Polycarbonate compositions, method of manufacture thereof, and articles therefrom
View Patent ↗A thermoplastic composition comprising, based on the total weight of the thermoplastic composition: 40 to 80 wt. % of an aromatic polycarbonate; 10 to 40 wt. % of a reinforcing mineral filler; 0.05 to 1.5 wt. % of a fluorinated polymer; 10 to 35 wt. % of a polyetherimide; 0 to 1.5 wt. % of sodium trichlorobenzene sulphonate; optionally, 1 to 8 wt. % of an organic phosphorus-containing flame retardant; optionally, 0.05 to 20 wt. % of an impact modifier; and optionally, 0.05 to 5 wt. % of an additive composition comprising an antioxidant, a mold release agent, and a stabilizer.
1. A thermoplastic composition comprising, based on the total weight of the thermoplastic composition:
40 to less than 80 wt. % of a linear bisphenol A polycarbonate homopolymer;
10 to 40 wt. % of a reinforcing mineral filler comprising talc, mica, or a combination thereof;
0.05 to 1.5 wt. % of a fluorinated polymer;
10 to 20 wt. % of a polyetherimide fiber;
1 to 8 wt. % of an organic phosphorus-containing flame retardant;
0.05 to 20 wt. % of an impact modifier; and
0.05 to 5 wt. % of an additive composition comprising an antioxidant, a mold release agent, and a stabilizer,
wherein the thermoplastic composition does not contain sodium trichlorobenzene sulphonate and the thermoplastic composition does not contain any glass fibers, and
a sample of the thermoplastic composition has
a maximum average heat release (MAHRE) of equal to or less than 90 kW/m 2 measured in accordance with ISO 5660-1 on a 3 mm thick plaque at 50 kW/m 2 ,
a smoke density after 4 minutes (Ds-4) of equal to or less than 300 measured in accordance with ISO 5659-2 on a 3 mm thick plaque at 50 kW/m 2 , and
a critical flux extinguishment (CFE) of equal to or greater than 20 kW/m 2 measured in accordance with ISO 5658-2 on a 3 mm thick plaque.
2. The composition of claim 1 , wherein the fluorinated polymer is polytetrafluoroethylene optionally associated with a thermoplastic fluorinated polymer having a fluorinated backbone or a styrene-acrylonitrile copolymer.
3. The composition of claim 1 , wherein the impact modifier comprises from 1 to 20 wt. % of a polycarbonate-polysiloxane impact modifier, based on the total weight of the composition.
4. The composition of claim 1 , wherein the impact modifier comprises 0.1 to 5 wt. % of a silicone oil impact modifier, based on the total weight of the composition.
5. The thermoplastic composition of claim 4 , wherein the silicone oil comprises octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane, polydimethylsiloxane, or polyphenylmethylsiloxane, or a combination comprising at least one of the foregoing.
6. The thermoplastic composition of claim 1 , wherein the impact modifier comprises silicon oil and a bulk acrylonitrile-butadiene-styrene.
7. The thermoplastic composition of claim 1 , wherein the organic phosphorus-containing flame retardant comprises units derived from bisphenol A.
8. The thermoplastic composition of claim 1 , further comprising titanium dioxide.
9. The thermoplastic composition of claim 1 , wherein:
the linear bisphenol A polycarbonate homopolymer is present in an amount of 50 wt. % to 60 wt. %;
the reinforcing mineral filler comprises 15 wt. % to 20 wt. % of talc;
the fluorinated polymer is present in an amount of 0.2 wt. % to 0.8 wt. % the fluorinated polymer being a polytetrafluoroethylene associated with a thermoplastic fluorinated polymer having a fluorinated backbone or a styrene-acrylonitrile copolymer;
the impact modifier comprises 0.1 wt. % to 5 wt. % of a silicon oil and 0.5 wt. % to 5 wt. % of a bulk acrylonitrile-butadiene-styrene; and
the phosphorus-containing flame retardant is present in the composition in an amount of 2 to 6 wt. % and comprises units derived from bisphenol A, and
the additive is present in an amount of 0.1 to 2.5 wt. %,
each based on the total weight of the thermoplastic composition.
10. The thermoplastic composition of claim 9 , wherein the impact modifier comprises 1 to 4 wt. % of the bulk acrylonitrile-butadiene-styrene and 0.5 to 1.5 wt. % of the silicone oil, each based on the total weight of the thermoplastic composition.
11. The thermoplastic composition of claim 9 , wherein the polyetherimide comprises 10 to 500 structural units of formula (11)
wherein R is m-phenylene or p-phenylene; and
T is —O—Z—O—;
wherein Z is a divalent group of formula (13a)
and Q is 2,2-isopropylidene.
12. An article comprising the composition of claim 1 .
13. The article of claim 12 , wherein the article is a sheet having a thickness of 0.1 mm to 10 mm.
14. The article of claim 12 , wherein the reinforcing mineral filler is talc, and no clay is present.
15. The article of claim 12 , in the form of an interior component for a train, or airplane.
16. The article of claim 15 , wherein the interior component is a ceiling, wall, seating, seat tray, seat back, cladding, and window surrounding.
17. A method for the manufacture of an article, comprising molding, extruding, or shaping the composition of claim 1 .