Interior train components having low smoke and low heat release, and methods of their manufacture

Abstract

Seat components and claddings for railway molded or formed from a thermoplastic polymer composition comprising, based on the total weight of the composition, 50 to 93 wt. % of a specific polycarbonate; 4 to 30 wt. % of a poly(carbonate-siloxane) comprising bisphenol A carbonate units, and siloxane units; 3 to 20 wt. % of an organophosphorus compound in an amount effective to provide 0.1 to 2.0 wt. % of phosphorus, based on the total weight of the thermoplastic polymer composition; wherein an article having a thickness of 0.5 to 10 mm molded from the composition has a Ds-4 smoke density≦300 measured according to ISO 5659-2, and a MAHRE≦90 kW/m 2 measured according to ISO 5660-1, a multiaxial impact energy≧100 J, and a ductility in multiaxial impact of 80 to 100% at +23° C. according to ISO 6603.

1 - 32 . (canceled) 
     
     
         33 . A railway component,
 wherein the component is a molded or extruded train seat component or a molded or extruded interior train cladding, comprising a thermoplastic composition comprising, based on the total weight of the composition:   50 to 93 wt. % of a polycarbonate copolymer comprising bisphenol A carbonate units and units of the formula   
       
         
           
           
               
               
           
         
       
       wherein R 5  is hydrogen, phenyl optionally substituted with up to five C 1-10  alkyl groups, or C 1-4  alkyl;
 4 to 30 wt. % of a poly(carbonate-siloxane) comprising
 bisphenol A carbonate units, and 
 siloxane units of the formula 
 
 
       
         
           
           
               
               
           
         
         or a combination comprising at least one of the foregoing, wherein E has an average value of 2 to 200, wherein the poly(carbonate-siloxane) comprises 0.5 to 55 wt. % of siloxane units based on the total weight of the poly(carbonate-siloxane); 
         3 to 20 wt. % of an organophosphorus compound in an amount effective to provide 0.1 to 2.0 wt. % of phosphorus, based on the total weight of the thermoplastic polymer composition; and 
         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 after 4 minutes (Ds-4) of equal to or less than 300 measured according to ISO 5659-2 on a 3 mm thick plaque, 
         an integral of the smoke density as a function of time up to 4 minutes (VOF4) of equal to or less than 600 measured according to ISO 5659-2 on a 3 mm thick plaque, 
         a maximum average heat release (MAHRE) of equal to or less than 90 kW/m 2  measured according to ISO 5660-1 on a 3 mm thick plaque, and 
         a ductility in multiaxial impact of 80 to 100%, measured at 0+23° C. at an impact speed of 4.4 m/second according to ISO 6603 on 3.2 mm thick discs; and 
         when the component is a molded or extruded interior train cladding, the component further has a critical heat flux at extinguishment ((CFE) of equal to or greater than 20 kW/m 2  measured according to ISO 5658-2 on a 3 mm thick plaque. 
       
     
     
         34 . (canceled) 
     
     
         35 . (canceled) 
     
     
         36 . The railway component of  claim 33 , wherein the thermoplastic composition comprises from 4 to 20 wt. % of the poly(carbonate-siloxane) comprising from 1 to 10 wt. % of siloxane units based on the total weight of the poly(carbonate-siloxane), and wherein a molded or formed sample of the thermoplastic polymer composition has a transmission of greater than 80% or a haze of 5 or less measured according to ASTM D 1003 using the color space CIE1931 (Illuminant C and a 2° observer) at a thickness of 3 mm. 
     
     
         37 . The railway component of  claim 33 , wherein R 5  is phenyl; and E has an average value of 2 to 60. 
     
     
         38 . (canceled) 
     
     
         39 . The railway component of  claim 33 , wherein the organophosphorus compound is an aromatic organophosphorus compound having at least one organic aromatic group and at least one phosphorus-containing group, or an organic compound having at least one phosphorus-nitrogen bond. 
     
