Needle flame flame-retardant polycarbonate composite material as well as preparation method and application thereof

Abstract

The invention belongs to the field of composite materials, and discloses a needle flame flame retardant polycarbonate composite material as well as a preparation method and application thereof. The needle flame flame retardant polycarbonate composite material comprises the following components in percentage by weight: 51.8%-99.45% of polycarbonate; 0.5%-8% of special magnesium carbonate; 0.05% to 0.2% of monopotassium phosphate; 0%-2% of talcum powder; 0%-30% of glass fiber; 0%-1% of an antioxidant; 0%-1% of a release agent; and 0-6% of a toughening agent. A preparation process of the special magnesium carbonate comprises the following steps: placing magnesium carbonate in a carbon dioxide atmosphere, heating to 180-260 DEG C, and keeping for more than 4 hours; and naturally cooling in a carbon dioxide atmosphere, and sealing after cooling to room temperature. The polycarbonate composite material disclosed by the invention can realize a relatively high needle flame flame retardant grade, has relatively small influence on the comprehensive performance of plastics, and is relatively low in cost.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of composite materials, and particularly relates to a needle flame-retardant polycarbonate composite material and a preparation method and application thereof. BACKGROUND

[0002] Flame-retardant plastic parts are an important type of plastic products, especially in the field of engineering plastics, and flame-retardant products account for about half of the market applications. In the past, the industry often used the UL94 flame-retardant standard to determine the flame-retardant grade of plastic parts. With the gradual improvement of safety regulations, the requirements for matching the flame-retardant standard and the actual situation in various application fields are becoming higher and higher. In recent years, in addition to UL94, needle flame-retardant based on GB / T5169.5 and IEC60695-11-5 test standards has become an increasingly strong demand. For polycarbonate, the technical difficulties of needle flame-retardant are completely different from the conventional UL94 vertical burning, and common bromine-based and phosphorus-based flame retardants have no effect on needle flame-retardant, and even have a negative effect. There is no general flame retardant on the market that can achieve efficient needle flame-retardant of polycarbonate materials. SUMMARY

[0003] In order to overcome the shortcomings and deficiencies of the prior art, the primary purpose of the present application is to provide a high-efficiency needle flame-retardant polycarbonate composite material. At the same time, the plastic part has low cost and less effect on other properties.

[0004] Another purpose of the present application is to provide a preparation method of the high-efficiency needle flame-retardant polycarbonate composite material.

[0005] Still another purpose of the present application is to provide an application of the high-efficiency needle flame-retardant polycarbonate composite material.

[0006] The purposes of the present application are achieved by the following solutions:

[0007] A needle flame-retardant polycarbonate composite material comprises the following components by weight percentage:

[0008]

[0009]

[0010] The preparation process of the special magnesium carbonate is as follows: commercially available magnesium carbonate is placed in a carbon dioxide atmosphere, heated to 180-260℃, and kept for more than 4 hours; then naturally cooled in a carbon dioxide atmosphere, and sealed after being cooled to room temperature. The obtained special magnesium carbonate needs to be processed by double-screw extrusion within 24 hours.

[0011] Preferably, the weight percentage of the special magnesium carbonate is 2%-8%, and more preferably 4-8%.

[0012] Preferably, the weight percentage of potassium dihydrogen phosphate is 0.1%-0.15%; more preferably, 0.1%.

[0013] Preferably, the weight percentage of talc is 0.5%-1%, and the D50 particle size of talc is less than 2 microns.

[0014] Preferably, the weight percentage of glass fiber is 10%-25%.

[0015] Preferably, the antioxidant is a hindered phenolic antioxidant, and the release agent is a pentaerythritol ester release agent.

[0016] Preferably, the toughening agent is a core-shell toughening agent with a silicone rubber core and a methyl methacrylate shell. More preferably, the toughening agent is at least one of Mitsubishi Chemical S-2100 and Dow Chemical MBS EXL-2691.

