Glass fiber filled thermoplastic flame retardant composition

Abstract

The present invention relates to a thermoplastic composition comprising, based on the weight of the composition, a) from 50 - 94 wt.% of aromatic polycarbonate, b) from 5 - 45 wt.% of glass fibers, c) from 0.05 - 0.50 wt.% of halogen free flame retardant salt, d) from 0 - 5 wt.% of further components, wherein the sum of components a) - d) is 100 wt.% and wherein the thermoplastic composition has or is selected to have a UL94 rating of V-0 performed at 3.0 mm. The present invention furthermore relates to an article comprising the thermoplastic composition.

Description

[0001] 23POLY0115-WO-ORD

[0002] TITLE glass fiber filled thermoplastic flame retardant composition

[0003] FIELD OF THE INVENTION

[0004] The present invention relates to a thermoplastic composition and articles obtained therefore.

[0005] Background

[0006] Glass fibre filled polycarbonates are used for example in electrical and electronics applications, such as MCE (Micro Circuit Engineering) protection, TV enclosures, domestic wired devices, microelectronics. These applications are currently facing down gauging and miniaturization with design constraints in flame resistance and processing (mould filling). Especially for new applications in 5G equipment & microelectronics, there is a need for new glass-fibre filled flame retardant polycarbonate compositions for replacing metal or glass-fibre filled polyamide or glassfibre filled PBT materials. The main difficulty is obtaining a UL 94 V-0 rating for very low thickness, such as at 1.5 mm or 1.2 mm, with flame retardants that are halogen free, more in particular that are non-brominated, non-chlorinated and PFAS (per / poly- fluoroalkyl substances) free.

[0007] WO2018 / 198046 discloses a composition comprising from about 70 wt. % to about 98 wt. % of a polycarbonate polymer component; from about 0.01 to about 1 wt.% of a flame retardant additive, wherein the flame retardant additive is free or substantially free of bromine and / or chlorine; from about 2 to about 20 wt. % of a non-bonding glass fiber; and from about 0.001 to about 5 wt. % of a stabilizer additive component, wherein the stabilizer additive component comprises butyl tosylate, wherein a molded sample formed from the composition exhibits a multi-axial impact (MAI) rating energy at max force of greater than about 60 Joules when tested in accordance with ISO 6603 standard and wherein a molded sample of the composition achieves a VI rating at a thickness of about 0.8 millimeter (mm) and a flame out time of less than about 60 seconds when tested in accordance with UL 94. The examples in this references are all based on the use of Rimar salt (potassium perfluorobutanesulfonate). WO2018198045 discloses a composition comprising from about 70 wt. % to about 99 wt. % of a polycarbonate polymer component; from about 0.01 wt. % to about 1 wt. % of a flame retardant additive, wherein the flame retardant additive is free or substantially free of bromine and / or chlorine; and from about 0.01 wt.% to about 20 wt.% of a non-bonding glass fiber; from about 0.01 wt. % to about 10 wt. % of a surface modified talc, wherein the surface modified talc has a mean particle diameter of from about 0.5 nanometer (nm) to about 2 micrometer (pm); and wherein a molded sample formed from the composition exhibits a multi-axial impact (MAI) rating energy at max force of 70 Joules or greater at 23 degrees Celsius (0C) when tested in accordance with IS066O3 standard and wherein a molded sample of the composition achieves a V2 rating at a thickness of about 0.8 mm and a flame out time ofless than 50 seconds when tested in accordance UL94. The examples in this references are all based on the use of Rimar salt (potassium perfluorobutanesulfonate).

[0008] CN1 16041929 discloses a polycarbonate composition as well as a preparation method and application thereof, and the polycarbonate composition comprises the following components in parts by weight: 50-89 parts of aromatic polycarbonate; 10 to 30 parts of glass fiber; 0.1 to 10 parts of a flame retardant; 0.1 to 0.5 part of a dispersant; and 0.2 to 1 .5 parts of a flame retardant synergist. The polycarbonate composition provided by the invention not only has good flame retardant property, but also has excellent infrared transmission property.

