# US 8,771,829 B2 · Flame retardant thermoplastic polymer composition, method of manufacture, and articles formed therefrom

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- Number: US 8,771,829 B2
- Document ID: US8771829B2
- Status: Granted
- Kind: B2
- Application number: 12/566,914
- Filed: 2009-09-25
- Published: 2010-03-25
- Granted: 2014-07-08
- Earliest claimed: 2008-09-25
- Assignees: Sabic Innovative Plastics IP B.V.
- Applicants: Christianus Johannes Jacobus Maas; Hendrik Cornelus Jacobus de Nooijer; Vandita Pai-Paranjape; Srinivas Siripurapu; Joshua Arie van den Bogerd; Andries Adriaan Volkers Volkers
- Inventors: Christianus Johannes Jacobus Maas; Hendrik Cornelus Jacobus de Nooijer; Vandita Pai-Paranjape; Srinivas Siripurapu; Joshua Arie van den Bogerd; Andries Adriaan Volkers Volkers
- Web page: https://patentgrep.com/patent/US8771829B2

## CPC

- C08L 69/00: Compositions of polycarbonates; Compositions of derivatives of polycarbonates
- B29C 48/07: Flat, e.g. panels
- B29C 48/022: {characterised by the choice of material}
- B29C 48/18: the components being layers
- B29K 2069/00: Use of PC, i.e. polycarbonates {or derivatives thereof}, as moulding material
- B29K 2105/256: {Sheets, plates, blanks or films}
- C08K 5/42: Sulfonic acids; Derivatives thereof
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)

## Abstract

A thermoplastic polymer composition comprises a cyanophenyl endcapped polycarbonate, a potassium diphenyl sulphon-3-sulphonate; and brominated polycarbonate. In some embodiments, when the thermoplastic polymer composition is in the form of a 3 mm thick extruded sheet, the sheet has a smoke density of less than 200 at an exposure period of 240 seconds in accordance with the smoke density test as set forth in ASTM E662-06, and has no burning drips on the sheet for a duration of 10 minutes in accordance with the flammability test as set forth in NF-P-92-505.

## Claims

### Claim 1

A sheet having a thickness of 2-3 mm, comprising a thermoplastic polymer composition, wherein the thermoplastic polymer composition comprises:
a branched cyanophenyl endcapped polycarbonate having:
repeating structural carbonate units of the formula:
wherein at least 60 percent of the total number of R1 groups contain aromatic organic groups and the balance thereof are aliphatic, alicyclic, or aromatic groups;
branching groups derived from reaction with a branching agent; and
cyanophenyl endcapping groups derived from reaction with a cyanophenol;
0.01 wt. % to 0.6 wt. % of an aromatic sulphone sulphonate;
a brominated polycarbonate, in an amount such that the composition comprises 0.26 wt. % to 5.2 wt. % bromine,
wherein, said sheet has smoke density and flammability properties such that a 3 mm thick extruded sheet has a smoke density of less than 200 at an exposure period of 240 seconds in accordance with the smoke density test as set forth in ASTM E662-06, and has no burning drips on the sheet for a duration of 10 minutes in accordance with the flammability test as set forth in NF-P-92-505.

### Claim 2 (depends on 1)

The sheet of claim 1, having a thickness of 3 mm.

### Claim 3 (depends on 2)

An aircraft interior component comprising the sheet of claim 2.

### Claim 4 (depends on 3)

The component of claim 3, in the form of a partition wall, cabinet wall, sidewall panel, ceiling panel, floor panel, equipment panel, light panel, window molding, window slide, storage compartment, galley surface, equipment housing, seat housing, speaker housing, duct housing, storage housing, shelf, tray, or a combination comprising at least one of the foregoing.

### Claim 5

A method for the manufacture of a sheet having a thickness of 2-3 mm, comprising
extruding a thermoplastic polymer composition, wherein the thermoplastic polymer composition comprises:
a branched cyanophenyl endcapped polycarbonate having:
repeating structural carbonate units of the formula:
wherein at least 60 percent of the total number of R1 groups contain aromatic organic groups and the balance thereof are aliphatic, alicyclic, or aromatic groups;
branching groups derived from reaction with a branching agent; and
cyanophenyl endcapping groups derived from reaction with a cyanophenol;
0.01 wt. % to 0.6 wt. % of an aromatic sulphone sulphonate;
a brominated polycarbonate, in an amount such that the composition comprises 0.26 wt. % to 5.2 wt. % bromine;
wherein, said sheet has smoke density and flammability properties such that a 3 mm thick extruded sheet has a smoke density of less than 200 at an exposure period of 240 seconds in accordance with the smoke density test as set forth in ASTM E662-06, and has no burning drips on the sheet for a duration of 10 minutes in accordance with the flammability test as set forth in NF-P-92-505.

