Flame retardant polycarbonate compositions, methods of manufacture, and articles formed therefrom

Abstract

A composition comprising: a first polycarbonate comprising a poly(siloxane-carbonate); a second polycarbonate different from the first polycarbonate; and optionally, a third polycarbonate different from the first and second polycarbonate; wherein the first polycarbonate is present in an amount effective to provide the siloxane units of in the first polycarbonate in an amount of at least 0.3 wt %, and the second polycarbonate is present in an amount effective to provide the bromine of the second polycarbonate in an amount of at least 7.8 wt %; and further wherein an article molded from the composition has an OSU integrated 2 minute heat release test value of less than 65 kW-min/m 2 and a peak heat release rate of less than 65 kW/m 2 , and an E662 smoke test Dmax value of less than 200.

We claim: 
     
         1 . A composition comprising:
 a first polycarbonate comprising a poly(siloxane-carbonate) derived from at least one dihydroxy aromatic containing polycarbonate unit, and at least one polysiloxane bisphenol of formula (1), formula (2), or a combination thereof   
       
         
           
           
               
               
           
         
         wherein
 R is each independently a C 1 -C 30  hydrocarbon group, 
 R 2  is each independently a C 7 -C 30  hydrocarbon group, 
 Ar is each independently a C 6 -C 30  aromatic group and 
 E has an average value of 5 to 200; 
 
         a bromine-containing compound different from the first polycarbonate, wherein the bromine-containing compound is a second polycarbonate comprising
 brominated carbonate units derived from 2,2′,6,6′-tetrabromo-4,4′-isopropylidenediphenol and 
 carbonate units derived from at least one dihydroxy aromatic compound that is not 2,2′,6,6′-tetrabromo-4,4′-isopropylidenediphenol; or 
 a brominated oligomer having a weight average molecular weight of less than 18,000 Daltons as measured by gel permeation chromatography using polystyrene standards; and 
 
         optionally, a third polycarbonate different from the first polycarbonate and the bromine-containing compound, the third polycarbonate comprising carbonate units and ester units; wherein
 the wt % of the first polycarbonate, the bromine-containing compound, and the optional third polycarbonate sum to 100 wt %, 
 the first polycarbonate is present in an amount effective to provide the siloxane units in an amount of at least 0.3 wt %, based on the sum of the wt % of the first polycarbonate, the bromine-containing compound, and the optional third polycarbonate, and 
 the bromine-containing compound is present in an amount effective to provide the bromine of the bromine-containing compound in an amount of at least 7.8 wt %, based on the sum of the wt % of the first polycarbonate, the bromine-containing compound, and the optional third polycarbonate; and 
 further wherein if present, the optional third polycarbonate is present in an amount 
 
         such that an article molded from the composition has
 an OSU integrated 2 minute heat release test value of less than 65 kW-min/m 2  and a peak heat release rate of less than 65 kW/m 2  as measured using the method of FAR F25.4, in accordance with Federal Aviation Regulation FAR 25.853 (d), and 
 an E662 smoke test Dmax value of less than 200 when measured at a thickness of 1.6 mm. 
 
       
     
     
         2 . The composition of  claim 1 , wherein the composition comprises 8 to 12 wt. % of the third polycarbonate. 
     
     
         3 . The composition of  claim 1 , wherein the first polycarbonate and the bromine-containing compound are free of ester units. 
     
     
         4 . The composition of  claim 1 , wherein the first polycarbonate is present in an amount of at least 10 wt %, and the bromine-containing compound is present in an amount of at least 20 wt %, each based on the sum of the wt % of the first polycarbonate, the bromine-containing compound, and the optional third polycarbonate. 
     
     
         5 . The composition of  claim 1 , wherein
 E in formula (1) and formula (2) has an average value of 25 to 75,   the siloxane units of the first polycarbonate are present in an amount of at least 2.0 wt %, based on the sum of the wt % of the first polycarbonate, the bromine-containing compound, and the optional third polycarbonate, and   an article molded from the composition further has a room temperature notched Izod impact of greater than 500 J/m as measured according to ASTM D 256-10 at a 0.125 inch (3.2 mm) thickness.   
     
