Flame-retardant material, preparation method thereof and product

Abstract

The invention discloses a flame-retardant material, a preparation method thereof and a product. The flame-retardant material is prepared from the following components in parts by mass: 60 to 75 parts of polycarbonate; 6 to 10 parts of acrylonitrile-butadiene-styrene copolymer; 15 to 25 parts of talcum powder; 9-15 parts of a flame retardant; 0.5 to 1 part of an anti-dripping agent; 2-5 parts of a toughening agent; and 0.5 to 3 parts of an interface compatilizer; wherein the aspect ratio of the talcum powder is 15 to 25; the interfacial compatibilizer includes an organic compound having an epoxy group. According to the flame-retardant material disclosed by the invention, the high modulus is ensured through the talcum powder with the high aspect ratio, and meanwhile, flame retardance and solution flow are considered through coupling between the interface compatilizer and the talcum powder.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of flame-retardant materials, in particular to a flame-retardant material capable of achieving both flame retardation and melt flow, and having high modulus and high impact strength, a preparation method thereof, and an article manufactured based on the flame-retardant material. BACKGROUND

[0002] Engineering plastics are widely used in the fields of automobiles, electronic appliances, medical devices, etc. Polycarbonate / acrylonitrile-butadiene-styrene copolymer (PC / ABS) alloy material is one of the main materials. It has excellent mechanical properties, excellent impact resistance, and temperature resistance, ultraviolet (UV) resistance, and excellent formability of ABS. However, in high-end applications, it is required to simultaneously meet the requirements of high modulus (rigidity requirement, such as thin-walled structural parts), high flowability (complex structure injection molding), high impact strength (anti-falling, impact resistance), flame retardancy (UL94 V-0 level), etc.

[0003] The traditional flame-retardant PC / ABS system has the following defects: adding glass fibers can improve the modulus, but significantly reduces the flowability and impact toughness, and causes poor appearance due to floating fibers and other factors; conventional flame retardants (such as bromine-based) can easily reduce the toughness of the material, and have insufficient environmental protection; although conventional talc powder filling can provide a certain degree of modulus, excessive addition can degrade the impact strength and melt flow rate. SUMMARY

[0004] In order to solve at least one of the above problems, the present application discloses a flame-retardant material, a preparation method thereof, and an article. The flame-retardant material ensures high modulus by using talc powder with high aspect ratio, and simultaneously ensures flame retardation and melt flow by coupling between the interface compatibilizer and the talc powder.

[0005] The first aspect of the present application discloses a flame-retardant material, which comprises the following components in mass fraction: polycarbonate 60-75 parts; acrylonitrile-butadiene-styrene copolymer 6-10 parts; talc powder 15-25 parts; flame retardant 9-15 parts; anti-dripping agent 0.5-1 part; toughening agent 2-5 parts; and interface compatibilizer 0.5-3 parts; wherein the aspect ratio of the talc powder is 15-25; and the interface compatibilizer comprises an organic compound with an epoxy group.

[0006] According to some embodiments of the present application, the melt index of the polycarbonate is 10-20 g / 10 min.

[0007] According to some embodiments of the present application, the flame retardant comprises a phosphorus-containing flame retardant selected from one or more of phosphazene compounds and / or one or more of phosphate compounds.

[0008] According to some embodiments of the present application, the flame retardant comprises one or more of triphenyl phosphate, bisphenol A bisdi(phenyl phosphate), resorcinol bis(diphenyl phosphate), resorcinol bis[dioctyl(2,6-dimethylphenyl) phosphate].

[0009] According to some embodiments of the present application, the interfacial same agent comprises polyolefin elastomer grafted with glycidyl methacrylate.

[0010] According to some embodiments of the present application, the flame retardant material further comprises 0.1-0.6 parts of lubricant, the lubricant comprising one or more of calcium stearate, stearic acid, ethylene bis-stearamide, pentaerythritol stearate, silicone powder, polyethylene wax.

[0011] According to some embodiments of the present application, the flame retardant material further comprises 0.2-0.6 parts of antioxidant, the antioxidant comprising one or more of antioxidant 168, antioxidant 1010, antioxidant 1098.

[0012] According to some embodiments of the present application, the toughening agent comprises one or more of methyl methacrylate-butadiene-styrene copolymer, methyl methacrylate-acrylic acid copolymer, ethylene-methyl acrylate copolymer, ethylene-butyl acrylate copolymer, ethylene-acrylate-glycidyl methacrylate terpolymer, maleic anhydride functionalized ethylene-vinyl acetate copolymer, acrylic toughening agent, and acrylic-silicone rubber toughening agent.

[0013] The second aspect of the present application provides a preparation method of the flame retardant material as described above, the preparation method comprising: according to the mass ratio of each component of the flame retardant material, mixing each component in a mixing device to obtain a mixture; using an extrusion device to extrude the mixture into a strip, and transferring the strip to a granulation device for granulation, to obtain the flame retardant material after post-processing.

[0014] The third aspect of the present application provides an article, which can be manufactured from the flame retardant material as described above.

[0015] Additional aspects and advantages of the present application will be in part apparent and in part pointed out hereinafter. DETAILED DESCRIPTION

[0016] In order to make the above objectives, features and advantages of the present application more clear and comprehensible, the following will make a detailed description of the specific embodiments of the present application. In the following description, a large number of specific details are set forth in order to provide a thorough understanding of the present application. However, the present application can be implemented in many different ways other than the ways described herein, and one of ordinary skill in the art can make similar improvements without departing from the spirit of the present application, and therefore the present application is not limited to the specific embodiments disclosed below.

[0017] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used in the description of the application herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. As used in this application, the term "comprises" or "comprising" and the like are intended to mean that the elements listed after the word are present in the compositions, products, articles, processes and / or methods described herein, but not excluding the presence of one or more other elements or steps. The use of the term "and / or", e.g., "X and / or Y" shall cover a combination of X and Y and the individual members of the combination and any of the individual members if the values of X and Y are inconsistent.

[0018] The flame retardant material disclosed in the present application improves the impact strength while improving the modulus by bonding the interfacial compatibilizer having an epoxy group with talc. Also, it does not contain glass fibers and ensures the flame retardancy and increases the modulus using a flame retardant while improving the flowability.

[0019] Some preferred embodiments of the present application are described below. It should be noted that the following description is for the purpose of illustration and is not intended to limit the scope of protection of the present application. The steps involved in the present application can be executed in order or in reverse order or simultaneously process various steps. At the same time, other operations can be added to these processes, or one or more steps can be removed from these processes.

[0020] The present application discloses a flame retardant material including polycarbonate, acrylonitrile-butadiene-styrene copolymer, talc, flame retardant, toughening agent, and interfacial compatibilizer.

[0021] The polycarbonate (PC) applied to the present application can include, but is not limited to, bisphenol A type polycarbonate (BPA-PC), bisphenol S type polycarbonate (BPS-PC), bisphenol TMC type polycarbonate, aliphatic polycarbonate, aromatic-aliphatic copolycarbonate, poly(1,4-cyclohexanedimethanol) carbonate (PCHC), silicon-containing polycarbonate, poly(paradiphenol) carbonate, poly(metaphenol) carbonate, poly(2,2,4,4-tetramethyl-1,3-cyclobutanediol) carbonate, phosphorus-containing polycarbonate, etc.

