FLAME RETARDANT POLYCARBONATE COMPOSITIONS, METHODS OF MANUFACTURE THEREOF AND ARTICLES COMPRISING THE SAME
Disclosed herein is a flame retardant composition comprising 20 to 90 weight percent of a polycarbonate composition; where the polycarbonate composition comprises a post-consumer recycle polycarbonate and a polysiloxane-carbonate copolymer; and 1 to 20 weight percent of a phosphazene compound; where all weight percents are based on a total weight of the flame retardant composition. Disclosed herein too is a flame retardant composition comprising 50 to 90 wt % of a polycarbonate composition; where the polycarbonate composition comprises a polysiloxane-carbonate copolymer; 0.5 to 10 weight percent of a silicone oil; and 1 to 20 weight percent of a phosphazene compound; where all weight percents are based on the total weight of the flame retardant composition; where the composition displays a flame retardancy of 5VA at a thickness of 2.0 millimeters or greater; when tested as per a UL-94 protocol.
1 . A flame retardant composition comprising:
20 to 90 weight percent of a polycarbonate composition; where the polycarbonate composition comprises a post-consumer recycle polycarbonate and a polysiloxane-carbonate copolymer; and
1 to 20 weight percent of a phosphazene compound; where all weight percents are based on a total weight of the flame retardant composition.
2 . The flame retardant composition of claim 1 , where the post-consumer recycle polycarbonate is present in an amount of 20 to 60 weight percent based on the total weight of the flame retardant composition.
3 . The flame retardant composition of claim 1 , where the post-consumer recycle polycarbonate comprises polyester in an amount of 0.05 to 1 wt %, based on a total weight of the post-consumer recycle polycarbonate.
4 . The flame retardant composition of claim 1 , where the polysiloxane-carbonate copolymer comprises 15 to 25 weight percent polysiloxane based on the total weight of the flame retardant composition, and wherein the polysiloxane has a molecular weight of greater than 30,000 Daltons.
5 . The flame retardant composition of claim 1 , where the polycarbonate composition further comprises 2 to 30 weight percent of a copolycarbonate derived from a dihydroxy compound having a structure of at least one of formula (9), formula (10), or formula (11):
where the weight percent is based on the total weight of the flame retardant composition.
6 . The flame retardant composition of claim 1 , comprising 2 to 10 weight percent of the phosphazene compound.
7 . The flame retardant polycarbonate composition of claim 1 , where the phosphazene compound has the structure
where m represents an integer of 3 to 25, R 1 and R 2 are the same or different and are independently a hydrogen, a hydroxyl, a C 7-30 aryl, a C 1-12 alkoxy, or a C 1-12 alkyl.
8 . The flame retardant composition of claim 1 , where the phosphazene compound is phenoxy cyclotriphosphazene, octaphenoxy cyclotetraphosphazene, decaphenoxy cyclopentaphosphazene, or a combination comprising at least one of the foregoing phosphazene compounds.
9 . The flame retardant composition of claim 1 , where the phosphazene compound has the structure:
where X 1 represents a —N═P(OPh) 3 group or a —N═P(O)OPh group, Y 1 represents a —P(OPh) 4 group or a —P(O)(OPh) 2 group, Ph represents a phenyl group, n represents an integer from 3 to 10000, R 1 and R 2 are the same or different and are independently a hydrogen, a hydroxyl, a C 7-30 aryl, a C 1-12 alkoxy, or a C 1-12 alkyl.
10 . The flame retardant composition of claim 1 , where the phosphazene compound is a crosslinked phenoxyphosphazene.
11 . The flame retardant composition of claim 1 , where the phosphazene compound has a structure
where R 1 to R 6 can be the same of different and can be an aryl group, an aralkyl group, a C 1-12 alkoxy, a C 1-12 alkyl, or a combination thereof.
12 . The flame retardant composition of claim 1 , where the phosphazene compound has a structure
13 . The flame retardant composition of claim 1 , further comprising a pigment in an amount of 0.2 to 15 weight percent, based on the total weight of the flame retardant composition.
14 . The flame retardant composition of claim 1 , where the pigment comprises titanium dioxide or carbon black.
15 . The flame retardant composition of claim 1 , displaying a probability of a first time pass of 90% or greater to achieve a flame retardancy of V-0 at a sample thickness of at least 0.8 millimeters when tested per a UL-94 protocol.
16 . The flame retardant composition of claim 1 , displaying an impact strength of 50 to 80 kilojoules per square meter when tested as per ASTM D 256 at 23° C., a Vicat softening point of greater than or equal to 130° C., when measured as per B120, and a flame out time of less than 50 seconds.
17 . The flame retardant composition of claim 1 , displaying an impact strength of 50 to 80 kilojoules per square meter when tested as per ASTM D 256 at 23° C., a probability of a first time pass of 90% or greater to achieve a flame retardancy of V-0 at a sample thickness of at least 0.8 millimeters when tested per a UL-94 protocol; a Vicat softening point of greater than or equal to 130° C., when measured as per B120, and a flame out time of less than 50 seconds.
18 . A method of manufacturing a flame retardant composition:
blending 20 to 90 weight percent of a polycarbonate composition; where the polycarbonate composition comprises a post-consumer recycle polycarbonate and a polysiloxane-carbonate copolymer; and 1 to 20 weight percent of a phosphazene compound to form the flame retardant composition; where all weight percents are based on a total weight of the flame retardant composition; and
extruding the flame retardant composition.