     
         40 . (canceled) 
     
     
         41 . (canceled) 
     
     
         42 . The railway component of  claim 33 , wherein the thermoplastic composition further comprises 0.05 to 5.0 wt. % of a light diffuser additive comprising silicone, polymethylsilsesquioxane, crosslinked poly(methyl methacrylate), methyl methacrylate/ethyleneglycol dimethacrylate copolymer, TiO 2 , or a combination comprising at least one of the foregoing. 
     
     
         43 . The railway component of  claim 33 , wherein the thermoplastic composition further comprises 0.00002 to 5.0 wt. % of a colorant based on the total weight of the polymers in the thermoplastic composition. 
     
     
         44 . The component of  claim 33 , wherein the thermoplastic composition further comprises 0.1 to 12 wt. % of TiO 2 . 
     
     
         45 . The railway component of  claim 33 , wherein the thermoplastic composition further comprises 5 to 20 wt. % of a bisphenol polycarbonate. 
     
     
         46 - 58 . (canceled) 
     
     
         59 . The railway component of claim  46 , wherein the cladding is an interior vertical surface selected from room dividers, flaps, boxes, hoods and louvres; an interior door or lining for internal and external doors; a window insulation; a kitchen interior surface; an interior horizontal surface selected from ceiling paneling, flaps, boxes, hoods and louvres; a luggage storage area selected from overhead and vertical luggage racks, luggage containers and compartments; a driver's desk application selected from paneling and surfaces of driver's desk; an interior surface of gangways selected from interior sides of gangway membranes (bellows) and interior linings; a window frame; an optionally folding table with downward facing surface; an interior or exterior surface of air ducts, a device for passenger information, a side wall, a front wall, an end-wall, a partition, a room divider, an interior door, a window insulation, a lining, a kitchen interior surface, a ceiling panel, an overhead or vertical luggage rack, a luggage container, a luggage compartment, a window frame, an optionally folding table with downward facing surface, an information display screen. 
     
     
         60 - 62 . (canceled) 
     
     
         63 . A railway component,
 wherein the component is a molded or extruded train seat component or a molded or extruded interior train cladding comprising a thermoplastic composition comprising, based on the total weight of the composition:
 50 to 93 wt. % of a combination comprising (i) 5 to 50 wt. % of bisphenol A polycarbonate and (ii) 50 to 95 wt. % of a poly(bisphenol arylate) of the formula 
   
       
         
           
           
               
               
           
         
         wherein R a  and R b  are each independently C 1-12  alkyl, C 1-12  alkenyl, C 3-8  cycloalkyl, or C 1-12  alkoxy, p and q are each independently 0 to 4, and X a  is a bridging group between the two arylene groups, and is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, a C 1-11  alkylidene of the formula —C(R c )(R d )— wherein R and Rd are each independently hydrogen or C 1-10  alkyl, or a group of the formula —C(═R c )— wherein R is a divalent C 1-10  hydrocarbon group, based on the weight of the combination;
 4 to 30 wt. % of a poly(carbonate-siloxane) comprising
 bisphenol A carbonate units, and 
 siloxane units of the formula 
 
 
       
       
         
           
           
               
               
           
         
         
           or a combination comprising at least one of the foregoing, wherein E has an average value of 2 to 200, wherein the poly(carbonate-siloxane) comprises 0.5 to 55 wt. % of siloxane units based on the total weight of the poly(carbonate-siloxane); 
           3 to 20 wt. % of an organophosphorus compound in an amount effective to provide 0.1 to 2.0 wt. % of phosphorus, based on the total weight of the thermoplastic polymer composition; and 
           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 after 4 minutes (Ds-4) of equal to or less than 300 measured according to ISO 5659-2 on a 3 mm thick plaque at 50 kW/m 2 , 
         an integral of the smoke density as a function of time up to 4 minutes (VOF4) of equal to or less than 600 measured according to ISO 5659-2 on a 3 mm thick plaque at 50 kW/m 2 , 
         a maximum average heat release (MAHRE) of equal to or less than 90 kW/m 2  measured according to ISO 5660-1 on a 3 mm thick plaque at 50 kW/m 2 , and 
         a ductility in multiaxial impact of 80 to 100%, measured at +23° C. at an impact speed of 4.4 m/second measured according to ISO 6603 on 3.2 mm thick discs. 
       
