ELECTRICAL TRACKING RESISTANCE COMPOSITIONS, METHODS & ARTICLES OF MANUFACTURE

• US 20120248382A1
• Filed: 08/11/2011
• Published: 10/04/2012
• Est. Priority Date: 03/31/2011
• Status: Active Grant

• Current Assignee: SHPP Global Technologies BV (Government of Saudi Arabia)
• Original Assignee: Sabic Innovative Plastics IP BV (Government of Saudi Arabia)
• Inventors: van de Wetering, Karin, van de Grampel, Robert D., Pal, Jaykisor, Van Zyl, Andries J. P.
• Granted Patent: US 8,703,856 B2
• Time in Patent Office: Days
• US Class Current: 252/506
• CPC Class Codes: C08K 3/04 Carbon
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 5/0066 Flame-proofing or flame-retarding additives
• CPC Class Codes: C08K 9/06 with silicon-containing compounds
• CPC Class Codes: C08L 2201/02 Flame or fire retardant/resistant
• CPC Class Codes: C08L 23/28 by reaction with halogens or compounds containing halogen C08L23/32 takes precedence
• CPC Class Codes: C08L 27/18 Homopolymers or copolymers or tetrafluoroethene
• CPC Class Codes: C08L 63/00 Compositions of epoxy resins; Compositions of derivatives of epoxy resins
• CPC Class Codes: C08L 69/00 Compositions of polycarbonates; Compositions of derivatives of polycarbonates
• 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
• CPC Class Codes: H01B 7/295 using material resistant to flame

Abstract

This disclosure relates to polycarbonate compositions, methods, and articles of manufacture that at least meets certain electrical tracking resistance requirements. The compositions, methods, and articles of manufacture that meet these requirements contain at least a polycarbonate; a polysiloxane block co-polycarbonate; and a transition metal oxide, e.g. titanium dioxide.

Claims

1. A composition comprising:

a polycarbonate that is not a polysiloxane block co-polycarbonate;

a polysiloxane block co-polycarbonate;

a transition metal oxide;

a brominated organic flame retardant or a halogen organic flame retardant compound;

optionally 0 to 1 wt % of a fluorinated polyolefin;

optionally an additive that imparts a desired performance property; and

optionally a carbon black containing material, wherein said composition has a p(FTP)V0 flammability rating of greater than 0.85 at 1.5 mm, 1.0 mm, or 0.8 mm or between 1.5 mm and 0.8 mm according to the method of UL 94, and further wherein the composition does not show tracking through at least 50 drops of a 0.1% aqueous ammonium chloride solution at 250V according to ASTM D-3638.

2. The composition of claim 1, wherein the polycarbonate is derived from a bisphenol comprising Bisphenol-A.

3. The composition of claim 1, wherein the polysiloxane block co-polycarbonate is derived from at least Bisphenol-A or dihydroxy aromatic containing unit(s), and polysiloxane bisphenol having the structure 1,

4. The composition of claim 3, wherein the average value of E of structure 1 is 20 to 60.

5. The composition of claim 3, wherein the average value of E of structure 1 is 30 to 50.

6. The composition of claim 1, wherein the transition metal oxide is a titanium dioxide and optionally wherein the titanium dioxide has an average particle size is greater than 50 nm and less than 350 nm.

7. The composition of claim 6, wherein the titanium dioxide is an inorganic coated titanium dioxide without an organic coating.

8. The composition of claim 6, wherein the titanium dioxide is an organic coated titanium dioxide with an organic coating.

9. The composition of claim 8, wherein the organic coating is a polysiloxane coating.

10. The composition of claim 1, wherein the brominated organic flame retardant has a bromine content of between 0.3 wt % and 10 wt % bromine atoms based on the total weight of the composition.

11. The composition of claim 1, wherein the brominated organic flame retardant has a bromine content of between 2 wt % and 6 wt % bromine atoms based on the total weight of the composition.

12. The composition of claim 1, wherein the transitional metal oxide is chromium dioxide.

13. The composition of claim 1, wherein the polysiloxane block co-polycarbonate is derived from at least Bisphenol-A or dihydroxy aromatic containing unit(s), and polysiloxane bisphenol having the structure 3:

14. The composition of claim 13, wherein said transitional metal oxide is titanium dioxide with an average particle size of greater than or equal to 100 nm to less than 350 nm.

33. The composition of claim 1, wherein said metal oxide is titanium dioxide.

34. The composition of claim 1, wherein said composition has 7.5 to 25 wt % of a polysiloxane block co-polycarbonate;

5 to 15 wt % of titanium dioxide;

2 to 30 wt % of a brominated organic flame retardant or a halogen organic flame retardant compound; and

optionally 0.1 to 0.5 wt % of a fluorinated polyolefin.

35. The composition of claim 1, wherein the brominated organic flame retardant is at least one of the following:

a brominated polycarbonate, a brominated polycarbonate oligomer, a brominated polyacrylate, a brominated polyether, a brominated polyether (repeated), and a brominated polyimide.

36. The composition of claim 1, wherein the brominated organic flame retardant is a polycarbonate copolymer derived from at least a bisphenol-A and a 2,2′

6,6′

-tetrabromo bisphenol-A and wherein the average wt % of bromine atoms in the polycarbonate copolymer is 26 wt % bromine atoms based on the total weight of the polycarbonate copolymer.