[0022] In some embodiments, the polycarbonate can be prepared based on a bisphenol compound. Some suitable, but non-limiting, bisphenol compounds can include 2,2-bis(4- hydroxyphenyl)propane (bisphenol A), 4,4'-dihydroxydiphenyl sulfone (bisphenol S), bis(4- hydroxyphenyl)methane (bisphenol F), l,l-bis(4-hydroxyphenyl)cyclohexane (bisphenol Z), l,l-bis(4-hydroxyphenyl)-4-isopropylcyclohexane (bisphenol C), l,l-bis(4-hydroxyphenyl)-l- phenylethane (bisphenol AP), 4,4'-(l,3-phenyl diisopropyl)diphenol (bisphenol M), 4,4'-(l,4- phenyl diisopropyl)diphenol (bisphenol P), l,l-bis(4-hydroxy-3-methylphenyl)cyclohexane (bisphenol TMC), 4,4'-dihydroxydiphenyl, 2,2'-dihydroxydiphenyl, 3,3'-dihydroxydiphenyl, 4,4'- dihydroxydiphenyl ether, 3,3'-dihydroxydiphenyl ether, 4,4'-dihydroxydiphenylmethane, 2,2'- dihydroxydiphenylmethane, 4,4'-dihydroxydiphenylethane, 4,4'-dihydroxydiphenylpropane, 4,4'- dihydroxydiphenylbutane, 4,4'-dihydroxydiphenylpentane, 4,4'-dihydroxydiphenylhexane, 4,4'- dihydroxydiphenylheptane, 4,4'-dihydroxydiphenyloctane, 4,4'-dihydroxydiphenylnonane, 4,4'- dihydroxydiphenyldecane, 1,4-dihydroxynaphthalene, 1,5-dihydroxynaphthalene, 2,6- dihydroxynaphthalene, 2,7-dihydroxynaphthalene, l,l-bis(4-hydroxyphenyl)cyclopentane, l,l-bis(4- hydroxy-3-methylphenyl)cyclohexane, l,l-bis(4-hydroxyphenyl)cycloheptane, l,l-bis(4- hydroxyphenyl)cyclooctane, 9,9-bis(4-hydroxyphenyl)fluorene, 4,4'-dihydroxydiphenyl sulfone, 3,3'- dihydroxydiphenyl sulfone, 4,4'-dihydroxydiphenyl sulfide, 3,3'-dihydroxydiphenyl sulfide, 4,4'- dihydroxybenzophenone, 2,2'-dihydroxybenzophenone, 4,4'-dihydroxyphenyl vinyl, 4,4'- dihydroxydiphenylacetylene, 4,4'-dihydroxybenzaldehyde, 4,4'-dihydroxybenzyl alcohol, 4,4'- dihydroxybenzyl phenol, 4,4'-dihydroxybenzyl propanol, 4,4'-dihydroxybenzyl butanol, 4,4'- dihydroxybenzyl pentanol, 4,4'-dihydroxybenzyl hexanol, 4,4'-dihydroxybenzyl heptanol, 4,4'- dihydroxybenzyl octanol, 4,4'-dihydroxybenzyl nonanol, 4,4'-dihydroxybenzyl decanol, 4,4'- dihydroxythiobenzophenone, 4,4'-dihydroxydiphenyl sulfone ether, and the like. 3,3-bis(4- hydroxyphenyl)phthalimidine, 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine, and the like. The functional groups contained in the above bisphenol compounds, such as alkyl groups, can also contain heteroatoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, and the like.

[0023] In some embodiments, the polycarbonate can be obtained based on bisphenol A. For example, an interfacial polycondensation reaction of bisphenol A with phosgene in a two-phase system can be used to obtain bisphenol A polycarbonate. Exemplary steps can include dissolution of bisphenol A in aqueous sodium hydroxide solution, mixing of the solution with an organic solvent (e.g., dichloromethane, 1,2-dichloroethane, chlorobenzene, toluene, etc.) containing phosgene, polycondensation reaction at the interface of the two phases under stirring, separation of the organic phase after completion of the reaction, washing and drying, and solvent evaporation to obtain bisphenol A polycarbonate. Subsequent optional polycondensation can be used to obtain higher molecular weight polymers. Of course, melt transesterification polycondensation or non-phosgene melt transesterification polycondensation can also be used to obtain bisphenol A polycarbonate. Endcapping agents can also be used during the preparation of the polycarbonate for controlling and improving the molecular weight and properties of the polymer. For example, monophenolic compounds (e.g., phenol, p-tert-butyl phenol, p-isooctyl phenol, p-dodecyl phenol, p-phenyl phenol, etc. for improving stability and heat resistance), phenolic compounds (e.g., 2,4-di-tert-butyl phenol, 2,6-di-tert-butyl-4-methyl phenol (BHT), 2,6-di-tert-butyl phenol, etc. for improving thermal stability, enhancing antioxidation, and improving yellowing resistance), ester compounds (e.g., p-tert-butyl benzoic acid, methyl p-tert-butyl benzoate, benzoic acid, methyl benzoate, etc. for improving hydrolysis resistance and improving thermal stability), long-chain alkyl phenols (e.g., nonyl phenol, dodecyl phenol, octadecyl phenol, etc. for improving weather resistance), epoxy compounds (e.g., phenyl glycidyl ether, p-tert-butyl phenyl glycidyl ether, etc. for improving weather resistance and improving hydrolysis resistance), phosphate ester compounds (e.g., triphenyl phosphate, tris(2,6-dimethylphenyl) phosphate, etc. for improving flame retardancy and increasing thermal stability), multifunctional compounds (e.g., 4-hydroxybenzoic acid methyl ester, 4-hydroxyacetophenone, etc. for providing multiple functionalities), and the like can be used as endcapping agents. In addition, a thioether carbonyl endcapping agent as shown in the formula G-C(=0)-L-S-R can also be used. In the formula, G represents a leaving group, which can typically be a hydroxyl group (-OH) or other reactive groups, L can be a C1-C 12 aliphatic or aromatic linking group such as an alkyl or aryl group, and R can be a C1-C 30 alkyl or aryl group. Suitable, but non-limiting, thioether carbonyl endcapping agents can include, but are not limited to, 2-mercaptobenzoic acid, thiosalicylic acid, S-(4-hydroxyphenyl)thioacetic acid, 2-(phenylthio)acetic acid, methyl 4-mercaptobenzoate, 3,3'-thiobis(2-methylpropanoic acid), 2-[(4-hydroxyphenyl)thio]benzoic acid, 4-(methylthio)benzoic acid, 2-mercapto-5-methylbenzoic acid, S-phenylthioacetic acid, and the like or any combination thereof.

[0024] The polycarbonate used in the present application can have a melt index of 10-20 g / 10 min, for example, 10 g / 10 min, 11 g / 10 min, 12 g / 10 min, 13 g / 10 min, 14 g / 10 min, 15 g / 10 min, 16 g / 10 min, 17 g / 10 min, 18 g / 10 min, 19 g / 10 min, 20 g / 10 min, etc.