     
         6 . The composition of  claim 1 , wherein
 E in formula 1 and formula 2 has an average value of 25 to 50,   the siloxane units of the first polycarbonate are present in an amount of at least 2.0 wt %, based on the sum of the wt % of the first polycarbonate, the bromine-containing compound, and the optional third polycarbonate,   the bromine-containing compound is present in an amount of 35 to 50 wt %, based on the sum of the wt % of the first polycarbonate, the bromine-containing compound, and the optional third polycarbonate, and   an article molded from the composition further has a haze less of less than 10% and a transmission greater than 70%, each measured using the color space CIE1931 (Illuminant C and a 2° observer) at a 0.125 inch (3.2 mm) thickness.   
     
     
         7 . A composition comprising:
 a first polycarbonate comprising a poly(siloxane-carbonate) derived from at least one dihydroxy aromatic compound, and at least one polysiloxane bisphenol of formula (1), formula (2), or a combination thereof   
       
         
           
           
               
               
           
         
         wherein
 R is each independently a C 1 -C 30  hydrocarbon group, 
 Ar is each independently a C 6 -C 30  aromatic group, and 
 R 2  is each independently a C 7 -C 30  hydrocarbon group, and 
 E has an average value of 5 to 75; 
 
         a second polycarbonate different from the first polycarbonate, the second polycarbonate comprising
 brominated carbonate units derived from 2,2′,6,6′-tetrabromo-4,4′-isopropylidenediphenol and 
 carbonate units derived from at least one dihydroxy aromatic compound that is not 2,2′,6,6′-tetrabromo-4,4′-isopropylidenediphenol; and 
 
         optionally, a third polycarbonate different from the first polycarbonate and the second polycarbonate, the third polycarbonate comprising carbonate units and ester units; wherein
 the wt % of the first polycarbonate, second polycarbonate, and optional third polycarbonate sum to 100 wt %, 
 the first polycarbonate is present in an amount effective to provide the siloxane units of the first polycarbonate in an amount of at least 0.3 wt %, based on the sum of the wt % of the first, second, and optional third polycarbonate, and 
 the second polycarbonate is present in an amount effective to provide bromine in the second polycarbonate in an amount of at least 5.0 wt %, based on the sum of the wt % of the first, second, and optional third polycarbonate; and 
 
         further wherein if present, the optional third polycarbonate is present in an amount such that an article molded from the composition has
 an OSU integrated 2 minute heat release test value of less than 65 kW-min/m 2  and a peak heat release rate of less than 65 kW/m 2  as measured using the method of FAR F25.4, in accordance with Federal Aviation Regulation FAR 25.853 (d), 
 an E662 smoke test Dmax value of less than 200 when tested at a thickness of 1.6 mm; and 
 a haze less of less than 3% and a transmission greater than 85%, each measured using the color space CIE1931 (Illuminant C and a 2° observer) at a 0.062 inch (1.5 mm) thickness. 
 
       
     
     
         8 . The composition of  claim 7 , wherein the first polycarbonate is present in an amount of at least 30 wt %, and the second polycarbonate is present in an amount of at least 20 wt %, each based on the sum of the wt % of the first, second, and optional third polycarbonate. 
     
     
         9 . The composition of  claim 1 , wherein the first polycarbonate is present in an amount of at least 10 wt %, and the brominated oligomer is present in an amount of at least 15 wt %, each based on the sum of the wt % of the first polycarbonate, the brominated oligomer, and the optional third polycarbonate. 
     
     
         10 . The composition of  claim 1 , wherein the polysiloxane bisphenol (1) has the formula: 
       
         
           
           
               
               
           
         
       
       and
 the polysiloxane bisphenol (2) has the formula: 
 
       
         
           
           
               
               
           
         
       
     
     
         11 . The composition of  claim 10 , wherein the dihydroxy aromatic compound of the first polycarbonate is Bisphenol-A. 
     
     
         12 . The composition of  claim 1 , wherein
 the siloxane units of the first polycarbonate are present in an amount of between 1.5 and 3.5 wt % based on the sum of the wt % of the first polycarbonate, the bromine-containing compound, and the third polycarbonate,   the bromine of the bromine-containing compound is present in an amount of between 7.8 and 13 wt % based on the sum of the wt % of the first polycarbonate, the bromine-containing compound, and the third polycarbonate; and   the third polycarbonate is present in an amount of 8 to 50 wt % based on the sum of the first polycarbonate, the bromine-containing compound, and the third polycarbonate.   
     