[0009] CN1 12430388 discloses a high-performance halogen-free flame-retardant PC / GF composite material and a product thereof. Every 100 parts by mass of the high- performance halogen-free flame-retardant PC / GF composite material comprises the following components by mass: 63-94.4 parts of polycarbonate; 5-30 parts of glass fiber; 0.3-5 parts of a graft elastomer; 0.2-1 part of a flame retardant; and 0.1-1 part of an anti-dripping agent. The high-performance halogen-free flame-retardant PC / GF composite material and the product thereof have high flame retardancy and good toughness. WO2016 / 087296 discloses polycarbonate compositions that are reinforced with glass fibers, carbon fibers and / or carbon nanotubes, contain flame retardants, diglycerol monoesters and, optionally, anti-drip agents, and have great flowability, great rigidity and, if necessary, improved flame-retarding properties. The invention further relates to the use of the disclosed compositions in particular for manufacturing housing parts in the EE and IT fields, e.g. for electric housings / switchgear cabinets or for frames of LCD / LED screens and for components used for manufacturing ultrabooks.

[0010] EP3670597 discloses a thermoplastic composition, comprising:40 to 94 weight percent of a polycarbonate, a polycarbonate copolymer, or a combination thereof; 5 to 20 weight percent of a fiber reinforcement; optionally 1 to 20 ppm of a phosphorous- containing acid stabilizer; 0.01 to 2 weight percent of a first colorant, wherein the first colorant does not comprise titanium dioxide; 0.05 to 0.5 weight percent of an anti-drip agent; and 0.3 to 0.9 weight percent of potassium perfluorobutane sulfonate, wherein all weight percent values are based on the total weight of the composition, and wherein the total weight percent is 100 wt% and wherein an injection molded sample of the composition subjected to molding conditions comprising a residence time of 600 seconds at 340°C has a AE value of less than or equal to 3.5, preferably less than or equal to 3, more preferably less than or equal to 2.8, according to the CIE1976 L*a*b* color measurement system as specified by ISO 11664-4:2008(E) / CIE S 014-4 / E:2007, as measured at a thickness of 2.5 mm according to ASTM D2244 (2011).

[0011] Objects

[0012] It is an object of the present invention to provide an improved glass-fibre reinforced thermoplastic composition having excellent mechanical and flammability properties. In particular, it is object of the present invention to provide thermoplastic compositions that are suitable for thin applications and that are halogen free.

[0013] STATEMENT OF THE INVENTION

[0014] In a first aspect, the invention relates to a thermoplastic composition comprising, based on the weight of the composition, a) from 50 - 94 wt.% of aromatic polycarbonate, b) from 5 - 45 wt.% of glass fibres, preferably non-bonding glass fibres, c) from 0.05 - 0.50 wt.% of halogen free flame retardant salt, preferably a alkali metal salt of an aromatic sulfonate, more preferably the potassium salt of diphenyl sulfone sulfonate (KSS) or the sodium salt of toluene sulfonate (NaTS) or a combination thereof, d) from 0 - 5 wt.% of further components, wherein the sum of components a) - d) is 100 wt.% and wherein the thermoplastic composition has or is selected to have a UL94 rating of V0 performed at 3.0 mm, preferably at 2.3 mm, more preferably 2.0 mm.

[0015] In a second aspect, the invention relates to an article comprising the thermoplastic composition of the first aspect.

[0016] Corresponding embodiments of the thermoplastic composition are also applicable for the article according to the present invention.

[0017] DETAILED DESCRIPTION

[0018] The present invention is elucidated below with a detailed description.

[0019] Drawings

[0020] The drawings include Tables 1 to 15.

[0021] List of definitions

[0022] The following definitions are used in the present description and claims to define the stated subject matter. Other terms not cited below are meant to have the generally accepted meaning in the field.

[0023] “non-bonding glass fibers” as used in the present description means: glass fibres that have been coated with a sizing composition that is results in poor adhesion of the coated glass fibers to the polycarbonate matrix, in other words that are non-bonding with respect to the aromatic polycarbonate. The individual fibers of the glass fiber filler may not demonstrate an affinity towards the polymer matrix. The term “glass” here refers generally to a material, natural or synthetic, which contains silicon dioxide (SiO2) or silica as its main material.

[0024] “bonding glass fibers” as used in the present description means: glass fibers that have been coated with a sizing composition that is results in good / improved adhesion of the coated glass fibers to the polycarbonate matrix, in other words that are bonding with respect to the aromatic polycarbonate. The individual fibers of glass fiber filler may exhibit affinity toward the polycarbonate resin matrix. This affinity may be attributed to the glass sizing, among a number of other forces.

[0025] “halogen free flame retardant salt” as used in the present description means: a flame retardant in the form of a salt that contains to halogen atoms, in other words that is free of bromine, free of chlorine, free of fluorine and free of iodine. There are flame retardants that are free of bromine and free of chlorine but that do comprise fluorine, such as Rimar Salt (potassium salt of the fluorinated alkyl sulfonate perfluorobutane sulfonate). These are not according to the present invention.

