Flame resistant thermoplastic composition, articles thereof, and method of making articles

• US 20040232598A1
• Filed: 05/20/2003
• Published: 11/25/2004
• Est. Priority Date: 05/20/2003
• Status: Abandoned Application

• Current Assignee: Sabic Innovative Plastics IP BV (Government of Saudi Arabia)
• Original Assignee: Sabic Innovative Plastics IP BV (Government of Saudi Arabia)
• Inventors: Tande, Brian, Williams, Patrick G., Kirkpatrick, Lyle, Gallucci, Robert R., Kernick, William, Donea, Constantin, Mulcahy, Charles
• Application Number:
  US10/441,829
• Publication Number:
  US 20040232598A1
• Time in Patent Office: Days
• US Class Current: 264/322
• CPC Class Codes: C08K 3/346 Clay
• CPC Class Codes: C08L 2205/02 containing two or more polymers of the same C08L -group
• CPC Class Codes: C08L 2205/03 containing three or more polymers in a blend
• CPC Class Codes: C08L 2666/14 Macromolecular compounds according to C08L59/00 - C08L87/00; Derivatives thereof
• CPC Class Codes: C08L 2666/18 Polyesters or polycarbonates according to C08L67/00 - C08L69/00; Derivatives thereof
• CPC Class Codes: C08L 2666/20 Macromolecular compounds having nitrogen in the main chain according to C08L75/00 - C08L79/00; Derivatives thereof
• CPC Class Codes: C08L 65/00 Compositions of macromolecular compounds obtained by reactions forming a carbon-to-carbon link in the main chain C08L7/00 - C08L57/00, C08L61/00 take precedence; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 69/00 Compositions of polycarbonates; Compositions of derivatives of polycarbonates
• CPC Class Codes: C08L 79/08 Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
• CPC Class Codes: C08L 83/00 Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 83/10 Block- or graft-copolymers containing polysiloxane sequences obtained by polymerising a compound having a carbon-to-carbon double bond on to a polysiloxane C08L51/08, C08L53/00

Abstract

A thermoplastic composition comprising a polyimide resin, a polycarbonate resin, a polyimide-polysiloxane copolymer and talc.

Claims

1. A thermoplastic composition comprising a polyimide resin, a polycarbonate resin, a polyimide-polysiloxane copolymer and about 1 to about 30 weight percent talc based on the total weight of the composition, wherein the composition has a biaxial impact maximum load greater than or equal to about 975 kilograms per square meter, as measured by ASTM D3763 and a sixty degree gloss less than or equal to about 70, as measured by ASTM D523.

2. The composition of claim 1, wherein the composition has a two minute heat release of less than or equal to about 10 kilowatt minutes per square meter, as determined by ASTM E906.

3. The composition of claim 1, wherein the composition has a peak heat release of less than or equal to about 60 kilowatt minutes per square meter, as determined by ASTM E906.

4. The composition of claim 1, wherein the talc has an average particle size less than or equal to about 40 micrometers and greater than or equal to about 99% of the talc particles are less than or equal to about 50 micrometers.

5. The composition of claim 1, wherein the composition comprises about 10 to about 90 weight percent polyimide, based on the total weight of the composition.

6. The composition of claim 1, wherein the composition comprises about 10 to about 90 weight percent polycarbonate, based on the total weight of the composition.

8. The composition of claim 1, wherein the composition comprises about 1 to about 20 weight percent of the polyimide-polysiloxane copolymer, based on the total weight of the composition.

9. The composition of claim 1, further comprising about 0.1 to about 15 weight percent of a colorant.

10. The composition of claim 1, wherein the composition has a heat distortion value greater than or equal to about 170°

C. at 264 psi, as determined by ASTM D648.

11. The composition of claim 1, wherein the composition has an NBS smoke density value less than or equal to about 10, as determined by ASTM E662.

12. The composition of claim 1, wherein the polyimide is a polyetherimide.

13. The composition of claim 1, wherein the composition comprises less than 0.01 weight percent chlorine or bromine, based on the total weight of the composition.

14. A method of making an article comprising

heating a thermoplastic composition above its softening point;

putting the softened thermoplastic composition into a mold to make the article, wherein the thermoplastic composition comprises a polyimide resin, a polycarbonate resin, a polyimide-polysiloxane copolymer and about 1 to about 30 weight percent talc based on the total weight of the composition, and the article has a biaxial impact maximum load greater than or equal to about 975 kilograms per square meter, as measured by ASTM D3763 and a sixty degree gloss less than or equal to about 70, as measured by ASTM D523;

cooling the article until its is capable of supporting its own weight; and

removing the article from the mold.

15. The method of claim 14, wherein the softened thermoplastic composition is injected into a mold under pressure in the molten state.

16. The method of claim 14, wherein the softened thermoplastic composition is in the form of a sheet and is shaped into the article by application of pressure.

17. A thermoformed article comprising

about 35 to about 75 weight percent of a polyimide resin;

about 10 to about 30 weight percent of a polycarbonate resin;

about 2 to about 10 weight percent of a polyimide-polysiloxane copolymer; and

about 5 to about 12 weight percent talc, wherein all weights are based on the total weight of the composition and further wherein the composition has a biaxial impact maximum load greater than or equal to about 4,880 kilograms per square meter, as measured by ASTM D3763 and a sixty degree gloss less than or equal to about 70, as measured by ASTM D523.

18. The composition of claim 17, wherein the talc has an average particle size less than or equal to about 40 micrometers and greater than or equal to about 99% of the talc particles are less than or equal to about 50 micrometers.

19. The composition of claim 17, wherein the talc has an average particle size less than or equal to about 10 micrometer and greater than or equal to about 99% of the talc particles are less than or equal to about 20 micrometers.

20. The composition of claim 17, wherein the talc has an average particle size less than or equal to about 1 micrometer and greater than or equal to about 99% of the talc particles are less than or equal to about 2 micrometers.

21. The composition of claim 17, wherein the polyimide is a polyetherimide.

22. The composition of claim 17, wherein the composition comprises less than 0.01 weight percent chlorine or bromine, based on the total weight of the composition.