POLYCARBONATE COMPOSITION, METHOD OF MANUFACTURE THEREOF AND ARTICLES COMPRISING THE SAME

Abstract

Disclosed herein is composition comprising a polycarbonate composition; a fibrous reinforcing composition comprising glass fibers or a combination of glass fibers and carbon fibers; and a flame retardant composition comprising a phosphorus based flame retardant; and a synergist composition; wherein the composition has a flame retardancy of V-1 or better for a sample having a thickness of up to about 1.6 millimeters as measured in a UL-94 test and a heat distortion temperature of greater than or equal to about 75° C. when subjected to a deforming force of about 1.8 megapascals.

Description

Claims

1. A composition comprising: a polycarbonate composition;a fibrous reinforcing composition comprising glass fibers or a combination of glass fibers and carbon fibers; anda flame retardant composition comprising a phosphorus based flame retardant; anda synergist composition; wherein the composition has a flame retardancy of V-1 or better for a sample having a thickness of up to about 1.6 millimeters, as measured in a UL-94 test and a heat distortion temperature of greater than or equal to about 75° C. when subjected to a deforming force of about 1.8 megapascals.

2. The composition of claim 1, wherein the composition comprises the synergist is an amount of about 1 to about 10 wt %.

3. The composition of claim 2, wherein the synergist composition comprises polysiloxane, alumina trihydrate, aluminum hydroxide, magnesium hydroxide, zeolite, zinc borate, mica, intercalated graphite, or a combination comprising at least one of the foregoing synergists.

4. The composition of claim 1, wherein the composition comprises the flame retardant composition in an amount of about 1 to about 10 wt %.

5. The composition of claim 1, wherein the polycarbonate composition comprises polycarbonate, polycarbonate blended with acrylonitrile-butadiene-styrene, a polycarbonate-polysiloxane copolymer, a polycarbonate-polysiloxane copolymer blended with polycarbonate, a polycarbonate-polysiloxane copolymer blended with polycarbonate and acrylonitrile-butadiene-styrene, a polycarbonate-polyester copolymer, a polycarbonate-polyarylate copolymer, a polycarbonate-polysiloxane copolymer blended with polycarbonate, a polycarbonate-polysiloxane copolymer blended with polycarbonate and acrylonitrile-butadiene-styrene, a polycarbonate-polyester copolymer blended with either polycarbonate or polyester or both, a polycarbonate-polyarylate copolymer blended with polycarbonate, polyester, polyarylate, or a combination comprising at least one of polycarbonate, polyester or polyarylate or a combination comprising at least one of the foregoing polycarbonate compositions.

6. The composition of claim 1, comprising about 5 to about 70 wt % of the polycarbonate composition.

7. The composition of claim 1, comprising about 5 to about 60 wt % of the fibrous reinforcing composition.

8. The composition of claim 1, further comprising about 5 to about 20 wt % of non-fibrous fillers.

9. The composition of claim 1, wherein the phosphorus based flame retardant is an aromatic phosphate compound of the formula (I):

10. The composition of claim 1, wherein the phosphorus based flame retardant comprises phenyl bis(dodecyl)phosphate, phenyl bis(neopentyl)phosphate, phenyl bis(3,5,5′-trimethylhexyl phosphate), ethyl diphenyl phosphate, 2-ethylhexyl bis(p-tolyl)phosphate, bis(2-ethylhexyl)p-tolyl phosphate, tritolyl phosphate, bis(2-ethylhexyl)phenyl phosphate, tri(nonylphenyl)phosphate, bis(dodecyl)p-tolyl phosphate, tricresyl phosphate, triphenyl phosphate, dibutylphenyl phosphate, 2-chloroethyl diphenyl phosphate, p-tolyl bis(2,5,5′-trimethylhexyl)phosphate, 2-ethylhexyl diphenyl phosphate or a combination comprising at least one of the foregoing flame retardants.

11. The composition of claim 1, wherein the phosphorus based flame retardant comprises a di- or polyfunctional compound or polymer having the formula (II), (III), or (IV) below:

12. The composition of claim 1, wherein the phosphorus based flame retardant is bis(diphenyl phosphate), bisphenol A bis(diphenyl phosphate), N,N′-bis[di-(2,6-xylyl)phosphoryl]-piperazine or a combination comprising at least one of the phosphorus based flame retardants.

