Polycarbonate compositions
View Patent ↗Disclosed herein are methods and compositions of blended polycarbonate resins with improved flame resistance and impact strength. The resulting compositions can be used in the manufacture of articles while still retaining the advantageous physical properties of blended polycarbonate compositions with improved flame resistance and impact strength. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present invention.
1. A polycarbonate composition comprising:
(a) from 20 to 80 weight percent of a first polycarbonate component;
(b) from greater than 0 to 25 weight percent of a polysiloxane-polycarbonate block copolymer comprising a polycarbonate block derived from bisphenol A and a diorganopolysiloxane block of the general formula (I):
wherein “x” is an integer from 40 to 60 and wherein the organopolysiloxane block is randomly distributed in a Bisphenol-A polycarbonate block copolymer such that the siloxane content within the polysiloxane-polycarbonate block copolymer is about 20% and the weight average molecular weight of the polysiloxane-polycarbonate block copolymer is from 29,000 to 31,000 daltons using Bisphenol-A polycarbonate absolute molecular weight standards;
(c) from greater than 0 to 5 weight percent of an impact modifier;
(d) from greater than 0 to 5 weight percent of an anti-dripping agent;
(e) from greater than 0 to 25 weight percent of a flame retardant;
(f) from greater than 0 to 30 weight percent of a high heat polycarbonate component comprising 2-Phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine (PPPBP); and
(g) balance of one or more additional polymer composition additives;
wherein the polycarbonate composition exhibits a notched Izod impact strength greater than 400 J/m as measured according to American Society for Testing and Materials (ASTM) D256 as measured on a bar having a thickness of about 3.2 mm and wherein the composition exhibits a UL-94 flammability rating of V0 as measured on a flame bar having a thickness of about 0.60 mm.
2. The polycarbonate composition of claim 1 , wherein the flame retardant comprises bisphenol A diphenylphosphate.
3. The polycarbonate composition of claim 1 , wherein the impact modifier comprises a methyl methacrylate-butadiene-styrene (MBS) impact modifier.
4. The polycarbonate composition of claim 1 , wherein the composition comprises less than 1000 ppm of a bromine and/or chlorine containing compound.
5. The polycarbonate composition of claim 1 , wherein the first polycarbonate component comprises a blend of two or more polycarbonate polymers.
6. The polycarbonate composition of claim 1 , further comprising from greater than 0 to 5 weight percent of a fluorinated polyolefin anti-dripping agent.
7. A polycarbonate composition comprising:
(a) from 20 to 80 weight percent of a first polycarbonate component;
(b) from 10 to 25 weight percent of a polysiloxane-polycarbonate block copolymer comprising a polycarbonate block derived from Bisphenol-A and diorganopolysiloxane block of the general formula (I):
where in “x” is an integer from 40 to 60 and wherein the organopolysiloxane block is randomly distributed in a Bisphenol-A polycarbonate block copolymer such that the siloxane content within the polysiloxane-polycarbonate block copolymer is about 20% and the weight average molecular weight of the polysiloxane-polycarbonate block copolymer is from 29,000 to 31,000 daltons using Bisphenol-A polycarbonate absolute molecular weight standards;
(c) from greater than 0 to 5 weight percent of a methyl methacrylate-butadiene-styrene (MBS) impact modifier;
(d) from greater than 0 to 25 weight percent of a bisphenol A diphenylphosphate flame retardant;
(e) from greater than 0 to 5 weight percent of an anti-dripping agent;
(f) from greater than 0 to 15 weight percent of a high heat polycarbonate component comprising 2-Phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine (PPPBP), and
(g) balance of one or more additional polymer composition additives;
wherein the composition exhibits a notched Izod impact strength greater than 400 J/m as measured according to American Society for Testing and Materials (ASTM) D256 as measured on a bar having a thickness of 3.2 mm and wherein the composition exhibits a UL-94 flammability rating of V0 as measured on a flame bar having a thickness of 0.60 mm.
8. The polycarbonate composition of claim 7 , wherein the composition comprises less than 1000 ppm of a bromine and/or chlorine containing compound.
9. The polycarbonate composition of claim 7 , wherein the first polycarbonate component comprises a blend of two or more polycarbonate polymers.
10. The polycarbonate composition of claim 7 , further comprising from greater than 0 to 5 weight percent of a fluorinated polyolefin anti-dripping agent.
