Flame retardant poly(arylene ether)/polyamide compositions, methods, and articles
View Patent ↗A flame retardant poly(arylene ether)/polyamide composition includes a poly(arylene ether), a polyamide, about 5 to about 15 weight percent glass fiber, and a flame retardant consisting of a metal dialkyl phosphinate. Methods of preparing the composition are described, as are articles that include it.
1. A composition comprising:
a poly(arylene ether);
a polyamide;
about 5 to about 15 weight percent glass fiber; and
a flame retardant consisting of a metal dialkyl phosphinate;
wherein the composition excludes any polymer other than the poly(arylene ether) and the polyamide;
wherein the composition excludes electrically conductive fillers;
wherein all weight percents are based on the total weight of the composition; and
wherein the composition has
a flammability rating of V-0 or V-1 measured according to the UL 94 Vertical Burning Test at a thickness of 3 millimeters, and
a notched Izod impact strength of at least 40 Joules/meter measured at 23° C. according to ASTM D256, Method A.
2. The composition of claim 1 , wherein the composition has a flammability rating of V-0 measured according to the UL 94 Vertical Burning Test at a thickness of 3 millimeters.
3. The composition of claim 1 , wherein the composition has a flammability rating of V-0 measured according to the UL 94 Vertical Burning Test at a thickness of 2 millimeters.
4. The composition of claim 1 , wherein the composition has a notched Izod impact strength of 50 to 65 Joules/meter measured at 23° C. according to ASTM D256, Method A.
5. The composition of claim 1 , wherein the composition has a tensile elongation at break of at least 3 percent, measured at 23° C. according to ASTM D638.
6. The composition of claim 1 , wherein the composition has a tensile elongation at break of 3 to 10 percent, measured at 23° C. according to ASTM D638 .
7. The composition of claim 1 , wherein the poly(arylene ether) comprises repeating structural units having the formula
wherein for each structural unit, each Z 1 is independently halogen, unsubstituted or substituted C 1 -C 12 hydrocarbyl with the proviso that the hydrocarbyl group is not tertiary hydrocarbyl, C 1 -C 12 hydrocarbylthio, C 1 -C 12 hydrocarbyloxy, or C 2 -C 12 halohydrocarbyloxy wherein at least two carbon atoms separate the halogen and oxygen atoms; and each Z 2 is independently hydrogen, halogen, unsubstituted or substituted C 1 -C 12 hydrocarbyl with the proviso that the hydrocarbyl group is not tertiary hydrocarbyl, C 1 -C 12 hydrocarbylthio, C 1 -C 12 hydrocarbyloxy, or C 2 -C 12 halohydrocarbyloxy wherein at least two carbon atoms separate the halogen and oxygen atoms.
8. The composition of claim 1 , wherein the poly(arylene ether) comprises 2,6-dimethyl-1,4-phenylene ether units or a combination of 2,6-dimethyl-1,4-phenylene ether units and 2,3,6-trimethyl-1,4-phenylene ether units.
9. The composition of claim 1 , wherein the poly(arylene ether) has a glass transition temperature of 160 to 250° C.
10. The composition of claim 1 , wherein the polyamide is selected from the group consisting of nylon-6, nylon-6,6, nylon-4, nylon-4,6, nylon-12, nylon-6,10, nylon 6,9, nylon-6,12, amorphous polyamide resins, nylon 6/6T, nylon 6,6/6T, nylon 9T, and combinations of two or more of the foregoing polyamides.
11. The composition of claim 1 , wherein the polyamide comprises nylon-6 and nylon-6,6.
12. The composition of claim 1 , wherein the poly(arylene ether) and polyamide are compatibilized.
13. The composition of claim 1 , wherein the metal dialkyl phosphinate has the formula
wherein R 1 and R 2 are independently C 1-C 6 alkyl, phenyl, or aryl; M is calcium, magnesium, aluminum, or zinc; and d is 2 or 3.
14. The composition of claim 13 , wherein R 1 and R 2 are ethyl, M is aluminum, and d is 3.
15. The composition of claim 1 , comprising about 25 to about 40 weight percent of the poly(arylene ether), about 40 to about 50 weight percent of the polyamide, about 9 to about 15 weight percent of the flame retardant, and about 8 to about 12 weight percent of the glass fibers.
