Flame-retardant polymer composition and article

• US 8,552,095 B1
• Filed: 09/25/2012
• Issued: 10/08/2013
• Est. Priority Date: 09/25/2012
• Status: Expired due to Fees

• Current Assignee: SABIC Global Technologies BV (Government of Saudi Arabia)
• Original Assignee: Sabic Innovative Plastics IP BV (Government of Saudi Arabia)
• Inventors: Grcev, Snezana, Hagenaars, Arno
• Primary Examiner(s): SZEKELY, PETER A
• Application Number:
  US13/626,363
• Time in Patent Office: 378 Days
• Field of Search: 524/126, 524/133
• US Class Current: 524/126
• CPC Class Codes: C08G 73/1046 Polyimides containing oxygen in the form of ether bonds in the main chain
• CPC Class Codes: C08G 73/1053 with oxygen only in the tetracarboxylic moiety
• CPC Class Codes: C08G 77/46 containing polyether sequences
• CPC Class Codes: C08K 3/32 Phosphorus-containing compounds
• CPC Class Codes: C08K 5/0066 Flame-proofing or flame-retarding additives
• CPC Class Codes: C08K 5/5313 Phosphinic compounds, e.g. R2=P(:O)OR'
• CPC Class Codes: C08K 7/14 Glass
• CPC Class Codes: C08L 71/126 modified by chemical after-treatment
• CPC Class Codes: C08L 77/00 Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain of polyhydrazides C08L79/06; of polyamideimides or polyamide acids C08L79/08; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 77/02 Polyamides derived from omega-amino carboxylic acids or from lactams thereof C08L77/10 takes precedence
• CPC Class Codes: C08L 77/06 Polyamides derived from polyamines and polycarboxylic acids C08L77/10 takes precedence
• CPC Class Codes: C08L 79/08 Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
• CPC Class Codes: C08L 83/12 containing polyether sequences

Abstract

A flame-retardant polymer composition includes specific amounts of polyamide, acid-functionalized poly(phenylene ether), polyimide, and metal dialkylphosphinate. The composition, which exhibits improved flame retardancy and tensile modulus relative to known blends of poly(phenylene ether), polyamide, and polyimide, is useful for forming electrical components, such as photovoltaic junction boxes and connectors, inverter housings, automotive electrical connectors, electrical relays, and charge couplers.

Claims

1. A composition comprising the product of melt blending:

40 to 70 weight percent polyamide;

20 to 50 weight percent acid-functionalized poly(phenylene ether);

5 to 30 weight percent polyimide; and

an amount of metal dialkylphosphinate effective to provide a flammability rating of V-1 or V-0 in the 20 mm Vertical Burning Flame Test of Underwriter'"'"'s Laboratory Bulletin 94 “

Tests for Flammability of Plastic Materials, UL 94”

;

wherein all weight percents are based on the total weight of the composition.

2. The composition of claim 1, wherein the polyamide is selected from the group consisting of polyamide-6, polyamide-6,6, polyamide-4,6, polyamide-11, polyamide-12, polyamide-6,10, polyamide-6,12, polyamide 6/6,6, polyamide-6/6,12, polyamide MXD,6, polyamide-6,T, polyamide-6,I, polyamide-6/6,T, polyamide-6/6,I, polyamide-6,6/6,T, polyamide-6,6/6,I, polyamide-6/6,T/6,I, polyamide-6,6/6,T/6,I, polyamide-6/12/6,T, polyamide-6,6/12/6,T, polyamide-6/12/6,I, polyamide-6,6/12/6,I, and combinations thereof.

3. The composition of claim 1, wherein the polyamide is selected from the group consisting of polyamide-6, polyamide-6,6, and combinations thereof.

4. The composition of claim 1, wherein the polyamide comprises polyamide-6,6.

5. The composition of claim 1, wherein the acid-functionalized poly(phenylene ether) is the product of melt blending 95 to 99.5 parts by weight of a poly(phenylene ether) with 0.5 to 5 parts by weight of a functionalizing agent selected from the group consisting of citric acid, fumaric acid, maleic acid, maleic anhydride, and combinations thereof.

6. The composition of claim 5, wherein the poly(phenylene ether) comprises a homopolymer or copolymer of monomers selected from the group consisting of 2,6-dimethylphenol, 2,3,6-trimethylphenol, and combinations thereof.

7. The composition of claim 6, comprising 4 to 15 weight percent of the metal dialkylphosphinate.

8. The composition of claim 5, wherein the poly(phenylene ether) comprises a poly(phenylene ether)-polysiloxane block copolymer.

