Flame retardant resin composition and molded article using the same

• US 10,370,535 B2
• Filed: 05/31/2017
• Issued: 08/06/2019
• Est. Priority Date: 06/03/2016
• Status: Active Grant

• Current Assignee: Lotte Advanced Materials Co., Ltd. (Lotte Chemical Corporation)
• Original Assignee: Lotte Advanced Materials Co., Ltd. (Lotte Chemical Corporation)
• Inventors: Lee, Jo Won
• Primary Examiner(s): Chin, Hui H
• Application Number:
  US15/609,105
• Publication Number:
  US 20170349746A1
• Time in Patent Office: 797 Days
• Field of Search: 524424
• CPC Class Codes: C08K 2003/265 Calcium, strontium or barium carbonate
• CPC Class Codes: C08K 2003/267 Magnesium carbonate
• CPC Class Codes: C08K 2201/014 Additives containing two or more different additives of the same subgroup in C08K
• CPC Class Codes: C08K 3/016 Flame-proofing or flame-retarding additives
• CPC Class Codes: C08K 3/26 Carbonates; Bicarbonates
• CPC Class Codes: C08L 2201/02 Flame or fire retardant/resistant
• CPC Class Codes: C08L 2207/53 Core-shell polymer
• 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: C09K 21/02 Inorganic materials

Abstract

A flame retardant resin composition that can have excellent low smoke properties includes (A) a polycarbonate resin, (B) a silicon impact modifier, and (C) a flame retardant, wherein the (B) silicon impact modifier comprises particles having a core-shell structure, and including about 60 wt % or more of a siloxane polymer, and wherein the (C) flame retardant includes a mixture of magnesium carbonate represented by Formula 1 and magnesium calcium carbonate represented by Formula 2:
Mg_a(CO₃)_b(OH)_2a−2b.cH₂O  [Formula 1]

• • wherein a, b and c are as defined in the detailed description;
    Mg_xCa_y(CO₃)_x+y.mH₂O  [Formula 2]
  • wherein x, y and m are as defined in the detailed description.

Claims

1. A flame retardant resin composition comprising:

(A) a polycarbonate resin;

(B) a silicon impact modifier; and

(C) a flame retardant,

wherein the (B) silicon impact modifier comprises particles having a core-shell structure and comprises about 60 wt % or more of a siloxane polymer,

wherein the (C) flame retardant comprises a mixture of magnesium carbonate represented by Formula 1 and magnesium calcium carbonate represented by Formula 2;

Mg_a(CO₃)_b(OH)<sub>2a−

2b</sub>.cH₂O 

 

[Formula 1]

wherein a is 1 to 6, b is greater than 0 to 5, and c is 0 to 6;

Mg_xCa_y(CO₃)_x+ymH₂O 

 

[Formula 2]

wherein x and y are the same or different and are each independently 1 to 5, and m is 0 to 5, and

wherein the flame retardant includes the magnesium carbonate represented by Formula 1 and the magnesium calcium carbonate represented by Formula 2 in a weight ratio of about 3;

1 to about 2;

1.

2. The resin composition according to claim 1, comprising the (B) silicon impact modifier in an amount of about 1 part by weight to about 10 parts by weight relative to about 100 parts by weight of the (A) polycarbonate resin.

3. The resin composition according to claim 1, wherein the (B) silicon impact modifier comprises a core comprising a siloxane polymer and optionally further comprising a (meth)acrylic polymer and a shell comprising a (meth)acrylic polymer.

4. The resin composition according to claim 3, wherein the (B) silicon impact modifier comprises a core composed of a siloxane polymer and a shell composed of a (meth)acrylic polymer.

5. The resin composition according to claim 3, wherein the (B) silicon impact modifier comprises a core comprising a siloxane polymer and a (meth)acrylic polymer and a shell comprising a (meth)acrylic polymer.

6. The resin composition according to claim 3, wherein the (B) silicon impact modifier comprises the siloxane polymer and the (meth)acrylic polymer in a weight ratio of about 3:

1 to about 10;

1.

7. The resin composition according to claim 1, comprising the mixture of magnesium carbonate represented by Formula 1 and magnesium calcium carbonate represented by Formula 2 in an amount of about 1 part by weight to about 20 parts by weight relative to about 100 parts by weight of the (A) polycarbonate resin.

8. The resin composition according to claim 1, wherein the magnesium carbonate represented by Formula 1 is hydromagnesite.

9. The resin composition according to claim 1, wherein the magnesium calcium carbonate represented by Formula 2 is huntite.

10. The resin composition according to claim 1, wherein the flame retardant comprises a mixture of hydromagnesite and huntite.

11. The resin composition according to claim 1, wherein a molded article produced from the resin composition has a cumulative value of specific optical densities in the first 4 min of the test (VOF4) of about 150 minutes to about 300 minutes as measured in accordance with ISO 5659-2;

a critical heat flux at extinguishment (CFE) of about 10 to about 25 kW/m² as measured in accordance with ISO 5658-2; and

a maximum average rate of heat emission (MARHE) of about 80 to about 105 kW/m² as measured in accordance with ISO 5660-1.

12. A molded article produced from the flame retardant resin composition according to claim 1.

13. The molded article according to claim 12, wherein the molded article has a cumulative value of specific optical densities in the first 4 min of the test (VOF4) of about 300 minutes or less, as measured in accordance with ISO 5659-2.

14. The molded article according to claim 12, wherein the molded article has a cumulative value of specific optical densities in the first 4 min of the test (VOF4) of about 150 minutes to about 300 minutes, as measured in accordance with ISO 5659-2.

15. The molded article according to claim 12, wherein the molded article has a critical heat flux at extinguishment (CFE) of about 10 kW/m² or more, as measured in accordance with ISO 5658-2.

16. The molded article according to claim 12, wherein the molded article has a critical heat flux at extinguishment (CFE) of about 10 to about 25 kW/m², as measured in accordance with ISO 5658-2.

17. The molded article according to claim 12, wherein the molded article has a maximum average rate of heat emission (MARHE) of about 105 kW/m² or less, as measured in accordance with ISO 5660-1.

18. The molded article according to claim 12, wherein the molded article has a maximum average rate of heat emission (MARHE) of about 80 to about 105 kW/m², as measured in accordance with ISO 5660-1.

19. The molded article according to claim 12, wherein the molded article is an interior and/or exterior material of transportation equipment.