     
         13 . The composition of  claim 1 , wherein the bromine-containing compound comprises 25 to 35 mol % of units derived from 2,2′6,6′ tetrabromo-4,4′-isopropylidenediphenol and 65 to 75 mole % of units derived from Bisphenol-A. 
     
     
         14 . The composition of  claim 1 , wherein the first polycarbonate is derived from bisphenol A and formula 2 and wherein formula 2 has the formula 
       
         
           
           
               
               
           
         
       
       wherein
 E has an average value of 8 to 100, 
 the siloxane units of the first polycarbonate are present in an amount of 0.5 to 25 wt % based on the total weight of the first polycarbonate. 
 
     
     
         15 . The composition of  claim 5 , wherein the first polycarbonate is derived from bisphenol A and formula 2 and wherein formula 2 has the formula 
       
         
           
           
               
               
           
         
       
       wherein
 E has an average value of between 40 to 50, and 
 the siloxane units of the first polycarbonate are present in an amount of 2 to 30 wt % based on the total weight of the first polycarbonate. 
 
     
     
         16 . The composition of  claim 6 , wherein the first polycarbonate is derived from bisphenol A and formula 2 and wherein formula 2 has the formula 
       
         
           
           
               
               
           
         
       
       wherein
 E has an average value of between 40 to 50, and 
 the siloxane units of the first polycarbonate are present in an amount of 4 to 8 wt % based on the total weight of the first polycarbonate. 
 
     
     
         17 . The composition of  claim 7 , wherein the first polycarbonate is derived from bisphenol A and formula 2 and wherein formula 2 has the formula 
       
         
           
           
               
               
           
         
       
       wherein
 E has an average value of 8 to 12, and the siloxane units of the first polycarbonate are present in an amount of 0.5 to 7 wt % based on the total weight of the first polycarbonate. 
 
     
     
         18 . The composition of  claim 1 , wherein an article molded from the composition has at least one of the following properties: an E662 smoke test Dmax value of less than 100 when tested at a thickness of 1.6 mm; a room temperature notched Izod impact of greater than 500 J/m as measured according to ASTM D 256-10 at a 0.125 inch (3.2 mm) thickness; or a haze less of less than 15% and a transmission greater than 75%, each measured using the color space CIE1931 (Illuminant C and a 2° observer) at a 0.125 inch (3.2 mm) thickness. 
     
     
         19 . The composition of  claim 1 , wherein the brominated oligomer is a brominated polycarbonate oligomer or a brominated epoxy oligomer. 
     
     
         20 . The composition of  claim 1 , further comprising 0.5 to 3 parts by weight of titanium dioxide per hundred parts by weight of the combination of the first polycarbonate, second polycarbonate or brominated oligomer, and optional third polycarbonate. 
     
     
         21 . The composition of  claim 1 , wherein the difference in the melt volume flow rate of the composition at 300° C. at 6 minutes and 18 minutes is less than 10%, wherein melt volume flow rate is determined at 300° C. under a load of 1.2 Kg through a 2.1 mm diameter×8 mm long orifice. 
     
     
         22 . An article selected from a molded article, a thermoformed article, a foamed article, an extruded film, an extruded sheet, one or more layers of a multi-layer article, a substrate for a coated article or a substrate for a metallized article made from the composition of  claim 1 . 
     
     
         23 . The article of  claim 22 , wherein the article is a component of an aircraft interior or a train interior. 
     
     
         24 . The article of  claim 23 , wherein the article is selected from an access panel, access door, air flow regulator, air gasper, air grille, arm rest, baggage storage door, balcony component, cabinet wall, ceiling panel, door pull, door handle, duct housing, enclosure for an electronic device, equipment housing, equipment panel, floor panel, food cart, food tray, galley surface, handle, housing for television, light panel, magazine rack, telephone housing, partition, part for trolley cart, seat back, seat component, railing component, seat housing, shelve, side wall, speaker housing, storage compartment, storage housing, toilet seat, tray table, tray, trim panel, window molding, window slide, window, a balcony component, baluster, ceiling panel, cover for a life vest, cover for a storage bin, dust cover for a window, layer of an electrochromic device, lens for a television, electronic display, gauge, or instrument panel, light cover, light diffuser, light tube, light pipes, mirror, partition, railing, refrigerator door, shower door, sink bowl, trolley cart container, or trolley cart side panel.