[0026] Thermoplastic composition

[0027] The thermoplastic composition of the present invention comprises the following components: a) one or more aromatic polycarbonates, b) one or more glass fibers; and c) one or more halogen free flame retardant salts. Optionally, the thermoplastic composition further comprises d) one or more further components. The sum of components a) - d) is 100 wt.% of the thermoplastic composition.

[0028] UL rating

[0029] The thermoplastic composition has or is selected to have a UL94 rating of V-0 performed at 3.0 mm, preferably performed at 2.3 mm, more preferably performed at 2.0 mm.

[0030] An important requirement of the present thermoplastic composition is that it has excellent properties in view of safety / flammability. The UL 94 is the Standard for Safety of Flammability of Plastic Materials for Parts in Devices and Appliances testing, being a plastics flammability standard of the United States. This test determines the material's tendency to either extinguish or spread the flame once the specimen has been ignited. According to the present invention, the rating must be a V-0 (V-zero) which states that burning stops within 10 second on a vertical specimen. UL ratings can be measured at various thicknesses and this can drastically change the rating. This thicker the specimen, the better the UL rating. For the present invention, it is required that a V-0 rating is obtained for a specimen having a thickness of 3.0 mm, even more preferably for a thickness of 2.3 or even 2.0 mm.

[0031] HDT

[0032] The Heat Deflection Temperature or Heat Distortion Temperature (HDT) is a measure of a polymer's resistance to alteration under a given load at an elevated temperature. It is the temperature at which a polymer deforms under a specified load. Other names for this are 'deflection temperature under load' (DTUL) or 'heat deflection temperature under load (HDTUL). The heat distortion temperature (HDT) was measured according to ISO 75 / Af, 80*10*4 sp=64mm.

[0033] In an embodiment, the thermoplastic composition has or selected to have a heat distortion temperature (HDT) of at least 130 °C, preferably at least 132 °C.

[0034] Specific embodiment

[0035] In a specific embodiment, the thermoplastic composition comprising, based on the weight of the composition, a) from 50-94 wt.% of aromatic polycarbonate, b) from 5-45 wt.% of glass fibers, preferably non-bonding glass fibers, c) from 0.05-0.50 wt.% of halogen free flame retardant salt, preferably a alkali metal salt of an aromatic sulfonate, more preferably the potassium salt of diphenyl sulfone sulfonate (KSS) or the sodium salt of toluene sulfonate (NaTS) or a combination thereof, d) from 0-5 wt.% of further components, such as from 0 - 3 wt.% of further components.

[0036] Aromatic polycarbonate

[0037] The thermoplastic composition comprises (as component a) one or more aromatic polycarbonates in an amount of between 50 to 94 wt.% based on the total weight of the thermoplastic composition. In an embodiment, the thermoplastic composition comprises as aromatic polycarbonate one or more bisphenol-A polycarbonates, preferably bisphenol A- homopolymers. In an embodiment, the thermoplastic composition comprises no further polymer components.

[0038] In an embodiment, the thermoplastic composition has a melt volume rate (MVR) of between 5 and 20 cc / 10 min, preferably between 8 and 15 cc / 10min measured according to ISO 1133 at 300° C under a 1 .2 kg load.

[0039] In an embodiment, the aromatic polycarbonate is a blend of two or more aromatic polycarbonates having different weight average molecular weights, preferably a blend of a first polycarbonate having a melt volume rate (MVR) of between 3 and 10 cc / 10 min and a second polycarbonate having a melt volume rate (MVR) of between 20 and 35 cc / 10 min measured according to ISO 1133 at 300° C under a 1 .2 kg load.

[0040] Even more preferably, the aromatic polycarbonate is a blend of a first bisphenol-A- polycarbonate homopolymer having a melt volume rate (MVR) of between 3 and 10 cc / 10 min and a second bisphenol-A-polycarbonate homopolymer having a melt volume rate (MVR) of between 20 and 35 cc / 10 min measured according to ISO 1133 at 300° C under a 1 .2 kg load.

[0041] In an embodiment the aromatic polycarbonate is a blend of two polycarbonate, preferably two bisphenol-A-polycarbonate homopolymers, more preferably having a different MVR as discussed directly above, wherein the ratio of the two polycarbonates (also called split ratio) is between 10:90 and 90:10, such as between 20:80 and 80:20, or between 30:70 and 70:30 or between 40:60 and 60:40, for example 50:50.

