Fiber reinforced composition with good impact performance and flame retardance
A composition includes a polymer base resin, a fiber filler including a sizing agent component, and an additive. The sizing agent component includes a sizing agent and a reactive aid. The composition exhibits a notched Izod impact strength of 140 to 190 J/m, and an unnotched impact strength of 500 to 1200 J/m when tested in accordance with ASTM D256.
1. A composition comprising:
a polymer base resin comprising polycarbonate, a polycarbonate copolymer, or a mixture thereof;
from 10 wt. % to 60 wt. % of a fiber filler comprising a sizing agent component and a diisocyanate component as a coating, wherein the sizing agent component is present in an amount of from 0.1 wt. % to 2 wt. % based on the weight of the fiber filler, wherein the diisocyanate component comprises hexamethylene diisocyanate; and
an additive,
wherein a molded article formed from the composition exhibits a notched Izod impact strength of 140 to 190 Joules/meter (J/m), and an unnotched Izod impact strength of 500 to 1200 J/m when tested in accordance with ASTM D256.
2. The composition according to claim 1 , wherein the composition comprises:
from 15 wt. % to 89.5 wt. % of the polymer base resin; and
from 0.5 wt. % to 20 wt. % of the additive.
3. The composition according to claim 1 , wherein the fiber filler comprises glass fiber, carbon fiber, basalt fiber, or a combination thereof.
4. The composition according to claim 3 , wherein the fiber filler comprises glass fiber.
5. The composition according to claim 1 , wherein the sizing agent comprises epoxy, polyurethane, nylon, polypropylene, polyimide, phenoxy resin, ethylene/propylene maleic anhydride copolymer resin, or a combination thereof.
6. The composition according to claim 1 , wherein the diisocyanate component further comprises isophorone diisocyanate.
7. The composition according to claim 1 , wherein the polymer base resin further comprises polyester resin.
8. The composition according to claim 1 , wherein the polymer base resin further comprises an aliphatic or aromatic polyamide.
9. The composition according to claim 1 , wherein the diisocyanate component interacts with functional end-groups of the polymer base resin.
10. The composition according to claim 1 , wherein the fiber filler comprises glass fibers, and the composition has a notched Izod impact strength that is at least 12% higher than that of a comparative composition that includes glass fibers that do not include the diisocyanate component.
11. The composition according to claim 1 , further comprising a flame retardant additive and wherein the composition exhibits a flame retardance of at least V0 at 1.0 mm when tested in accordance with UL 94.
12. The composition according to claim 1 , wherein the composition has improved adhesion between the polymer base resin and the fiber filler as compared to a comparative composition that includes a fiber filler that does not include the diisocyanate component.
13. The composition according to claim 1 , wherein:
the sizing agent comprises epoxy, polyurethane, phenoxy resin, or a combination thereof; and
the diisocyanate component further comprises isophorone diisocyanate and hexamethylene diisocyanate.
14. The composition according to claim 1 , wherein the sizing agent comprises BPA-epoxy resin and the diisocyanate component further comprises isophorone diisocyanate and hexamethylene diisocyanate.
15. The composition according to claim 1 , wherein the composition comprises from about 20 wt. % to about 60 wt. % of the fiber filler.