### Claim 6 (depends on 5)

The method of claim 5, wherein the sheet has a thickness of 3 mm.

### Claim 7 (depends on 1)

The sheet of claim 1, wherein the sheet has a percent transmission of greater than 85%, a % haze of less than 2.0 and a yellowness index of 2.5 YI units or less, when tested according to ANSI/ASTM D1003-00, Procedure A, illuminant C.

### Claim 8 (depends on 1)

The sheet of claim 1, wherein the aromatic sulphone sulphonate is potassium diphenysulphone sulphonate, present in an amount from 0.25 to 0.35 wt. % based on the total weight of the thermoplastic polymer composition.

### Claim 9 (depends on 1)

The sheet of claim 1, wherein the branching agent is
a triacid trichloride of formula:
wherein each Z is independently a hydrogen, halogen, C1-3 alkyl group, C1-3 alkoxy group, C7-12 arylalkyl, alkylaryl, or nitro group, and z is 0 to 3;
a tri-substituted phenol of formula:
wherein T is a C1-20 alkyl group, C1-20 alkeneoxy group, C7-12 arylalkyl group, or alkylaryl group, each S is independently a hydrogen, halogen, C1-3 alkyl group, C1-3 alkoxy group, C7-12 arylalkyl, alkylaryl, or nitro group, and each s is independently 0 to 4;
a benzimidazole of formula:
or a combination comprising at least one of the foregoing branching agents, and further wherein
the cyanophenol is of the formula:
wherein Y is a halogen, C1-3 alkyl group, C1-3 alkoxy group, C7-12 arylalkyl, alkylaryl, or nitro group, y is 0 to 4, and c is 1 to 5, provided that y+c is 1 to 5.

### Claim 10 (depends on 1)

The sheet of claim 1, wherein the branching agent is trimellitic acid, trimellitic anhydride, trimellitic trichloride, tris-(p-hydroxyphenyl)ethane, isatin-bis-phenol, 1,3,5-tris((p-hydroxyphenyl)isopropyl)benzene), 4(4(1,1-bis(p-hydroxyphenyl)-ethyl) alpha,alpha-dimethyl benzyl)phenol), 4-chloroformyl phthalic anhydride, trimesic acid, benzophenone tetracarboxylic acid, or a combination comprising one or more of the foregoing branching agents.

### Claim 11 (depends on 1)

The sheet of claim 1, wherein
the branching agent is trimellitic trichloride, tris-(p-hydroxyphenyl)ethane, or a combination comprising both of the foregoing branching agents, and
the cyanophenol is p-cyanophenol, 3,4-dicyanophenol, or a combination comprising both of the foregoing phenols.

### Claim 12 (depends on 1)

The sheet of claim 1, wherein the branching groups are present in an amount of 0.1 to 10 branching units per 100 R1 units, and the cyanophenyl endcapping groups are present in an amount of 1 to 20 cyanophenyl carbonate units per 100 R1 units.

### Claim 13 (depends on 1)

The sheet of claim 1, wherein the brominated polycarbonate is present in an amount such that the composition comprises 0.26 wt. % to 3.1 wt. % bromine.

### Claim 14 (depends on 1)

The sheet of claim 1, wherein the branched cyanophenyl endcapped polycarbonate comprises about 2.5 to 3.5 tris-(p-hydroxyphenyl)ethane units and about 7 to 11 cyanophenyl carbonate units per 100 R1 units, and has a weight average molecular weight of about 25,000 to 35,000 grams per mole as measured by gel permeation chromatography.

### Claim 15 (depends on 1)

The sheet of claim 1, wherein the aromatic sulphone sulphonate comprises an alkali metal aromatic sulphone sulphonate.

### Claim 16 (depends on 1)

The sheet of claim 1, wherein the alkali metal aromatic sulphone sulphonate comprises potassium diphenylsulphone sulphonate.

### Claim 17 (depends on 1)

The sheet of claim 1, wherein the brominated polycarbonate comprises 24 wt. % to 28 wt. % bromine, based on the total weight of the brominated polycarbonate.