Thermoplastic polycarbonate copolymer compositions, methods of their manufacture, and uses thereof

Abstract

This disclosure relates to thermoplastic compositions comprising a polycarbonate copolymer, the polycarbonate copolymer comprising first repeating carbonate units and second repeating units selected from carbonate units that are different from the first carbonate units, polysiloxane units, and a combination comprising at least one of the foregoing unit; and an organophosphorus flame retardant in an amount effective to provide 0.1 to 1.0 wt % phosphorus based on the total weight of the composition, wherein an article molded from the composition has a smoke density after 4 minutes (Ds-4) of less than or equal to 600 determined according to ISO 5659-2 on a 3 mm thick plaque, and a material heat release of less than or equal to 160 kW/m 2 determined according to ISO 5660-1 on a 3 mm thick plaque.

What is claimed is: 
     
         1 . A thermoplastic composition comprising
 60 to 99.5 wt % based on the weight of the composition of a polycarbonate copolymer comprising first repeating units repeating units and second repeating units, wherein the second repeating units are polysiloxane units; and   an organophosphorus compound in an amount effective to provide 0.1-1 wt % phosphorus, based on the total weight of the polycarbonates in the composition;   wherein the first carbonate units are of the formula   
       
         
           
           
               
               
           
         
       
       wherein
 R a  and R b  are each independently a C 1-12  alkyl group, 
 p and q are each independently integers of 0 to 4, and 
 X a  is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, a C 1-12  alkylidene of formula —C(R c )(R d )— wherein R c  and R d  are each independently hydrogen or C 1-11  alkyl, or a group of the formula —C(═R e )— wherein R e  is a divalent C 1-11  hydrocarbon group; and 
 the second repeating units are siloxane units of the formulas 
 
       
         
           
           
               
               
           
         
         or a combination comprising at least one of the foregoing, wherein 
         R is each independently a C 1-13  monovalent hydrocarbon group 
         Ar is each independently a C 6 -C 30  aromatic group, 
         R 2  is each independently a C 2-8  alkylene group, 
         E has an average value of 2 to 200; and 
         wherein an article molded from the composition has
 a smoke density after 4 minutes (Ds-4) of equal to or less than 600 as determined according to ISO 5659-2 on a 3 mm thick plaque, 
 a maximum average rate of heat emission (MAHRE) of less than or equal to 160 kW/m 2  as determined according to ISO 5660-1 on a 3 mm thick plaque, and 
 a multiaxial impact energy equal to or higher than 100 J as determined according to ISO 6603 on a 3.2 mm thick disc. 
 
       
     
     
         2 . The composition of  claim 1 , wherein the first units are bisphenol-A carbonate units. 
     
     
         3 . The composition of  claim 1 , wherein the siloxane units are of the formula 
       
         
           
           
               
               
           
         
         or a combination comprising at least one of the foregoing, wherein E has an average value of 2 to 200. 
       
     
     
         4 . The composition of  claim 1 , wherein the siloxane units are of the formula 
       
         
           
           
               
               
           
         
         wherein 
         R is each independently a C 1-13  monovalent hydrocarbon group, 
         R 3  is independently a divalent C 2-8  aliphatic group, 
         M is each independently a halogen, cyano, nitro, C 1-8  alkylthio, C 1-8  alkyl, C 1-8  alkoxy, C 2-8  alkenyl, C 2-8  alkenyloxy group, C 3-8  cycloalkyl, C 3-8  cycloalkoxy, C 6-10  aryl, C 6-10  aryloxy, C 7-12  arylalkyl, C 7-12  arylalkoxy, C 7-12  alkylaryl, or C 7-12  alkylaryloxy, or a combination comprising at least one of the foregoing, 
         n is each independently 0, 1, 2, 3, or 4, and 
         E has an average value of 2 to 200. 
       
     
     
         5 . The composition of  claim 4 , wherein the siloxane units are of the formula 
       
         
           
           
               
               
           
         
         or a combination comprising at least one of the foregoing, wherein E has an average value of 5 to 60. 
       
     
     
         6 . The composition of  claim 5 , wherein the siloxane units are present in an amount effective to provide 0.3% to 10% of siloxane units based on the weight of the composition. 
     
     
         7 . The composition of  claim 1 , wherein the polycarbonate copolymer is present in an amount of 80 to 99.95 wt % based on the weight of the composition. 
     
     
         8 . The composition of  claim 1 , wherein the polycarbonate copolymer is present in an amount of 90 to 99.95 wt % based on the weight of the composition. 
     
     
         9 . The composition of  claim 1 , wherein the aromatic organophosphorus compound is bisphenol-A bis(diphenyl phosphate), triphenyl phosphate, resorcinol bis(diphenyl phosphate), tricresyl phosphate, or a combination comprising at least one of the foregoing. 
     
     
         10 . The composition of  claim 9 , wherein the organophosphorus compound is present in an amount effective to provide 0.3% to 0.85% of phosphorus, based on the weight of the composition. 
     