9. The composition of claim 8, comprising 2 to 15 weight percent of the metal dialkylphosphinate.

10. The composition of claim 8, wherein the poly(phenylene ether)-polysiloxane block copolymer contributes 0.4 to 4 weight percent of polysiloxane blocks to the composition.

11. The composition of claim 1, wherein the polyimide comprises a polyetherimide comprising 10 to 1000 repeating units having the structure

12. The composition of claim 1, further comprising 2 to 20 weight percent glass fibers.

13. The composition of claim 1, comprising less than 2 weight percent glass fibers.

14. The composition of claim 1,

wherein the polyamide comprises polyamide-6,6;

wherein the polyamide amount is 42 to 50 weight percent;

wherein the acid-functionalized poly(phenylene ether) is the product of melt blending 96 to 99 parts by weight of a poly(phenylene ether) with 1 to 4 parts by weight of a functionalizing agent selected from the group consisting of citric acid, fumaric acid, maleic acid, maleic anhydride, and combinations thereof;

wherein the poly(phenylene ether) comprises a homopolymer or copolymer of monomers selected from the group consisting of 2,6-dimethylphenol, 2,3,6-trimethylphenol, and combinations thereof;

wherein the acid-functionalized poly(phenylene ether) amount is 30 to 48 weight percent;

wherein the polyimide comprises a polyetherimide comprising 10 to 1000 repeating units having the structure

15. The composition of claim 1,

wherein the polyamide comprises polyamide-6,6;

wherein the polyamide amount is 42 to 50 weight percent;

wherein the acid-functionalized poly(phenylene ether) is the product of melt blending 96 to 99 parts by weight of a poly(phenylene ether) with 1 to 4 parts by weight of a functionalizing agent selected from the group consisting of citric acid, fumaric acid, maleic acid, maleic anhydride, and combinations thereof;

wherein the poly(phenylene ether) comprises a poly(phenylene ether)-polysiloxane block copolymer;

wherein the poly(phenylene ether)-polysiloxane block copolymer contributes 0.8 to 3 weight percent of polysiloxane blocks to the composition;

wherein the acid-functionalized poly(phenylene ether) amount is 30 to 48 weight percent;

wherein the polyimide comprises a polyetherimide comprising 10 to 1000 repeating units having the structure

16. An article comprising a composition comprising the product of melt blending:

40 to 70 weight percent polyamide;

20 to 50 weight percent acid-functionalized poly(phenylene ether);

5 to 30 weight percent polyimide; and

an amount of metal dialkylphosphinate effective to provide a flammability rating of V-1 or V-0 in the 20 mm Vertical Burning Flame Test of Underwriter'"'"'s Laboratory Bulletin 94 “

Tests for Flammability of Plastic Materials, UL 94”

;

wherein all weight percents are based on the total weight of the composition.

17. The article of claim 16,

wherein the polyamide comprises polyamide-6,6;

wherein the polyamide amount is 42 to 50 weight percent;

wherein the acid-functionalized poly(phenylene ether) is the product of melt blending 96 to 99 parts by weight of a poly(phenylene ether) with 1 to 4 parts by weight of a functionalizing agent selected from the group consisting of citric acid, fumaric acid, maleic acid, maleic anhydride, and combinations thereof;

wherein the poly(phenylene ether) comprises a homopolymer or copolymer of monomers selected from the group consisting of 2,6-dimethylphenol, 2,3,6-trimethylphenol, and combinations thereof;

wherein the acid-functionalized poly(phenylene ether) amount is 30 to 48 weight percent;

wherein the polyimide comprises a polyetherimide comprising 10 to 1000 repeating units having the structure

18. The article of claim 16,

wherein the polyamide comprises polyamide-6,6;

wherein the polyamide amount is 42 to 50 weight percent;

wherein the acid-functionalized poly(phenylene ether) is the product of melt blending 96 to 99 parts by weight of a poly(phenylene ether) with 1 to 4 parts by weight of a functionalizing agent selected from the group consisting of citric acid, fumaric acid, maleic acid, maleic anhydride, and combinations thereof;

wherein the poly(phenylene ether) comprises a poly(phenylene ether)-polysiloxane block copolymer;

wherein the poly(phenylene ether)-polysiloxane block copolymer contributes 0.8 to 3 weight percent of polysiloxane blocks to the composition;

wherein the acid-functionalized poly(phenylene ether) amount is 30 to 48 weight percent;

wherein the polyimide comprises a polyetherimide comprising 10 to 1000 repeating units having the structure