[0042] Glass fibers

[0043] The thermoplastic composition comprises (as component b) one or more glass fibers in an amount of between 5 - 45 wt.% based on the total weight of the thermoplastic composition. In an embodiment, the present composition comprises non-bonding glass fibers. In an embodiment, substantially all glass fibers of the thermoplastic composition are nonbonding glass fibres. In an embodiment, the thermoplastic composition comprises (as component b) non-bonding glass fibers in an amount of between 5 - 45 wt.% based on the total weight of the thermoplastic composition.

[0044] In an embodiment, the thermoplastic composition comprises (as component b) bonding glass fibers in an amount of between 5 - 30 wt.% based on the total weight of the thermoplastic composition. The present inventors have observed that for glass fiber amounts of above 30 wt.%, bonding fibers show less optimal results. Bonded or bonding glass fibers lead to a composite having increased fiber bridging and increased crack deflection. Without wishing to be bound to a particular theory, the present inventors believe that the covalent bonds of the crosslinked polycarbonate matrix are formed on the glass fiber through chemically anchoring the organic polycarbonate matrix to the inorganic glass fiber.

[0045] The glass fibers may be selected from E-glass, S-glass, AR-glass, T-glass, D-glass and R-glass, in particular from E-glass, S-glass, and combinations thereof, more in particular an E-glass or EC glass. The glass fibers can be made by standard processes, e.g., by steam or air blowing, flame blowing, and mechanical pulling. Exemplary glass fibers for polycarbonate reinforcement are made by mechanical pulling.

[0046] In preparing the non-bonding or bonding glass fibers, a number of filaments can be formed simultaneously, sized with the coating agent and then bundled into what is called a strand. Alternatively the strand itself may be first formed of filaments and then sized. The amount of sizing employed is generally that amount which is sufficient to bind the glass filaments into a continuous strand and ranges from about 0.1 to about 5 wt. %, about 0.1 to 2 wt.% based on the weight of the glass fibers. Generally, this may be about 1 .0 wt. % based on the weight of the glass filament.

[0047] The glass fibers may be continuous or chopped. In some examples, the glass fibers are chopped glass fibers in the form of chopped strands, e.g. having a length of about 0.3 mm to about 10 cm, specifically about 0.5 mm to about 5 cm, and more specifically about 1 .0 mm to about 2.5 cm, e.g. between 0.2 mm to 20 mm or from about 0.2 mm to about 10 mm.

[0048] The glass fibers may have a round (or circular), flat, or irregular cross-section. The width or diameter of the non-bonding glass fiber may be from about 1 to about 20 pm, or from about 5 to about 20 pm, or from about 5 to about 15 pm.

[0049] Flame retardant salt

[0050] The thermoplastic composition comprises (as component c) one or more halogen free flame retardant salt in an amount of between 0.05 and 0.50 wt.% based on the total weight of the thermoplastic composition.

[0051] Preferably, the flame retardant salt is an alkali metal salt of an aromatic sulfonate, such as the potassium salt. In an embodiment, the flame retardant salt is the potassium salt of diphenyl sulfone sulfonate (KSS) or the sodium salt of toluene sulfonate (NaTS) or a combination thereof.

[0052] Further components

[0053] The thermoplastic composition optionally comprises (as component f) one or more further components in an amount of between 0 to 5 wt.%, or between 0 and 3 wt.%, based on the total weight of the thermoplastic composition. This amount of between 0 to 5 wt.% is the total amount of all further components combined.

[0054] In an embodiment, the further components comprise a plasticizer, an anti-static agent, an impact modifier, a colorant, an antioxidant, a mould release agent, an UV absorber, a lubricant, or a blowing agent, or a combination of two or more thereof.

[0055] Article / applications

[0056] In an embodiment, the article is selected from the group consisting of aerospace and aircraft components, (electronic) vehicle components, components for electrical & electronics, components for energy production and storage, components for communication infrastructure or infrastructure, articles for sports and recreation, components for architecture, and components for industry.

