Flame retardant fiber reinforced composition with improved flow
A composition comprising at least one high Tg amorphous resin with a fibrous filler shows improved melt processability. Addition of a sulfonate salt to the compositions gives increased melt flow as well as enhanced flame retardancy in a composition which is substantially free of bromine and chlorine.
1 . A thermoplastic resin composition comprising:
(a) a polyimide, a polysulfone or mixture thereof;
(b) a fibrous reinforcement selected from the group consisting of: fiber glass, carbon fiber and ceramic fiber; and
(c) a sulfonate salt.
2 . The composition of claim 1 wherein the sulfonate salt is an alkali metal or alkaline earth metal salt.
3 . The composition of claim 2 wherein the sulfonate salt is selected from the group consisting of: fluoroalkyl sulfonate salts, aryl sulfonate salts, alkyl aryl sulfonate salts and mixtures thereof.
4 . The composition of claim 3 wherein the sulfonate salt is selected from the group consisting of: perfluorobutyl potassium sulfonate, potassium sulfone sulfonate and sodium dodecylbenzene sulfonate.
5 . The composition of claim 1 wherein the fibrous reinforcement is present at a level of from 1% to 50% by weight of the entire composition.
6 . The composition of claim 5 wherein the fibrous reinforcement is present at a level of from 10% to 40% by weight of the entire composition.
7 . The composition of claim 1 wherein the polyimide is a selected from the group consisting of polyetherimides and polyetherimide sulfones.
8 . The composition of claim 1 wherein the polysulfone is a selected from the group consisting of polyether sulfones, polyaryl ether sulfones and polyphenylene ether sulfones.
9 . The composition of claim 1 which has an Underwriters Laboratory (UL) 94 testing value of V-0 at a test part thickness of less than or equal to 1.6 mm.
10 . The composition of claim 1 which is substantially free of bromine and chlorine.
11 . The composition of claim 1 further comprising a fluoropolymer.
12 . The composition of claim 11 wherein the fluoropolymer is present at a level of from 0.5% to 5.0% by weight of the entire composition.
13 . The composition of claim 11 wherein the fluoropolymer is poly(tetrafluoroethylene).
14 . The composition of claim 1 further comprising 1-50% by weight of the entire composition of a non-fibrous mineral filler.
15 . The composition of claim 14 wherein the non-fibrous filler is selected from the group consisting of: mica, clay, talc, glass flake, milled glass, barium sulfate, titanium dioxide, zinc sulfide, silica and zeolites.
16 . The composition of claim 1 wherein the composition has a melt flow of from 20 to 60 milliliters/10 minutes as measured by ASTM Test Method D1238 at 337 degrees C using a die 8 millimeters long and 9.5 millimeters wide with an orifice of 2 millimeters with a load of 6.7 kilograms.
17 . The composition of claim 1 further comprising a mold release agent selected from the group consisting of: polyolefins and alkyl esters of carboxylic acids.
18 . A thermoplastic resin composition comprising:
(a) a polyetherimide, a polysulfone or mixture thereof;
(b) fiber glass;
(c) a sulfonate salt selected from the group consisting of perfluorobutyl potassium sulfonate, potassium sulfone sulfonate and sodium dodecylbenzene sulfonate; and
(d) an alkyl ester of a carboxylic acid;
wherein said composition has a melt flow of from 20 to 60 milliliters/10 minutes as measured by ASTM Test Method D1238 at 337 degrees C using a die 8 millimeters long and 9.5 millimeters wide with an orifice of 2 millimeters with a load of 6.7 kilograms.
19 . The composition of claim 18 comprising a polyetherimide comprising structural units derived from at least one dianhydride selected from the group consisting of 2,2-bis[4-(3,4-dicarboxyphenoxy)phenyl]propane dianhydride, 2,2-bis[4-(2,3-dicarboxyphenoxy)phenyl]propane dianhydride; 2-[4-(3,4-dicarboxyphenoxy)phenyl]-2-[4-(2,3-dicarboxyphenoxy)phenyl]propane dianhydride; and structural units derived from at least one diamine selected from the group consisting of meta- phenylene diamine, para-phenylene diamine, diamino diphenyl sulfone and oxydianiline.
