Flame-resistant polycarbonate molding compositions

• US 7,220,790 B2
• Filed: 07/25/2003
• Issued: 05/22/2007
• Est. Priority Date: 07/29/2002
• Status: Active Grant

• Current Assignee: Bayer Materialscience AG (Covestro AG)
• Original Assignee: Bayer AG
• Inventors: Wittmann, Dieter, Eckel, Thomas, Seidel, Andreas, Kurzidim, Dirk
• Primary Examiner(s): SZEKELY, PETER A
• Application Number:
  US10/627,015
• Publication Number:
  US 20040059031A1
• Time in Patent Office: 1,397 Days
• Field of Search: 524/127, 524140-141, 525/67, 525/316
• US Class Current: 524/127
• CPC Class Codes: C08K 5/0066 Flame-proofing or flame-retarding additives
• CPC Class Codes: C08K 5/51 Phosphorus bound to oxygen
• CPC Class Codes: C08K 5/523 with hydroxyaryl compounds
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 27/12 containing fluorine atoms
• CPC Class Codes: C08L 51/04 grafted on to rubbers
• CPC Class Codes: C08L 67/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds C08L67/06 takes precedence
• CPC Class Codes: C08L 69/00 Compositions of polycarbonates; Compositions of derivatives of polycarbonates
• CPC Class Codes: C08L 69/005 Polyester-carbonates

Abstract

A thermoplastic molding composition having good flame resistance, melt flowability, resistance to chemicals and creep is disclosed. The composition contains A) at least one member having weight average molecular weight (M_w) of 25,000 to 35,000 g/mol, selected from the group consisting of aromatic polycarbonate and polyestercarbonate B) ABS graft polymer produced by the mass polymerization process and characterized in (i) having a butadiene content of 8 to 15% in relation to the weight of the graft polymer, (ii) having an acrylic acid derivative content of 15 to 30% in relation to the total weight of the acrylic derivative and styrene monomer, and (iii) containing styrene monomer-acrylic acid derivative copolymer having a weight average molecular weight of 5·10⁴ to 14·10⁴ g/mol. The composition may further contain one or more of halogen-free phosphorus compounds, fluorinated polyolefin, a polymer containing acrylate monomer and an inorganic material in particulate form.

Claims

1. A thermoplastic molding composition comprising

A) 50 to 80 parts by weight of at least one member having weight average molecular weight of 25,000 to 35,000 g/mol, selected from the group consisting of aromatic polycarbonate and polyestercarbonate,

B) 7 to 30 parts by weight of ABS graft polymer produced by the mass polymerization process from at least one of acrylonitrile and methacrylonitrile, further butadiene and at least one styrene monomer, said graft polymer

(i) having a butadiene content of 11 to 14 % in relation to the weight of the graft polymer, and

(ii) having a (meth)acrylonitrile content of 15 to 30 % in relation to the total weight of the (meth)acrylonitrile and styrene monomer in said graft polymer, and

(iii) containing styrene monomer-(meth)acrylontrile copolymer having a weight average molecular weight of 5·

10⁴ to 14·

10⁴ g/mol.

C) 2 to 18 parts by weight of a halogen-free phosphorus compound,

D) 0 to 1 parts by weight fluorinated polyolefin,

E) 0 to 5 parts by weight of a polymer containing acrylate monomer and

F) 0 to 3 parts by weight of an inorganic material in particulate form with an average maximum particle diameter of no more than 1000 nm, said parts by weight totaling 100.

2. The composition according to claim 1, wherein said A has a weight average molecular weight of 26,000 to 31,000 g/mol.

3. The composition according to claim 1, in which Component B) is produced from acrylonitrile, butadiene and styrene.

4. The composition according to claim 1, in which Component B) contains styrene-acrylic-(meth)acrylonitrile copolymer having weight average molecular weight of 6·

10⁴, to 11·

10⁴ g/mol.

5. The composition according to claim 1, in which Component B) contains 21 to 26 wt.% (meth)acrylonitrile in relation to the total weight of the (meth)acrylonitrile and styrene monomers.

6. The composition according to claim 1 wherein said A) is present in an amount of 60 to 80 parts by weight.

7. The composition according to claim 6 wherein said B) is present in an amount of 10 to 20 parts by weight.

8. The composition according to claim 1 wherein said C) is present in an amount of 8 to 16 parts by weight.

9. The composition according to claim 1 wherein said D) is present in an amount of 0.2 to 0.5 parts by weight.

10. The composition according to claim 1 wherein said E) is present in an amount of 0.5 to 2 parts by weight.

11. The composition according to claim 1 wherein said F) is present in an amount of 0.2 to 1.5 parts by weight.

12. The composition according to claim 1 further containing at least one additive selected from the group consisting of mold lubricants, mold release agents, nucleation agents, antistatics, stabilizers, UV-protectors, hydrolysis stabilizers, fillers, reinforcing agents, flame-retardants, flame retarding synergists, dyes and pigments.

13. The composition according to claim 1 wherein C) conforms to the general formula

14. The composition according to claim 13, wherein X represents a member selected from the group consisting of

15. The composition according to claim 1, in which D) is in the form of a master batch, a pre-compound or a co-precipitation of polytetrafluoroethylene and a vinyl monomer-containing polymer.

16. The composition according to claim 1, in which E) is a graft polymer ofto 90 wt. % of a mixture of

0 to 60 wt. % of at least one vinyl aromatic and

to 100 wt. % of at least one member selected from the group consisting of methacrylic acid-(C₁–

C₈)-alkyl ester and acrylic acid-(C₁–

C₈)-alkyl ester on

90 to 10 wt. % of one or more rubbers with glass transition temperature of <

0°

C.

17. The composition according to claim 16, in which the rubber is selected from the group consisting of polybutadiene rubbers, silicon rubbers and silicon-acrylate composite rubbers.

18. The composition according to claim 1, in which F) has an average maximum particle diameter of no more than 200 nm.

19. The composition according to claim 1, characterized in the absence of ABS produced by the emulsion-polymerization process therefrom.

20. A molded article comprising the composition according to claim 1.