[0057] Examples or aerospace and aircraft components are rudder, elevator, fuselage, landing gear doors, leading and trailing edge wing components, fuel tanks and floors. Examples of (electronic) vehicle components are automotive component, such as air deflectors and spoilers, air-intake manifolds, battery casings and covers, bumpers and bumper beams, cylinder head (e.g. valve, rocker, cam) covers, frames for windows / sunroofs, front-end grill opening panels, headlamp housings for forwardfacing headlamps, heat shields (e.g. engine, transmission), pillars and coverings, or components of marine vessels, such as superyachts, racing yachts workboats, and leisure crafts, such as boat hulls, frames, keels, masts, poles and boom, carbon winch drums, shafting, bearings, propellers, commercial hatch covers, exhausts, and topside structures.

[0058] Examples of electrical and electronics components are electrical enclosures, electrical outlets, battery enclosure cases - e.g. for smart phones and computers or other electrical equipment-, microprocessors, (micro or miniature) circuit breakers, circuit protection, personal and (5G) industrial computer casing or parts.

[0059] Examples of components for energy production and storage are turbine and rotor blades for land-based and off-shore wind turbines, multifunctional energy storage composites (MESO), hydrogen tanks for aerospace, hydrogen fuel cells, and battery cells.

[0060] Examples of components for communication infrastructure are components for 5G infrastructure and mobiles, such as antenna systems.

[0061] Examples of components for infrastructure are components for reinforcing concrete, for example of bridges, or to replace steel rebars, e.g. in bridge decks or other outdoor concrete flooring structures. Examples of sports and recreation articles are fishing rods, tennis racquets, spars / shafts for kayak paddles, windsurfing masts and boards, hockey sticks, kites, and bicycle handlebars, as well as in niche applications, such as fairings for recumbent bikes.

[0062] Examples of components for architecture are interior or exterior building panels, pipes, ducts and tank installations.

[0063] Examples of industrial components are pipes, ducts and tank installations for i) (chemical) manufacturing plants, ii) oil & gas mining, treatment and transport, or iii) (waste)water treatment.

[0064] Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage. The scope of the present invention is defined by the appended claims. One or more of the objects of the invention are achieved by the appended claims.

[0065] EXAMPLES

[0066] The present invention is further elucidated based on the Examples below which are illustrative only and not considered limiting to the present invention. Table 1 shows the materials as used in the Examples.

[0067] Methods

[0068] Melt volume rates (MVR) were measured in accordance with the ISO 1133 standard at 300° C under a load of 1.2 kg with a dwell time of 5 minutes. The granules were dried for 4 hours at 100° C before testing. MVR is reported in cubic centimeters (cc or cm3) of polymer melt / 10 minutes. Flame rating (VO flammability tests) were performed following the procedure of Underwriter's Laboratory Bulletin 94 entitled “Tests for Flammability of Plastic Materials, UL94. ” According to this procedure, materials may be classified as VO, V1 or V2 on the basis of the test results obtained for samples of a specified thickness. The samples are made according to the UL94 test procedure using standard ASTM moulding criteria. It should be noted that when a VO performance is given for a specified thickness, VO performance is also obtained at greater thicknesses. Samples were burned in a vertical orientation after aging for 48 hours at 23 ± 2 °C, 50% relative humidity or 168 hours at 70° C. The criteria for each of the flammability classifications tested are described below.

[0069] VO: In a sample placed so that its long axis is 180 degrees to the flame, the maximum period of flaming and / or smouldering after removing the igniting flame does not exceed 10 seconds and none of the vertically placed samples produces drips of burning particles that ignite absorbent cotton, and no specimen burns up to the holding clamp after flame or after glow. The criteria for flammability classifications according to V-0 are <10 seconds individual flame time and <50 seconds total flame time of 5 specimens.

[0070] V1 , V2: In a sample placed so that its long axis is 180 degrees to the flame, the average period of flaming and / or smouldering after removing the igniting flame does not exceed 30 seconds and, for a V1 rating, none of the vertically placed samples produces drips of burning particles that ignite absorbent cotton. The V2 standard is the same as V1 , except that flaming drips that ignite the cotton are permitted. The criteria for flammability classifications according to V-1 are <20 seconds individual flame time and <250 seconds total flame time of 5 specimens. The criteria for flammability classifications according to V-2 are <30 seconds individual flame time and <250 seconds total flame time of 5 specimens.

[0071] Heat deflection temperature (HDT) measurements were performed on 80mm *10mm *4 mm un-annealed bars with a span length of 64 mm in accordance with ISO 75 / Af-1 :2020 (method A and flat wise) at 1.8 MPa and 120 degrees Celsius per hour and are reported in degrees Celsius.

