Flame retardant polycarbonate compositions, methods of manufacture thereof and articles comprising the same
View Patent ↗Disclosed herein is a flame retardant composition comprising a polycarbonate composition, glass fibers, and a flame retardant that comprises a phenoxyphosphazene compound. Disclosed herein too are methods for manufacturing a flame retardant composition that comprises blending a polycarbonate composition, glass fibers and a flame retardant that comprises a phenoxyphosphazene compound.
1. A flame retardant composition comprising:
45 to 90 weight percent of a polycarbonate composition; where the polycarbonate composition comprises a polysiloxane-carbonate copolymer and a copolyester carbonate copolymer;
10 to 40 weight percent of glass fibers; 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.
2. The flame retardant composition of claim 1 , where the copolyester carbonate copolymer comprises poly(1,4-cyclohexane-dimethanol-1,4-cyclohexanedicarboxylate) in an amount of 5 to 25 wt %, based on the total weight of the flame retardant composition.
3. The flame retardant composition of claim 1 , where the polysiloxane-carbonate copolymer comprises 4 to 10 weight percent polysiloxane and wherein the polysiloxane is present in an amount of 40 to 82 weight percent, based on the total weight of the flame retardant composition.
4. The flame retardant polycarbonate composition of claim 1 , where the phosphazene compound has the structure of formula (23)
where in the formula (23), 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.
5. The flame retardant polycarbonate 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.
6. The flame retardant polycarbonate 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.
7. The flame retardant polycarbonate composition of claim 1 , where the phosphazene compound is a crosslinked phenoxyphosphazene.
8. The flame retardant polycarbonate 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.
9. The flame retardant polycarbonate composition of claim 1 , where the phosphazene compound has a structure:
10. The flame retardant polycarbonate composition of claim 1 , where the glass fiber is a flat glass fiber, a round glass fiber, a chopped fiber, a woven glass fiber, or a non-woven glass fiber.
11. The flame retardant composition of claim 1 , where the glass fiber is fiber glass.
12. The flame retardant composition of claim 11 , where the fiber glass is bonding fiber glass and is bonded with polycarbonate.
13. The flame retardant composition of claim 11 , where the fiber glass is non-bonding fiber glass.
14. The flame retardant polycarbonate composition of claim 1 , displaying a flame retardancy of V-1 at a sample thickness of at least 2.0 millimeters when tested per a UL-94 protocol.
15. The flame retardant polycarbonate composition of claim 1 , displaying an impact strength of 60 to 250 joules per meter when tested as per ASTM D 256 at 23° C., and a transparency of greater than 75% at a thickness of 2 millimeters or less.
16. The flame retardant polycarbonate composition of claim 1 , displaying an impact strength of 60 to 250 joules per meter when tested as per ASTM D 256 at 23° C., and a haze of less than 60% at a thickness of 2 millimeters or less.
17. The flame retardant polycarbonate composition of claim 1 , displaying a flame retardancy of at least V-1 at a thickness of 2.0 millimeters when measured as per the UL-94 protocol and an impact strength of greater than or equal to 120 joules per meter, when tested as per ASTM D 256 at 23° C.
18. A method comprising:
blending 45 to 90 weight percent of a polycarbonate composition; where the polycarbonate composition comprises a polysiloxane-carbonate copolymer and a copolyester carbonate copolymer; 10 to 40 weight percent of glass fibers; and 1 to 20 weight percent of a phosphazene compound to produce a flame retardant composition; where all weight percents are based on the total weight of the flame retardant composition; and
extruding the flame retardant composition.
19. The method of claim 18 , further comprising molding the composition.
20. A flame retardant composition comprising:
50 to 90 wt % of a polycarbonate composition; where the polycarbonate composition comprises a polysiloxane-carbonate copolymer and a copolyester-carbonate copolymer; where the copolyester carbonate copolymer comprises a polycarbonate and a polyester derived from sebacic acid and a dihydroxy compound;
10 to 40 weight percent of glass fibers; 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.
21. The flame retardant composition of claim 20 , where the polysiloxane-carbonate copolymer is present in amounts of about 5 to about 30 wt %, based on the total weight of the flame retardant composition.