16. A composition comprising:
about 25 to about 40 weight percent of a poly(arylene ether) comprising 2,6-dimethyl-1,4-phenylene ether units or a combination of 2,6-dimethyl-1 ,4-phenylene ether units and 2,3,6-trimethyl-1,4-phenylene ether units;
about 40 to about 50 weight percent of a polyamide comprising nylon-6 and nylon-6,6;
about 0.5 to about 2 weight percent citric acid;
about 8 to about 12 weight percent glass fiber; and
about 9 to about 15 weight percent of a flame retardant consisting of aluminum tris(diethyl phosphinate);
wherein the composition excludes any polymer other than the poly(arylene ether) and the polyamide;
wherein the composition excludes electrically conductive fillers;
wherein all weight percents are based on the total weight of the composition; and
wherein the composition exhibits
a flammability rating of V-0 measured according to the UL 94 Vertical Burning Test at a thickness of 3 millimeters,
a notched Izod impact strength of at least 50 Joules/meter measured at 23° C. according to ASTM D256, Method A, and
a tensile elongation at break of at least 3 percent, measured at 23° C. according to ASTM D638.
17. The composition of claim 16 , wherein the composition exhibits
a notched Izod impact strength of 50 to 65 Joules/meter measured at 23° C. according to ASTM D256, Method A, and
a tensile elongation at break of 3 to 10 percent, measured at 23° C. according to ASTM D638.
18. A composition comprising:
about 25 to about 40 weight percent of a poly(arylene ether) comprising 2,6-dimethyl-1,4-phenylene ether units or a combination of 2,6-dimethyl-1 ,4-phenylene ether units and 2,3,6-trimethyl-1,4-phenylene ether units;
about 40 to about 50 weight percent of a polyamide comprising nylon-6 and nylon-6,6;
about 0.5 to about 2 weight percent citric acid;
about 8 to about 12 weight percent glass fiber; and
about 9 to about 15 weight percent of a flame retardant consisting of aluminum tris(diethyl phosphinate);
wherein the composition excludes any polymer other than the poly(arylene ether) and the polyamide;
wherein the composition excludes electrically conductive fillers;
wherein all weight percents are based on the total weight of the composition; and
wherein the composition exhibits
a flammability rating of V-0 measured according to the UL 94 Vertical Burning Test at a thickness of 2 millimeters,
a notched Izod impact strength of at least 50 Joules/meter measured at 23° C. according to ASTM D256, Method A, and
a tensile elongation at break of at least 3 percent, measured at 23° C. according to ASTM D638.
19. The composition of claim 18 , wherein the composition exhibits
a notched Izod impact strength of 50 to 65 Joules/meter measured at 23° C. according to ASTM D256, Method A, and
a tensile elongation at break of 3 to 10 percent, measured at 23° C. according to ASTM D638.
20. A composition comprising:
about 25 to about 40 weight percent of a poly(arylene ether) comprising 2,6-dimethyl-1,4-phenylene ether units or a combination of 2,6-dimethyl-1,4-phenylene ether units and 2,3,6-trimethyl-1,4-phenylene ether units;
about 40 to about 50 weight percent of a polyamide comprising nylon-6 and nylon-6,6;
about 0.5 to about 2 weight percent citric acid;
about 8 to about 12 weight percent glass fiber; and
about 9 to about 15 weight percent of a flame retardant consisting of aluminum tris(diethyl phosphinate);
wherein the composition excludes any polymer other than the poly(arylene ether) and the polyamide;
wherein the composition excludes electrically conductive fillers;
wherein all weight percents are based on the total weight of the composition; and
wherein the composition exhibits
a flammability rating of V-0 measured according to the UL 94 Vertical Burning Test at a thickness of 1.6 millimeters,
a notched Izod impact strength of at least 50 Joules/meter measured at 23° C. according to ASTM D256, Method A, and
a tensile elongation at break of at least 3 percent, measured at 23° C. according to ASTM D638.
21. The composition of claim 20 , wherein the composition exhibits
a notched Izod impact strength of 50 to 65 Joules/meter measured at 23° C. according to ASTM D256, Method A, and
a tensile elongation at break of 3 to 10 percent, measured at 23° C. according to ASTM D638.
22. A composition consisting of:
about 25 to about 40 weight percent of a poly(arylene ether) comprising 2,6-dimethyl-1,4-phenylene ether units or a combination of 2,6-dimethyl-1,4-phenylene ether units and 2,3,6-trimethyl-1,4-phenylene ether units;
about 40 to about 50 weight percent of a polyamide comprising nylon-6 and nylon-6,6;
about 0.5 to about 2 weight percent citric acid;
about 8 to about 12 weight percent glass fiber, wherein the glass fiber is not electrically conductive; and
about 9 to about 15 weight percent of a flame retardant consisting of aluminum tris(diethyl phosphinate); and
optionally, up to 5 weight percent of an additive selected from the group consisting of stabilizers, mold release agents, processing aids, drip retardants, nucleating agents, dyes, pigments, antioxidants, anti-static agents, blowing agents, metal deactivators, antiblocking agents, fragrances, and combinations thereof;
wherein the composition is free of impact modifier;
wherein all weight percents are based on the total weight of the composition; and
wherein the composition exhibits
a flammability rating of V-0 measured according to the UL 94 Vertical Burning Test at a thickness of 2 millimeters,
a notched Izod impact strength of at least 50 Joules/meter measured at 23° C. according to ASTM D256, Method A, and
a tensile elongation at break of at least 3 percent, measured at 23° C. according to ASTM D638.