[0072] Unnotched Izod impact (“UNH”) measurements were performed on 80mm *10mm *4 mm bars at 23° ± 2°C in accordance with the ISO 180-2019 standard with a 11 Joule Hammer and are reported in units of kJ / m2. Tensile modulus (TM) measurements were performed according to ISO 527 standard with a speed of 1 mm / min (Extensometer) and 5 mm / min (testing speed) in a stress-strain test by a Universal Testing Machine (UTM) and are reported in units of Pa.

[0073] Extrusion profile for blends

[0074] A ZSK-25 compounder was used with a 1500 mm barrel size and 2x2 mm die, a die temperature of 280 °C. The following temperature profile was used: Zone 1 (feeding) 40 °C; Zone 2 170 °C; Zone 3 220 °C; Zone 4 240 °C; Zones 5-6 255 °C; Zone 7 270 °C; Zones 8-10 280 °C. The screw speed was 300 rpm, the throughput 9-10 kg / hr, the torque 60-65%, with a vacuum 1 of -0.08 MpA with the side feeder in zone 6. The moulding profile of glass fiber filled Polycarbonate FR resin is shown in Table 2.

[0075] Compositions with and without TSAN with 40 wt.% of non-bonding glass

[0076] Table 3 shows thermoplastic composition according to the invention having 40 wt.% of non-bonding glass fibers with PFAS compound TSAN (IE1 a, IE2a, IE3a, and IE4a) as well as without this PFAS compound (IE1 b, IE2b IE3b, and IE4b). The values for HDT, UNII, UL-94 and the MVR were measured. Table 3 shows that it is possible to obtain robust flame retardancy with a reasonably good flow (MVR 5.5 - 12.2) for 40 wt.% glass fiber filled composition with different types and different blends of polycarbonates (different split ratio). For the experiments using TSAN (all a- experiments) a V-0 rating is obtained up to 2.0 mm for all different blends. For experiments which were completely halogen free (all b-experiments) there is a V-0 rating using interfacial PC up to 2.3 mm (with an MVR of 9.6) and even up to 2.0 mm for interfacial PC with an MVR of 6.

[0077] Compositions with 50:50 blends of polycarbonate without TSAN with 40 wt.% of non-bonding glass

[0078] Table 4 shows thermoplastic composition according to the invention having 40 wt.% of non-bonding glass fibers without TSAN (IE5, IE6, IE7) each with a 50:50 split of two types of PC, respectively for interfacial PC; for melt PC with a quenching agent, and melt PC without a quenching agent. The values for HDT, UNII, UL-94 and the MVR were measured. Table 4 shows it is possible to obtain robust flame retardancy and a reasonably good flow (MVR 8-13.6) for 40 wt.% glass fiber compositions with all fully PFAS free examples with V-0 ratings at 2.3 mm (for interfacial even at 2.0 mm).

[0079] Compositions with 30 wt.% of glass fiber, bonded and non-bonded, with and without TSAN

[0080] Table 5 shows thermoplastic composition according to the invention having 30 wt.% of (non-)bonding glass fibers with or without TSAN. The values for HDT, UL-94 and the MVR were measured. Table 5 shows it is possible to obtain robust flame retardancy and a reasonably good flow (MVR 6.3-14.7) for 30 wt.% glass fiber filled compositions for both bonding as well as non-bonding glass fibers with all types of polycarbonates with or without TSAN with V-0 ratings at 2.0 mm for all but one example (V-0 at 2.3 mm for IE13).

[0081] Compositions with 20 wt.% of non-bonded glass fiber, with and without TSAN

[0082] Table 6 shows thermoplastic composition according to the invention having 20 wt.% of non-bonding glass fibers with or without TSAN. The values for HDT, UNI I, UL-94 and the MVR were measured. Table 6 shows it is possible to obtain robust flame retardancy and a reasonably good flow (MVR 9.2-15.6) for 20 wt.% glass fiber filled compositions with several types of polycarbonates with or without TSAN with V-0 ratings at 2.0 mm for all.

[0083] Compositions with 9.5 wt.% of non-bonded glass fiber, with and without TSAN

[0084] Table 7 shows thermoplastic composition according to the invention having 9.5 wt.% of non-bonding glass fibers with or without TSAN. The values for HDT, UNI I, UL-94 and the MVR were measured. Table 7 shows it is possible to obtain robust flame retardancy and a reasonably good flow (MVR 6.9-11.2) for 9.5 wt.% glass fiber filled compositions with several types of polycarbonates with or without TSAN with V-0 ratings at 2.3 mm for all of then and even at 2.0 mm for some.

