Flame retardant poly(siloxane-etherimide) copolymer compositions, methods of manufacture, and articles formed therefrom

1. A composition comprising:

a first polymer comprising a poly(etherimide-siloxane) copolymer comprising (a) a repeating polyetherimide unit, and (b) a repeating poly(siloxane) block unit, the poly(siloxane) block unit having the formula:

wherein

R is each independently a C 1 -C 30 hydrocarbon group, and

E has an average value of 5 to 200;

a second polymer different from the first polymer and comprising bromine; and

an optional one or more polymers comprising a polycarbonate different from the second polymer;

wherein

the composition is free of copolymers comprising carbonate units and ester units,

the wt % of the first polymer, second polymer, and optional one or more polymers sum to 100 wt %,

siloxane units are present in the composition in an amount of 0.3 to 3.5 wt %, based on the sum of the wt % of the first, second, and optional one or more polymers, and

bromine is present in the composition in an amount of 7.8 wt % to 13 wt %, based on the sum of the wt % of the first, second, and optional one or more polymers; and

further wherein an article molded or formed from the composition has

an OSU integrated 2 minute heat release test value of less than 65 kW-min/m 2 and a peak heat release rate of less than 65 kW/m 2 as measured using the method of FAR F25.4, in accordance with Federal Aviation Regulation FAR 25.853 (d), and

an E662 smoke test Dmax value of less than 200 when measured at a thickness of 1.6 mm.

2. The composition of claim 1 , wherein the polysiloxane unit of the first polymer is derived from a polysiloxane diamine of the formula:

wherein

R is each independently a C 1 -C 12 hydrocarbon group,

R 4 is each independently a C 2 -C 20 hydrocarbon group, and

E has an average value of 5 to 100.

3. The composition of claim 2 , wherein

R is each independently a C 1 -C 6 hydrocarbon group,

R 4 is each independently a C 2 -C 6 alkyl group, and

E has an average value of 5 to 80.

4. The composition of claim 2 , wherein R is methyl, R 4 is 1,3-propylene, and E is 5 to 100.

5. The composition of claim 1 , wherein the polysiloxane unit of the first polymer is derived from a polysiloxane dianhydride of formulas:

or a combination thereof, wherein

R is each independently a C 1 -C 12 hydrocarbon group,

Ar is a C 6 -C 30 aromatic group, and

E has an average value of 5 to 200.

6. The composition of claim 1 , wherein the polysiloxane unit of the first polymer is present in an amount of at least 2.0 wt %, based on the weight of the first polymer.

7. The composition of claim 1 , wherein the polyetherimide unit comprises a unit of the formula:

wherein

R is a C 6-20 aromatic hydrocarbon group or halogenated derivative thereof, a straight or branched chain C 2-20 alkylene group or halogenated derivative thereof, a C 3-20 cycloalkylene group or halogenated derivative thereof; and

Z is an aromatic C 6-24 monocyclic or polycyclic moiety optionally substituted with 1 to 6 C 1-8 alkyl groups, 1 to 8 halogen atoms, or a combination thereof.

8. The composition of claim 7 , wherein in the polyetherimide unit,

R is a group of the formula:

wherein Q 1 is —O—, —S—, —C(O)—, —SO 2 —, —SO—, or —C y H 2y — or a halogenated derivative thereof wherein y is an integer from 1 to 5; and

Z is a group of the formula:

wherein Q is —O—, —S—, —C(O)—, —SO 2 —, —SO—, or —C y H 2y — or a halogenated derivative thereof wherein y is an integer from 1 to 5.

9. The composition of claim 8 , wherein in the polyetherimide unit R is m-phenylene, p-arylene diphenylsulfone, or a combination comprising at least one of the foregoing, and Z is 2,2-(4-phenylene)isopropylidene.

10. The composition of claim 1 , wherein the bromine is present in the second polymer in an amount of at least 30 wt %, based on the weight of the second polymer.

11. The composition of claim 1 , wherein the second polymer is a brominated polycarbonate.

12. The composition of claim 11 , wherein the brominated polycarbonate comprises 25 to 35 mol % of units derived from 2,2′6,6′tetrabromo-4,4′isopropylidienediphenol and 65 to 75 mole % of units derived from Bisphenol A.

