Flame retardant polycarbonate compositions, method of manufacture thereof, and articles therefrom
First Claim
1. A thermoplastic polycarbonate composition comprising, based on the total weight of the thermoplastic polycarbonate composition:
- (a) greater than 10 to less than 30 wt % of a reinforcing mineral filler, wherein the reinforcing mineral filler consists of talc; and
(b) greater than 60 to less than 90 wt. % of a polymer component, comprising, based on the weight of the polymer component,68 to 99.9 wt. % of an aromatic polycarbonate,0.1 to 2 wt. % of a fluorinated polymer,0.1 to 5 wt. % of a silicone oil,optionally, 0.1 to 25 wt. % of an impact modifier; and
optionally, 0.1 to 5 wt. % of an additive composition comprising an antioxidant, a mold release agent, and a stabilizer;
wherein a molded sample of the thermoplastic polycarbonate composition hasno drips when measured in accordance with NF P 92-505 at a thickness of 1.5 mm,a smoke density index of less than 10, determined in accordance with the formula;
SDI=(Ds max/100)+(VOF4/30)whereinSDI is the smoke density index;
Ds max is the maximum smoke density; and
VOF4 is the average smoke density measured over the first four minutes, and is calculated in accordance with the formula;
½
Ds0+Ds1+Ds2+Ds3+½
Ds4;
whereinDs0 is the smoke density at 0 minutes,Ds1 is the smoke density at 1 minute,Ds2 is the smoke density at 2 minutes,Ds3 is the smoke density at 3 minutes, andDs4 is the smoke density at 4 minutes; and
Ds max, Ds0, Ds1, Ds2, Ds3, and Ds4 are measured in accordance with NF X 10-702 at a thickness of 3 mm, and100% ductility in a multi-axial impact test at 23°
C., measured in accordance with ISO 6603.
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Accused Products
Abstract
A thermoplastic polycarbonate composition includes, based on the total weight of the thermoplastic polycarbonate composition: 15 to less than 40 wt. % of a reinforcing mineral filler; and greater than 60 to 85 wt. % of a polymer component, including, based on the weight of the polymer component, 68 to 99.9 wt. % of an aromatic polycarbonate, 0.1 to 2 wt. % of a fluorinated polymer, optionally, 0.1 to 25 wt. % of an impact modifier; and optionally, 0.1 to 5 wt. % of an additive composition including an antioxidant, a mold release agent, and a stabilizer; wherein a molded sample of the thermoplastic polycarbonate composition has no drips when measured in accordance with NF P 92-505 at a thickness of 3.0 mm.
47 Citations
25 Claims
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1. A thermoplastic polycarbonate composition comprising, based on the total weight of the thermoplastic polycarbonate composition:
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(a) greater than 10 to less than 30 wt % of a reinforcing mineral filler, wherein the reinforcing mineral filler consists of talc; and (b) greater than 60 to less than 90 wt. % of a polymer component, comprising, based on the weight of the polymer component, 68 to 99.9 wt. % of an aromatic polycarbonate, 0.1 to 2 wt. % of a fluorinated polymer, 0.1 to 5 wt. % of a silicone oil, optionally, 0.1 to 25 wt. % of an impact modifier; and optionally, 0.1 to 5 wt. % of an additive composition comprising an antioxidant, a mold release agent, and a stabilizer; wherein a molded sample of the thermoplastic polycarbonate composition has no drips when measured in accordance with NF P 92-505 at a thickness of 1.5 mm, a smoke density index of less than 10, determined in accordance with the formula;
SDI=(Ds max/100)+(VOF4/30)wherein SDI is the smoke density index; Ds max is the maximum smoke density; and VOF4 is the average smoke density measured over the first four minutes, and is calculated in accordance with the formula;
½
Ds0+Ds1+Ds2+Ds3+½
Ds4;wherein Ds0 is the smoke density at 0 minutes, Ds1 is the smoke density at 1 minute, Ds2 is the smoke density at 2 minutes, Ds3 is the smoke density at 3 minutes, and Ds4 is the smoke density at 4 minutes; and Ds max, Ds0, Ds1, Ds2, Ds3, and Ds4 are measured in accordance with NF X 10-702 at a thickness of 3 mm, and 100% ductility in a multi-axial impact test at 23°
C., measured in accordance with ISO 6603.- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A thermoplastic polycarbonate composition comprising, based on the total weight of the thermoplastic polycarbonate composition,
(a) 15 to 22 wt. % of talc; -
