Flame-retardant reinforced polycarbonate compositions
View Patent ↗A composition containing a polycarbonate, a polycarbonate-polysiloxane copolymer, an alicyclic hydrocarbon resin flow promoter, an inorganic filler, a flame retardant and an impact modifier. The compositions may include polycarbonate in an amount of 40% by weight or more of the combined weights of the polycarbonate, polycarbonate-polysiloxane copolymer, inorganic filler, flame retardant, flow promoter, and impact modifier compound wherein a molded sample of the thermoplastic composition is capable of achieving UL94 V0 rating at a thickness of 1.2 mm (±10%); wherein the polymer composition has a melt viscosity of 185 Pa·sec or less, when measured at 270° C. and 1500 sec −1 ; and wherein a molded sample of the thermoplastic composition has a flexural modulus determined in accordance with ASTM D790 within 3800-8000 MPa; and wherein a 3.2-mm thick molded NII bar comprising the composition has a notched Izod impact strength of 40 to 200 J/m determined in accordance with ASTM D256 at 23° C.
1. A thermoplastic composition comprising:
a polycarbonate;
a polycarbonate-polysiloxane copolymer;
an impact modifier;
an inorganic filler, wherein the inorganic filler comprises talc, wollastonite, glass fiber or a combination including at least one of the foregoing inorganic fillers;
a flame retardant; and
an alicyclic hydrocarbon resin flow promoter;
wherein the polymer composition has a melt viscosity of 185 Pa-sec or less, when measured at 270° C. and 1500 sec −1 ;
wherein a molded sample of the thermoplastic composition is capable of achieving UL94 V0 rating at a thickness of 1.2 mm (±10%);
wherein a 3.2-mm thick molded Nil bar comprising the composition has a notched Izod impact strength of 40 to 200 J/m determined in accordance with ASTM D256 at 23° C.;
wherein a molded sample of the thermoplastic composition has a heat deformation temperature determined in accordance with ASTM D648 of 85° C. or greater; and
wherein a molded sample of the thermoplastic composition has a flexural modulus determined in accordance with ASTM D790 within 3800-8000 MPa.
2. The composition of claim 1 wherein a 3.2-mm thick molded Nil bar comprising the composition has a notched Izod impact strength of 70 to 150 J/m determined in accordance with ASTM D256 at 23° C.
3. The composition of claim 1 wherein a molded sample of the thermoplastic composition is capable of achieving UL94 V0 rating at a thickness of 0.8 mm (±10%).
4. The composition of claim 1 wherein the impact modifier is selected from acrylonitrile butadiene styrene; methylmethacrylate-butadiene-styrene copolymer; a compound rubber-based graft copolymer produced by grafting a vinyl monomer to a compound rubber containing a polyorganosiloxane and a polyalkyl (meth)acrylate, or a combination including at least one of the foregoing impact modifiers.
5. The composition of claim 1 wherein the flame retardant comprises an organic phosphate.
6. An article comprising the composition of claim 1 .
7. A method for forming an article comprising molding, extruding, shaping, or forming the composition of claim 1 to form the article.
8. A composition comprising:
40 wt. % or more of a polycarbonate;
1 to 20 wt. % of a polycarbonate-polysiloxane copolymer;
1 to 15 wt. % of an impact modifier;
10 to 40 wt. % of an inorganic filler, wherein the inorganic filler comprises talc, wollastonite, glass fiber or a combination including at least one of the foregoing inorganic fillers;
1 to 10 wt. % of an alicyclic hydrocarbon resin flow promoter; and 3 to wt. % of a flame retardant;
wherein the polymer composition has a melt viscosity of 185 Pa-sec or less, when measured at 270° C. and 1500 sec −1 ;
wherein a molded sample of the thermoplastic composition is capable of achieving UL94 V0 rating at a thickness of 1.2 mm (±10%);
wherein a 3.2-mm thick molded Nil bar comprising the composition has a notched Izod impact strength of 40 to 200 J/m determined in accordance with ASTM D256 at 23° C.;
wherein a molded sample of the thermoplastic composition has a heat deformation temperature determined in accordance with ASTM D648 of 85° C. or greater; and
wherein a molded sample of the thermoplastic composition has a flexural modulus determined in accordance with ASTM D790 within 3800-8000 MPa.
9. The composition of claim 8 wherein a 3.2-mm thick molded Nil bar comprising the composition has a notched Izod impact strength of 70 to 150 J/m determined in accordance with ASTM D256 at 23° C.
10. The composition of claim 8 wherein a molded sample of the thermoplastic composition is capable of achieving UL94 V0 rating at a thickness of 0.8 mm (±10%).
11. The composition of claim 8 wherein the impact modifier is selected from acrylonitrile butadiene styrene; methylmethacrylate-butadiene-styrene copolymer; a compound rubber-based graft copolymer produced by grafting a vinyl monomer to a compound rubber containing a polyorganosiloxane and a polyalkyl (meth)acrylate, or a combination including at least one of the foregoing impact modifiers.
12. The composition of claim 8 wherein the flame retardant comprises an organic phosphate.
13. An article comprising the composition of claim 8 .
14. A method for forming an article comprising molding, extruding, shaping, or forming the composition of claim 8 to form the article.
15. A composition comprising:
40 wt. % or more of a polycarbonate;
3 to 15 wt. % of a polycarbonate-polysiloxane copolymer;
2 to 10 wt. % of an impact modifier;
15 to 30 wt. % of an inorganic filler selected from talc, wollastonite, glass fiber or a combination including at least one of the foregoing inorganic fillers; 2 to 8 wt. % of an alicyclic hydrocarbon resin; and 5 to 15 wt. % of an organic phosphate;
wherein the polymer composition has a melt viscosity of 165 Pa-sec or less, when measured at 270° C. and 1500 sec-1;
wherein a molded sample of the thermoplastic composition is capable of achieving UL94 VO rating at a thickness of 0.8 mm (±10%);
wherein a 3.2-mm thick molded Nil bar comprising the composition has a notched Izod impact strength of 70 to 150 J/m determined in accordance with ASTM D256 at 23° C.;
wherein a molded sample of the thermoplastic composition has a heat deformation temperature determined in accordance with ASTM D648 of 85° C. or greater; and
wherein a molded sample of the thermoplastic composition has a flexural modulus determined in accordance with ASTM D790 within 3800-7000 MPa.