23. The composition of claim 22 , wherein the composition exhibits
a notched Izod impact strength of 50 to 65 Joules/meter measured at 23° C. according to ASTM D256, Method A, and
a tensile elongation at break of 3 to 10 percent, measured at 23° C. according to ASTM D638.
24. A method of preparing a thermoplastic composition, comprising:
melt kneading
a poly(arylene ether),
a polyamide,
about 5 to about 15 weight percent glass fiber, and
a flame retardant consisting of a metal dialkyl phosphinate to form a thermoplastic composition;
wherein all weight percents are based on the total weight of the composition;
wherein the thermoplastic composition excludes any polymer other than the poly(arylene ether) and the polyamide;
wherein the composition excludes electrically conductive fillers; and
wherein the composition has
a flammability rating of V-0 or V-1 measured according to the UL 94 Vertical Burning Test at a thickness of 3 millimeters, and
a notched Izod impact strength of at least 40 Joules/meter measured at 23° C. according to ASTM D256, Method A.
25. The method of claim 24 , wherein the flame retardant and a portion of the polyamide are provided in the form of a masterbatch comprising about 30 to about 50 weight percent flame retardant and about 50 to about 70 weight percent polyamide, based on the weight of the masterbatch.
26. A thermoplastic composition prepared by the method of claim 24 .
27. A method of preparing a thermoplastic composition, comprising:
melt kneading
about 25 to about 40 weight percent of a poly(arylene ether) comprising 2,6-dimethyl-1,4-phenylene ether units or a combination of 2,6-dimethyl- 1,4-phenylene ether units and 2,3,6-trimethyl-1,4-phenylene ether units,
about 40 to about 50 weight percent of a polyamide comprising nylon-6 and nylon-6,6,
about 0.5 to about 2 weight percent citric acid,
about 8 to about 12 weight percent glass fiber, and
about 9 to about 15 weight percent of a flame retardant consisting of
aluminum tris(diethyl phosphinate) to form a thermoplastic composition;
wherein the thermoplastic composition excludes any polymer other than the poly(arylene ether) and the polyamide;
wherein the composition excludes electrically conductive fillers;
wherein all weight percents are based on the total weight of the thermoplastic composition; and
wherein the thermoplastic composition exhibits
a flammability rating of V-0 measured according to the UL 94 Vertical Burning Test at a thickness of 2 millimeters,
a notched Izod impact strength of at least 50 Joules/meter measured at 23° C. according to ASTM D256, Method A, and
a tensile elongation at break of at least 3 percent, measured at 23° C. according to ASTM D638.
28. The method of claim 27 , wherein the composition exhibits
a notched Izod impact strength of 50 to 65 Joules/meter measured at 23° C. according to ASTM D256, Method A, and
a tensile elongation at break of 3 to 10 percent, measured at 23° C. according to ASTM D638.
29. The method of claim 27 , wherein the flame retardant and a portion of the polyamide are provided in the form of a masterbatch comprising about 30 to about 50 weight percent flame retardant and about 50 to about 70 weight percent polyamide, based on the weight of the masterbatch.
30. A thermoplastic composition prepared by the method of claim 27 .
31. An article comprising a composition comprising:
a poly(arylene ether);
a polyamide;
about 5 to about 15 weight percent glass fiber; and
a flame retardant consisting of a metal dialkyl phosphinate;
wherein the composition excludes any polymer other than the poly(arylene ether) and the polyamide;
wherein the composition excludes electrically conductive fillers;
wherein all weight percents are based on the total weight of the composition; and
wherein the composition has
a flammability rating of V-0 or V-1 measured according to the UL 94 Vertical Burning Test at a thickness of 3 millimeters, and
a notched Izod impact strength of at least 40 Joules/meter measured at 23° C. according to ASTM D256, Method A.