20 . A thermoplastic resin composition comprising:
(e) a polyimide, a polysulfone or mixture thereof,
(f) an amorphous polycarbonate, polyestercarbonate or polyarylate polymer, or mixture thereof, comprising recurring units of the formula
wherein Ar is a divalent aromatic residue of a dicarboxylic acid or mixture of dicarboxylic acids and Ar′ is a divalent aromatic residue of a dihydroxy-substituted aromatic compound or mixture of dihydroxy-substituted aromatic compounds and wherein, based on mole percent, x and y each have a value of between 0 and 100 percent and the total of x and y is 100 percent;
(g) a fibrous reinforcement selected from the group consisting of: fiber glass, carbon fiber and ceramic fiber; and
(h) a sulfonate salt.
21 . The composition of claim 20 wherein the polyimide is a selected from the group consisting of polyetherimides and polyetherimide sulfones.
22 . The composition of claim 20 wherein Ar′ is represented by the formula:
wherein A 2 is a substituted or unsubstituted divalent radical comprising from 1 to about 15 carbon atoms or a linking group selected from the group consisting of —S—; —SO 2 — or —O—; each X is independently selected from the group consisting of a monovalent radical, an alkyl group of from 1 to about 8 carbon atoms, an aryl group of from 6 to about 18 carbon atoms, an aralkyl group of from 7 to about 14 carbon atoms, and an alkoxy group of from 1 to about 8 carbon atoms; m is 0 or 1 and n is an integer of from 0 to about 5.
23 . The composition of claim 20 wherein x is 0 and said amorphous polymer is a polycarbonate resin.
24 . The composition of claim 23 wherein said polycarbonate resin comprises structural units derived from bisphenol A.
25 . The composition of claim 20 wherein y is 0 and said amorphous polymer is a polyarylate resin.
26 . The composition of claim 23 wherein said polyarylate resin comprises structural units derived from bisphenol A.
27 . The composition of claim 20 wherein said amorphous polymer is a polyestercarbonate resin.
28 . The composition of claim 27 wherein Ar is derived from the aromatic residue of isophthalic acid, terephthalic acid or a mixture thereof.
29 . The composition of claim 20 wherein the sulfonate salt is an alkali metal or alkaline earth metal salt.
30 . The composition of claim 29 wherein the sulfonate salt is selected from the group consisting of: fluoroalkyl sulfonate salts, aryl sulfonate salts and alkyl aryl sulfonate salts.
31 . The composition of claim 30 wherein the sulfonate salt is selected from the group consisting of: perfluorobutyl potassium sulfonate, potassium sulfone sulfonate and sodium dodecylbenzene sulfonate.
32 . The composition of claim 20 wherein the fibrous reinforcement is present at a level of from 1% to 50% by weight of the entire composition.
33 . The composition of claim 32 wherein the fibrous reinforcement is present at a level of from 10% to 40% by weight of the entire composition.
34 . The composition of claim 20 wherein the polyimide is a selected from the group consisting of polyetherimides and polyetherimide sulfones.
35 . The composition of claim 20 wherein the polysulfone is a selected from the group consisting of polyether sulfones, polyaryl ether sulfones and polyphenylene ether sulfones.
36 . The composition of claim 20 which has an Underwriters Laboratory (UL) 94 testing value of V-0 at a test part thickness of less than or equal to 1.6 mm.
37 . The composition of claim 20 which is substantially free of bromine and chlorine.
38 . The composition of claim 20 further comprising a fluoropolymer.
39 . The composition of claim 38 wherein the fluoropolymer is present at a level of from 0.5% to 5.0% by weight of the entire composition.
40 . The composition of claim 38 wherein the fluoropolymer is poly(tetrafluoroethylene).
41 . The composition of claim 20 further comprising 1-50% by weight of the entire composition of a non-fibrous mineral filler.
42 . The composition of claim 41 wherein the non-fibrous filler is selected from the group consisting of: mica, clay, talc, glass flake, milled glass, barium sulfate, titanium dioxide, zinc sulfide, silica and zeolites.
43 . The composition of claim 20 wherein the composition has a melt flow of from 20 to 60 milliliters/10 minutes as measured by ASTM Test Method D1238 at 337 degrees C using a die 8 millimeters long and 9.5 millimeters wide with an orifice of 2 millimeters with a load of 6.7 kilograms.
44 . The composition of claim 20 further comprising a mold release selected from the group consisting of: polyolefins and alkyl esters of carboxylic acids.