(b) less than 5 wt. % of clay; and (c) 78 to 85 wt. % of a polymer component, comprising, based on the weight of the polymer component, 79 to 98.7 wt. % of a polycarbonate comprising units derived from bisphenol A; 0.1 to 2 wt. % of a fluorinated polymer; 1 to 8 wt. % of a phosphorus-containing flame retardant comprising units derived from bisphenol A; 0 to 5 wt. % of a bulk acrylonitrile-butadiene-styrene; 0.1 to 5 wt. % of a silicone oil; and 0.1 to 1 wt. % of an additive composition comprising an antioxidant, a mold release agent, and a stabilizer; wherein a molded sample of the thermoplastic polycarbonate composition has no drips when measured in accordance with NF P 92-505; a smoke density index of less than 10 determined in accordance with the formula;
SDI=(Ds max/100)+(VOF4/30)wherein SDI is the smoke density index; Ds max is the maximum smoke density; and VOF4 is the average smoke density measured over the first four minutes, and is calculated in accordance with the formula;
½
Ds0+Ds1+Ds2+Ds3+½
Ds4;wherein Ds0 is the smoke density at 0 minutes, Ds1 is the smoke density at 1 minute, Ds2 is the smoke density at 2 minutes, Ds3 is the smoke density at 3 minutes, and Ds4 is the smoke density at 4 minutes; and Ds max, Ds0, Ds1, Ds2, Ds3, and Ds4 are measured in accordance with NF X 10-702 at a thickness of 3 mm; 100% ductility in a multi-axial impact test at 23°
C., measured in accordance with ISO 6603; and
an M1 rating at a thickness of 4 mm.- View Dependent Claims (15)
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16. A sheet, comprising:
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a thermoplastic polycarbonate composition comprising, based on the total weight of the thermoplastic polycarbonate composition; (a) greater than 10 to less than 30 wt. % of a reinforcing mineral filler, wherein the reinforcing mineral filler consists of talc; (b) greater than 60 to less than 90 wt. % of a polymer component, comprising, based on the weight of the polymer component, 68 to 99.7 wt. % of an aromatic polycarbonate, 0.3 to 2 wt. % of a fluorinated polymer comprising a polytetrafluoroethylene associated with a thermoplastic, fluorinated polymer having a fluorinated backbone, 0.1 to 5.0 wt. % of a silicone oil, optionally, 0.1 to 25 wt. % of an impact modifier; and optionally, 0.1 to 5 wt. % of an additive composition comprising an antioxidant, a mold release agent, and a stabilizer; wherein the sheet has no drips when measure in accordance with NF P 92-505 at a thickness of 1.5 mm, a smoke density index of less than 10 determined in accordance with the formula;
SDI=(Ds max/100)+(VOF4/30)wherein SDI is the smoke density index; Ds max is the maximum smoke density; and VOF4 is the average smoke density measured over the first four minutes, and is calculated in accordance with the formula;
½
Ds0+Ds1+Ds2+Ds3+½
Ds4;wherein Ds0 is the smoke density at 0 minutes, Ds1 is the smoke density at 1 minute, Ds2 is the smoke density at 2 minutes, Ds3 is the smoke density at 3 minutes, and Ds4 is the smoke density at 4 minutes; and Ds max, Ds0, Ds1, Ds2, Ds3, and Ds4 are measured in accordance with NF X 10-702 at a thickness of 3 mm, and an M1 rating and an F1 rating at a sheet thickness of 4 mm, and 100% ductility in a multi-axial impact test at 23°
C., measured in accordance with ISO 6603.- View Dependent Claims (17, 18, 19, 20, 21, 22)
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23. A sheet comprising, based on the total weight of the thermoplastic polycarbonate composition:
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(a) greater than 10 to less than 30 wt. % of reinforcing mineral filler, wherein the reinforcing mineral filler consists of talc; and (b) greater than 60 to less than 90 wt. % of a polymer component, comprising, based on the weight of the polymer component, 68 to 99.9 wt. % of an aromatic polycarbonate, 0.1 to 2 wt. % of a fluorinated polymer, 0.1 to 5 wt. % of a silicone oil, optionally, 0.1 to 25 wt. % of an impact modifier; and optionally, 0.1 to 5 wt. % of an additive composition comprising an antioxidant, a mold release agent, and a stabilizer; wherein the sheet has no drips when measured in accordance with NF P 92-505 at a thickness of 1.5 mm, and a smoke density index of less than 10, determined in accordance with the formula;
SDI=(Ds max/100)+(VOF4/30)wherein SDI is the smoke density index; Ds max is the maximum smoke density; and VOF4 is the average smoke density measured over the first four minutes, and is calculated in accordance with the formula;
½
Ds0+Ds1+Ds2+Ds3+½
Ds4;wherein Ds0 is the smoke density at 0 minutes, Ds1 is the smoke density at 1 minute, Ds2 is the smoke density at 2 minutes, Ds3 is the smoke density at 3 minutes, and Ds4 is the smoke density at 4 minutes; and Ds max, Ds0, Ds1, Ds2, Ds3, and Ds4 are measured in accordance with NF X 10-702 at a thickness of 3 mm, and 100% ductility in a multi-axial impact test at 23°
C., measured in accordance with ISO 6603.- View Dependent Claims (24, 25)
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Specification