Granted Patent B2

US 7,622,522 · App. 11/862,478 · Granted Nov 24, 2009

Abstract

Claims (136)

1. A thermoplastic composition, comprising:

20 to 44 weight percent of a poly(arylene ether);

29 to 57 weight percent of total polyolefin; wherein total polyolefin consists of polyolefins and the polyolefin content of block copolymers comprising a poly(alkenyl aromatic) block and a polyolefin block; and

10 to 25 weight percent of a flame retardant consisting of

1 to 10 weight percent of a metal dialkyl phosphinate;

1 to 17 weight percent of a nitrogen-containing flame retardant selected from the group consisting of melamine phosphate, melamine pyrophosphate, melamine polyphosphates, and mixtures thereof;

1 to 10 weight percent of a triaryl phosphate that is a liquid at one atmosphere and at least one temperature in the range 25 to 50° C.; and

optionally, 0.05 to 2.5 weight percent of zinc borate;

wherein all weight percents are based on the total weight of the thermoplastic composition;

wherein the poly(arylene ether) and total polyolefin are present in a weight ratio of 0.53:1 to 1.2:1; and

wherein a test sample coated wire exhibits

a tensile stress at break of at least 10 megapascals, measured at 23° C. according to UL 1581, Section 470,

a tensile elongation at break of at least 100 percent, measured at 23° C. according to UL 1581, Section 470, and

a passing flame test rating according to UL 1581, Section 1080,

wherein the test sample coated wire consists of an AWG 24 conductor having a nominal cross sectional area of 0.205 millimeter 2 , and a tubular covering comprising the thermoplastic composition and having a nominal outer diameter of 2 millimeters.

2. The thermoplastic composition of claim 1 , wherein the test sample coated wire exhibits

a tensile stress at break of 10 to 30 megapascals, measured at 23° C. according to UL1581, Section 470, and

a tensile elongation at break of 100 to 240 percent, measured at 23° C. according to UL1581, Section 470.

3. The thermoplastic composition of claim 1 , wherein the test sample coated wire further exhibits a triaryl phosphate migration rating of 0, 1, or 2, measured as described in the working examples.

4. The thermoplastic composition of claim 1 , wherein the test sample coated wire further exhibits a heat deformation of 5 to 40 percent, measured at 121° C. and a 250 gram load according to UL 1581.

5. The thermoplastic composition of claim 1 , wherein the liquid triaryl phosphate represents 10 to 70 percent of the total weight of the flame retardant composition.

6. The thermoplastic composition of claim 1 , wherein the nitrogen-containing flame retardant and the metal dialkyl phosphate are present in a weight ratio of 0.5 to 8.

7. The thermoplastic composition of claim 1 , wherein the flame retardant composition further comprises 0.05 to 2.5 weight percent zinc borate.

8. The thermoplastic composition of claim 1 , further comprising 8 to 20 weight percent of total poly(alkenyl aromatic); wherein total poly(alkenyl aromatic) consists of poly(alkenyl aromatic)s and the poly(alkenyl aromatic) content of block copolymers comprising a poly(alkenyl aromatic) block and a polyolefin block.

9. The thermoplastic composition of claim 1 ,

wherein the thermoplastic composition comprises 30 to 36 weight percent of the poly(arylene ether);

wherein the poly(arylene ether) is a poly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of 0.3 to 0.6 deciliter per gram measured in chloroform at 25° C.;

wherein the thermoplastic composition comprises 38 to 46 weight percent of total polyolefin weight percent of total polyolefin;

wherein the total polyolefin comprises polypropylene, ethylene-propylene copolymer, a poly(ethylene-co-propylene) block of a block copolymer comprising a polystyrene block and a poly(ethylene-co-propylene) block, and a poly(ethylene-co-butylene) block of a block copolymer comprising a polystyrene block and a poly(ethylene-co-butylene) block;

wherein the thermoplastic composition comprises 10 to 14 weight percent of the flame retardant composition consisting of

1 to 3 weight percent of aluminum tris(diethyl phosphinate),

1 to 3 weight percent of melamine polyphosphate, and

6 to 10 weight percent of bisphenol A bis(diphenyl phosphate);

wherein the poly(arylene ether) and total polyolefin are present in a weight ratio of 0.6 to 0.9; and

wherein the test sample coated wire exhibits

a tensile stress at break of 10 to 30 megapascals, measured at 23° C. according to UL1581, Section 470, and

a tensile elongation at break of 100 to 240 percent, measured at 23° C. according to UL1581, Section 470.

