Reinforced polyester compositions, methods of manufacture, and articles thereof

1. A composition comprising, based on the total weight of the composition:

from 20 to 90 wt. % of a polyester component comprising a poly(alkylene terephthalate);

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 m+ x   (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; and R 3 is C 1 -C 10 , alkylene, linear or branched, C 6 -C 10 arylene, C 7 -C 11 alkylarylene, or C 7 -C 11 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;

from 1 to 25 wt. % of a melamine polyphosphate, melamine cyanurate, melamine pyrophosphate, and/or melamine phosphate;

from 0 to 30 weight percent of other polymers, based on the total weight of polymers in the composition;

from greater than zero to 50 wt. % of a glass fiber having a non-circular cross-section; and

from 0 to 5 wt. % of an additive selected from the group consisting of a mold release agent, an antioxidant, a nucleating agent, a thermal stabilizer, an anti-drip agent, a flow-promoting additive, a chain extender, a platy filler, and a UV stabilizer;

wherein the components have a combined total weight of 100 wt. %;

wherein a molded article comprising the composition has a comparative tracking index that is more than 350 volts in accordance with ASTM D3638-85, UL746A, or IEC-112, 3 rd publication and a notched impact strength of 60 to 75 J/m, measured at 23° C. in accordance with ASTM D256.

2. The composition of claim 1 , further comprising a charring polymer in an amount from 0.1 to 15 percent by weight of the composition, which charring polymer has no more than 85% weight loss at 400° C. to 500° C. upon heating under nitrogen using a thermogravimetric analysis at a heating rate of 20° C. per minute, wherein the charring polymer is polyetherimide, poly(phenylene ether), poly(phenylenesulfide), polysulphone, polyethersulphone, poly(phenylenesulphide oxide), polyphenolic or a combination comprising one of the foregoing charring polymers.

3. The composition of claim 1 , wherein a molded article comprising the composition has a comparative tracking index ranging from 350 volts to 600 volts in accordance with ASTM D3638-85, UL746A, or IEC-112 3 rd publication.

4. The composition of claim 1 , wherein the composition contains more than 0 and less than 2 weight % halogen, based on the total weight of the composition.

5. The composition of claim 1 , wherein the composition contains less than 900 ppm of a halogen selected from the group consisting of bromine, chlorine, and combinations thereof.

6. The composition of claim 1 , wherein a molded article comprising the composition has an unnotched Izod impact strength of from 400 to 600 J/m, measured at 23° C. in accordance with ASTM D256.

7. The composition of claim 6 , wherein a molded article comprising the composition has a notched Izod impact strength of from to 60 to 75 J/m, measured at 23° C. in accordance with ASTM D256.

8. The composition of claim 1 , wherein a molded article comprising the composition has a notched Izod impact strength at least 20% higher than the same composition having the same amount of circular glass fibers, each measured at 23° C. in accordance with ASTM D256.

9. The composition of claim 6 , wherein a molded article comprising the composition has a notched Izod impact strength at least 20% higher than the same composition having the same amount of circular glass fibers, each measured at 23° C. in accordance with ASTM D256.

10. The composition of claim 1 , wherein a molded article comprising the composition has a tensile modulus of elasticity from 2000 MPa to 15000 MPa, measured in accordance with ASTM 790.

11. The composition of claim 1 , wherein a molded article comprising the composition has a tensile stress at break from 80 to 150 MPa, measured in accordance with ASTM 790.

12. The composition of claim 1 , wherein a molded article comprising the composition has a tensile stress at break at least 10% higher than the same composition having the same amount of circular glass fibers, each measured in accordance with ASTM 790.

13. The composition of claim 1 , wherein a molded article comprising the composition has a flexural modulus of 3000 to 20,000 MPa, measured in accordance with ASTM 790.

14. The composition of claim 1 , wherein a molded article comprising the composition has a heat deflection temperature of from 200 to 225 ° C., measured in accordance with ASTM D 648 at 1.82 MPa.

15. The composition of claim 1 , wherein a 0.8 mm thick molded sample comprising the composition has a UL-94 flammability rating of V0.

16. The composition of claim 1 , wherein a 0.4 mm thick molded sample comprising the composition has a UL-94 flammability rating of V0.

17. The composition of claim 1 , wherein the polyester component further comprises a polyester 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-cyclohexanedimethylene 1,4-cyclohexanedicarboxylate), poly(1,4-cyclohexanedimethylene terephthalate), poly(1,4-butylene-co-1,4-but-2-ene diol terephthalate), poly(cyclohexanedimethylene-co-ethylene terephthalate), and a combination thereof.

