Flameproofed impact-strength-modified poly(ester)carbonate compositions

• US 7,833,448 B2
• Filed: 03/19/2007
• Issued: 11/16/2010
• Est. Priority Date: 03/22/2006
• Status: Active Grant

• Current Assignee: Covestro Deutschland AG
• Original Assignee: Bayer Materialscience AG (Covestro AG)
• Inventors: Wittmann, Dieter, Buchholz, Vera, Wenz, Eckhard, Eckel, Thomas, Thuermer, Burkhard
• Primary Examiner(s): Szekely; Peter
• Application Number:
  US11/725,362
• Publication Number:
  US 20070225413A1
• Time in Patent Office: 1,338 Days
• Field of Search: 264/176.1, 264/210.1, 264/210.2, 524/127, 524/140, 524/141, 524/404, 524/451, 524/405
• US Class Current: 264/176.1
• CPC Class Codes: B29C 51/002 characterised by the choice of material
• CPC Class Codes: B29C 51/08 Deep drawing or matched-mould forming, i.e. using mechanical means only
• CPC Class Codes: B29C 51/082 by shaping between complementary mould parts
• CPC Class Codes: B29C 51/10 Forming by pressure difference, e.g. vacuum
• CPC Class Codes: B29K 2069/00 Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: C08K 3/346 Clay
• CPC Class Codes: C08K 3/38 Boron-containing compounds
• CPC Class Codes: C08K 5/523 with hydroxyaryl compounds
• CPC Class Codes: C08L 2666/24 Graft or block copolymers according to groups C08L51/00, C08L53/00 or C08L55/02; Derivatives thereof
• CPC Class Codes: C08L 51/00 Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds for ABS polymers C08L55/02; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 51/085 on to polysiloxanes
• CPC Class Codes: C08L 69/00 Compositions of polycarbonates; Compositions of derivatives of polycarbonates
• CPC Class Codes: C08L 69/005 Polyester-carbonates

Abstract

A process for producing a three-dimensional article comprising a poly(ester)carbonate compositions characterized by its flame resistance and high impact strength is disclosed. The composition that contains

• • branched aromatic poly(ester)carbonate, a graft polymer wherein the graft base is silicone rubber or silicone-acrylate rubber, talc, phosphorus-containing flameproofing agent, and an inorganic boron compound, and
  • an optional anti-dripping agent
    satisfies enhanced fire-protection requirements.

Claims

1. A process for producing a three-dimensional article comprising

A) melt-blending a thermoplastic composition that contains

i. 40-95 parts by weight of branched aromatic poly(ester)carbonate,

ii. 1-25 parts by weight of a graft polymer including at least one graft base selected from the group consisting of silicone rubber and silicone-acrylate rubber,

iii. 9-18 parts by weight of talc,

iv. 0.4-20 parts by weight of phosphorus-containing flameproofing agent,

v. 1-6 parts by weight of at least one inorganic boron compound selected from the group consisting of Zn₄B₂O₇.H₂O, Zn₂B₆O₁₁.3.5H₂O and ZnB₄O₇.4H₂O, and

vi. 0-3 parts by weight of an anti-dripping agent to obtain a molten blend,

B) cooling and granulating said molten blend to obtain a plurality of granules

C) extruding said granules to produce a sheet and

D) shaping said sheet into a three-dimensional article.

2. The process according to claim 1 wherein said shaping is carried out by at least one thermoforming method selected from the group consisting of hot forming, draw forming, deep drawing and vacuum forming.

3. The process according to claim 2 wherein said shaping is carried out by deep drawing.

4. The process according to claim 1 wherein the branched poly(ester)carbonate contains at least one residue having at least one amine functionality.

5. The process according to claim 1 wherein the phosphorus-containing flameproofing agent conforms to formula (VIII)

6. The process according to claim 1 wherein the thermoplastic composition contains neither thermoplastic vinyl (co)polymer nor polyalkylene terephthalate.

7. The process according to claim 1 wherein in the thermoplastic composition further contains at least one member selected from the group consisting of lubricant, mold-release agent, nucleating agent, antistatic agent, stabilizer, dyestuff, pigment, filler, and reinforcing material different from talc.

8. The three-dimensional article prepared by the process of claim 1.

9. The composition according to claim 1, wherein the inorganic boron compound is present in 2-4 parts by weight.

10. The composition according to claim 1, wherein the inorganic boron compound is Zn₂B₆O₁₁.3.5H₂O.

11. The composition according to claim 9, wherein the inorganic boron compound is Zn₂B₆O₁₁.3.5H₂O.