45 . A thermoplastic resin composition comprising:
(e) a polyetherimide, a polysulfone or mixture thereof;
(f) an amorphous polyestercarbonate comprising recurring units of the formula
wherein Ar is a divalent aromatic residue of a dicarboxylic acid or mixture of dicarboxylic acids and Ar′ is a divalent aromatic residue of a dihydroxy-substituted aromatic compound or mixture of dihydroxy-substituted aromatic compounds and wherein, based on mole percent, x and y each have a value of between 1 and 99 percent and the total of x and y is 100 percent;
(g) fiber glass;
(h) a sulfonate salt selected from the group consisting of perfluorobutyl potassium sulfonate, potassium sulfone sulfonate and sodium dodecylbenzene sulfonate; and
(i) an alkyl ester of a carboxylic acid;
wherein said composition has a melt flow of from 20 to 60 milliliters/10 minutes as measured by ASTM Test Method D1238 at 337 degrees C using a die 8 millimeters long and 9.5 millimeters wide with an orifice of 2 millimeters with a load of 6.7 kilograms.
46 . The composition of claim 45 comprising a polyetherimide comprising structural units derived from at least one dianhydride selected from the group consisting of 2,2-bis[4-(3,4-dicarboxyphenoxy)phenyl]propane dianhydride, 2,2-bis[4-(2,3-dicarboxyphenoxy)phenyl]propane dianhydride; 2-[4-(3,4-dicarboxyphenoxy)phenyl]-2-[4-(2,3-dicarboxyphenoxy)phenyl]propane dianhydride; and structural units derived from at least one diamine selected from the group consisting of meta-phenylene diamine, para-phenylene diamine, diamino diphenyl sulfone and oxydianiline.
47 . A flame retardant thermoplastic resin composition comprising:
(j) a polyestercarbonate, a polyarylate or mixture thereof,
(k) a fibrous reinforcement selected from the group consisting of: fiber glass, carbon fiber and ceramic fiber; and
(l) a sulfonate salt.
48 . The composition of claim 47 wherein the sulfonate salt is an alkali metal or alkaline earth metal salt.
49 . The composition of claim 48 wherein the sulfonate salt is selected from the group consisting of: fluoroalkyl sulfonate salts, aryl sulfonate salts and alkyl aryl sulfonate salts.
50 . The composition of claim 49 wherein the sulfonate salt is selected from the group consisting of: perfluorobutyl potassium sulfonate, potassium sulfone sulfonate and sodium dodecylbenzene sulfonate.
51 . The composition of claim 47 wherein the fibrous reinforcement is present at a level of from 1% to 50% by weight of the entire composition.
52 . The composition of claim 51 wherein the fibrous reinforcement is present at a level of from 10% to 40% by weight of the entire composition.
53 . The composition of claim 47 which has an Underwriters Laboratory (UL) 94 testing value of V-0 at a test part thickness of less than or equal to 1.6 mm.
54 . The composition of claim 47 which is substantially free of bromine and chlorine.
55 . The composition of claim 47 further comprising a fluoropolymer.
56 . The composition of claim 55 wherein the fluoropolymer is present at a level of from 0.5% to 5.0% by weight of the entire composition.
57 . The composition of claim 55 wherein the fluoropolymer is poly(tetrafluoroethylene).
58 . The composition of claim 47 further comprising 1-50% by weight of the entire composition of a non-fibrous mineral filler.
59 . The composition of claim 58 wherein the non-fibrous filler is selected from the group consisting of: mica, clay, talc, glass flake, milled glass, barium sulfate, titanium dioxide, zinc sulfide, silica and zeolites.
60 . The composition of claim 47 wherein the composition has a melt flow of from 20 to 60 milliliters/10 minutes as measured by ASTM Test Method D1238 at 337 degrees C using a die 8 millimeters long and 9.5 millimeters wide with an orifice of 2 millimeters with a load of 6.7 kilograms.
61 . The composition of claim 47 further comprising a mold release selected from the group consisting of: polyolefins and alkyl esters of carboxylic acids.
62 . A flame retardant thermoplastic resin composition comprising:
(j) a polyestercarbonate,
(k) fiber glass;
(l) a sulfonate salt selected from the group consisting of perfluorobutyl potassium sulfonate, potassium sulfone sulfonate and sodium dodecylbenzene sulfonate; and
(m) an alkyl ester of a carboxylic acid;
wherein said composition has a melt flow of from 20 to 60 milliliters/10 minutes as measured by ASTM Test Method D1238 at 337 degrees C. using a die 8 millimeters long and 9.5 millimeters wide with an orifice of 2 millimeters with a load of 6.7 kilograms.
63 . An article made from the composition of claim 1 .
64 . An article made from the composition of claim 18 .
65 . An article made from the composition of claim 20 .
66 . An article made from the composition of claim 45 .
67 . An article made from the composition of claim 47 .
68 . An article made from the composition of claim 62.