Flame retardant aromatic polycarbonate with good mechanical properties and melt stability

Claim 2

A thermoplastic aromatic polycarbonate composition consisting essentially of: (a) a thermoplastic aromatic polycarbonate having a melt flow of between 1 and 24 grams per ten minutes, (b) between about 0.01 and 1 wt. %, based on the weight of the total composition, of an alkali metal salt of an inorganic acid, (c) between about 0.01 and 1 wt. %, based on the weight of the total composition, of a fibril forming polytetrafluoroethylene, and (d) between 0.05 and 1.0 wt. %, based on the weight of the total comparison, of aromatically bound chlorine or bromine contained in a compound other than an organic alkali metal or alkaline earth metal salt.

Claim 3

The polycarbonate composition of claim 1 having a UL item 94 rating of 94V-O at 1.6 mm and having thermal stability at 300° C.

Claim 4

The polycarbonate composition of claim 1 consisting essentially of: (a) between about 0.1 and 0.5 wt. % of alkali metal inorganic acid salt, (b) between about 0.05 and 0.2 wt. % fibril forming polytetrafluoroethylene, and (c) between about 0.1 and 0.5 wt. % of aromatically bound chlorine or bromine contained in a compound other than an organic alkali metal or alkaline earth metal salt wherein the weight percents are based on the total composition.

Claim 5

The polycarbonate composition of claim 1 containing between about 0.1 and 0.5 wt. % of aromatically bound chlorine or bromine contained in a compound other than an organic alkali metal or alkaline earth metal salt.

Claim 6

The polycarbonate composition of claim 1 wherein the alkali metal inorganic acid salts are salts of K, Li or Na.

Claim 7

An unreinforced molding composition having a UL item 94 rating of 94V-O at 1.6 mm, thermal stability at 300° C. and good mechanical properties consisting essentially of: (a) an aromatic thermoplastic polycarbonate which has a melt flow of between about 1 and 24 grams per 10 minutes and which is derived from 4,4'-dihydroxy diaryl methanes, (b) between about 0.1 and 0.5 wt. % of a Li, K, or Na salt of an inorganic acid, (b) between about 0.05 and 0.2 wt. % of fibril forming polytetrafluoroethylene, and (d) between about 0.1 and 0.5 wt. % of aromatically bound chlorine or bromine contained in a compound other than an organic alkali metal or alkaline earth metal salt wherein the weight percents are based on the total composition.

Claim 8

An unreinforced molding composition having a UL item 94 rating of 94V-O at 1.6 mm, thermal stability at 300° C. and good mechanical properties consisting essentially of: (a) an aromatic thermoplastic polycarbonate which has a melt flow of between about 1 and 24 grams per 10 minutes and which is derived from 4,4'-dihydroxy diaryl methanes, (b) between about 0.1 and 0.5 wt. % of a Li, K, or Na salt of an inorganic acid, (b) between about 0.05 and 0.2 wt. % of fibril forming polytetrafluoroethylene, and (d) between about 0.1 and 0.5 wt. % of aromatically bound chlorine or bromine contained in a compound other than an organic alkali metal or alkaline earth metal salt wherein the weight percents are based on the total composition.

Claim 9

A thermoplastic aromatic polycarbonate composition consisting essentially of: (a) between about 0.01 and 1 wt. %, based on the weight of the total composition, of an inorganic alkali metal complex fluoro anion salt, (b) between about 0.01 and 1 wt. %, based on the weight of the total composition, of a fibril forming polytetrafluoroethylene, and (c) between 0.05 and 1.0 wt. %, based on the weight of the total composition, of aromatically bound chlorine or bromine.

Claim 10

A thermoplastic aromatic polycarbonate composition consisting essentially of: (a) between about 0.01 and 1 wt. %, based on the weight of the total composition, of an inorganic alkali metal complex fluoro anion salt, (b) between about 0.01 and 1 wt. %, based on the weight of the total composition, of a fibril forming polytetrafluoroethylene, and (c) between 0.05 and 1.0 wt. %, based on the weight of the total composition, of aromatically bound chlorine or bromine.

Claim 11

The polycarbonate composition of claim 7 having a UL item 94 rating of 94V-O at 1.6 mm and having thermal stability at 300° C.

Claim 12

The polycarbonate composition of claim 7 consisting essentially of: (a) between about 0.1 and 0.5 wt. % of the inorganic alkali metal complex fluoro anion salt. (b) between about 0.05 and 0.2 wt. % of fibril forming polytetrafluoroethylene, and (c) between about 0.1 and 0.5 wt. % of aromatically bound chlorine or bromine, wherein the weight percents are based on the total composition.

Claim 13

The polycarbonate composition of claim 7 containing between about 0.1 and 0.5 wt. % of aromatically bound chlorine or bromine.

Claim 14

The polycarbonate composition of claim 7 wherein the inorganic alkali metal complex fluoro anion salt has a pH of about 7 or less.

Claim 15

The polycarbonate composition of claim 11 wherein the inorganic alkali metal complex fluoro anion salt is neutral.

Claim 16

The polycarbonate composition of claim 7 wherein the inorganic alkali metal complex fluoro anion salt is selected from the group consisting of KBF 4 , K 3 AlF 6 , KAlF 4 , K 2 SiF 6 , Na 3 AlF 6 , KPF 6 , NaSbF 6 , Na 3 FeF 6 , NaPF 6 , Na 2 SiF 6 , Na 2 TiF 6 , NaBF 4 , K 2 TaF 7 , K 2 NbF 7 , KSbF 6 , K 2 NiF 6 , K 2 TiF 6 , LiBF 4 , LiPF 6 and LiBeF 4 .

Claim 17

The polycarbonate composition of claim 13 wherein the inorganic alkali metal complex fluoro anion salt is selected from the group consisting of KBF 4 , K 3 AlF 6 , KAlF 4 , K 2 SiF 6 and Na 3 AlF 6 .

Claim 18

The polycarbonate composition of claim 14 wherein the inorganic alkali metal complex fluoro anion salt is Na 3 AlF 6 .

Claim 19

An unreinforced molding composition having a UL item 94 rating of 94V-O at 1.6 mm, thermal stability at 300° C. and good mechanical properties consisting essentially of: (a) an aromatic thermoplastic polycarbonate which has a melt flow of between about 1 and 24 grams per 10 minutes and which is derived from 4,4'-dihydroxy diaryl methanes, (b) between about 0.1 and 0.5 weight % of an inorganic alkali metal complex fluoro anion salt, (c) between about 0.05 and 0.2 weight % of fibril forming polytetrafluoroethylene, and (d) between about 0.1 and 0.5 weight % of aromatically bound chlorine or bromine, wherein the weight percents are based on the total composition.

Claim 20

An unreinforced molding composition having a UL item 94 rating of 94V-O at 1.6 mm, thermal stability at 300° C. and good mechanical properties consisting essentially of: (a) an aromatic thermoplastic polycarbonate which has a melt flow of between about 1 and 24 grams per 10 minutes and which is derived from 4,4'-dihydroxy diaryl methanes, (b) between about 0.1 and 0.5 weight % of an inorganic alkali metal complex fluoro anion salt, (c) between about 0.05 and 0.2 weight % of fibril forming polytetrafluoroethylene, and (d) between about 0.1 and 0.5 weight % of aromatically bound chlorine or bromine, wherein the weight percents are based on the total composition.