Thermally conductive liquid crystalline polymer compositions and articles formed therefrom

• US 20060014876A1
• Filed: 09/03/2003
• Published: 01/19/2006
• Est. Priority Date: 09/03/2002
• Status: Abandoned Application

• Current Assignee: Solvay Advanced Polymers LLC (Solvac SA)
• Original Assignee: Solvay Advanced Polymers LLC (Solvac SA)
• Inventors: Bushelman, Corinne, Crowe, Christie
• Application Number:
  US10/526,231
• Publication Number:
  US 20060014876A1
• Time in Patent Office: Days
• US Class Current: 524/439
• CPC Class Codes: C08K 3/08 Metals
• CPC Class Codes: C09K 19/38 Polymers
• CPC Class Codes: C09K 19/3809 Polyesters; Polyester derivatives, e.g. polyamides
• CPC Class Codes: C09K 19/52 characterised by components which are not liquid crystals, e.g. additives with special physical aspect: solvents, solid particles
• CPC Class Codes: F24C 15/16 Shelves, racks or trays inside ovens; Supports therefor

Abstract

This invention relates to thermally conductive liquid crystalline polymer compositions. The composition is comprised of a liquid crystalline polymer and metal particles. At least about 90% by weight of the metal particles have an average particle size larger than 200 μm. In other embodiments of the invention, the average particle size of the metal particles is larger than 420 μm. Aluminum flakes are exemplary metal particles for use in this invention. The thermally conductive liquid crystalline polymer composition is useful for the manufacture of cookware and has sufficient thermal conductivity to provide browning during cooking. The composition is useful for the manufacture of oven cookware such as cooking pans, sheets, trays, dishes, casseroles, and the like.

Claims

1-29. -29. (canceled)

30. A polymer composition comprising a liquid crystalline polymer and metal particles having a particle size, wherein the particle size of at least 90 weight % of the metal particles is greater than about 200 μ

m.

31. The polymer composition according to claim 30, wherein the particle size of at least 90 weight % of the metal particles is greater than about 400 μ

m.

32. The polymer composition according to claim 30, wherein the polymer composition comprises from about 20 weight % to about 70 weight % of the metal particles based on the total weight of the polymer composition.

33. The polymer composition according claim 30, wherein the metal particles are selected from the group consisting of aluminum, brass, copper, magnesium, nickel, stainless steel, steel, silver, tin, and zinc particles.

34. The polymer composition according to claim 30, wherein the metal particles are aluminum flakes.

35. The polymer composition according to claim 30, wherein the composition further comprises a non-thermally conductive filler.

36. The polymer compositions according to claim 30, wherein the liquid crystalline polymer is a polyester that is at least partially aromatic.

37. The polymer composition according to claim 30, wherein:

the liquid crystalline polymer is a polyester that is at least partially aromatic, the particle size of at least 90 weight % of the metal particles is greater than about 400 μ

m, and

the polymer composition comprises from about 20 weight % to about 70 weight % of the metal particles based on the total weight of the polymer composition.

38. The polymer composition according to claim 37, wherein the polyester is formed from the reaction product of at least one dicarboxylic acid selected from the group consisting of terephthalic acid, isophthalic acid, 2,6-naphthalic dicarboxylic acid, 3,6-naphthalic dicarboxylic acid, 1,5-naphthalic dicarboxylic acid, and 2,5-naphthalic dicarboxylic acid;

and at least one diol selected from the group consisting of hydroquinone, resorcinol, 4,4′

-biphenol, 3,3′

-biphenol, 2,4′

-biphenol, 2,3′

-biphenol, and 3,4′

-biphenol.

39. The polymer composition according to claim 37, wherein the polyester is formed from the reaction product of at least one dicarboxylic acid selected from the group consisting of terephthalic acid, isophthalic acid, 2,6-naphthalic dicarboxylic acid, 3,6-naphthalic dicarboxylic acid, 1,5-naphthalic dicarboxylic acid, and 2,5-naphthalic dicarboxylic acid;

and at least one diol selected from the group consisting of hydroquinone, resorcinol, 4,4′

-biphenol, 3,3′

-biphenol, 2,4′

-biphenol, 2,3′

-biphenol, and 3,4′

-biphenol ; and

at least one hydroxycarboxylic acid selected from the group consisting of p-hydroxybenzoic acid, m-hydroxybenzoic acid, 2,6-hydroxynaphthalic acid, 3,6-hydroxynaphthalic acid, 1,6 hydroxynaphthalic acid, and 2,5-hydroxynaphthalic acid.

40. The polymer composition according to claim 37, wherein the metal particles are aluminum flakes.

41. The polymer composition according to claim 40, wherein the average length of the aluminum flakes is from about 0.5 mm to about 5 mm, the average width of the aluminum flakes is from about 0.5 mm to about 5 mm, and the average thickness of the aluminum flakes is from about 10 μ

m to about 100 μ

m.

42. A melt fabricated article made from the polymer composition according to claim 30.

43. A melt fabricated article made from the polymer composition according to claim 37.

44. A cookware made from the polymer composition according to claim 30.

45. A cookware made from the polymer composition according to claim 37.

46. A polymer composition comprising a liquid crystalline polymer and metal particles having an average particle size, wherein an average particle size of the metal particles is greater than about 420 μ

m.

47. The polymer composition according to claim 46, wherein the average particle size is greater than about 500 μ

m.

48. A method of increasing the thermal conductivity of an article formed from a polymer composition, said method comprising compounding metal particles having a particle size, wherein the particle size of at least 90 weight % of the metal particles is greater than about 200 μ

m with a liquid crystalline polymer and forming said article from said polymer composition.

49. A method of increasing the thermal conductivity of an article formed from a polymer composition comprising compounding metal particles having an average particle size, Wherein the average particle size of the metal particles is greater than about 420 μ

m.