22. The flame retardant composition of claim 20 , the copolyester carbonate copolymer comprises a first polycarbonate copolymer and a second polycarbonate copolymer; where the first polycarbonate copolymer and the second polycarbonate copolymer are each separately present in amounts of about 15 to about 70 wt %, based on the total weight of the flame retardant composition.
23. The flame retardant composition of claim 22 , where the first polycarbonate copolymer comprises 3 to 8 mole percent of the polyester derived from sebacic acid and where the first polycarbonate copolymer has a weight average molecular weight of 15,000 to 28,000 Daltons and is present in an amount of 20 to 55 weight percent based on the total weight of the flame retardant composition.
24. The flame retardant composition of claim 22 , where the second polycarbonate copolymer comprises 7 to 12 mole percent of the polyester derived from sebacic acid and where the first polycarbonate copolymer has a weight average molecular weight of 30,000 to 45,000 Daltons and is present in an amount of 10 to 35 weight percent based on the total weight of the flame retardant composition.
25. The flame retardant composition of claim 20 , polysiloxane-carbonate copolymer is present in an amount of 15 to 25 weight percent based on the total weight of the flame retardant composition and where the weight average molecular weight of the polysiloxane is 25,000 to 30,000 Daltons using gel permeation chromatography with a bisphenol A polycarbonate absolute molecular weight standard.
26. The flame retardant composition of claim 20 , comprising 3 to 10 weight percent of the phosphazene compound.
27. The flame retardant polycarbonate composition of claim 20 , 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.
28. The flame retardant polycarbonate composition of claim 20 , where the phosphazene compound is phenoxy cyclotriphosphazene, octaphenoxy cyclotetraphosphazene, decaphenoxy cyclopentaphosphazene, or a combination comprising at least one of the foregoing phosphazene compounds.
29. The flame retardant polycarbonate composition of claim 20 , 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.
30. The flame retardant polycarbonate composition of claim 20 , where the phosphazene compound is a crosslinked phenoxyphosphazene.
31. The flame retardant polycarbonate composition of claim 20 , 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.
32. The flame retardant polycarbonate composition of claim 20 , where the phosphazene compound has a structure:
33. The flame retardant polycarbonate composition of claim 20 , where the glass fiber is a flat glass fiber, a round glass fiber, a chopped fiber, a woven glass fiber, or a non-woven glass fiber.
34. The flame retardant composition of claim 33 , where the glass fiber is fiber glass.
35. The flame retardant composition of claim 33 , where the fiber glass is bonding fiber glass and is bonded with polycarbonate.
36. The flame retardant composition of claim 33 , where the fiber glass is non-bonding fiber glass.
37. The flame retardant polycarbonate composition of claim 20 , displaying a flame retardancy of V-0 or V-1 at a sample thickness of at least 1.5 millimeters when tested per a UL-94 protocol.
38. The flame retardant polycarbonate composition of claim 20 , displaying an impact strength of 150 to 300 joules per meter when tested as per ASTM D 256 at 23° C. and a flame retardancy of V-0 at a sample thickness of at least 1.5 millimeters when tested per a UL-94 protocol.
39. The flame retardant polycarbonate composition of claim 20 , displaying an impact strength of 150 to 300 joules per meter when tested as per ASTM D 256 at 23° C. and a flame retardancy of V-1 at a sample thickness of at least 1.5 millimeters when tested per a UL-94 protocol.
40. The flame retardant polycarbonate composition of claim 20 , displaying a flame retardancy of at least V-1 at a thickness of 1.5 millimeters when measured as per the UL-94 protocol and a melt volume rate of 14 to 22 cm 3 per 10 minutes when tested as per ASTM D 1238 at 300° C. and 1.2 kilograms.
41. A method comprising:
blending 50 to 90 wt% of a polycarbonate composition; where the polycarbonate composition comprises a polysiloxane-carbonate copolymer and a copolyester-carbonate copolymer; where the copolyester carbonate copolymer comprises a polycarbonate and a polyester derived from sebacic acid and a dihydroxy compound; 10 to 40 weight percent of glass fibers; and 1 to 20 weight percent of a phosphazene compound to produce a flame retardant composition; and
extruding the composition.
42. The method of claim 41 , further comprising molding the composition.
43. An article manufactured from the composition of claim 1 .
44. An article manufactured from the composition of claim 20 .