Polyester compositions, method of manufacture, and uses thereof
View Patent ↗A composition is described, comprising: (a) from 20 to 80 wt % of a polyester; (b) from 5 to 35 wt % of a flame retardant phosphinate of the formula (I) [(R 1 )(R 2 )(PO)—O] − m M m+ (I), a flame retardant diphosphinate of the formula (II) [(O—POR 1 )(R 3 )(POR 2 —O)] 2− n M x m+ (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), wherein R 1 and R 2 are identical or different and are H, C 1 -C 6 -alkyl, linear or branched, or C 6 -C 10 -aryl; R 3 is C 1 -C 10 -alkylene, linear or branched, C 6 -C 10 -arylene, -alkylarylene or -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; (c) from 1 to 25 wt % of a melamine polyphosphate, melamine cyanurate, melamine pyrophosphate, and/or melamine phosphate; (d) from more than 0 to 25 wt % of a polyetherimide; and (e) optionally, an additive.
1. A composition comprising:
(a) from 20 to 80 wt % of a polyester;
(b) from 5 to 35 wt % of
a flame retardant phosphinate of the formula (I)
[(R 1 )(R 2 )(PO)—O] − m M m+ (I)
a flame retardant diphosphinate of the formula (II)
[(O—POR 1 )(R 3 )(POR 2 —O)] 2− n M x m+ (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),
wherein R 1 and R 2 are identical or different and are H, C1-C6-alkyl, linear or branched, and/or aryl; R 3 is C1-C10, alkylene, linear or branched, C6-C10-arylene, -alkylarylene or -arylalkylene; M is an alkaline earth metal, alkali metal, Al, Ti, Zn, Fe, boron; m is 1, 2, 3 or 4; n is 1, 2, or 3; and x is 1 or 2;
(c) from 1 to 25 wt % of a melamine polyphosphate, melamine cyanurate, melamine pyrophosphate, and/or melamine phosphate; and
(d) from about 2 to about 8 wt % of a polyetherimide;
(e) a quencher component selected from the group consisting of from 0.1 to 1 wt % of poly(methyl hydrogensiloxane), from 0.1 to 1 wt % 3-aminopropyl trialkoxysilane, and mixtures of ZnS and ZnO, wherein the ZnO is present in an amount of less than 50 wt % of the mixture, and combinations thereof;
wherein an article molded or extruded from the composition has a heat deflection temperature that is equal to or greater than 190° C. and an unnotched Izod impact strength from to 25 to 50 kJ/m 2 measured at 23° C. in accordance with ISO 180, and a 0.8 mm thick molded sample comprising the composition has a UL-94 flammability rating of V0;
wherein components (a), (b), (c), (d), (e) and optionally an additive component have a combined total weight of 100 wt %.
2. The composition of claim 1 , wherein the polyester is selected from the group consisting of poly(ethylene terephthalate), poly(1,4-butylene terephthalate), poly(ethylene naphthalate), poly(1,4-butylene naphthalate), (polytrimethylene terephthalate), poly(1,4-cyclohexylenedimethylene 1,4-cyclohexanedicarboxylate), poly(1,4-cyclohexylenedimethylene terephthalate), poly(1,4-butylene-co-1,4-but-2-ene diol terephthalate), poly(cyclohexylenedimethylene-co-ethylene terephthalate), and a combination thereof.
3. The composition of claim 2 , wherein the polyester is poly(1,4-butylene terephthalate).
4. The composition of claim 3 , wherein the poly(1,4-butylene terephthalate) has a weight average molecular weight of 45,000 a.m.u, or greater, as determined by gel permeation chromatography with a polystyrene standard.
5. The composition of claim 3 , wherein the composition further comprises more than 0 to 35 wt % of a polyester that is different from the poly(1,4-butylene terephthalate).
6. The composition of claim 1 , wherein M is selected from the group consisting of magnesium, calcium, aluminum, zinc, and a combination thereof.
7. The composition of claim 6 , wherein M is aluminum.
8. The composition of claim 6 , wherein the flame retardant phosphinate of the formula (I) or of the formula (II) is comprises an aluminum phosphinate.
9. The composition of claim 1 , wherein polyetherimide is an aromatic polyetherimide.
10. The composition of claim 1 , wherein reinforcing filler is present in the composition in an amount from greater than 0 to 50 wt % of the reinforcing filler.
11. The composition of claim 10 , wherein the reinforcing filler is present in the composition in an amount from 10 to 30 wt % of the reinforcing filler.