[0025] The acrylonitrile (AN)-butadiene (Bd)-styrene (St) copolymer (ABS) used in the present application can include emulsion graft copolymerization ABS, in which butadiene rubber latex is first prepared by emulsion polymerization, then AN and St monomers are grafted onto the surface of the rubber particles, and finally SAN resin (styrene-acrylonitrile copolymer) is blended. It can also include bulk polymerization ABS, in which the three monomers are directly polymerized in the bulk (without solvent), and butadiene is dispersed into a rubber phase by screw shearing. It can also include suspension polymerization ABS, in which water is used as the medium, and the monomers are dispersed into droplets by a suspending agent (such as polyvinyl alcohol), and the polymerization is completed in the droplets. It should be noted that, regardless of the polymerization method, the final copolymer obtained by using acrylonitrile (AN), butadiene (Bd), and styrene (St) as raw materials, regardless of the adjustment of the proportions of the three, is within the scope of protection of the present application "acrylonitrile-butadiene-styrene copolymer".

[0026] The acrylonitrile-butadiene-styrene copolymer used in the present application can have a melt index of 1-40 g / 10 min, for example, 1 g / 10 min, 5 g / 10 min, 10 g / 10 min, 15 g / 10 min, 20 g / 10 min, 25 g / 10 min, 30 g / 10 min, 35 g / 10 min, 40 g / 10 min, etc. An exemplary but non-limiting choice is that the melt index of the linear homopolycarbonate is 20 g / 10 min. The melt index of the acrylonitrile-butadiene-styrene copolymer used can also be adjusted according to actual conditions, for example, the application scenario of the product prepared from the flame-retardant material.

[0027] The talc used in the present application can be talc with a high aspect ratio. That is, the talc has a flaky structure, and the length / diameter is much greater than the thickness. In some implementations, the talc has an aspect ratio of 15-25. Exemplarily, the talc has an aspect ratio of 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, etc., or any value within the above range. The flaky talc can directly bear and transmit stress through a large plane, and limit the segment movement of the PC / ABS matrix, thereby improving the modulus of the flame-retardant material.

[0028] In some implementations, the talc powder can include modified talc powder or unmodified talc powder. The modified talc powder can be obtained by modifying the surface of the talc powder by physical or chemical means. By surface modification, the talc powder can be rendered hydrophobic or have specific reactivity, thereby improving the compatibility and dispersibility with the organic matrix (e.g., the aforementioned polycarbonate and / or acrylonitrile-butadiene-styrene copolymer).

[0029] Some exemplary modification methods can include coupling agent modification, surfactant modification, polymer coating modification, or other modification methods. Coupling agent modification can be through the "dual functional groups" of the coupling agent molecules, one end reacting with the hydroxyl groups on the surface of the talc powder (forming a chemical bond), and the other end being compatible (or reacting) with the organic matrix, thereby building an "inorganic-organic bridge". Commonly used coupling agents can include silane coupling agents, titanate coupling agents, aluminate coupling agents, etc. An exemplary modification process can be to dry the talc powder to remove water, then stir it uniformly with the coupling agent in a high-speed mixer to obtain the modified talc powder. Surfactant modification can be to use the "amphiphilic" property of surfactants (hydrophilic groups adsorbed on the surface of the talc powder, and hydrophobic groups facing outward), to improve the surface hydrophobicity through physical adsorption or weak chemical action (such as hydrogen bonding). Commonly used surfactants can include anionic surfactants such as stearic acid (C 17 H 35 COOH), sodium stearate (C 17 H 35 COONa), etc., nonionic surfactants such as polyethylene glycol, sorbitan stearate, etc. An exemplary modification process can be to dissolve the surfactant in hot water or an organic solvent, then mix it with the talc powder, stir it uniformly at an appropriate temperature, and then dry and crush it. Polymer coating modification can be to graft or coat a layer of polymer chains similar to the matrix on the surface of the talc powder through polymerization, so that the surface properties match the matrix perfectly. Commonly used grafting methods can be graft copolymerization (using the hydroxyl groups on the surface of the talc powder to initiate the polymerization of monomers (such as styrene, acrylonitrile), forming polymer grafting chains), emulsion polymerization coating (in a talc powder suspension, monomers (such as acrylate) are allowed to form a polymer film on the surface of the particles through emulsion polymerization), etc. Other suitable modification methods such as plasma modification (using low-temperature plasma (such as argon, ethylene plasma) to bombard the surface of the talc powder, introducing active groups (such as -OH, -COOH, double bonds, etc.), and then reacting with organic matter) can also be applied to the present application.

[0030] The talc powder can also be ordinary talc powder, that is, talc powder without surface modification. Applying ordinary talc powder to this application can improve the dispersion effect in PC / ABS by acting as an interfacial compatibilizer in the flame retardant material composition. In some implementations, the interfacial compatibilizer may include an organic compound having epoxy groups, such as a polymer. The epoxy groups can react with the hydroxyl groups on the surface of the talc powder, forming stable covalent bonds with the epoxy groups through a nucleophilic ring-opening reaction of the epoxy ring, thereby improving the dispersion effect using the composition of the organic compound. In some embodiments, the organic compound may be a polyolefin elastomer (POE) grafted with glycidyl methacrylate (GMA), or referred to as POE-g-GMA. The GMA unit contains a highly reactive epoxy ring (three-membered ring), which can undergo a nucleophilic reaction with the hydroxyl groups on the surface of the talc powder to form stable covalent bonds. The main chain of POE consists of flexible polyolefin segments. After the GMA epoxy groups bond with talc, the POE main chain forms a continuous, flexible coating layer on the surface of the talc. This flexible coating layer is an elastic polymer chain network that can fill the micropores on the surface of the talc and mask its hydrophilic groups. Furthermore, the molecular chain structure of the POE main chain is similar to that of polyolefin matrices (such as ABS), which can improve the compatibility of talc with PC / ABS through chain entanglement effects.

[0031] The flame retardant used in this application may be a phosphorus-containing flame retardant, including one or more phosphazene compounds and / or one or more phosphate ester compounds. Phosphazene compounds may be inorganic or organic-inorganic hybrids containing phosphazene groups (-P=N-) within their molecules. In this application, the general structural formula of the phosphazene compounds may be (NPX2). n The notation is as follows: N represents a nitrogen atom, P represents a phosphorus atom, X represents a substituent group, such as amino, substituted or unsubstituted alkyl, substituted or unsubstituted aryl, etc., and n represents the number of repeating units, which can be 3 or a larger integer. Examples of suitable mono-non-limiting phosphazene compounds may include hexa(dimethylamino)cyclotriphosphazene [NP(N(CH3)2)2]3, hexaphenylcyclotriphosphazene (NPPh2)3, hexa(diethylamino)cyclotriphosphazene [NP(N(C2H5)2)2]3, hexa(morpholinyl)cyclotriphosphazene [NP(NC4H8O)2]3, and hexa(piperidinyl)cyclotriphosphazene [NP(NC5H]3, 2, 3, 4, 5, 6, 7, 8, 9, 1 ... 10)2]3, hexakis(p-methylphenyl)cyclotriphosphazene [NP(p-CH3C6H4)2]3, hexakis(methoxy)cyclotriphosphazene [NP(OCH3)2]3, hexakis(ethoxy)cyclotriphosphazene [NP(OC2H5)2]3, hexakis(isopropoxy)cyclotriphosphazene [NP(OCH(CH3)2)2]3, hexakis(tert-butoxy)cyclotriphosphazene [NP(OC(CH3)3)2]3, hexakis(cyano)cyclotriphosphazene [NP(CN)2]3, hexakis(nitro)cyclotriphosphazene [NP(NO2)2]3, hexakis(amino)cyclotriphosphazene [NP(NH2)2]3, hexakis(acetylamino)cyclotriphosphazene [NP(NHCOCH3)2]3, hexakis(phenoxy)cyclotriphosphazene [NP(OC6H5)2]3, hexakis(phenylthio)cyclotriphosphazene [NP(SC6H5)2]3, and the like. In some embodiments, the phosphazene compound is hexakis(phenoxy)cyclotriphosphazene.