11. A method for the manufacture of a polycarbonate composition that exhibits a notched Izod impact strength greater than 400 J/m as measured according to American Society for Testing and Materials (ASTM) D256 as measured on a bar having a thickness of 3.2 mm and wherein the composition exhibits a UL-94 flammability rating of V0 as measured on a flame bar having a thickness of 0.60 mm, wherein the method comprises combining
(a) a first polycarbonate component, wherein the first polycarbonate component is combined in an amount of from about 20 to 80 weight percent of the composition;
(b) a polysiloxane-polycarbonate block copolymer comprising a polycarbonate block derived from bisphenol A and a diorganopolysiloxane block of the general formula (I):
wherein “x” is an integer from 40 to 60, wherein the organopolysiloxane block is randomly distributed in a Bisphenol-A polycarbonate block copolymer such that the siloxane content within the polysiloxane-polycarbonate block copolymer is about 20% and the weight average molecular weight of the polysiloxane-polycarbonate block copolymer is from 29,000 to 31,000 daltons using Bisphenol-A polycarbonate absolute molecular weight standards, and wherein the polysiloxane-polycarbonate block copolymer is combined in an amount from greater than 0 to 25 weight percent of the composition;
(c) an impact modifier, wherein the impact modifier is combined in an amount of from greater than 0 to 5 weight percent of the composition;
(d) an anti-dripping agent, wherein the anti-dripping agent is combined in an amount from greater than 0 to 5 weight percent of the composition;
(e) a flame retardant, wherein the flame retardant is combined in an amount from greater than 0 to 25 weight percent of the composition;
(f) a high heat polycarbonate component comprising 2-Phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine (PPPBP), wherein the high heat polycarbonate component is combined in an amount from greater than 0 to 30 weight percent of the composition; and
(g) a balance amount of one or more additional polymer composition additives.
12. The method of claim 11 , wherein the flame retardant comprises bisphenol A diphenylphosphate.
13. The method of claim 11 , wherein the impact modifier comprises a methyl methacrylate-butadiene-styrene (MBS) impact modifier.
14. The method of claim 11 , wherein the composition comprises less than 1000 ppm of a bromine and/or chlorine containing compound.
15. The method of claim 11 , wherein the first polycarbonate component comprises a blend of two or more polycarbonate polymers.
16. The method of claim 11 , wherein the anti-dripping agent comprises a fluorinated polyolefin anti-dripping agent.
17. A method for the manufacture of a polycarbonate composition that exhibits a notched Izod impact strength greater than 400 J/m as measured according to American Society for Testing and Materials (ASTM) D256 as measured on a bar having a thickness of 3.2 mm and wherein the composition exhibits a UL-94 flammability rating of V0 as measured on a flame bar having a thickness of 0.60 mm, wherein the method comprises combining
(a) a first polycarbonate component, wherein the first polycarbonate component is combined in an amount of from about 20 to 80 weight percent of the composition;
(b) a polysiloxane-polycarbonate block copolymer comprising a polycarbonate block derived from bisphenol A and a diorganopolysiloxane block of the general formula (I):
where in “x” is an integer from 40 to 60, wherein the organopolysiloxane block is randomly distributed in a Bisphenol-A polycarbonate block copolymer such that the siloxane content within the polysiloxane-polycarbonate block copolymer is about 20% and the weight average molecular weight of the polysiloxane-polycarbonate block copolymer is from 29,000 to 31,000 daltons using Bisphenol-A polycarbonate absolute molecular weight standards, and wherein the polysiloxane-polycarbonate block copolymer is combined in an amount from greater than 0 to 25 weight percent of the composition;
(c) a methyl methacrylate-butadiene-styrene (MBS) impact modifier impact modifier, wherein the impact modifier is combined in an amount of from greater than 0 to 5 weight percent of the composition;
(d) an anti-dripping agent, wherein the anti-dripping agent is combined in an amount from greater than 0 to 5 weight percent of the composition;
(e) a bisphenol A diphenylphosphate flame retardant, wherein the flame retardant is combined in an amount from greater than 0 to 25 weight percent of the composition;
(f) a high heat polycarbonate component comprising 2-Phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine (PPPBP), wherein the high heat polycarbonate component is combined in an amount from greater than 0 to 15 weight percent of the composition, and
(g) a balance amount of one or more additional polymer composition additives.
18. The method of claim 17 , wherein the composition comprises less than 1000 ppm of a bromine and/or chlorine containing compound.
19. The method of claim 17 , wherein the first polycarbonate component comprises a blend of two or more polycarbonate polymers.
20. The method of claim 17 , wherein the anti-dripping agent comprises a fluorinated polyolefin anti-dripping agent.
21. An article of manufacture comprising the polycarbonate composition of claim 1 .
22. An article of manufacture comprising the polycarbonate composition of claim 7 .