[0017] Preferably, the needle flame-retardant polycarbonate composite material comprises the following weight percentages of each component:

[0018]

[0019]

[0020] More preferably, the needle flame-retardant polycarbonate composite material comprises the following weight percentages of each component:

[0021]

[0022] A preparation method of the above-mentioned needle flame-retardant polycarbonate composite material, comprising the following steps: weighing the components in the proportions by weight, then mixing the components, and granulating with a twin-screw extruder to obtain a polycarbonate composite, the granulation temperature being 220-300℃.

[0023] The above-mentioned needle flame-retardant polycarbonate composite material is applied in consumer electronic products such as mobile phones, tablet computers, smart watches, etc.

[0024] Compared with the prior art, the present application has the following advantages and beneficial effects:

[0025] The polycarbonate composite material of the present application can achieve a high needle flame-retardant grade, while having a relatively small impact on the comprehensive performance of plastics and a relatively low cost. Moreover, the preparation method of the present application is simple and easy to implement, suitable for large-scale production, and can reduce costs. DETAILED DESCRIPTION

[0026] The application will be further described in conjunction with the following examples. The application is not limited to the examples. The specific conditions not mentioned in the examples are carried out according to the conventional conditions or the conditions recommended by the manufacturer. The reagents or instruments not mentioned by the manufacturer are conventional products that can be purchased on the market.

[0027] The technical solutions of the present application are described in detail below using examples. The raw materials in the examples can be purchased on the market, and are as follows: polycarbonate is SABIC Lexan 141R, commercially available magnesium carbonate is Jiangsu Zehui Magnesium-based New Material ZH-6, potassium dihydrogen phosphate is analytical pure from Sinopharm, talc powder is Imersy JET Fine 3CA, glass fiber is CPIC ECS307, antioxidant is AO1076, release agent is PETS, toughening agent is Mitsubishi Chemical S-2100 and Dow Chemical MBS EXL-2691. The mechanical properties are tested according to the ISO527 and ISO179 standards, and the needle flame retardant test refers to the IEC60695-11-5 standard.

[0028] The special magnesium carbonate in the examples is prepared by the following method: commercially available light magnesium carbonate ZH-6 is placed in a carbon dioxide atmosphere, heated to 200 degrees Celsius, kept for 6 hours, then naturally cooled to room temperature in a carbon dioxide atmosphere, and sealed. The obtained special magnesium carbonate needs to be processed by double screw extrusion within 24 hours.

[0029] Examples 1-9 and Comparative Examples 1-3

[0030] The polycarbonate composite materials in Examples 1-9 and Comparative Examples 1-3 are prepared by the following steps: the components are weighed according to the percentage by weight, then the components are mixed, and the polycarbonate composite is obtained by using a double screw extruder for granulation, and the granulation temperature is 220-300°C. The weight percentage of each component in Examples 1-9 and Comparative Examples 1-3 and the properties of the prepared polycarbonate composite materials are shown in Table 1.

[0031] Table 1. The weight percentage of each component in Examples 1-9 and Comparative Examples 1-3 and the performance data of the prepared polycarbonate composite materials

[0032]

[0033]

[0034] From the comparison of Comparative Example 1 and Comparative Example 2 in Table 1, it can be seen that when the commercially available magnesium carbonate and potassium dihydrogen phosphate are added to pure PC, the needle flame retardant performance is improved, but the mechanical properties of PC are significantly reduced. However, when the commercially available magnesium carbonate is replaced by the specially prepared magnesium carbonate, the needle flame retardant performance is improved, and the mechanical properties of the polycarbonate composite material are improved to the level of pure PC.

[0035] From the comparison of Example 1, Example 3, Example 5-7 and Comparative Example in Table 1, it can be seen that the specially prepared magnesium carbonate and potassium dihydrogen phosphate are used together, and when the content of magnesium carbonate is 2-8% and the content of potassium dihydrogen phosphate is 0.1%, high-efficiency needle flame retardant can be achieved, and the mechanical properties are well maintained. From the comparison of Comparative Example 3 and Example 8 in Table 1, it can be seen that the flame retardant system is suitable for both non-glass fiber reinforced and glass fiber reinforced materials.