     
     
         64 . The railway component of  claim 63 , wherein the combination comprises (i) 35 to 45 wt. % of bisphenol A polycarbonate and (ii) 55 to 65 wt. % of a poly(bisphenol A-arylate ester). 
     
     
         65 . (canceled) 
     
     
         66 . (canceled) 
     
     
         67 . A railway component,
 wherein the component is a molded or extruded train seat component or a molded or extruded interior train cladding comprising a thermoplastic composition comprising, based on the total weight of the composition:
 75 to 96.5 wt. % of a poly(bisphenol A carbonate)-co-(bisphenol phthalate ester); 
 0.5 to 5 wt. % of a poly(siloxane) oil; 
 3 to 20 wt. % of an organophosphorus compound in an amount effective to provide 0.1 to 2.0 wt. % of phosphorus, based on the total weight of the thermoplastic polymer composition; and 
 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 after 4 minutes (Ds-4) of equal to or less than 300 measured according to ISO 5659-2 on a 3 mm thick plaque at 50 kW/m 2 ,   an integral of the smoke density as a function of time up to 4 minutes (VOF4) of equal to or less than 600 measured according to ISO 5659-2 on a 3 mm thick plaque at 50 kW/m 2 ,   a maximum average heat release (MAHRE) of equal to or less than 90 kW/m 2  measured according to ISO 5660-1 on a 3 mm thick plaque at 50 kW/m 2 , and   a ductility in multiaxial impact of 80 to 100%, measured at +23° C. at an impact speed of 4.4 m/second measured according to ISO 6603 on 3.2 mm thick discs.   
     
     
         68 . (canceled) 
     
     
         69 . The railway component of  claim 67 , wherein the poly(bisphenol-A carbonate)-co-poly(bisphenol phthalate ester) comprises 75 to 85 wt. % of ester units, wherein the ester units have a molar ratio of isophthalate to terephthalate in the ester units of 98:2 to 88:12. 
     
     
         70 . The railway component of  claim 67 , wherein the a poly(bisphenol-A carbonate)-co-poly(bisphenol phthalate ester) comprises 35 to 45 wt. % of carbonate units and 55 to 65 wt. % of ester units, wherein the ester units have a molar ratio of isophthalate to terephthalate of 45:55 to 55:45. 
     
     
         71 . The railway component of  claim 67 , wherein the organophosphorus compound is an aromatic organophosphorus compound having at least one organic aromatic group and at least one phosphorus-containing group, or an organic compound having at least one phosphorus-nitrogen bond. 
     
     
         72 . The railway component of  claim 70 , wherein the organophosphorus compound of the thermoplastic composition is bisphenol A bis(diphenyl phosphate), triphenyl phosphate, resorcinol bis(diphenyl phosphate), tricresyl phosphate, a phenol/bi-phenol polyphosphate, or a combination comprising at least one of the foregoing. 
     
     
         73 . The railway component of  claim 67 , wherein the thermoplastic composition further comprises 0.1 to 12 wt. % of TiO 2 . 
     
     
         74 . The railway component of  claim 67 , wherein the thermoplastic composition further comprises 0.05 to 5.0 wt. % of a light diffuser additive comprising silicone, polymethylsilsesquioxane, crosslinked poly(methyl methacrylate), methyl methacrylate/ethylene glycol dimethacrylate copolymer, TiO 2 , or a combination comprising at least one of the foregoing. 
     
     
         75 . The railway component of  claim 67 , wherein the thermoplastic composition further comprises 0.00002 to 5.0 wt. % of a colorant based on the total weight of the polymers in the thermoplastic composition. 
     
     
         76 . The railway component of  claim 67 , wherein the thermoplastic composition further comprises 5 to 20 wt. % of a bisphenol A polycarbonate.