12. The composition of claim 10 , wherein the reinforcing filler is present in the composition in an amount from 30 to 50 wt % of the reinforcing filler.
13. The composition of claim 10 , wherein the reinforcing filler is selected from the group consisting of particulate fillers, glass fibers, and a combination thereof.
14. The composition of claim 11 , wherein the reinforcing filler is selected from the group consisting of particulate fillers, glass fibers, and a combination thereof.
15. The composition of claim 1 , wherein the additive component is selected from the group consisting of an antioxidant, a lubricant, a thermal stabilizer, an ultraviolet light absorbing additive, a plasticizer, an anti-dripping agent, a mold release agent, an antistatic agent, a dye, a pigment, a laser marking additive, a radiation stabilizer, and a combination thereof.
16. A method of forming an article, comprising shaping, extruding, calendaring, or molding the composition of claim 1 to form the article.
17. A composition consisting essentially of, based on the total weight of the composition:
from 40 to 65 wt % of a poly(1,4-butylene terephthalate) having a weight average molecular weight of 45,000 a.m.u, or greater, as determined by gel permeation chromatography with a polystyrene standard;
from 7 to 20 wt % of
a flame retardant phosphinate of the formula (Ia)
[(R 1 )(R 2 )(PO)—O] 3 − Al 3+ (Ia),
a flame retardant diphosphinate of the formula (IIa)
[(O—POR 1 )(R 3 )(POR 2 —O)] 3 2− Al 2 3+ (IIa), and/or
a flame retardant polymer comprising formula (Ia) or (IIa),
wherein R 1 and R 2 are identical or different and are H, C1-C6-alkyl, linear or branched, and/or aryl; R 3 is C1-C10, alkylene, linear or branched, C6-C10-arylene, -alkylarylene or -arylalkylene;
from 2 to 8 wt % of melamine polyphosphate and/or melamine cyanurate;
from about 5 to about 7.5 wt % of an aromatic polyetherimide; and
from 20 to 35 wt % of a reinforcing filler.
18. The composition of claim 17 , further comprising a quencher component selected from the group consisting of poly(methyl hydrogensiloxane), 3-aminopropyl trialkoxysilane, mixtures of ZnS and ZnO, and combinations thereof in an odor-inhibiting amount that is sufficient to form a composition having a heat deflection temperature that is equal to or greater than 190° C. and an unnotched Izod impact strength from 25 to 50 kJ/m 2 , measured at 23° C. in accordance with ISO 180, and a 0.8 mm thick molded sample comprising the composition has a UL-94 flammability rating of V0.
19. The composition of claim 18 , wherein the poly(methyl hydrogensiloxane) and/or the 3-aminopropyl trialkoxysilane are present in an amount from 0.1 to 1 wt % of the total composition.
20. The composition of claim 17 , further comprising a chlorinated and/or brominated organic compound that is present in the composition in an amount from more than 0 to less than 5 wt % of the chlorinated and/or brominated organic compound.
21. The composition of claim 20 , wherein the chlorinated and/or brominated organic compound is present in the composition in an amount from 0 to less than 3 wt % of the chlorinated and/or brominated organic compound.
22. The composition of claim 20 , wherein the chlorinated and/or brominated organic compound is present in the composition in an amount of less than 2000 ppm of the chlorinated and/or brominated organic compound.
23. The composition of claim 17 , wherein a molded article comprising the composition has a tensile strength at yield from to 90 to 120 MPa, measured in accordance with ISO 527.
24. The composition of claim 17 , wherein a molded article comprising the composition has an unnotched Izod impact strength from to 20 to 50 kJ/m 2 , measured at 23° C. in accordance with ISO 180.
25. The composition of claim 17 , wherein a molded article comprising the composition has a heat deflection temperature of from 175 to 225° C., measured in accordance with ISO 75 at 1.8 MPa.
26. The composition of claim 17 , wherein a 0.8 mm thick molded sample comprising the composition has a UL-94 flammability rating of V0.
27. The composition of claim 17 , wherein a 0.4 mm thick molded sample comprising the composition has a UL-94 flammability rating of V0.
28. The composition of claim 17 , wherein a molded article comprising the composition has a tensile modulus of elasticity from 8.0 to 10.0 GPa, measured in accordance with ISO 527.
29. The composition of claim 17 , wherein a molded article comprising the composition has an elongation at break from 1 to 3%, measured in accordance with ISO 527.
