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Solvent cast flame retardant polycarbonate coatings, films and laminates

A technology of polycarbonate and polycarbonate resin, applied in the field of products that introduce solvent casting film, can solve the problems of poor stability, unsolved casting of polycarbonate resin system, low boiling point, etc., and achieve good flame retardancy and mechanical effect

Inactive Publication Date: 2012-01-25
SCHNELLER
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

But dichloromethane is a suspected carcinogen, and its additional problem is its low boiling point (41°C)
THF is also an effective solvent for polycarbonate resins, but also has a low boiling point (65-67°C), produces solutions that are less stable at higher concentrations, and is costly
The prior art relates specifically to films for optical applications and does not address the casting of polycarbonate resin systems made for specific properties such as flame retardancy and strength

Method used

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Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0030] About 182 g of Lexan FST 9705 colored resin was dissolved in about 380 g of 1,3-dioxolane by slow mixing to produce a solution / dispersion of Lexan FST 9705 with a solids content of about 32.5%. Lexan FST 9705 resin was coated on release paper between two parallel lab coater rods with a clear gap of 0.005 inches. The solvent was removed under ambient conditions. The dried coating was removed from the release paper to produce a free standing film having a nominal thickness of 0.002 inches. Use this film to construct decorative laminates consisting of a 0.4 mil clear fluoropolymer skin, a 4 mil flame retardant vinyl embossing layer, and a solvent cast Lexan FST 9705 film as a backing layer composition. The laminate was pressure consolidated at laboratory scale for 5 minutes at 310°F and 150 psi, followed by a cooling cycle. The resulting decorative laminate has an areal density of 254 g / m 2 . The laminate yielded a tensile strength of 201 N / 25mm width. Flame retardan...

Embodiment 2

[0032] Lexan FST 9705 resin and thermoplastic polyurethane resin Estane 5713 (available from Lubrizol) were dispersed in 1,3-dioxolane to a final solids content of about 28%. The ratio of Lexan resin:Estane resin is about 4:1. The dispersion was coated on release paper between two parallel laboratory coating rods with a clear gap of 0.005 inches. The solvent was removed at ambient conditions and then left at 95°C for 10 minutes. The dried coating was removed from the release paper to produce a free-standing film having a nominal thickness of 0.002 inches. Use this film to construct decorative laminates consisting of a 0.4 mil clear fluoropolymer skin, a 4 mil flame retardant vinyl embossing layer, and solvent cast Lexan FST 9705 as a backing layer membrane composition. The laminate was pressure consolidated at laboratory scale for 5 minutes at 310°F and 150 psi, followed by a cooling cycle. The flame retardancy of this laminate was measured in accordance with Parts IV and ...

Embodiment 3

[0034] Lexan FST 9705 resin and acrylic resin Korad 6510AXP (available from Spartech) were dispersed in 1,3-dioxolane to a final solids content of about 30%. The ratio of Lexan resin: Korad resin is about 4:1. The dispersion was coated on release paper between two parallel laboratory coating rods with a clear gap of 0.005 inches. The solvent was removed under ambient conditions and then left at 95°C for 10 minutes. The dried coating was removed from the release paper to produce a free-standing film having a nominal thickness of 0.002 inches. Use this film to construct decorative laminates consisting of a 0.4 mil clear fluoropolymer skin, a 4 mil flame retardant vinyl embossing layer, and a solvent cast Lexan FST 9705 film as a backing layer composition. The laminate was pressure consolidated at laboratory scale for 5 minutes at 310°F and 150 psi, followed by a cooling cycle. The flame retardancy of this laminate was measured in accordance with Parts IV and V of FAR25.853 A...

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Abstract

Solvent cast polycarbonate-based films for use in laminates with flame retardance, low heat release and low smoke production, and methods of manufacture. Polycarbonate resin or polymer blends of polycarbonate resin and one or more polymer resins are solvent cast and incorporated into decorative, fire retardant and protective laminates.

Description

[0001] related application [0002] This application claims priority to US Provisional Patent Application Serial No. 61 / 362,330, filed July 8, 2010, which is hereby incorporated by reference in its entirety. technical field [0003] The present invention relates to solvent cast flame retardant polycarbonate based coatings and films. Furthermore, it relates to products incorporating solvent cast films. The solvent cast films described in this invention are particularly useful in the design and production of laminates for construction and mass transportation, such as decorative laminates for railroad and commercial aviation applications. Background technique [0004] Increasing fuel economy is increasingly important throughout the transportation sector, driving the need for lighter weight designs with the associated difficulty of maintaining or even improving the strength and structural integrity of previous designs. Weight reduction is especially important for mass transpor...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B32B27/08B32B27/36B32B27/30C08L69/00
CPCC08L75/04C08L69/00C08L33/00C08L27/06Y10T428/31507C08L2666/04C08L2666/20
Inventor C·哈博R·L·格里H·C·阿什脱
Owner SCHNELLER