13. The composition of claim 1, comprising about 1 to about 9 wt % of the flame retardant composition and about 1 to about 9 wt % of the synergist composition.

14. An article manufactured from the composition of claim 1.

15. A composition comprising: a polycarbonate composition;a fibrous reinforcing composition comprising glass fibers or a combination of glass fibers and carbon fibers;about 1 to about 10 wt % of a flame retardant composition; wherein the flame retardant composition comprises a phosphorus based flame retardant; andabout 1 to about 10 wt % of a synergist composition.

16. The composition of claim 15, wherein the synergist composition comprises alumina, alumina trihydrate, aluminum hydroxide, magnesium hydroxide, zeolite, zinc borate, antimony trioxide, antimony pentoxide, mica, intercalated graphite, or a combination comprising at least one of the foregoing synergists.

17. The composition of claim 15, wherein the polycarbonate composition comprises polycarbonate, polycarbonate blended with acrylonitrile-butadiene-styrene, a polycarbonate-polysiloxane copolymer, a polycarbonate-polysiloxane copolymer blended with polycarbonate, a polycarbonate-polysiloxane copolymer blended with polycarbonate and acrylonitrile-butadiene-styrene, a polycarbonate-polyester copolymer, a polycarbonate-polyarylate copolymer, a polycarbonate-polysiloxane copolymer blended with polycarbonate, a polycarbonate-polysiloxane copolymer blended with polycarbonate and acrylonitrile-butadiene-styrene, a polycarbonate-polyester copolymer blended with either polycarbonate or polyester or both, a polycarbonate-polyarylate copolymer blended with polycarbonate, polyester, polyarylate, or a combination comprising at least one of polycarbonate, polyester or polyarylate or a combination comprising at least one of the foregoing polycarbonate compositions.

18. The composition of claim 15, comprising about 5 to about 70 wt % of the thermoplastic polymer.

19. The composition of claim 15, wherein the phosphorus based flame retardant is an aromatic phosphate compound of the formula (I):

20. The composition of claim 15, wherein the phosphorus based flame retardant comprises phenyl bis(dodecyl)phosphate, phenyl bis(neopentyl)phosphate, phenyl bis(3,5,5′-trimethylhexyl phosphate), ethyl diphenyl phosphate, 2-ethylhexyl bis(p-tolyl)phosphate, bis(2-ethylhexyl)p-tolyl phosphate, tritolyl phosphate, bis(2-ethylhexyl)phenyl phosphate, tri(nonylphenyl)phosphate, bis(dodecyl)p-tolyl phosphate, tricresyl phosphate, triphenyl phosphate, dibutylphenyl phosphate, 2-chloroethyl diphenyl phosphate, p-tolyl bis(2,5,5′-trimethylhexyl)phosphate, 2-ethylhexyl diphenyl phosphate, or a combination comprising at least one of the foregoing flame retardants.

21. The composition of claim 15, wherein the phosphorus based flame retardant comprises a di- or polyfunctional compound or polymer having the formula (II), (III), or (IV) below:

22. The composition of claim 15, wherein the phosphorus based flame retardant is bis(diphenyl phosphate), bisphenol A bis(diphenyl phosphate), N,N′-bis[di-(2,6-xylyl)phosphoryl]-piperazine or a combination comprising at least one of the phosphorus based flame retardants.

23. The composition of claim 15, comprising about 1 to about 9 wt % of the flame retardant composition and about 1 to about 9 wt % of the synergist composition.

24. A method comprising: melt blending a composition comprising:a polycarbonate composition; a fibrous reinforcing composition comprising glass fibers or a combination of glass fibers and carbon fibers; and a flame retardant composition comprising a phosphorus based flame retardant composition and a synergist composition; wherein the composition has a flame retardancy of V-1 or better at a sample thickness of up to about 1.6 millimeters, as measured in a UL-94 test and a heat distortion temperature of greater than or equal to about 75° C. when subjected to a deforming force of about 1.8 megapascals.

25. The method of claim 24, further comprising extruding the composition.

26. The method of claim 25, wherein the extruding is conducted in a twin screw extruder.

27. The method of claim 25, further comprising injection molding the composition.

28. An article manufactured by the method of claim 25.