10. An extruded article, comprising:

the product of extrusion molding a composition comprising

20 to 44 weight percent of a poly(arylene ether);

29 to 57 weight percent of total polyolefin; wherein total polyolefin consists of polyolefins and the polyolefin content of block copolymers comprising a poly(alkenyl aromatic) block and a polyolefin block; and

10 to 25 weight percent of a flame retardant composition consisting of

1 to 10 weight percent of a metal dialkyl phosphinate;

1 to 17 weight percent of a nitrogen-containing flame retardant selected from the group consisting of melamine phosphate, melamine pyrophosphate, melamine polyphosphates, and mixtures thereof;

1 to 10 weight percent of a triaryl phosphate that is a liquid at one atmosphere and at least one temperature in the range 25 to 50° C.; and

optionally, 0.05 to 2.5 weight percent of zinc borate;

wherein all weight percents are based on the total weight of the thermoplastic composition;

wherein the poly(arylene ether) and total polyolefin are present in a weight ratio of 0.53:1 to 1.2:1; and

wherein a test sample coated wire exhibits

a tensile stress at break of at least 10 megapascals, measured at 23° C. according to UL 1581, Section 470,

a tensile elongation at break of at least 100 percent, measured at 23° C. according to UL 1581, Section 470, and

a passing flame test rating according to UL 1581, Section 1080,

wherein the test sample coated wire consists of an AWG 24 conductor having a nominal cross sectional area of 0.205 millimeter 2 , and a tubular covering comprising the thermoplastic composition and having a nominal outer diameter of 2 millimeters.

11. The extruded article of claim 10 , wherein the test sample coated wire exhibits

a tensile stress at break of 10 to 30 megapascals, measured at 23° C. according to UL1581, Section 470, and

a tensile elongation at break of 100 to 240 percent, measured at 23° C. according to UL1581, Section 470.

12. The extruded article of claim 10 ,

wherein the thermoplastic composition comprises 30 to 36 weight percent of the poly(arylene ether);

wherein the poly(arylene ether) is a poly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of 0.3 to 0.6 deciliter per gram measured in chloroform at 25° C.;

wherein the thermoplastic composition comprises 38 to 46 weight percent of total polyolefin weight percent of total polyolefin;

wherein the total polyolefin comprises polypropylene, ethylene-propylene copolymer, a poly(ethylene-co-propylene) block of a block copolymer comprising a polystyrene block and a poly(ethylene-co-propylene) block, and a poly(ethylene-co-butylene) block of a block copolymer comprising a polystyrene block and a poly(ethylene-co-butylene) block;

wherein the thermoplastic composition comprises 10 to 14 weight percent of the flame retardant composition consisting of

1 to 3 weight percent of aluminum tris(diethyl phosphinate),

1 to 3 weight percent of melamine polyphosphate, and

6 to 10 weight percent of bisphenol A bis(diphenyl phosphate);

wherein the poly(arylene ether) and total polyolefin are present in a weight ratio of 0.6 to 0.9; and

wherein the test sample coated wire exhibits

a tensile stress at break of 10 to 30 megapascals, measured at 23° C. according to UL1581, Section 470, and

a tensile elongation at break of 100 to 240 percent, measured at 23° C. according to UL1581, Section 470.

13. A coated wire, comprising:

a conductor, and

a covering disposed on the conductor;

wherein the covering comprises a composition comprising

20 to 44 weight percent of a poly(arylene ether);

29 to 57 weight percent of total polyolefin; wherein total polyolefin consists of polyolefins and the polyolefin content of block copolymers comprising a poly(alkenyl aromatic) block and a polyolefin block; and

10 to 25 weight percent of a flame retardant composition consisting of

1 to 10 weight percent of a metal dialkyl phosphinate;

1 to 17 weight percent of a nitrogen-containing flame retardant selected from the group consisting of melamine phosphate, melamine pyrophosphate, melamine polyphosphates, and mixtures thereof;

1 to 10 weight percent of a triaryl phosphate that is a liquid at one atmosphere and at least one temperature in the range 25 to 50° C.; and

optionally, 0.05 to 2.5 weight percent of zinc borate;

wherein all weight percents are based on the total weight of the thermoplastic composition;

wherein the poly(arylene ether) and total polyolefin are present in a weight ratio of 0.53:1 to 1.2:1; and

wherein a test sample coated wire exhibits

a tensile stress at break of at least 10 megapascals, measured at 23° C. according to UL1581, Section 470,

a tensile elongation at break of at least 100 percent, measured at 23° C. according to UL1581, Section 470, and

a passing flame test rating according to UL 1581, Section 1080,

wherein the test sample coated wire consists of an AWG 24 conductor having a nominal cross sectional area of 0.205 millimeter 2 , and a tubular covering comprising the thermoplastic composition and having a nominal outer diameter of 2 millimeters.

