Reinforced polyester compositions, methods of manufacture, and articles thereof
First Claim
Patent Images
1. A composition comprising, based on the total weight of the composition:
- from 20 to 90 wt. % of a polyester component comprising a poly(alkylene terephthalate);
from 5 to 35 wt. % ofa flame retardant phosphinate of the formula (I)
[(R1)(R2)(PO)—
O]−
mMm+
(I)a flame retardant diphosphinate of the formula (II)
[(O—
POR1)(R3)(POR2—
O)]2−
nMm+x
(II), and/ora flame retardant polymer derived from the flame retardant phosphinate of the formula (I) or the flame retardant diphosphinate of the formula (II),wherein R1 and R2 are identical or different and are H, C1-C6 alkyl, linear or branched, or C6-C10 aryl; and
R3 is C1-C10, alkylene, linear or branched, C6-C10 arylene, C7-C11 alkylarylene, or C7-C11 arylalkylene;
M is an alkaline earth metal, alkali metal, Al, Ti, Zn, Fe, or boron;
m is 1, 2, 3 or 4;
n is 1, 2, or 3; and
x is 1 or 2;
from 1 to 25 wt. % of a melamine polyphosphate, melamine cyanurate, melamine pyrophosphate, and/or melamine phosphate;
from 0 to 30 weight percent of other polymers, based on the total weight of polymers in the composition;
from greater than zero to 50 wt. % of a glass fiber having a non-circular cross-section; and
from 0 to 5 wt. % of an additive selected from the group consisting of a mold release agent, an antioxidant, a nucleating agent, a thermal stabilizer, an anti-drip agent, a flow-promoting additive, a chain extender, a platy filler, and a UV stabilizer;
wherein the components have a combined total weight of 100 wt. %;
wherein a molded article comprising the composition has a comparative tracking index that is more than 350 volts in accordance with ASTM D3638-85, UL746A, or IEC-112, 3rd publication and a notched impact strength of 60 to 75 J/m, measured at 23°
C. in accordance with ASTM D256.
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Abstract
A composition comprises, based on the total weight of the composition: from 20 to 90 wt. % of a polyester component comprising a poly(butylene terephthalate); from 5 to 35 wt. % of a flame retardant phosphinate of the formula (I)
[(R1)(R2)(PO)—O]−mMm+ (I)
a flame retardant diphosphinate of the formula (II)
[(O—POR1)(R3)(POR2—O)]2−nMm+x (II),
and/or a flame retardant polymer derived from the flame retardant phosphinate of the formula (I) or the flame retardant diphosphinate of the formula (II); from 1 to 25 wt. % of a melamine polyphosphate, melamine cyanurate, melamine pyrophosphate, and/or melamine phosphate; from greater than zero to 50 wt. % of a glass fiber having a non-circular cross-section; and from 0 to 5 wt. % of an additive selected from the group consisting of a mold release agent, an antioxidant, a thermal stabilizer, an antioxidant, and a UV stabilizer; wherein the components have a combined total weight of 100 wt. %.
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Citations
37 Claims
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1. A composition comprising, based on the total weight of the composition:
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from 20 to 90 wt. % of a polyester component comprising a poly(alkylene terephthalate); from 5 to 35 wt. % of a flame retardant phosphinate of the formula (I)
[(R1)(R2)(PO)—
O]−
mMm+
(I)a flame retardant diphosphinate of the formula (II)
[(O—
POR1)(R3)(POR2—
O)]2−
nMm+x
(II), and/ora flame retardant polymer derived from the flame retardant phosphinate of the formula (I) or the flame retardant diphosphinate of the formula (II), wherein R1 and R2 are identical or different and are H, C1-C6 alkyl, linear or branched, or C6-C10 aryl; and
R3 is C1-C10, alkylene, linear or branched, C6-C10 arylene, C7-C11 alkylarylene, or C7-C11 arylalkylene;
M is an alkaline earth metal, alkali metal, Al, Ti, Zn, Fe, or boron;
m is 1, 2, 3 or 4;
n is 1, 2, or 3; and
x is 1 or 2;from 1 to 25 wt. % of a melamine polyphosphate, melamine cyanurate, melamine pyrophosphate, and/or melamine phosphate; from 0 to 30 weight percent of other polymers, based on the total weight of polymers in the composition; from greater than zero to 50 wt. % of a glass fiber having a non-circular cross-section; and from 0 to 5 wt. % of an additive selected from the group consisting of a mold release agent, an antioxidant, a nucleating agent, a thermal stabilizer, an anti-drip agent, a flow-promoting additive, a chain extender, a platy filler, and a UV stabilizer; wherein the components have a combined total weight of 100 wt. %; wherein a molded article comprising the composition has a comparative tracking index that is more than 350 volts in accordance with ASTM D3638-85, UL746A, or IEC-112, 3rd publication and a notched impact strength of 60 to 75 J/m, measured at 23°