[0032] The phosphate compound can be represented as O=P(OR)3, where O represents an oxygen atom, P represents a phosphorus atom, and R represents a hydrogen or an organic group, including substituted or unsubstituted alkyl, aryl, and the like. Some examples of suitable phosphate compounds, without limitation, can include triphenyl phosphate, tricresyl phosphate, tris(2- ethylhexyl) phosphate, tris(2-butoxyethyl) phosphate, dimethyl resinate phosphate, bisphenol A bis(diphenyl phosphate), resorcinol bis(diphenyl phosphate), resorcinol bis[di(2,6-dimethylphenyl) phosphate], tris(4- isopropylphenyl) phosphate, tris(2,4-di-tert-butylphenyl) phosphate, tris(4- isopropylphenyl) phosphate, tris(2,6-dimethylphenyl) phosphate, tris(4-tert- butylphenyl) phosphate, tris(2-ethoxyethyl) phosphate, tris(2-methoxyethyl) phosphate, tris(2-propenyl) phosphate, tris(2-propynyl) phosphate, tris(4- bromophenyl) phosphate, tris(3,5-dimethylphenyl) phosphate, tris(2,4,6- trimethylphenyl) phosphate, tris(2-hydroxypropyl) phosphate, tris(2- propenyloxyethyl) phosphate, tris(2-cyanoethyl) phosphate, tris(2-carboxyethyl) phosphate, and the like. In some embodiments, the phosphate compound is bisphenol A bis(diphenyl phosphate), resorcinol bis[di(2,6-dimethylphenyl) phosphate], and / or resorcinol bis(diphenyl phosphate).

[0033] The above phosphorus-containing flame retardants are halogen-free flame retardants. Halogen-based flame retardants can also be used in the present application. For example, one or more of chlorinated paraffin, tetrachlorophthalic anhydride, tris (tribromophenoxy) triazine, tetra- bromoethane, decabromobiphenyl ether, decabromodiphenyl ethane, decabromodiphenyl, brominated polycarbonate, perbromotricyclopentadecane, tetrabromobisphenol A, octabromobiphenyl ether, octabromobiphenyl sulfide, brominated polystyrene, brominated phenoxy resin, brominated styrene-maleic anhydride copolymer, or brominated epoxy resin.

[0034] Anti-dripping agents applied in the present application can prevent the molten dripping from igniting secondary fire during combustion by enhancing the melt strength and flexural modulus of the flame-retardant material, while improving the flame-retardant performance. Exemplary anti-dripping agents can include, but are not limited to, fluorine-based anti-dripping agents such as polytetrafluoroethylene (PTFE), char-forming anti-dripping agents such as aromatic polyamide (PA66, PA6), polyimide (PI), pentaerythritol (PER), dipentaerythritol (DPER), melamine cyanurate (MCA), zinc oxide (ZnO), magnesium oxide (MgO), and the like. Other types of anti-dripping agents can also be applied in the present application.

[0035] Toughening agents applied in the present application can restore or improve the impact resistance, ductility, and processing flowability of the material without significantly compromising the flame-retardant performance. Exemplary toughening agents can include, but are not limited to, methyl methacrylate-butadiene-styrene copolymer, methyl methacrylate-acrylic acid copolymer, ethylene-methyl acrylate copolymer, ethylene-butyl acrylate copolymer, ethylene-acrylate-glycidyl methacrylate terpolymer, maleic anhydride-functionalized ethylene-vinyl acetate copolymer, acrylic acid-based toughening agent, and acrylic acid-silicone rubber-based toughening agent, and the like, or any combination thereof.

[0036] The flame retardant material can also include other auxiliary agents, such as, for example, antioxidants, lubricants, and the like. The antioxidants can be used to improve the durability of the flame retardant material and maintain the long-term performance of the flame retardant material. Exemplary antioxidants can include, but are not limited to, 2,6-di-tert-butyl-4-methylphenol, 2,2'-methylenebis(4-methyl-6-tert-butylphenol), pentaerythrityl tetra-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, tris(2,4-di-tert-butylphenyl)phosphite, N,N'-bis(3-hydroxyethyl)-5-methylhydrazine-1,3-dicarboxamide, 2,2'-thiodiethanol bis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate), 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxyphenyl)benzene, n-octyl 3,5-di-tert-butyl-4-hydroxybenzoate, 2,2'-methylenebis(4-ethyl-6-tert-butylphenol), distearyl thiodipropionate, 2-(1,1-dimethylethyl)-6-[3-(1,1-dimethylethyl)-2-hydroxy-5-methylphenyl]methyl-4-methylphenol, n-dodecyl beta-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, bis(2,2,6,6-tetramethyl-4-piperidyl) sebacate, 2,2'-sulfidioethanol bis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate), 1,6-hexanediol bis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate), 2,4-di-tert-butyl-6-(3-tert-butyl-2-hydroxy-5-methylbenzyl)phenol, pentamethylenedi(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate), 2,2'-methylenebis(6-tert-butyl-4-ethylphenol), and the like, or any combination thereof.

[0037] The lubricants can improve the processability, surface properties, and mechanical properties of the material. Exemplary lubricants can include, but are not limited to, stearic acid, calcium stearate, zinc stearate, magnesium stearate, montmorillonite, talc, polyethylene wax, polyethylene glycol, ethylene bis-stearamide, silicone oil, silicone powder, oxidized polyethylene wax, castor oil derivatives, lauramide, glyceryl stearate, pentaerythritol stearate, polypropylene wax, propylene glycol distearate, beeswax, paraffin wax, and the like, or any combination thereof.

[0038] In some embodiments, other auxiliary agents, such as, for example, release agents, thermal stabilizers, smoke suppressants, viscosity modifiers, and the like, or additives that achieve other functionalities, can be used to participate in the constitution of the flame retardant material.

[0039] The mass fraction of each component of the flame-retardant material includes 60-75 parts of polycarbonate, 6-10 parts of acrylonitrile-butadiene-styrene copolymer, 15-25 parts of talc, 9-15 parts of flame retardant, 0.5-1 part of anti-dripping agent, 2-5 parts of toughening agent, 0.5-3 parts of interfacial compatibilizer, 0.1-0.6 parts of lubricant, 0.2-0.6 parts of antioxidant, etc. The mass fraction of each component can be adjusted within the above respective numerical range, and finally 100 parts of the flame-retardant material is obtained.