13. The composition of claim 1 , wherein the brominated polymer is a brominated epoxy polymer.

14. The composition of claim 1 , wherein the optional at least one polymers comprise a carbonate unit of the formula

wherein R 1 is derived from a bisphenol compound of the formula:

wherein

each of Ra a and R b is independently a halogen atom or a monovalent hydrocarbon group;

p and q are each independently integers of 0 to 4; and

X a is a single bond or a group of the formula:

wherein each R c and R d is independently hydrogen, C 1-12 alkyl, C 1-12 cycloalkyl, C 7-12 arylalkyl, C 1-12 heteroalkyl, or cyclic C 7-12 heteroarylalkyl, and R e is a divalent C 1-12 hydrocarbon group.

15. The composition of claim 14 , wherein the carbonate unit is derived from bisphenol A.

16. The composition of claim 1 comprising, based on the sum of the wt % of the poly(etherimide-siloxane) copolymer, the second polymer, and the polycarbonate,

at least 1 wt % of the poly(etherimide-siloxane) copolymer,

at least 30 wt % of the second polymer; and

0 to 60 wt % of the polycarbonate.

17. The composition of claim 1 having a hydrogen to carbon ratio of 0.81:1 to 0.88:1.

18. The composition of claim 1 , having a density of less than 1.31 g/cc.

19. The composition of claim 1 , having a density of less than 1.30 g/cc.

20. The composition of claim 1 , having an E662 smoke test Dmax value of less than 100 when measured at a thickness of 1.6 mm.

21. The composition of claim 1 , wherein an article molded from the composition has a room temperature notched Izod impact of greater than 500 J/m as measured according to ASTM D 256-10 at a 0.125 inch (3.2 mm) thickness.

22. The composition of claim 1 , wherein an article molded from the composition has a haze less of less than 15% and a transmission greater than 75%, each measured using the color space CIE1931 (Illuminant C and a 2° observer) at a 0.125 inch (3.2 mm) thickness.

23. The composition of claim 22 , wherein an article molded from the composition has a room temperature notched Izod impact of greater than 500 J/m as measured according to ASTM D 256-10 at a 0.125 inch (3.2 mm) thickness.

24. The composition of claim 1 , further comprising 0.5 to 3 parts per hundred parts by weight of titanium dioxide, based on the sum of the wt % of the first, second, and optional at least one polymers.

25. The compositions of claim 1 , wherein the composition is substantially free of a fibrillated, fluorinated polyolefin.

26. An article selected from a molded article, a thermoformed article, a foamed article, an extruded film, an extruded sheet, one or more layers of a multi-layer article, a substrate for a coated article, or a substrate for a metallized article made from the composition of claim 1 .

27. The article of claim 26 , wherein the article is a component of an aircraft interior or a train interior.

28. The article of claim 27 , wherein the article is selected from an access panel, access door, air flow regulator, air gasper, air grille, arm rest, baggage storage door, balcony component, cabinet wall, ceiling panel, door pull, door handle, duct housing, enclosure for an electronic device, equipment housing, equipment panel, floor panel, food cart, food tray, galley surface, handle, housing for television, light panel, magazine rack, telephone housing, partition, part for trolley cart, seat back, seat component, railing component, seat housing, shelve, side wall, speaker housing, storage compartment, storage housing, toilet seat, tray table, tray, trim panel, window molding, window slide, or window.

29. A composition comprising:

a first polymer comprising a poly(etherimide-siloxane) copolymer comprising (a) a repeating polyetherimide unit, and (b) a repeating poly(siloxane) block unit derived from a polysiloxane diamine of the formula:

wherein

R is methyl, R 4 is 1,3-propylene, and E is 5 to 100;

a second polymer different from the first polymer and comprising bromine, the second polymer being a brominated polycarbonate comprising 25 to 35 mol % of units derived from 2,2′6,6′tetrabromo-4,4′isopropylidienediphenol and 65 to 75 mole % of units derived from Bisphenol A; and

an optional one or more polymers comprising a polycarbonate different from the second polymer;

wherein

the composition is free of copolymers comprising carbonate units and ester units,

the wt % of the first polymer, second polymer, and optional one or more polymers sum to 100 wt %,

siloxane units are present in the composition in an amount of 0.3 to 3.5 wt %, based on the sum of the wt % of the first, second, and optional one or more polymers, and

bromine is present in the composition in an amount of 7.8 to 13 wt %, based on the sum of the wt % of the first, second, and optional one or more polymers; and

further wherein an article molded or formed from the composition has

an OSU integrated 2 minute heat release test value of less than 65 kW-min/m 2 and a peak heat release rate of less than 65 kW/m 2 as measured using the method of FAR F25.4, in accordance with Federal Aviation Regulation FAR 25.853 (d), and

an E662 smoke test Dmax value of less than 200 when measured at a thickness of 1.6 mm.