C. in accordance with ASTM D256.- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 34, 35, 36, 37)
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32. A composition consisting essentially of, based on the total weight of the composition:
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from 20 to 90 wt. % of a polyester component comprising a poly(butylene terephthalate); from 5 to 35 wt. % of a flame retardant phosphinate of the formula (Ia)
[(R1)(R2)(PO)—
O]−
3 Al3 −
(Ia),a flame retardant diphosphinate of the formula (IIa)
[(O—
POR1)(R3)(POR2—
O)]2−
3Al3+2
(IIa), and/ora flame retardant polymer derived from formula (Ia) or (IIa), wherein R1 and R2 are identical or different and are H, C1-C6 alkyl, linear or branched, or C6-C10 aryl; and
R3 is C1-C10, alkylene, linear or branched, C6-C10 arylene, C7-C11 alkylarylene, or C7-C11 arylalkylene;from 1 to 25 wt. % of melamine polyphosphate and/or melamine cyanurate; from 0 to 30 weight percent of other polymers, based on the total weight of polymers in the composition but wherein the composition comprises no charring polymer; from 10 to 40 wt. % of a glass fiber having a flat cross-section; and from 0 to 5 wt. % of an additive selected from the group consisting of a mold release agent, an antioxidant, a thermal stabilizer, an antioxidant, and a UV stabilizer; wherein the composition contains less than 900 ppm of a halogen selected from the group consisting of bromine, chlorine, and combinations thereof; wherein the components and have a combined total weight of 100 wt. %, and wherein a molded sample comprising the composition has a comparative tracking index ranging from 350 volts to 600 volts in accordance with ASTM D3638-85, UL746A, or IEC-112 3rd publication a notched impact strength of 60 to 75 J/m measured at 23°
C. in accordance with ASTM D256, and a 0.8 mm thick molded sample comprising the composition has a UL-94 flammability rating of V0.
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33. A composition comprising no charring polymer and consisting essentially of, based on the total weight of the composition:
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from 20 to 90 wt. % of a polyester component comprising a poly(butylene terephthalate); from 5_to 25 wt. % of a flame retardant phosphinate of the formula (Ia)
[(R1)(R2)(PO)—
O]−
3 Al3+
(Ia),a flame retardant diphosphinate of the formula (IIa)
[(O—
POR1)(R3)(POR2—
O)]2-31 3Al3+2
(IIa), and/ora flame retardant polymer derived from formula (Ia) or (IIa), wherein R1 and R2 are both hydrogen; from 1 to 15 wt. % of melamine polyphosphate and/or melamine cyanurate; from 10 to 40 wt. % of a glass fiber having a flat cross-section, an average length of from 0.1 mm to 10 mm, and an average aspect ratio of 2 to 5; from 0 to 5 wt. % of an additive selected from the group consisting of a mold release agent, an antioxidant, a thermal stabilizer, an antioxidant, and a UV stabilizer; and less than 900 ppm of a halogen selected from the group consisting of bromine, chlorine, and combinations thereof; wherein the components have a combined total weight of 100 wt. %; and
wherein a molded sample comprising the composition has a comparative tracking index ranging from 575 volts to 600 volts in accordance with ASTM D3638-85, UL746A, or IEC-112 3rd publication, a notched impact strength of 60 to 75 J/m, measured at 23°
C. in accordance with ASTM D256, and a 0.8 mm thick molded sample comprising the composition has a UL-94 flammability rating of V0.
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Specification
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Current AssigneeSABIC Global Technologies BV (Government of Saudi Arabia)
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Original AssigneeSabic Innovative Plastics IP BV (Government of Saudi Arabia)
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InventorsDing, Tianhua, Kim, Sung Dug
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Primary Examiner(s)SANDERS, KRIELLION ANTIONETTE
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Application NumberUS12/346,064Publication NumberTime in Patent Office679 DaysField of Search524/100, 524/126, 524/133, 524/135, 524/494, 524/464US Class Current524/126CPC Class CodesC08K 2201/014 Additives containing two or...C08K 5/34928 SaltsC08K 5/5313 Phosphinic compounds, e.g. ...C08L 67/02 Polyesters derived from dic...