18. The composition of claim 1 , wherein the polyester component comprises poly(1,4-butylene terephthalate).

19. The composition of claim 1 , wherein the glass fiber has a trapezoidal cross section.

20. The composition of claim 1 , wherein the glass fiber has a rectangular cross-section.

21. The composition of claim 1 , wherein the glass fiber has a square cross-section.

22. The composition of claim 1 , wherein the glass fiber has an average aspect ratio of 2 to 5.

23. The composition of claim 1 , wherein the glass fibers have an average length of 0.1 mm to 10 mm.

24. The composition of claim 1 , wherein M is selected from the group consisting of magnesium, calcium, aluminum, zinc, and a combination thereof.

25. The composition of claim 1 , wherein M is aluminum.

26. The composition of claim 1 , wherein the flame retardant phosphinate of the formula (I) or of the formula (II) comprises an aluminum phosphinate.

27. The composition of claim 1 , wherein the composition comprises no polyetherimide.

28. The composition of claim 1 , wherein the composition comprises more than 0 to less than 10 wt % of a polyetherimide, based on the total weight of the composition.

29. The composition of claim 1 , wherein the antidripping agent comprises poly(tetrafluoro ethylene) encapsulated by a styrene-acrylonitrile copolymer.

30. The composition of claim 1 , wherein the composition further comprises an additive selected from the group consisting of a lubricant, a quencher, a plasticizer, an antistatic agent, a dye, a pigment, a laser marking additive, a radiation stabilizer, and a combination thereof.

31. The composition of claim 1 , wherein the composition comprises from more than 0 to less than 5 wt. % of a chlorinated organic compound and/or a brominated organic compound.

32. A composition consisting essentially of, based on the total weight of the composition:

from 20 to 90 wt. % of a polyester component comprising a poly(butylene terephthalate);

from 5 to 35 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)] 2− 3 Al 3+ 2   (IIa), and/or

a flame retardant polymer derived from formula (Ia) or (IIa),

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; and R 3 is C1-C 10 , alkylene, linear or branched, C 6 -C 10 arylene, C 7 -C 11 alkylarylene, or C 7 -C 11 arylalkylene;

from 1 to 25 wt. % of melamine polyphosphate and/or melamine cyanurate;

from 0 to 30 weight percent of other polymers, based on the total weight of polymers in the composition but wherein the composition comprises no charring polymer;

from 10 to 40 wt. % of a glass fiber having a flat cross-section; and

from 0 to 5 wt. % of an additive selected from the group consisting of a mold release agent, an antioxidant, a thermal stabilizer, an antioxidant, and a UV stabilizer;

wherein the composition contains less than 900 ppm of a halogen selected from the group consisting of bromine, chlorine, and combinations thereof;

wherein the components and have a combined total weight of 100 wt. %, and

wherein a molded sample comprising the composition has a comparative tracking index ranging from 350 volts to 600 volts in accordance with ASTM D3638-85, UL746A, or IEC-112 3 rd publication a notched impact strength of 60 to 75 J/m measured at 23° C. in accordance with ASTM D256, and a 0.8 mm thick molded sample comprising the composition has a UL-94 flammability rating of V0.

33. A composition comprising no charring polymer and consisting essentially of, based on the total weight of the composition:

from 20 to 90 wt. % of a polyester component comprising a poly(butylene terephthalate);

from 5_to 25 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)] 2-31 3 Al 3+ 2   (IIa), and/or

a flame retardant polymer derived from formula (Ia) or (IIa),

wherein R 1 and R 2 are both hydrogen;

from 1 to 15 wt. % of melamine polyphosphate and/or melamine cyanurate;

from 10 to 40 wt. % of a glass fiber having a flat cross-section, an average length of from 0.1 mm to 10 mm, and an average aspect ratio of 2 to 5;

from 0 to 5 wt. % of an additive selected from the group consisting of a mold release agent, an antioxidant, a thermal stabilizer, an antioxidant, and a UV stabilizer; and

less than 900 ppm of a halogen selected from the group consisting of bromine, chlorine, and combinations thereof;

wherein the components have a combined total weight of 100 wt. %; and wherein a molded sample comprising the composition has a comparative tracking index ranging from 575 volts to 600 volts in accordance with ASTM D3638-85, UL746A, or IEC-112 3 rd publication, a notched impact strength of 60 to 75 J/m, measured at 23° C. in accordance with ASTM D256, and a 0.8 mm thick molded sample comprising the composition has a UL-94 flammability rating of V0.

34. A method for the manufacture of a composition, comprising blending the components of the composition of claim 1 .

35. An article comprising the composition of claim 1 .

36. A method of forming an article, comprising shaping by extruding, calendaring, or molding the composition of claim 1 to form the article.

37. The article of claim 35 , wherein the article is an injection molded article.