19 . The method of claim 18 , further comprising blending 2 to 30 weight percent of a copolycarbonate derived from a dihydroxy compound having a structure of at least one of formula (9), formula (10), or formula (11):
where the weight percent is based on the total weight of the flame retardant composition.
20 . The method of claim 18 , further comprising blending a pigment in an amount of 0.2 to 15 weight percent, based on the total weight of the flame retardant composition
21 . The method of claim 18 , further comprising molding the flame retardant composition.
22 . A flame retardant composition comprising:
50 to 90 wt % of a polycarbonate composition; where the polycarbonate composition comprises a polysiloxane-carbonate copolymer;
0.5 to 10 weight percent of a silicone oil; and
1 to 20 weight percent of a phosphazene compound; where all weight percents are based on the total weight of the flame retardant composition; where the composition displays a flame retardancy of 5VA at a thickness of 2.0 millimeters or greater; when tested as per a UL-94 protocol.
23 . The flame retardant composition of claim 22 , where the polycarbonate composition further comprises a polycarbonate homopolymer having a weight average molecular weight of 15,000 to 40,000 Daltons.
24 . The flame retardant composition of claim 22 , where the polysiloxane-carbonate copolymer is present in amounts of about 5 to about 27 wt %, based on the total weight of the flame retardant composition.
25 . The flame retardant composition of claim 23 , where the polysiloxane-carbonate copolymer comprises 15 to 25 weight percent of polysiloxane based on the total weight of the polysiloxane-carbonate copolymer, and wherein the polysiloxane has a molecular weight of greater than 30,000 Daltons.
26 . The flame retardant composition of claim 22 , where the polysiloxane-carbonate copolymer comprises 4 to 10 weight percent of a polysiloxane based on the total weight of the polysiloxane-carbonate copolymer; and wherein the polysiloxane has a molecular weight of 25,000 to 30,000 Daltons.
27 . The flame retardant composition of claim 22 , further comprising an anti-drip agent in an amount of 1 to 10 weight percent; based on the total weight of the flame retardant composition; where the anti-drip agent is a fluorinated polyolefin or polytetrafluoroethylene.
28 . The flame retardant composition of claim 22 , where the flame retardant composition comprises a mineral filler.
29 . The flame retardant composition of claim 28 , where the mineral filler comprises talc.
30 . The flame retardant composition of claim 22 , where the silicone oil comprises a polysiloxane polymer endcapped with trimethylsilane; where the silicone oil has a viscosity at 25° C. of 20,000 to 900,000 square millimeter per second.
31 . The flame retardant composition of claim 22 , comprising 3 to 10 weight percent of the phosphazene compound.
32 . The flame retardant composition of claim 31 , where the phosphazene compound has the structure:
where m represents an integer of 3 to 25, R 1 and R 2 are the same or different and are independently a hydrogen, a hydroxyl, a C 7-30 aryl group, a C 1-12 alkoxy, or a C 1-12 alkyl.
33 . The flame retardant composition of claim 22 , where the phosphazene compound is phenoxy cyclotriphosphazene, octaphenoxy cyclotetraphosphazene, decaphenoxy cyclopentaphosphazene, or a combination comprising at least one of the foregoing phosphazene compounds.
34 . The flame retardant composition of claim 31 , where the phosphazene compound has the structure:
where X′ represents a —N═P(OPh) 3 group or a —N═P(O)OPh group, Y 1 represents a —P(OPh) 4 group or a —P(O)(OPh) 2 group, Ph represents a phenyl group, n represents an integer from 3 to 10000, R 1 and R 2 are the same or different and are independently a hydrogen, a hydroxyl, a C 7-30 aryl, a C 1-12 alkoxy, or a C 1-12 alkyl.
35 . The flame retardant composition of claim 31 , where the phosphazene compound is a crosslinked phenoxyphosphazene.
36 . The flame retardant composition of claim 31 , where the phosphazene compound has a structure:
where R 1 to R 6 can be the same of different and can be an aryl, an aralkyl group, a C 1-12 alkoxy, a C 1-12 alkyl, or a combination thereof.
37 . The flame retardant composition of claim 31 , where the phosphazene compound has a structure:
38 . The flame retardant composition of claim 31 , having a melt volume rate of greater than or equal to 4.00 cm 3 /10 minutes when tested as per ASTM D1238 and a flame out time of less than 20 seconds after being aged for 48 hours when tested as per a UL-94 protocol.
39 . A method of manufacturing a flame retardant composition comprising:
blending 50 to 90 wt % of a polycarbonate composition; where the polycarbonate composition comprises a polysiloxane-carbonate copolymer; 0.5 to 10 weight percent of a silicone oil; and 1 to 20 weight percent of a phosphazene compound to form the flame retardant composition; where all weight percents are based on the total weight of the flame retardant composition; where the composition displays a flame retardancy of 5VA at a thickness of 20 millimeters or greater; when tested as per a UL-94 protocol; and
extruding the composition.
40 . The method of claim 39 , further comprising molding the composition.
41 . An article manufactured from the composition of claim 1 .
42 . An article manufactured from the composition of claim 22 .