbonate composition:

(a) greater than 10 to less than 30 wt. % of a reinforcing mineral filler, wherein the reinforcing mineral filler consists of talc;

(b) greater than 60 to less than 90 wt. % of a polymer component, comprising, based on the weight of the polymer component,

68 to 99.7 wt. % of an aromatic polycarbonate,

0.3 to 2 wt. % of a fluorinated polymer comprising a polytetrafluoroethylene associated with a thermoplastic, fluorinated polymer having a fluorinated backbone,

0.1 to 5.0 wt. % of a silicone oil,

optionally, 0.1 to 25 wt. % of an impact modifier; and

optionally, 0.1 to 5 wt. % of an additive composition comprising an antioxidant, a mold release agent, and a stabilizer;

wherein the sheet has

no drips when measure in accordance with NF P 92-505 at a thickness of 1.5 mm,

a smoke density index of less than 10 determined in accordance with the formula:

SDI=( Ds max/100)+( VOF 4/30)

wherein

SDI is the smoke density index;

Ds max is the maximum smoke density; and

VOF4 is the average smoke density measured over the first four minutes, and is calculated in accordance with the formula:

½ Ds 0 +Ds 1 +Ds 2 +Ds 3+½ Ds 4;

wherein

Ds0 is the smoke density at 0 minutes,

Ds1 is the smoke density at 1 minute,

Ds2 is the smoke density at 2 minutes,

Ds3 is the smoke density at 3 minutes, and

Ds4 is the smoke density at 4 minutes; and

Ds max, Ds0, Ds1, Ds2, Ds3, and Ds4 are measured in accordance with NF X 10-702 at a thickness of 3 mm, and

an M1 rating and an F1 rating at a sheet thickness of 4 mm, and 100% ductility in a multi-axial impact test at 23° C., measured in accordance with ISO 6603.

17. The sheet of claim 16 , wherein the sheet has a thickness of 1 mm to 6 mm.

18. The sheet of claim 16 , comprising 0.25 to 2 wt. % of silicone oil, based on the total weight of the polymer component, wherein a 4 mm thick sheet has 100% ductility in a multi-axial impact test at 23° C., measured in accordance with ISO 6603.

19. The sheet of claim 16 , wherein the fluoropolymer comprises 70 to 90 wt. % of the polytetrafluoroethylene and 10 to 30 wt. % of the thermoplastic, fluorinated polymers having a fluorinated backbone, based on the total weight of the fluorinated polymer.

20. The sheet of claim 16 , in the form of an interior component for a hospital, school, train, or airplane, wherein the interior component is selected from the group consisting of a ceiling, wall, seating, seat trays, seat backs, cladding, and window surrounding.

21. A method of forming an article, comprising thermoforming the sheet of claim 16 to form the article.

22. The method of claim 21 , wherein the article has surfaces that are free from surface irregularities as viewed by the unaided eye.

23. A sheet comprising, based on the total weight of the thermoplastic polycarbonate composition:

(a) greater than 10 to less than 30 wt. % of reinforcing mineral filler, wherein the reinforcing mineral filler consists of talc; and

(b) greater than 60 to less than 90 wt. % of a polymer component, comprising, based on the weight of the polymer component,

68 to 99.9 wt. % of an aromatic polycarbonate,

0.1 to 2 wt. % of a fluorinated polymer,

0.1 to 5 wt. % of a silicone oil,

optionally, 0.1 to 25 wt. % of an impact modifier; and

optionally, 0.1 to 5 wt. % of an additive composition comprising an antioxidant, a mold release agent, and a stabilizer;

wherein the sheet has

no drips when measured in accordance with NF P 92-505 at a thickness of 1.5 mm, and

a smoke density index of less than 10, determined in accordance with the formula:

SDI=( Ds max/100)+( VOF 4/30)

wherein

SDI is the smoke density index;

Ds max is the maximum smoke density; and

VOF4 is the average smoke density measured over the first four minutes, and is calculated in accordance with the formula:

½ Ds 0 +Ds 1 +Ds 2 +Ds 3+½ Ds 4;

wherein

Ds0 is the smoke density at 0 minutes,

Ds1 is the smoke density at 1 minute,

Ds2 is the smoke density at 2 minutes,

Ds3 is the smoke density at 3 minutes, and

Ds4 is the smoke density at 4 minutes; and

Ds max, Ds0, Ds1, Ds2, Ds3, and Ds4 are measured in accordance with NF X 10-702 at a thickness of 3 mm, and

100% ductility in a multi-axial impact test at 23° C., measured in accordance with ISO 6603.

24. The sheet of claim 23 , wherein the fluorinated polymer comprises polytetrafluoroethylene associated with thermoplastic fluorinated polymers having a fluorinated backbone, based on the weight of the polymer component.

25. The sheet of claim 23 , comprising 0.25 to 2.0 wt % of silicone oil.