     
         11 . The composition of  claim 1 , further comprising a processing aid, a heat stabilizer, an antioxidant, an ultra violet light absorber, a colorant, or a combination comprising at least one of the foregoing in a total amount of 0.1 to 5 wt %, based on the weight of the composition. 
     
     
         12 . The composition of  claim 1 , wherein no or substantially no flame retarding brominated compounds, flame retardant salts, or a combination comprising at least one of the foregoing are present in the composition. 
     
     
         13 . The composition of  claim 12 , wherein the brominated compound is a brominated polycarbonate, and the flame retardant salt is potassium perfluorobutane sulfonate, potassium perfluorooctane sulfonate, tetraethylammonium perfluorohexane sulfonate, potassium diphenylsulfone sulfonate, Na 2 CO 3 , K 2 CO 3 , MgCO 3 , CaCO 3 , and BaCO 3 , an inorganic phosphate salt, Li 3 AlF 6 , BaSiF 6 , KBF 4 , K 3 AlF 6 , KAlF 4 , K 2 SiF 6 , Na 3 AlF 6 , or a combination comprising at least one of the foregoing. 
     
     
         14 . The composition of  claim 12 , wherein no or substantially no brominated polycarbonate, boron phosphate, or C 1-6  alkyl sulfonate salt is present in the composition. 
     
     
         15 . The composition of  claim 1 , having a transparency of more than 85% and a haze of less than 3%, each measured according to ASTM D 1003 (2007) using illuminant C on plaques with 3 mm thickness. 
     
     
         16 . The composition of  claim 1 , having a melt volume flow rate greater than or equal to 10 cc/10 min, determined according to ISO 1133. 
     
     
         17 . The composition of  claim 1 , having an MAI of 100 J or higher, determined at 23° C., 4.4 m/second in accordance with ISO 6603 on discs with a thickness of 3.2 mm. 
     
     
         18 . An article comprising the composition of  claim 1 , selected from a molded article, a thermoformed article, an extruded film, an extruded sheet, a foamed article, a layer of a multi-layer article, a substrate for a coated article, or a substrate for a metallized article. 
     
     
         19 . The article of  claim 18 , having a thickness of 0.1 to 10 mm. 
     
     
         20 . The article of  claim 18 , having a thickness of 0.5 to 5 mm. 
     
     
         21 . The article of  claim 18 , wherein the article is a transportation component. 
     
     
         22 . The article of  claim 18 , selected from a train or aircraft interior component, wherein the component is a partition, a room divider, a seat back, a food tray, a trim panel, an interior display panel, an interior wall, a side wall, an end wall, a ceiling panel, a door lining, a flap, a box, a hood, a louver, an insulation material, a handle, a body shell for a window, a window frame, an enclosure for an electronic device, a door, a luggage rack, a luggage container, an interior side of a gangway membrane, an interior lining of a gangway, or a component of a luggage compartment, a display unit, a television, a refrigerator door, a tray table, a food cart, a magazine rack, an air flow regulator, a door, a table, or a seat. 
     
     
         23 . A method of manufacture of an article, comprising molding, extruding, foaming, or casting the composition of  claim 1 . 
     
     
         24 . A thermoplastic composition comprises, based on the total weight of the composition,
 an organophosphorus compound effective to provide 0.1 to 1.0 wt % phosphorus based on the total weight of the composition, wherein the organophosphorus comprises bisphenol-A bis(diphenyl phosphate), tetraphenyl resorcinol diphosphate, or a combination thereof;   90 to 98 wt % of a polycarbonate copolymer comprising first repeating units and second repeating units, wherein the second repeating units are polysiloxane units; and   optionally up to 5 wt % of an additive selected from a processing aid, a heat stabilizer, an ultra violet light absorber, a colorant, or a combination comprising at least one of the foregoing,   wherein the component has a smoke density value of equal to or less than 600 determined according to ISO 5659-2 on a 3 mm thick plaque, and a material heat release of less than 160 kW/m 2  determined according to ISO 5660-1 on a 3 mm thick plaque.   
     
     
         25 . The composition of  claim 24 , wherein the first units are bisphenol-A carbonate units; and the siloxane units are of the formula 
       
         
           
           
               
               
           
         
         or a combination comprising at least one of the foregoing, wherein E has an average value of 5 to 60. 
       
     
     
         26 . A thermoplastic composition consisting of, based on the total weight of the composition,
 an organophosphorus compound effective to provide 0.1 to 1.0 wt % phosphorus based on the total weight of the composition, wherein the organophosphorus comprises bisphenol-A bis(diphenyl phosphate), tetraphenyl resorcinol diphosphate, or a combination thereof;   90 to 98 wt % of a polycarbonate copolymer comprising first repeating units and second repeating units, wherein the second repeating units are polysiloxane units; and   optionally up to 5 wt % of an additive selected from a processing aid, a heat stabilizer, an ultra violet light absorber, a colorant, or a combination comprising at least one of the foregoing,   wherein the component has a smoke density value of equal to or less than 600 determined according to ISO 5659-2 on a 3 mm thick plaque, and a material heat release of less than 160 kW/m 2  determined according to ISO 5660-1 on a 3 mm thick plaque.