[0040] The flame-retardant material disclosed in the present application ensures high modulus by high aspect ratio talc, and at the same time, ensures flame retardation and solvent flow by coupling between the interfacial compatibilizer and the talc. Moreover, the flame-retardant material ensures increased modulus and improved flowability under the premise of flame retardation by the flame retardant (e.g., BDP, RDP).

[0041] The present application also discloses a preparation method of the above flame-retardant material. The preparation method can include the following exemplary steps.

[0042] In the first step, according to the mass fraction of each component of the flame-retardant material, each component is placed in a mixing device to be uniformly mixed to obtain a mixture.

[0043] In some embodiments, after the components of the flame-retardant material are weighed, they can be placed in a mixing device for blending to obtain a mixture in which the components are uniformly mixed. The mixing device used can be any device capable of achieving the mixing function, such as a horizontal mixer, a vertical mixer, a double-cone mixer, a V-shaped mixer, a trough mixer, a kneader, a planetary mixer, a fluidized bed mixer, a screw-cone mixer, a belt mixer, a hopper mixer, an air-flow mixer, a high-speed mixer, a slurry mixer, a vacuum mixer, etc. The mixing of the components can be dry mixing, melt mixing, solution mixing, etc. or any combination thereof. In some embodiments, the mixing of the components of the flame-retardant material can be dry mixing. The mixer used can be a high-speed mixer, and after the components are added to the high-speed mixer, they can be mixed at a predetermined stirring speed (e.g., 500-800 rpm) for a set time (e.g., 5-15 min) to obtain the mixture. During this mixing process, if a liquid raw material, such as a liquid flame retardant, is used, the liquid flame retardant does not participate in this mixing in this first step.

[0044] In the second step, the mixture is extruded into a strip using an extrusion device, and then transferred to a granulation device for granulation. After post-processing, the flame-retardant material is obtained.

[0045] In some embodiments, the mixture can be transferred to an extrusion device for strand extrusion. Alternatively, the aforementioned mixing device can simultaneously implement an extrusion function to be further used as the extrusion device in the second step. For example, various types of extruders, including single-screw extruders, twin-screw extruders, conical twin-screw extruders, multi-screw extruders, planetary-screw extruders, etc. After the components for forming the flame-retardant material are uniformly mixed in any suitable extruder described above, strand extrusion is immediately performed. For example, in a twin-screw extruder with a length-diameter ratio L:D = 1:4.4, the rotation speed can be 300-400 rpm, the temperature settings can be 200-240°C for the feeding section, 250-255°C for the melting section, 250°C for the vacuum section, 250°C for the compression section, and 255°C for the die. The vacuum pressure can be set to -0.8 MPa. For example, the twin-screw extruder includes 1-9 zones, and the temperature settings are 190°C, 230°C, 245°C, 250°C, 250°C, 250°C, 250°C, 250°C, and 250°C, respectively. The screw combination can be a high-slot-depth ratio combined with appropriately arranged reverse-thread blocks to extend the mixing time.

[0046] In the extrusion process, the mixture described above can be fed into the twin-screw extruder through the main feeding port. When liquid raw materials not involved in the mixing, such as liquid flame retardants, are used in the first step, the liquid raw materials can be injected through the exhaust port (e.g., the first exhaust port) at the rear end at a set mass ratio by using a gear pump.

[0047] In some embodiments, the strand can be transferred to a granulation device for granulation, for example, the cutting of the strand using a hot cutter. Alternatively, the obtained strand can be cooled, for example, placed in a water tank and cooled by flowing cooling water (e.g., 15-20°C). Then, it is transferred to a cutter (e.g., a cold cutter, a rotary cutter, a swing cutter, etc.) for cutting the strand. The rotation speed of the cutter can be 500-700 rpm, for example, 500 rpm, 550 rpm, 600 rpm, 650 rpm, 700 rpm, etc., or can be adjusted according to the actual process or process requirements, which is not limiting.

[0048] In some embodiments, the granulation device can be an integrated device with the extrusion device. For example, a twin-screw granulator is used to realize strand extrusion and granulation. The twin-screw granulator can directly perform water-cooled cutting of the strand without transferring the strand to different devices, thereby improving the process efficiency.

[0049] The precursor particles of the flame-retardant material obtained after granulation can be treated to obtain the flame-retardant material. The post-treatment can include one or more of cooling (e.g., to stabilize the particle shape, prevent sticking), drying (e.g., to remove surface and internal moisture), sieving (e.g., to separate particles of different sizes, ensure uniformity), dedusting (e.g., to remove fine dust, improve product purity), metal separation (e.g., to remove metal impurities that can be mixed in), surface treatment (e.g., to improve performance), coloring (e.g., to meet specific color requirements), metering and packaging (e.g., to facilitate storage and transportation), and the like.

[0050] The flame-retardant material disclosed herein can be used to prepare various types of products, such as electronic and electrical components, automotive parts, household items, aerospace components, power facilities, medical devices, energy storage protection components, and the like. Common thermoplastic processes such as injection molding, extrusion molding, blow molding, hot press molding, calendering, hot melt bonding, heat sealing, 3D printing, and the like can be used to prepare the flame-retardant material into the aforementioned various types of products.

[0051] For example, an injection molding machine Arburg 420C can be used with an injection temperature of 245-260°C, a mold temperature of 50°C, an injection speed of 50 mm / s, a holding pressure of 600-850 bar, a holding time of 8 s, and a cooling time of 20 s.

[0052] The present application will be further described in detail with reference to the following examples. It should be noted that the following examples are only used to illustrate the present application and do not limit the scope of the present application.

[0053] Example 1 - Preparation of Flame-Retardant Material In this example, the materials were taken in a mass ratio of polycarbonate: acrylonitrile-butadiene-styrene copolymer: talc: flame retardant: anti-dripping agent: toughening agent: interfacial compatibilizer = 61.3:7.5:15:12.5:0.5:2.0:0.5, and the rest were antioxidants and lubricants. The specific component selection, mass ratio, and composition are shown in Table 1.

[0054] The preparation process is as follows: The above raw materials are mixed uniformly by a mixer. First, the other raw materials except the liquid flame retardant are added into a high-speed mixer for mixing. After mixing, the mixture is transferred to a twin-screw granulator for extrusion to obtain an extruded material. The temperature of the feeding section of the twin-screw granulator is 200-240°C, and the temperature of the melting section is 250-255°C. Among them, the mixture is fed into the twin-screw granulator through the main material port, and the liquid flame retardant is injected from the rear of the first exhaust port by a gear pump according to the set mass ratio. The length-diameter ratio of the twin-screw granulator is L:D = 1:44, the rotation speed is 350 rpm, the output is 50 kg / h, the temperature setting is that the feeding section is 200-240°C, the melting section is 245-250°C, the vacuum section is 250°C, the compression section is 250°C, the die is 255°C, and the vacuum pressure is set to -0.08 MPa. The extruded material is processed by water cooling and granulation to obtain a granulated sample, and the granulated sample is dried to obtain the flame-retardant material. The granulated sample is dried in a forced air drying oven at 80°C for 4 h.