30. The composition of claim 17 , wherein a molded article comprising the composition has a tensile strength at yield from to 90 to 120 MPa, measured in accordance with ISO 527.
31. The composition of claim 17 , wherein the composition maintains at least 80% of its initial weight average molecular weight after molding at 265° C., 275° C., or 285° C.
32. The composition of claim 17 , wherein composition has a polydispersity index after molding at 265° C., 275° C., or 285° C. that is from 80% to 120% of the polydispersity index of the composition prior to molding.
33. The composition of claim 17 , wherein a molded article comprising the composition has an unnotched Izod impact strength of equal to 20 to 50 kJ/m 2 , measured at 23° C. in accordance with ISO 180 and a heat deflection temperature from 175 to 225° C., measured in accordance with ISO 75 at 1.8 MPa; and wherein a 0.8 mm thick molded sample comprising the composition has a UL-94 flammability rating of V0.
34. The composition of claim 17 , further comprising a mixture of zinc sulfide and zinc oxide in sufficient amounts to produce a composition having a light grey appearance or a white appearance.
35. The composition of claim 34 , wherein the zinc sulfide is present in an amount from 3 to 14 wt %, based on the total weight of the composition.
36. The composition of claim 34 , wherein the zinc oxide is present in an amount from 0.05 to 14 wt %, based on the total weight of the composition.
37. A method for the manufacture of a composition, comprising blending the components of the composition of claim 17 .
38. The method of claim 37 , wherein the method further comprises adding a mixture of zinc sulfide and zinc oxide in sufficient amounts (i) to produce a composition having a light grey or white appearance and (ii) to inhibit formation of hydrogen sulfide.
39. The method of claim 38 , wherein the zinc sulfide is present in an amount from 3 to 14 wt %, based on the total weight of the composition.
40. The method of claim 38 , wherein the zinc oxide is present in an amount from 0.05 to 14 wt %, based on the total weight of the composition.
41. An article comprising the composition of claim 17 .
42. The article of claim 41 , wherein the article is an injection molded article.
43. The composition of claim 20 , wherein the chlorinated and/or brominated organic compound is present in an amount of less than 500 ppm of the chlorinated and/or brominated organic compound.
44. The composition of claim 20 , wherein the chlorinated and/or brominated organic compound is present in an amount of less than 100 ppm of the chlorinated and/or brominated organic compound.
45. A composition consisting essentially of, based on the total weight of the composition:
(a) from 40 to 65 wt % of a poly(1,4-butylene terephthalate) having a weight average molecular weight of 45,000 a.m.u, or greater, as determined by gel permeation chromatography with a polystyrene standard;
(b) from 7 to 20 wt % of
a flame retardant phosphinate of the formula (Ia)
[(R 1 )(R 2 )(PO)—O] − m M m+ (I)
a flame retardant diphosphinate of the formula (II)
[(O—POR 1 )(R 3 )(POR 2 —O)] 2− n M x m+ (II),
and/or
[(R 1 )(R 2 )(PO)—O] 3 − Al 3+ (Ia),
a flame retardant diphosphinate of the formula (IIa)
[(O—POR 1 )(R 3 )(POR 2 —O)] 3 2− Al 2 3+ (IIa),
and/or
a flame retardant polymer comprising formula (Ia) or (IIa),
wherein R 1 and R 2 are identical or different and are H, C1-C6-alkyl, linear or branched, and/or aryl; R 3 is C1-C10, alkylene, linear or branched, C6-C10-arylene, -alkylarylene or -arylalkylene; M is an alkaline earth metal, alkali metal, Al, Ti, Zn, Fe, boron; m is 1, 2, 3 or 4; n is 1, 2, or 3; and x is 1 or 2;
(c) from 2 to 8 wt % of melamine polyphosphate and/or melamine cyanurate;
(d) from about 5 to about 7.5 wt % of an aromatic polyetherimide; and
(e) from 20 to 35 wt % of a reinforcing filler;
(f) from 0 to 3 wt % of a chlorinated and/or brominated organic compound; and
wherein components (a), (b), (c), (d), (e), (f), and optionally an additive component have a combined total weight of 100 wt %; and
wherein a molded sample comprising the composition has a tensile strength at yield from 90 to 120 MPa measured in accordance with ISO 527, and an unnotched Izod impact strength from to 25 to 50 kJ/m 2 measured at 23° C. in accordance with ISO 180, and a 0.8 mm thick molded sample comprising the composition has a UL-94 flammability rating of V0.