Flame retardant laser direct structuring materials
View Patent ↗Flame retardant thermoplastic compositions that are capable of being used in a laser direct structuring process. The compositions include a thermoplastic resin, a laser direct structuring additive, and a flame retardant. The compositions offer flame retardant characteristics while also substantially maintaining the mechanical properties of the base thermoplastic resin, such as the impact strength and/or HDT of the composition. The compositions can be used in a variety of applications such as personal computers, notebook and portable computers, cell phone and other such communications equipment.
1. A thermoplastic composition, comprising:
a) from 70 to 85 wt % of a thermoplastic resin, wherein the thermoplastic resin comprises polyphenylene oxide, a polyphenylene oxide/polystyrene blend, or a combination comprising at least one of the foregoing resins;
b) from 0.5 to 15 wt % of a laser direct structuring additive, wherein the laser direct structuring additive is a copper chromium oxide spine; and
c) 0.1 to 15 wt % of a flame retardant, wherein the flame retardant comprises resorcinol bis(diphenyl phosphate), bisphenol-A bis(diphenyl phosphate), or a combination thereof;
wherein amounts are based on a total weight of the thermoplastic composition, and
wherein a molded sample of the thermoplastic composition is capable of being plated after being activated by a laser, wherein laser activation of the molded sample exposes metal atoms the LDS additive such that a roughened surface is formed containing embedded metal particles for crystal growth during plating, and wherein the molded sample has a UL94 VO rating at a thickness of 1.2 mm to 1.5 mm (±10%).
2. The composition of claim 1 , wherein the thermoplastic resin comprises polyphenylene oxide.
3. The composition of claim 1 , wherein a molded sample of the thermoplastic composition is capable of achieving UL94 VO rating at a thickness of 1.0 mm(±10%).
4. The composition of claim 1 , wherein a molded sample of the thermoplastic composition is capable of achieving UL94 VO rating at a thickness of 0.8 mm (±10%).
5. The composition of claim 1 , wherein the thermoplastic composition includes from 10 to 15 wt. % of the flame retardant.
6. An article of manufacture comprising the composition of claim 1 .
7. The article of claim 6 , wherein the article is selected from a personal computer, a notebook computer, a portable computers, a cell phone, or a personal digital assistant.
8. A method of forming a thermoplastic composition comprising the step of: blending in an extruder:
a) from 70 to 85 wt % of a thermoplastic resin, wherein the thermoplastic resin comprises polyphenylene oxide, a polyphenylene oxide/polystyrene blend, or a combination comprising at least one of the foregoing resins;
b) from 0.5 to 15 wt % of a laser direct structuring additive, wherein the laser direct structuring additive is a copper chromium oxide spinel; and
c) 0.1 to 15 wt % or less of a flame retardant, wherein the flame retardant comprises resorcinol bis(diphenyl phosphate), bisphenol-A bis(diphenyl phosphate), or a combination thereof;
wherein amounts are based on a total weight of the thermoplastic composition, and
wherein a molded sample of the thermoplastic composition is capable of being plated after being activated by a laser, wherein laser activation of the molded sample exposes metal atoms of the LDS additive such that a roughened surface is formed containing embedded metal particles for crystal growth during plating and wherein the molded sample has a UL94 VO rating at a thickness of 1.2 nun to 1.5 mm(±10%).
9. The method of claim 8 , wherein the thermoplastic resin comprises polyphenylene oxide.
10. The method of claim 8 , wherein a molded sample of the thermoplastic composition is capable of achieving UL94 VO rating at a thickness of 1.0 mm(±10%).
11. The method of claim 8 , wherein a molded sample of the thermoplastic composition is capable of achieving UL94 VO rating at a thickness of 0.8 mm (±10%).
12. The method of claim 8 , wherein the thermoplastic composition includes from 10 to 15 wt. % of the flame retardant.