POLYIMIDE POLYPHENYLSULFONE BLENDS WITH IMPROVED FLAME RESISTANCE

• US 20120100324A1
• Filed: 08/11/2011
• Published: 04/26/2012
• Est. Priority Date: 10/20/2010
• Status: Active Grant

• Current Assignee: SHPP Global Technologies BV
• Original Assignee: Mark Sanner, Rajendra K. Singh, Robert Russell Gallucci
• Inventors: Sanner, Mark, Gallucci, Robert Russell, Singh, Rajendra K.
• Granted Patent: US 8,309,637 B2
• Time in Patent Office: Days
• US Class Current: 428/36.9
• CPC Class Codes: C08G 73/1046 Polyimides containing oxygen in the form of ether bonds in the main chain
• CPC Class Codes: C08G 73/106 containing silicon
• CPC Class Codes: C08G 77/445 containing polyester sequences
• CPC Class Codes: C08G 77/448 containing polycarbonate sequences
• CPC Class Codes: C08G 77/455 containing polyamide, polyesteramide or polyimide sequences
• CPC Class Codes: C08G 77/46 containing polyether sequences
• CPC Class Codes: C08J 2379/08 Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
• CPC Class Codes: C08J 2381/06 Polysulfones; Polyethersulfones
• CPC Class Codes: C08J 2479/08 Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
• CPC Class Codes: C08J 2481/06 Polysulfones; Polyethersulfones
• CPC Class Codes: C08J 9/0061 characterized by the use of several polymeric components
• CPC Class Codes: C08L 2205/02 containing two or more polymers of the same C08L -group
• CPC Class Codes: C08L 2205/03 containing three or more polymers in a blend
• CPC Class Codes: C08L 79/02 Polyamines
• CPC Class Codes: C08L 79/08 Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
• CPC Class Codes: C08L 81/06 Polysulfones; Polyethersulfones
• CPC Class Codes: C08L 83/04 Polysiloxanes
• CPC Class Codes: C08L 83/10 Block- or graft-copolymers containing polysiloxane sequences obtained by polymerising a compound having a carbon-to-carbon double bond on to a polysiloxane C08L51/08, C08L53/00
• CPC Class Codes: C08L 83/12 containing polyether sequences
• CPC Class Codes: Y10T 428/1352 Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/139 : Open-ended, self-supporting conduit, cylinder, or tube-type article

Abstract

The present disclosure relates to a composition with improved flame resistance, to articles made from the composition, and to methods that include processing the composition. The composition can include from 15 to 85 percent by weight of a polyetherimide (PEI), from 15 to 85 percent by weight of a polyphenylsulfone (PPSU), a polyetherimide-siloxane copolymer in an amount up to 12 percent by weight, and from 0 to 0.30 percent by weight of a stabilizer.

Claims

1. A composition having a time to peak heat release of more than 150 seconds, as measured by FAR 25.853 (OSU test);

a peak heat release less than or equal to 35 kW/m2 as measured by FAR 25.853 (OSU test);

an NBS (National Bureau of Standards) optical smoke density with flame of less than 5 when measured at four (4) minutes, based on ASTM E-662 (FAR/JAR 25.853); and

a toxic gas release of less than or equal to 100 ppm based on Draeger Tube Toxicity test (Airbus ABD0031, Boeing BSS

     7239);

the composition comprising;

(a) from 15 to 85 percent by weight of a polyetherimide (PEI),

(b) from 15 to 85 percent by weight of a polyphenylsulfone (PPSU),

(c) from 0 to 0.30 percent by weight of a stabilizer, wherein an article made from the composition exhibits the following properties;

(1) a time to peak heat release of more than 150 seconds, as measured by FAR 25.853 (OSU test);

(2) a peak heat release less than or equal to 35 kW/m² as measured by FAR 25.853 (OSU test);

(3) an NBS (National Bureau of Standards) optical smoke density with flame of less than 5 when measured at four minutes, based on ASTM E-662 (FAR/JAR 25.853); and

(4) a toxic gas release of less than or equal to 100 ppm based on Draeger Tube Toxicity test (Airbus ABD0031, Boeing BSS

     7239).

2. The composition of claim 1, wherein component (a) has less than 20 ppm hydroxyl (—

OH) end-groups.

3. The composition of claim 1, wherein component (a) has a weight average molecular weight (Mw) of 20,000 to 80,000 daltons.

4. The composition of claim 1, wherein component (a) has a halogen content of less than 1000 ppm, and wherein component (a) has less than 100 ppm benzylic protons.

5. The composition of claim 1, wherein component (a) has less than or equal to 500 ppm of low molecular weight bis-imide compounds selected from the group consisting of:

meta-phenylene diamine bis-phthalimide, meta-phenylene diamine bis-chloro phthalimides, para-phenylene diamine bis-phthalimide, para-phenylene bis-chloro phthalimides, and combinations thereof.

6. The composition of claim 1, wherein component (b) is a copolymer comprising:

from 50 to 99.9 percent by weight of a polyphenylsulfone (PPSU), and

from 0.1% to 50 percent by weight of a polysulfone (PSU).

7. The composition of claim 1, wherein component (b) is a copolymer comprising:

80 percent by weight of a polyphenylsulfone (PPSU), and

20 percent by weight of a polysulfone (PSU).

8. The composition of claim 7, wherein component (b) has a glass transition temperature (Tg) greater than 200 degrees Celsius.

10. The composition of claim 1, wherein component (b) has hydroxyl (—

OH) end-groups less than 50 ppm.

11. The composition of claim 1, wherein component (b) has low oligomer cyclics (n=2, 3, 4) of less than 5 percent.

18. The composition of claim 1, wherein component (d) is present in an amount of from 0.05 to 0.30 percent by weight.

19. The composition of claim 1, wherein component (d) is a tri-aryl phosphite.

20. The composition of claim 1, wherein the toxic gas is selected from the group of HCN, CO, NO, NO₂, SO₂, H₂S, HF, HCl, and combinations thereof.

25. The composition of claim 1, comprising less than 100 ppm alkali metals based on the total weight of components (a) and (b).

26. A method comprising melt processing a composition according to claim 1.

27. The method according to claim 26, wherein the process further comprises forming a shaped product comprising the composition.

29. An article comprising the composition of claim 1.

32. The article of claim 29, wherein the article is at least one selected from the group consisting of:

cookware, food service items, medical devices, trays, plates, handles, helmets, animal cages, electrical connectors, enclosures for electrical equipment, engine parts, automotive engine parts, lighting sockets, lighting reflectors, electric motor parts, power distribution equipment, communication equipment, computers, devices having molded snap fit connectors, sheets, films, multilayer sheets, multilayer films, molded parts, extruded profiles, coated parts, fibers, foams, windows, luggage racks, wall panels, chair parts, lighting panels, diffusers, shades, partitions, lenses, skylights, lighting devices, reflectors, ductwork, cable trays, conduits, pipes, cable ties, wire coatings, electrical connectors, air handling devices, ventilators, louvers, insulation, bins, storage containers, doors, hinges, handles, sinks, mirror housing, mirrors, toilet seats, hangers, coat hooks, shelving, ladders, hand rails, steps, carts, trays, cookware, food service equipment, communications equipment, and instrument panels.

33. The article of claim 29, wherein the article is a component of a conveyance selected from the group consisting of aircraft, trains, buses, ships, and automobiles.

34. The article of claim 29, having a percent transmittance of greater than 50 percent.

35. The article of claim 29, having a percent haze below 25 percent.

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