14. The coated wire of claim 13 , wherein the test sample coated wire exhibits

a tensile stress at break of 10 to 30 megapascals, measured at 23° C. according to UL1581, Section 470, and

a tensile elongation at break of 100 to 240 percent, measured at 23° C. according to UL1581, Section 470.

15. The coated wire of claim 13 , wherein the test sample coated wire further exhibits a triaryl phosphate migration rating of 0, 1, or 2, measured as described in the working examples.

16. The coated wire of claim 13 ,

wherein the thermoplastic composition comprises 30 to 36 weight percent of the poly(arylene ether);

wherein the poly(arylene ether) is a poly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of 0.3 to 0.6 deciliter per gram measured in chloroform at 25° C.;

wherein the thermoplastic composition comprises 38 to 46 weight percent of total polyolefin weight percent of total polyolefin;

wherein the total polyolefin comprises polypropylene, ethylene-propylene copolymer, and a poly(ethylene-co-butylene) block of a block copolymer comprising a polystyrene block and a poly(ethylene-co-butylene) block;

wherein the thermoplastic composition comprises 10 to 14 weight percent of the flame retardant composition consisting of

1 to 3 weight percent of aluminum tris(diethyl phosphinate),

1 to 3 weight percent of melamine polyphosphate, and

6 to 10 weight percent of bisphenol A bis(diphenyl phosphate);

wherein the poly(arylene ether) and total polyolefin are present in a weight ratio of 0.6 to 0.9; and

wherein the test sample coated wire exhibits

a tensile stress at break of 10 to 30 megapascals, measured at 23° C. according to UL1581, Section 470,

a tensile elongation at break of 100 to 240 percent, measured at 23° C. according to UL1581, Section 470, and

a passing flame test rating according to UL 1581, Section 1080.

17. A thermoplastic composition, comprising:

20 to 44 weight percent of a poly(arylene ether);

29 to 57 weight percent of total polyolefin; wherein total polyolefin consists of polyolefins and the polyolefin content of block copolymers comprising a poly(alkenyl aromatic) block and a polyolefin block; and

10 to 25 weight percent of a flame retardant composition consisting of

1 to 10 weight percent of a metal dialkyl phosphinate;

1 to 17 weight percent of a nitrogen-containing flame retardant selected from the group consisting of melamine phosphate, melamine pyrophosphate, melamine polyphosphates, and mixtures thereof;

1 to 10 weight percent of a triaryl phosphate that is a liquid at one atmosphere and at least one temperature in the range 25 to 50° C.; and

optionally, 0.05 to 2.5 weight percent of zinc borate

wherein all weight percents are based on the total weight of the thermoplastic composition;

wherein the poly(arylene ether) and total polyolefin are present in a weight ratio of 0.53:1 to 1.2:1; and

wherein the thermoplastic composition exhibits

a UL 94 Vertical Burning Flame Test rating of V-0 or V-1 at a sample thickness less than or equal to 6.4 millimeters,

a tensile stress at break of at least 5 megapascals, measured at 23° C. according to ASTM D638, and

a flexural modulus of 10 to 1,000 megapascals, measured at 23° C. according to ASTM D790.

18. The thermoplastic composition of claim 17 ,

wherein the UL 94 Vertical Burning Flame Test is conducted at a sample thickness of 3.0 to 6.4 millimeters, and

wherein the tensile stress at break is 5 to 21 megapascals.

19. The thermoplastic composition of claim 17 ,

wherein the thermoplastic composition comprises 30 to 36 weight percent of the poly(arylene ether);

wherein the poly(arylene ether) is a poly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of 0.3 to 0.6 deciliter per gram measured in chloroform at 25° C.;

wherein the thermoplastic composition comprises 38 to 46 weight percent of total polyolefin weight percent of total polyolefin;

wherein the total polyolefin comprises polypropylene, ethylene-propylene copolymer, and a poly(ethylene-co-butylene) block of a block copolymer comprising a polystyrene block and a poly(ethylene-co-butylene) block;

wherein the thermoplastic composition comprises 10 to 14 weight percent of the flame retardant composition consisting of

1 to 3 weight percent of aluminum tris(diethyl phosphinate),

1 to 3 weight percent of melamine polyphosphate, and

6 to 10 weight percent of bisphenol A bis(diphenyl phosphate);

wherein the poly(arylene ether) and total polyolefin are present in a weight ratio of 0.6 to 0.9; and

wherein the thermoplastic composition exhibits

a UL 94 Vertical Burning Flame Test rating of V-0 or V-1 at a sample thickness of 6.4 millimeters,

a tensile stress at break of 12 to 21 megapascals, measured at 23° C. according to ASTM D638, and

a flexural modulus of 50 to 310 megapascals, measured at 23° C. according to ASTM D790.

Assignments (8)