[0085] Compositions with varying amounts of non-bonding glass fibers without TSAN Table 8 shows thermoplastic composition according to the invention having 9.3, 20, 30, or 40 wt.% of non-bonding glass fibers without TSAN. The values for HDT, UNI I, UL-94 and the MVR were measured. Table 8 shows it is possible to obtain robust flame retardancy and a reasonably good flow (MVR 7.1-9.8) for varying amounts of nonbonding glass fiber filled compositions without TSAN with V-0 ratings at 2.0 mm for all and V-0 ratings at 1 .5 mm for all but one (40 wt.% of glass).

[0086] Black compositions with varying amounts of non-bonding glass fibers without TSAN

[0087] Table 9 shows thermoplastic composition according to the invention having between 9.5 and 40 wt.% of non-bonding glass fibers without TSAN in black compositions. The values for HDT, UNII, UL-94 and the MVR were measured. Table 9 shows it is possible to obtain robust flame retardancy and a reasonably good flow (MVR 8.4 - 15.4) for up to 40 wt.% glass fiber filled compositions with several types of polycarbonates without TSAN with V-0 ratings at 1 .5 mm for all.

[0088] White compositions with varying amounts of non-bonding glass fibers without TSAN

[0089] Table 10 shows thermoplastic composition according to the invention having between 9.5 and 40 wt.% of non-bonding glass fibers without TSAN in white compositions. The values for HDT, UNII, UL-94 and the MVR were measured. Table 10 shows it is possible to obtain robust flame retardancy and a reasonably flow (MVR 8.7 - 17.2) for up to 40 wt.% glass fiber filled compositions with several types of polycarbonates without TSAN with V-0 ratings at 1 .5 mm for all.

[0090] Compositions with 9.5 wt.% of bonding glass fibers without TSAN

[0091] Table 11 shows thermoplastic composition according to the invention having 9.3 or 9.5 wt.% of bonding glass fibers without TSAN. The values for HDT, UNII, UL-94 and the MVR were measured. Table 11 shows it is possible to obtain robust flame retardancy and a reasonably good flow (MVR 8.1 - 16.2) for 9.3 / 9.5 wt.% bonding glass fiber filled compositions with several types of polycarbonates without TSAN with V-0 ratings at 2.0 mm for all, and at 1 .5 mm for some. It is also observed that with an additional UV stabiliser (STAB 2) a V-0 rating at 2 mm can be obtained.

[0092] Compositions with 20 wt.% of bonding glass fibers without TSAN Table 12 shows thermoplastic composition according to the invention having 20 wt.% of bonding glass fibers with or without TSAN. The values for HDT, UNI I, UL-94 and the MVR were measured. Table 12 shows it is possible to obtain robust flame retardancy and a reasonably good flow (MVR 8.1 -17.6) for 20 wt.% glass fiber filled compositions with or without TSAN with V-0 ratings at 2.0 mm for all (including black coloured) and at 1.5 mm using interfacial PC with black colour.

[0093] Compositions with 20 wt.% of bonding glass fibers without TSAN with different amounts of flame retardant

[0094] Table 13 shows thermoplastic composition according to the invention having 20 wt.% of bonding glass fibers without TSAN with different amounts of flame retardant and one example not according to the invention (CE69). The values for HDT, UNII, UL-94 and the MVR were measured. Table 13 shows it is possible to obtain robust flame retardancy and a reasonably flow (MVR 13.5 - 18.7) for 20 wt.% glass fiber filled compositions with several types of polycarbonates with several amounts of flame retardant with V-0 ratings at 2.0 mm for all.

[0095] Compositions with 30 wt.% of bonding glass fibers with or without TSAN

[0096] Table 14 shows thermoplastic composition according to the invention having 30 wt.% of bonding glass fibers with or without TSAN. The values for HDT, UNII, UL-94 and the MVR were measured. Table 14 shows it is possible to obtain robust flame retardancy and a reasonably good flow (MVR 12.2 - 17.3) for 30 wt.% glass fiber filled compositions with several types of polycarbonates with V-0 ratings at 2.0 mm for all but one and at 1.5 mm for interfacial PC with black colour.

[0097] Compositions with 40 wt.% of bonding glass fibers

[0098] Table 15 shows thermoplastic composition not according to the invention having 40 wt.% of bonding glass fibers with or without TSAN. The values for HDT, UNII, UL-94 and the MVR were measured. Table 15 shows it for 40 wt.% bonding glass fiber filled compositions with V-1 ratings at 3.0 mm are obtained, which is outside the scope of the invention. Concluding, the present invention allows for thermoplastic compositions that are completely halogen free (non-brominated, non-chlorinated, and non-fluorinated) for a variety of different PC blends and a variety of glass fiber content having a V-0 at 2.0 mm. The compositions have balanced properties.