37. The composition of claim 1, wherein the fluorinated polyolefin is a fibril forming fluorinated polyolefin.

38. The composition of claim 37, wherein the fibril forming fluorinated polyolefin is a polytetrafluoroethylene.

39. The composition of claim 38, wherein the polytetrafluorethylene is combined with polystyrene acrylonitrile (SAN).

40. The composition of claim 1, wherein the wt % of the carbon black in the composition is less than 1 wt % based on the total weight of the composition.

41. The composition of claim 1, wherein the wt % of the carbon black in the composition is less than 0.5 wt % based on the total weight of the composition.

42. The composition of claim 1, wherein the polysiloxane block co-polycarbonate is derived from at least Bisphenol-A or dihydroxy aromatic containing unit(s), and a polysiloxane bisphenol having the structure

43. An article of manufacture containing the composition of claim 1.

44. An insulating material comprising the composition of claim 1.

45. The article of claim 43, wherein said article is selected from at least one of the following:

a solar apparatus, an electrical junction box, an electrical connector, an electrical vehicle charger, an outdoor electrical enclosure, a smart meter enclosure, a smart grid power node, a PV frame and MCBs.

46. A junction box housing containing the composition of claim 1.

47. A method of controlling the tracking of an electrical current of an article of manufacture containing a polycarbonate containing material comprising:

providing a composition of claim 1, and processing said polycarbonate containing material to form an article of manufacture.

48. The method of claim 47, wherein said article is selected from at least one of the following:

a solar apparatus, an electrical junction box, an electrical connector, an electrical vehicle charger, an outdoor electrical enclosure, a smart meter enclosure, and a smart grid power node, PV frame and MCBs.

49. The composition of claim 6, wherein the polysiloxane block co-polycarbonate is derived from at least Bisphenol-A or dihydroxy aromatic containing unit(s), and a polysiloxane bisphenol having the structure

15. A composition comprising:

a polycarbonate that is a not a polysiloxane block-co-polycarbonate;

5 to 45 wt % of a polysiloxane block co-polycarbonate;

3 to 40 wt % of a transitional metal oxide;

1 to 10 wt % of bromine atoms from a brominated atoms or a halogen containing flame retardant;

optionally 0 to 1 wt % of a fluorinated polyolefin;

optionally an additive that imparts a desired performance property; and

optionally a carbon black containing material, wherein said composition has a p(FTP) V0 flammability rating of greater than 0.85 at 1.5 mm, 1.0 mm, or 0.8 mm or between 1.5 mm and 0.8 mm according to the method of UL 94, and further wherein the composition does not show tracking through at least 50 drops of a 0.1% aqueous ammonium chloride solution at 250V according to ASTM D-3638.

16. The composition of claim 15, wherein the polysiloxane block co-polycarbonate is derived from at least Bisphenol-A or dihydroxy aromatic containing unit(s) and polysiloxane bisphenol having the structure 3:

17. The composition of claim 15, wherein said metal oxide is titanium dioxide.

18. The composition of claim 15, wherein said composition has 7.5 to 25 wt % of a polysiloxane block co-polycarbonate;

5 to 15 wt % of titanium dioxide;

2 to 30 wt % of a brominated organic flame retardant or a halogen organic flame retardant compound; and

optionally 0.1 to 0.5 wt % of a fluorinated polyolefin.

19. The composition of claim 15, wherein the brominated organic flame retardant is at least one of the following:

a brominated polycarbonate, a brominated polycarbonate oligomer, a brominated polyacrylate, a brominated polyether, a brominated polyether (repeated), and a brominated polyimide.

20. The composition of claim 15, wherein the brominated organic flame retardant is a polycarbonate copolymer derived from at least a bisphenol-A and a 2,2′

6,6′

-tetrabromo bisphenol-A and wherein the average wt % of bromine atoms in the polycarbonate copolymer is 26 wt % bromine atoms based on the total weight of the polycarbonate copolymer.

21. The composition of claim 15, wherein the fluorinated polyolefin is a fibril forming fluorinated polyolefin.

22. The composition of claim 21, wherein the fibril forming fluorinated polyolefin is a polytetrafluoroethylene.

23. The composition of claim 22, wherein the polytetrafluorethylene is combined with polystyrene acrylonitrile (SAN).

24. The composition of claim 15, wherein the wt % of the carbon black in the composition is less than 1 wt % based on the total weight of the composition.

25. The composition of claim 15, wherein the wt % of the carbon black in the composition is less than 0.5 wt % based on the total weight of the composition.

26. The composition of claim 15, wherein the polysiloxane block co-polycarbonate is derived from at least Bisphenol-A or dihydroxy aromatic containing unit(s), and a polysiloxane bisphenol having the structure

27. An article of manufacture containing the composition of claim 15.

28. An insulating material comprising the composition of claim 15.

29. The article of claim 27, wherein said article is selected from at least one of the following:

a solar apparatus, an electrical junction box, an electrical connector, an electrical vehicle charger, an outdoor electrical enclosure, a smart meter enclosure, a smart grid power node, a PV frame and MCBs.

30. A junction box housing containing the composition of claim 15.

31. A method of controlling the tracking of an electrical current of an article of manufacture containing a polycarbonate containing material comprising:

providing a composition of claim 15, and processing said polycarbonate containing material to form an article of manufacture.

32. The method of claim 31, wherein said article is selected from at least one of the following:

a solar apparatus, an electrical junction box, an electrical connector, an electrical vehicle charger, an outdoor electrical enclosure, a smart meter enclosure, and a smart grid power node, PV frame and MCBs.