32. An article comprising a composition comprising:
about 25 to about 40 weight percent of a poly(arylene ether) comprising 2,6-dimethyl-1,4-phenylene ether units or a combination of 2,6-dimethyl-1,4-phenylene ether units and 2,3,6-trimethyl-1,4-phenylene ether units;
about 40 to about 50 weight percent of a polyamide comprising nylon-6 and nylon-6,6;
about 0.5 to about 2 weight percent citric acid;
about 8 to about 12 weight percent glass fiber; and
about 9 to about 15 weight percent of a flame retardant consisting of aluminum tris(diethyl phosphinate);
wherein the composition excludes any polymer other than the poly(arylene ether) and the polyamide;
wherein the composition excludes electrically conductive fillers;
wherein all weight percents are based on the total weight of the composition; and
wherein the composition exhibits
a flammability rating of V-0 measured according to the UL 94 Vertical Burning Test at a thickness of 3 millimeters,
a notched Izod impact strength of at least 50 Joules/meter measured at 23° C. according to ASTM D256, Method A, and
a tensile elongation at break of at least 3 percent, measured at 23° C. according to ASTM D638.
33. An article comprising a composition comprising:
about 25 to about 40 weight percent of a poly(arylene ether) comprising 2,6-dimethyl-1,4-phenylene ether units or a combination of 2,6-dimethyl-1,4-phenylene ether units and 2,3,6-trimethyl-1,4-phenylene ether units;
about 40 to about 50 weight percent of a polyamide comprising nylon-6 and nylon-6,6;
about 0.5 to about 2 weight percent citric acid;
about 8 to about 12 weight percent glass fiber; and
about 9 to about 15 weight percent of a flame retardant consisting of aluminum tris(diethyl phosphinate);
wherein the composition excludes any polymer other than the poly(arylene ether) and the polyamide;
wherein the composition excludes electrically conductive fillers;
wherein all weight percents are based on the total weight of the composition; and
wherein the composition exhibits
a flammability rating of V-0 measured according to the UL 94 Vertical Burning Test at a thickness of 2 millimeters,
a notched Izod impact strength of at least 50 Joules/meter measured at 23° C. according to ASTM D256, Method A, and
a tensile elongation at break of at least 3 percent, measured at 23° C. according to ASTM D638.
34. An article comprising a composition comprising:
about 25 to about 40 weight percent of a poly(arylene ether) comprising 2,6-dimethyl-1,4-phenylene ether units or a combination of 2,6-dimethyl-1,4-phenylene ether units and 2,3,6-trimethyl-1,4-phenylene ether units;
about 40 to about 50 weight percent of a polyamide comprising nylon-6 and nylon-6,6;
about 0.5 to about 2 weight percent citric acid;
about 8 to about 12 weight percent glass fiber; and
about 9 to about 15 weight percent of a flame retardant consisting of aluminum tris(diethyl phosphinate);
wherein the composition excludes any polymer other than the poly(arylene ether) and the polyamide;
wherein the composition excludes electrically conductive fillers;
wherein all weight percents are based on the total weight of the composition; and
wherein the composition exhibits
a flammability rating of V-0 measured according to the UL 94 Vertical Burning Test at a thickness of 1.6 millimeters,
a notched Izod impact strength of at least 50 Joules/meter measured at 23° C. according to ASTM D256, Method A, and
a tensile elongation at break of at least 3 percent, measured at 23° C. according to ASTM D638.
35. An article comprising a composition consisting of:
about 25 to about 40 weight percent of a poly(arylene ether) comprising 2,6-dimethyl-1,4-phenylene ether units or a combination of 2,6-dimethyl-1,4-phenylene ether units and 2,3,6-trimethyl-1,4-phenylene ether units;
about 40 to about 50 weight percent of a polyamide comprising nylon-6 and nylon-6,6;
about 0.5 to about 2 weight percent citric acid;
about 8 to about 12 weight percent glass fiber, wherein the glass fiber is not electrically conductive; and
about 9 to about 15 weight percent of a flame retardant consisting of aluminum tris(diethyl phosphinate); and
optionally, up to 5 weight percent of an additive selected from the group consisting of stabilizers, mold release agents, processing aids, drip retardants, nucleating agents, dyes, pigments, antioxidants, anti-static agents, blowing agents, metal deactivators, antiblocking agents, fragrances, and combinations thereof;
wherein the composition is free of impact modifier;
wherein all weight percents are based on the total weight of the composition; and
wherein the composition exhibits
a flammability rating of V-0 measured according to the UL 94 Vertical Burning Test at a thickness of 2 millimeters,
a notched Izod impact strength of at least 50 Joules/meter measured at 23° C. according to ASTM D256, Method A, and
a tensile elongation at break of at least 3 percent, measured at 23° C. according to ASTM D638.
36. An article comprising the composition of claim 26 .
37. An article comprising the composition of claim 30 .