[0055] Example 2 - Preparation of a flame-retardant material Example 2 is compared with Example 1, the difference is that the melt index of polycarbonate is different, and the mass ratio of each component is different.

[0056] In this example, the raw materials are taken in a mass ratio of polycarbonate: acrylonitrile-butadiene-styrene copolymer: talc: flame retardant: anti-dripping agent: toughening agent: interfacial compatibilizer = 58.6:7.5:15:12.5:0.5:2:3.0, and the rest is antioxidant and lubricant. The specific component selection, mass ratio and composition are shown in Table 1.

[0057] The preparation process is as follows: The above raw materials are mixed uniformly by a mixer. First, the other raw materials except the liquid flame retardant are added into a high-speed mixer for mixing. After mixing, the mixture is transferred to a twin-screw granulator for extrusion to obtain an extruded material. The temperature of the feeding section of the twin-screw granulator is 200-240°C, and the temperature of the melting section is 250-255°C. Among them, the mixture is fed into the twin-screw granulator through the main material port, and the liquid flame retardant is injected from the rear of the first exhaust port by a gear pump according to the set mass ratio. The length-diameter ratio of the twin-screw granulator is L:D = 1:44, the rotation speed is 350 rpm, the output is 50 kg / h, the temperature setting is that the feeding section is 200-240°C, the melting section is 245-250°C, the vacuum section is 250°C, the compression section is 250°C, the die is 255°C, and the vacuum pressure is set to -0.08 MPa. The extruded material is processed by water cooling and granulation to obtain a granulated sample, and the granulated sample is dried to obtain the flame-retardant material. The granulated sample is dried in a forced air drying oven at 80°C for 4 h.

[0058] Example 3 - Preparation of a flame-retardant material Example 3 is the same as Example 1 except that the melt index of the polycarbonate is different, no interfacial compatibilizer is used, and the mass ratio of the components is different.

[0059] In this example, the components are taken in a mass ratio of polycarbonate: acrylonitrile-butadiene-styrene copolymer: talc: flame retardant: anti-dripping agent: toughening agent = 61.6: 7.5: 15: 12.5: 0.5: 2, and the rest are antioxidants and lubricants. The specific component selection, mass ratio, and composition are shown in Table 1.

[0060] The preparation process is as follows: The above raw materials are mixed uniformly by a mixer. First, the other raw materials except the liquid flame retardant are added to the high mixer for mixing and mixing. After mixing, the mixture is transferred to a twin-screw granulator for extrusion to obtain an extruded material. The temperature of the feeding section of the twin-screw granulator is 200-240°C, and the temperature of the melting section is 250-255°C. Among them, the mixture is fed into the twin-screw granulator through the main material port, and the liquid flame retardant is injected through the first exhaust port by a gear pump according to the set mass ratio. The length-diameter ratio of the twin-screw granulator is L:D = 1:44, the rotation speed is 350 rpm, the output is 50 kg / h, the temperature setting is 200-240°C for the feeding section, 245-250°C for the melting section, 250°C for the vacuum section, 250°C for the compression section, and 255°C for the die, and the vacuum pressure is set to -0.08 MPa. The extruded material is obtained by water cooling and granulation, and the granulated sample is dried to obtain the flame-retardant material. The granulated sample is dried in a forced air drying oven at 80°C for 4h. Example 4 - Preparation of Flame-Retardant Material Example 4 is the same as Example 1 except that the toughening agent is different, and the mass ratio of the components is different.

[0061] In this example, the components are taken in a mass ratio of polycarbonate: acrylonitrile-butadiene-styrene copolymer: talc: flame retardant: anti-dripping agent: toughening agent: interfacial compatibilizer = 64.8: 2.5: 15: 10.5: 0.5: 2: 1, and the rest are antioxidants and lubricants. The specific component selection, mass ratio, and composition are shown in Table 1.

[0062] The preparation process is as follows: The above raw materials are mixed uniformly by a mixer. First, the other raw materials except for the liquid flame retardant are added into a high mixer for mixing. After mixing, the mixture is transferred to a twin-screw granulator for extrusion to obtain an extruded material. The temperature of the feeding section of the twin-screw granulator is 200-240°C, and the temperature of the melting section is 250-255°C. Among them, the mixture is fed into the twin-screw granulator through the main material port, and the liquid flame retardant is injected from the rear of the first exhaust port by a gear pump according to the set mass ratio. The length-diameter ratio of the twin-screw granulator is L:D = 1:44, the rotation speed is 350 rpm, the output is 50 kg / h, the temperature is set to 200-240°C for the feeding section, 245-250°C for the melting section, 250°C for the vacuum section, 250°C for the compression section, and 255°C for the die, and the vacuum pressure is set to -0.08 MPa. The extruded material is processed by water cooling and granulation to obtain a granulated sample, and the granulated sample is dried to obtain the flame-retardant material. The granulated sample is dried in a blast drying oven at 80°C for 4 h.

[0063] Preparation of the flame-retardant material Comparative Example 1 differs from Example 1 in that superfine talc powder is used instead of talc powder with a high aspect ratio, but the mass ratio is the same. The specific component selection and mass ratio are shown in Table 1.

[0064] The preparation process is as follows: The above raw materials are mixed uniformly by a mixer. First, the other raw materials except for the liquid flame retardant are added into a high mixer for mixing. After mixing, the mixture is transferred to a twin-screw granulator for extrusion to obtain an extruded material. The temperature of the feeding section of the twin-screw granulator is 200-240°C, and the temperature of the melting section is 250-255°C. Among them, the mixture is fed into the twin-screw granulator through the main material port, and the liquid flame retardant is injected from the rear of the first exhaust port by a gear pump according to the set mass ratio. The length-diameter ratio of the twin-screw granulator is L:D = 1:44, the rotation speed is 350 rpm, the output is 50 kg / h, the temperature is set to 200-240°C for the feeding section, 245-250°C for the melting section, 250°C for the vacuum section, 250°C for the compression section, and 255°C for the die, and the vacuum pressure is set to -0.08 MPa. The extruded material is processed by water cooling and granulation to obtain a granulated sample, and the granulated sample is dried to obtain the flame-retardant material. The granulated sample is dried in a blast drying oven at 80°C for 4 h.

[0065] Preparation of the flame-retardant material Comparative Example 2 differs from Example 2 in that the particle size of the superfine talc powder is different. The specific component selection and mass ratio are shown in Table 1.

