Flame-retardant polycarbonate compositions
View Patent ↗The present invention relates to flame-retardant polycarbonate compositions and methods for increasing the flame-retardancy of polycarbonate compositions. An α,ω-alkoxy phenyl phenyloligosiloxane compound and an alkali metal sulfonate salt are added to the polycarbonate compositions. The addition of the α,ω-alkoxy phenyl phenyloligosiloxane compound and the alkali metal sulfonate salt produces a polycarbonate composition having a flame-retardance rating of UL 94V-0 at 2 mm thickness or less.
1. A method for increasing the flame retardancy of a polycarbonate composition, the method comprising
adding about 0.1 wt. % to about 2.0 wt. % 1,3-dimethyltetraphenyldisiloxane to the polycarbonate composition; and
adding about 0.1 wt. % to about 1.0 wt. % perfluorobutanesulfonate alkali metal salt to the polycarbonate composition;
wherein the wt. %, all instances, are based on the total weight of the polycarbonate, the 1,3-dimethyltetraphenyldisiloxane, and the perfluorobutanesulfonate alkali metal salt; and wherein the composition exhibits a flame-retardance rating of UL 94V-0 at 2 mm thickness or less.
2. The method according to claim 1 , wherein the polycarbonate composition is substantially free of polytetrafluoroethylene-based anti-dripping agents.
3. The method according to claim 1 , wherein the 1,3-dimethyltetraphenyldisiloxane is added in an amount of about 0.1 wt. % to about 1.5 wt. %.
4. The method according to claim 1 , wherein the 1,3-dimethyltetraphenyldisiloxane is added in an amount of about 0.2 wt. % to about 1.4 wt. %.
5. The method according to claim 1 , wherein the perfluorobutanesulfonate alkali metal salt is added in an amount of about 0.1 wt. % to about 0.2 wt. %.
6. The method of claim 1 , wherein the perfluorobutanesulfonate alkali metal salt is added in an amount of 0.15 wt. % to 0.20 wt. %.
7. The method according to claim 1 , wherein the 1,3-dimethyltetraphenyldisiloxane and the perfluorobutanesulfonate alkali metal salt are mixed with the polycarbonate composition, and the mixture is melt compounded.
8. The method according to claim 1 , wherein the 1,3-dimethyltetraphenyldisiloxane and the perfluorobutanesulfonate alkali metal salt are mixed with the polycarbonate composition, and the mixture is melt extruded.
9. The method of claim 1 , wherein the 1,3-dimethyltetraphenyldisiloxane and the perfluorobutanesulfonate alkali metal salt are mixed with the polycarbonate composition, and the mixture is granulated.
10. A composition comprising:
(A) a polycarbonate;
(B) about 0.1 wt. % to about 2.0 wt. % 1,3-dimethyltetraphenyldisiloxane based on total weight of (A), (B), and (C); and
(C) about 0.1 wt. % to about 1.0 wt. % perfluorobutanesulfonate alkali metal salt wherein the wt. %, all instances, is based on total weight of (A), (B), and (C); and wherein the composition exhibits a flame-retardance rating of UL 94V-0 at 2 mm thickness or less.
11. The composition according to claim 10 , wherein the composition is substantially free of polytetrafluoroethylene-based anti-dripping agents.
12. The composition according to claim 10 , wherein the composition comprises about 0.1 wt. % to about 1.5 wt. % 1,3-dimethyltetraphenyldisiloxane based on the total weight of the composition.
13. The composition according to claim 10 , wherein the composition comprises about 0.2 wt. % to about 1.4 wt. % 1,3-dimethyltetraphenyldisiloxane based on the total weight of (A), (B), and (C).
14. The composition according to claim 10 , wherein the composition comprises about 0.1 wt. % to about 0.2 wt. % perfluorobutanesulfonate alkali metal salt based on the total weight of (A), (B), and (C).
15. The composition according to claim 10 , wherein the composition comprises about 0.15 wt. % to about 0.20 wt. % perfluorobutanesulfonate alkali metal salt based on the total weight of (A), (B), and (C).
16. A method for increasing the flame retardancy of a polycarbonate composition, the method comprising:
adding about 0.2 wt. % to about 1.4 wt. % of an α,ω-alkoxy diphenyloligosiloxane of the formula (2)
where n=2-4 to the polycarbonate composition; and
adding about 0.15 wt. % to about 0.20 wt. % of a perfluoroalkane sulfonate alkali metal salt to the polycarbonate composition;
wherein the wt. %, all instances, is based on the total weight of the polycarbonate, the α,ω-alkoxy diphenyloligosiloxane, and the potassium perfluorobutanesulfonate, and wherein the composition exhibits a flame-retardance rating of UL 94V-0 at 2 mm thickness or less.
17. The method according to claim 16 , wherein the α,ω-alkoxy phenyl phenyloligosiloxane compound comprises 1,3-dimethyltetraphenyldisiloxane, and wherein the alkali metal perfluoroalkane sulfonate salt comprises potassium perfluorobutanesulfonate.
18. The method according to claim 16 , wherein the polycarbonate composition is substantially free of polytetrafluoroethylene-based anti-dripping agents.
19. A composition comprising:
(A) a polycarbonate;
(B) about 0.2 wt. % to about 1.4 wt. % of an α,ω-alkoxy diphenyloligosiloxane of the formula (2)
where n=2-4 based on total weight of the composition; and
(C) about 0.15 wt. % to about 0.20 wt. % of a perfluoroalkane sulfonate alkali metal salt based on total weight of (A), (B), and (C);
wherein the composition exhibits a flame-retardance rating of UL 94V-0 at 2 mm thickness or less.
20. The composition according to claim 19 , wherein the α,ω-alkoxy phenyl phenyloligosiloxane compound comprises 1,3-dimethyltetraphenyldisiloxane, and wherein the alkali metal perfluoroalkane sulfonate salt comprises potassium perfluorobutanesulfonate.
21. The composition according to claim 19 , wherein the composition is substantially free of polytetrafluoroethylene-based anti-dripping agents.