[0036] Examples 10-17

[0037] The polycarbonate composite materials in Examples 10-17 and Comparative Example 4 were prepared by the following steps: weighing the components according to the weight percentage, then mixing the components, and granulating the polycarbonate composite material by using a double-screw extruder, and the granulation temperature was 220-300°C. The weight percentages of the components in Examples 10-17 and the properties of the prepared polycarbonate composite materials are shown in Table 2.

[0038] Table 2. Weight percentages of the components in Examples 10-17 and Comparative Example 4 and performance data of the prepared polycarbonate composite materials

[0039]

[0040]

[0041] From the comparison of Example 3 and Comparative Example 4 in Table 2, it can be seen that although talc is also a common synergistic flame retardant, its needle flame retardant effect on the composite material is much lower than that of the specially prepared magnesium carbonate.

[0042] From the comparison of Example 3, Comparative Example 4 and Example 10 in Table 2, it can be seen that when the specially prepared magnesium carbonate and a small amount of talc are used together, the needle flame combustion performance of the polycarbonate composite material can be further improved while maintaining the mechanical properties. That is, there is a synergistic effect between the specially prepared magnesium carbonate and talc. From Examples 13-17, it can be seen that when the composite material contains a toughening agent and glass fibers, it is also applicable.

[0043] The above embodiments are the preferred embodiments of the present application, but the embodiments of the present application are not limited to the above embodiments, and any changes, modifications, substitutions, combinations, simplifications, etc. made without departing from the spirit and principles of the present application should be equivalent replacement manners and should be included in the protection scope of the present application.

Claims

1. A needle flame flame retardant polycarbonate composite material, characterized in that The composition comprises the following components in percentage by weight: The preparation process of the special magnesium carbonate is as follows: the magnesium carbonate is placed in a carbon dioxide atmosphere, heated to 180-260° C., and maintained for more than 4 hours; then the temperature is naturally lowered in the carbon dioxide atmosphere, and the temperature is sealed after it is lowered to room temperature.

2. The needle flame flame retardant polycarbonate composite material according to claim 1, characterized in that: The antioxidant is a hindered phenol antioxidant; The release agent is a pentaerythritol ester release agent.

3. The needle flame flame retardant polycarbonate composite material according to claim 1, characterized in that: The D50 particle size of the talc is less than 2 microns.

4. The needle flame flame retardant polycarbonate composite material according to claim 1, characterized in that: The toughening agent is a core-shell toughening agent having a silicone rubber core and a methacrylate shell.

5. The needle flame flame retardant polycarbonate composite material according to claim 1, characterized in that: The toughening agent is at least one of Mitsubishi Chemical S-2100 and Dow Chemical MBS EXL-2691.

6. The needle flame flame retardant polycarbonate composite material according to claim 1, characterized in that: The needle flame flame retardant polycarbonate composite material comprises the following components in the following weight percentages:

7. The needle flame flame retardant polycarbonate composite material according to claim 1, characterized in that: The needle flame flame retardant polycarbonate composite material comprises the following components in the following weight percentages:

8. A method for preparing the needle flame flame retardant polycarbonate composite material according to any one of claims 1 to 7, characterized in that The following steps are involved: The components in corresponding amounts are weighed according to weight percentage, and then the components are mixed and granulated by a twin-screw extruder to obtain a polycarbonate compound at a granulation temperature of 220-300°C.

9. Use of the needle flame retardant polycarbonate composite material according to any one of claims 1 to 7 in consumer electronic products.

10. Use of the needle flame retardant polycarbonate composite material according to any one of claims 1 to 7 in mobile phones, tablet computers, and smart watches.

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