[0066] The preparation process is as follows: The above raw materials are mixed uniformly by a mixer. First, the other raw materials except the liquid flame retardant are added into a high-speed mixer for mixing. After mixing, the mixture is transferred to a twin-screw granulator for extrusion to obtain an extruded material. The temperature of the feeding section of the twin-screw granulator is 200-240°C, and the temperature of the melting section is 250-255°C. Among them, the mixture is fed into the twin-screw granulator through the main material port, and the liquid flame retardant is injected from the rear of the first exhaust port by a gear pump according to the set mass ratio. The length-diameter ratio of the twin-screw granulator is L:D = 1:44, the rotation speed is 350 rpm, the output is 50 kg / h, the temperature is set to 200-240°C for the feeding section, 245-250°C for the melting section, 250°C for the vacuum section, 250°C for the compression section, and 255°C for the die, and the vacuum pressure is set to -0.08 MPa. The extruded material is processed by water cooling and granulation to obtain a granulated sample, and the granulated sample is dried to obtain the flame-retardant material. The granulated sample is dried in a forced air drying oven at 80°C for 4 h.

[0067] Preparation of the flame-retardant material Comparative Example 3 and Example 1 differ in that the particle size of the superfine talc is different. The specific components and mass ratios are shown in Table 1.

[0068] The preparation process is as follows: The above raw materials are mixed uniformly by a mixer. First, the other raw materials except the liquid flame retardant are added into a high-speed mixer for mixing. After mixing, the mixture is transferred to a twin-screw granulator for extrusion to obtain an extruded material. The temperature of the feeding section of the twin-screw granulator is 200-240°C, and the temperature of the melting section is 250-255°C. Among them, the mixture is fed into the twin-screw granulator through the main material port, and the liquid flame retardant is injected from the rear of the first exhaust port by a gear pump according to the set mass ratio. The length-diameter ratio of the twin-screw granulator is L:D = 1:44, the rotation speed is 350 rpm, the output is 50 kg / h, the temperature is set to 200-240°C for the feeding section, 245-250°C for the melting section, 250°C for the vacuum section, 250°C for the compression section, and 255°C for the die, and the vacuum pressure is set to -0.08 MPa. The extruded material is processed by water cooling and granulation to obtain a granulated sample, and the granulated sample is dried to obtain the flame-retardant material. The granulated sample is dried in a forced air drying oven at 80°C for 4 h.

[0069] Preparation of the flame-retardant material Comparative Example 4 and Example 2 differ in that the particle size of the superfine talc is different. The specific components and mass ratios are shown in Table 1.

[0070] The preparation process is as follows: The above raw materials are mixed uniformly by a mixer. First, the other raw materials except the liquid flame retardant are added into a high-speed mixer for mixing. After mixing, the mixture is transferred to a twin-screw granulator for extrusion to obtain an extruded material. The temperature of the feeding section of the twin-screw granulator is 200-240°C, and the temperature of the melting section is 250-255°C. Among them, the mixture is fed into the twin-screw granulator through the main material port, and the liquid flame retardant is injected from the rear of the first exhaust port by a gear pump according to the set mass ratio. The length-diameter ratio of the twin-screw granulator is L:D = 1:44, the rotation speed is 350 rpm, the output is 50 kg / h, the temperature is set to 200-240°C for the feeding section, 245-250°C for the melting section, 250°C for the vacuum section, 250°C for the compression section, and 255°C for the die, and the vacuum pressure is set to -0.08 MPa. The extruded material is processed by water cooling and granulation to obtain a granulated sample, and the granulated sample is dried to obtain the flame-retardant material. The granulated sample is dried in a forced air drying oven at 80°C for 4 h.

[0071] Preparation of the flame-retardant material of Comparative Example 5 Comparative Example 5 differs from Example 4 in that no interfacial compatibilizer is used, and different particle size ultra-fine talc is used. The specific ingredients and mass ratios are shown in Table 1.

[0072] The preparation process is as follows: The above raw materials are mixed uniformly by a mixer. First, the other raw materials except the liquid flame retardant are added into a high-speed mixer for mixing. After mixing, the mixture is transferred to a twin-screw granulator for extrusion to obtain an extruded material. The temperature of the feeding section of the twin-screw granulator is 200-240°C, and the temperature of the melting section is 250-255°C. Among them, the mixture is fed into the twin-screw granulator through the main material port, and the liquid flame retardant is injected from the rear of the first exhaust port by a gear pump according to the set mass ratio. The length-diameter ratio of the twin-screw granulator is L:D = 1:44, the rotation speed is 350 rpm, the output is 50 kg / h, the temperature is set to 200-240°C for the feeding section, 245-250°C for the melting section, 250°C for the vacuum section, 250°C for the compression section, and 255°C for the die, and the vacuum pressure is set to -0.08 MPa. The extruded material is processed by water cooling and granulation to obtain a granulated sample, and the granulated sample is dried to obtain the flame-retardant material. The granulated sample is dried in a forced air drying oven at 80°C for 4 h.

[0073] Preparation of the flame-retardant material of Comparative Example 6 Comparative Example 6 differs from Example 4 in that no interfacial compatibilizer is used, and different particle size ultra-fine talc is used. The specific ingredients and mass ratios are shown in Table 1.

[0074] The preparation process is as follows: The above raw materials are mixed uniformly by a mixer. First, the other raw materials except for the liquid flame retardant are added into a high-speed mixer for mixing. After mixing, the mixture is transferred to a twin-screw granulator for extrusion to obtain an extruded material. The temperature of the feeding section of the twin-screw granulator is 200-240°C, and the temperature of the melting section is 250-255°C. Among them, the mixture is fed into the twin-screw granulator through the main material port, and the liquid flame retardant is injected from the rear of the first exhaust port according to the set mass ratio by a gear pump. The length-diameter ratio of the twin-screw granulator is L:D = 1:44, the rotation speed is 350 rpm, the output is 50 kg / h, the temperature is set to 200-240°C for the feeding section, 245-250°C for the melting section, 250°C for the vacuum section, 250°C for the compression section, and 255°C for the die, and the vacuum pressure is set to -0.08 MPa. The extruded material is processed by water cooling and granulation to obtain a granulated sample, and the granulated sample is dried to obtain the flame-retardant material. The granulated sample is dried in a forced air drying oven at 80°C for 4 h.

[0075] Preparation of the flame-retardant material Comparative Example 7 differs from Example 4 in that no interfacial compatibilizer is used, and different particle size ultra-fine talc is used. The specific ingredients and mass ratios are shown in Table 1.

[0076] The preparation process is as follows: The above raw materials are mixed uniformly by a mixer. First, the other raw materials except for the liquid flame retardant are added into a high-speed mixer for mixing. After mixing, the mixture is transferred to a twin-screw granulator for extrusion to obtain an extruded material. The temperature of the feeding section of the twin-screw granulator is 200-240°C, and the temperature of the melting section is 250-255°C. Among them, the mixture is fed into the twin-screw granulator through the main material port, and the liquid flame retardant is injected from the rear of the first exhaust port according to the set mass ratio by a gear pump. The length-diameter ratio of the twin-screw granulator is L:D = 1:44, the rotation speed is 350 rpm, the output is 50 kg / h, the temperature is set to 200-240°C for the feeding section, 245-250°C for the melting section, 250°C for the vacuum section, 250°C for the compression section, and 255°C for the die, and the vacuum pressure is set to -0.08 MPa. The extruded material is processed by water cooling and granulation to obtain a granulated sample, and the granulated sample is dried to obtain the flame-retardant material. The granulated sample is dried in a forced air drying oven at 80°C for 4 h.