Claims

CLAIMS1. A thermoplastic composition comprising, based on the weight of the composition, a) from 50 - 94 wt.% of aromatic polycarbonate, b) from 5 - 45 wt.% of glass fibers, preferably non-bonding glass fibers, c) from 0.05 - 0.50 wt.% of halogen free flame retardant salt, preferably a alkali metal salt of an aromatic sulfonate, more preferably the potassium salt of diphenyl sulfone sulfonate (KSS) or the sodium salt of toluene sulfonate (NaTS) or a combination thereof, d) from 0 - 5 wt.% of further components, wherein the sum of components a) - d) is 100 wt.% and wherein the thermoplastic composition has or is selected to have a UL94 rating of V-0 performed at 3.0 mm, preferably at 2.3 mm, more preferably 2.0 mm.

2. The thermoplastic composition according to claim 1 , having or selected to have a heat distortion temperature (HDT) of at least 130 °C, preferably at least 132 °C.

3. The thermoplastic composition according to claim 1 or 2, wherein the aromatic polycarbonate is a bisphenol-A polycarbonate, preferably bisphenol A- homopolymer, preferably wherein the thermoplastic composition comprises as further components no polymer components.

4. The thermoplastic composition according to any one of the preceding claims, wherein the glass fibers are non-bonding glass fibers which are present in an amount of between 5 - 45 wt.%.

5. The thermoplastic composition according to any one of claims 1-3, wherein the glass fibers are bonding glass fibers which are present in an amount of between 5 and 30 wt.%.

6. The thermoplastic composition according to any one of the preceding claims, wherein the polysiloxane is a homopolymer of siloxane, preferably of dimethylsiloxane.

7. The thermoplastic composition according to any one of the preceding claims, wherein the further components comprise a plasticizer, an anti-static agent, animpact modifier, a colorant, an antioxidant, a mould release agent, an UV absorber, a lubricant, or a blowing agent, or a combination of two or more thereof.

8. The thermoplastic composition according to any one of the preceding claims, wherein the composition is essentially free of anti-drip agent.

9. The thermoplastic composition according to any one of the preceding claims, having a melt volume rate (MVR) of between 5 and 20 cc / 10 min, preferably between 8 and 15 cc / 10min measured according to ISO 1133 at 300° C under a 1.2 kg load.

10. The thermoplastic composition according to any one of the preceding claims, wherein the aromatic polycarbonate is a blend of two or more aromatic polycarbonates having different weight average molecular weights, preferably a blend of a first polycarbonate having a melt volume rate (MVR) of between 3 and 10 cc / 10 min and a second polycarbonate having a melt volume rate (MVR) of between 20 and 35 cc / 10 min measured according to ISO 1133 at 300° C under a 1 .2 kg load.11 . The thermoplastic composition according to any one of the preceding claims, comprising, based on the weight of the composition, a) from 50-94 wt.% of aromatic polycarbonate, b) from 5-45 wt.% of non-bonding glass fibers, c) from 0.05-0.5 wt.% of halogen free flame retardant salt, preferably a alkali metal salt of an aromatic sulfonate, more preferably the potassium salt of diphenyl sulfone sulfonate (KSS) or the sodium salt of toluene sulfonate (NaTS) or a combination thereof, d) from 0-5 wt.% of further components.

12. The thermoplastic composition according to any one of the preceding claims, comprising, based on the weight of the composition, a) from 50-94 wt.% of aromatic polycarbonate, b) from 5-30 wt.% of bonding glass fibers, c) from 0.05-0.5 wt.% of halogen free flame retardant salt, preferably a alkali metal salt of an aromatic sulfonate, more preferably the potassium salt of diphenyl sulfone sulfonate (KSS) or the sodium salt of toluene sulfonate (NaTS) or a combination thereof, d) from 0-5 wt.% of further components.

13. An article comprising the thermoplastic composition of claims 1 - 12.

14. The article according to claim 13, wherein the article is selected from the group consisting of aerospace and aircraft components, (electronic) vehicle components, components for electrical & electronics, components for energy production and storage, components for communication infrastructure or infrastructure, articles for sports and recreation, components for architecture, and components for industry.