[0077] Test Example 1 - Flexural strength test The products prepared from the flame-retardant materials obtained in Examples 1-4 and Comparative Examples 1-7 are subjected to flexural strength tests, and the test standard refers to ISO 178:2019, and the test conditions are 2 mm / min. The test results are shown in Table 2.

[0078] Test Example 2 - Flexural modulus test The articles prepared from the flame-retardant materials obtained in Examples 1-4 and Comparative Examples 1-7 were subjected to flexural modulus test, the test standard referred to ISO 178:2019, and the test condition was 2 mm / min. The test results were collected in Table 2.

[0079] Test Example 3 - Charpy Notched Impact Strength Test The articles prepared from the flame-retardant materials obtained in Examples 1-4 and Comparative Examples 1-7 were subjected to Charpy Notched Impact Strength Test, the test standard referred to ISO 179-1:2023, and the test condition was (23±2)℃. The test results were collected in Table 2.

[0080] Test Example 4 - Heat Deflection Temperature (HDT) Test The articles prepared from the flame-retardant materials obtained in Examples 1-4 and Comparative Examples 1-7 were subjected to Heat Deflection Temperature (HDT) Test, the test standard referred to ISO 75-1:2020 and ISO 75-2:2013, and the test condition was 1.80 MPa. The test results were collected in Table 2.

[0081] Test Example 5 - Melt Mass Flow Rate (MFR) Test The articles prepared from the flame-retardant materials obtained in Examples 1-4 and Comparative Examples 1-7 were subjected to Melt Mass Flow Rate (MFR) Test, the test standard referred to ISO 1133-1:2022, and the test condition was 240℃ / 5.0 kg. The test results were collected in Table 2.

[0082] Test Example 6 - Vertical Burning Grade Test The articles prepared from the flame-retardant materials obtained in Examples 1-4 and Comparative Examples 1-7 were subjected to Vertical Burning Grade Test, the test standard referred to GB / T 2408-2021, and the test condition was 1.2 mm. The test results were collected in Table 2.

[0083] Table 1 - Composition of Flame-Retardant Materials Table 1 - Composition of Flame-Retardant Materials (continued) Table 2 - Test Results Table 2 - Test Results (continued) From the above Table 2, it can be seen that the flame-retardant materials provided by the embodiments of the present application can achieve higher flexural strength and flexural modulus compared to the comparative examples, and have higher impact strength. At the same time, the high melt mass flow rate under the flame-retardant V-0 level is ensured.

[0084] In addition, the flame retardant material provided in the present application is compared with an excellent benchmark product (Koshibori FR3021) in the industry, and the bending modulus, melt flow rate, notched impact strength, and flame retardant grade (1.5 mm) are tested, and the test results are shown in Table 3.

[0085] Table 3 Test results two As shown in Table 3, the flame retardant material provided in the present application has higher bending modulus, higher melt flow rate, and higher notched impact strength, and can maintain a good appearance compared with the excellent benchmark product in the industry.

[0086] The basic concepts have been described in the present application, and it is obvious that the above detailed disclosure is only used as an example and does not limit the present application. Although it is not explicitly stated here, those skilled in the art can make various modifications, improvements and corrections to the present application. Such modifications, improvements and corrections are suggested in the present application, so such modifications, improvements and corrections still belong to the spirit and scope of the exemplary embodiments of the present application.

[0087] At the same time, specific words are used in the present application to describe the embodiments of the present application. As "one embodiment", "an embodiment", "some embodiments", and / or "some implementations" mean a certain feature, structure or characteristic related to at least one embodiment of the present application. Therefore, it should be emphasized and noted that "an embodiment" or "one embodiment" or "one alternative embodiment" mentioned in different positions in the present application does not necessarily refer to the same embodiment. In addition, some features, structures or characteristics in one or more embodiments of the present application can be properly combined.

[0088] Similarly, it should be noted that, in order to simplify the description of the present application and to help understand one or more embodiments of the present application, sometimes multiple features are combined into one embodiment or its description. However, this method of disclosure does not mean that the features required by the present application are more than the features mentioned in the claims. In fact, the features of the embodiment are less than all the features of the disclosed single embodiment.

[0089] Finally, it should be understood that the embodiments described in the present application are only used to illustrate the principles of the embodiments of the present application. Other variations can also be within the scope of the present application. Therefore, as an example but not limitation, alternative configurations of the embodiments of the present application can be considered consistent with the teachings of the present application. Accordingly, the embodiments of the present application are not limited to the embodiments explicitly introduced and described in the present application.

Claims

1. A flame retardant material, characterized in that, The flame-retardant material comprises the following components in mass fraction: Polycarbonate 60-75 parts; Acrylonitrile-butadiene-styrene copolymer 6-10 parts; Talc 15-25 parts; Flame retardant 9-15 parts; Anti-dripping agent 0.5-1 part; Toughening agent 2-5 parts; and Interfacial compatibilizer 0.5-3 parts; wherein, The aspect ratio of the talc is 15-25; the interfacial compatibilizer comprises an organic compound having an epoxy group.

2. The flame retardant material of claim 1, wherein, The melt index of the polycarbonate is 10-20 g / 10 min.

3. The flame retardant material of claim 1, wherein, The flame retardant comprises a phosphorus-containing flame retardant selected from one or more of phosphazene compounds and / or one or more of phosphate compounds.

4. The flame retardant material of claim 3, wherein, The flame retardant comprises one or more of triphenyl phosphate, bisphenol A bisdi(phenyl phosphate), resorcinol bis(diphenyl phosphate), resorcinol bis[dio(2,6-dimethylphenyl) phosphate].

5. The flame retardant material of claim 1, wherein, The interfacial compatibilizer comprises a polyolefin elastomer grafted with glycidyl methacrylate.

6. The flame retardant material of claim 1, wherein, The flame-retardant material further comprises 0.1-0.6 parts of a lubricant, the lubricant comprising one or more of calcium stearate, stearic acid, ethylene bis-stearamide, pentaerythritol stearate, silicone powder, polyethylene wax.

7. The flame retardant material according to claim 6, characterized in that The flame-retardant material further comprises 0.2-0.6 parts of an antioxidant, the antioxidant comprising one or more of antioxidant 168, antioxidant 1010, antioxidant 1098.

8. The flame retardant material of claim 1, wherein, The toughening agent comprises one or more of methyl methacrylate-butadiene-styrene copolymer, methyl methacrylate-acrylic acid copolymer, ethylene-methyl acrylate copolymer, ethylene-butyl acrylate copolymer, ethylene-acrylate-glycidyl methacrylate terpolymer, maleic anhydride-functionalized ethylene-vinyl acetate copolymer, acrylic toughening agent, and acrylic-silicone rubber toughening agent.

9. A process for the preparation of a flame retardant material as claimed in any one of claims 1 to 8, characterised in that, The preparation method comprises: According to the mass fraction of each component of the flame-retardant material, the components are placed in a mixing device and mixed uniformly to obtain a mixture; The mixture is extruded into a strip using an extrusion device and transferred to a granulation device for granulation, and after post-processing, the flame-retardant material is obtained.

10. An article manufactured from the flame-retardant material according to any one of claims 1-9.

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