Polyimide polyphenylsulfone blends with improved flame resistance
View Patent ↗The present disclosure relates to a composition with improved flame resistance, to articles made from the composition, and to methods that include processing the composition. The composition can include from 15 to 85 percent by weight of a polyetherimide (PEI), from 15 to 85 percent by weight of a polyphenylsulfone (PPSU), a polyetherimide-siloxane copolymer in an amount up to 12 percent by weight, and from 0 to 0.30 percent by weight of a stabilizer.
1. A composition having a time to peak heat release of more than 150 seconds, as measured by FAR 25.853 (OSU test); a peak heat release less than or equal to 35 kW/m2 as measured by FAR 25.853 (OSU test); an NBS (National Bureau of Standards) optical smoke density with flame of less than 5 when measured at four (4) minutes, based on ASTM E-662 (FAR/JAR 25.853); and a toxic gas release of less than or equal to 100 ppm based on Draeger Tube Toxicity test (Airbus ABD0031, Boeing BSS 7239); the composition comprising:
(a) from 15 to 85 percent by weight of a polyetherimide (PEI),
(b) from 15 to 85 percent by weight of a polyphenylsulfone (PPSU),
(c) a silicone copolymer is present in an amount up to 12 percent by weight, and
(d) from 0 to 0.30 percent by weight of a stabilizer,
wherein an article made from the composition exhibits the following properties:
(1) a time to peak heat release of more than 150 seconds, as measured by FAR 25.853 (OSU test);
(2) a peak heat release less than or equal to 35 kW/m 2 as measured by FAR 25.853 (OSU test);
(3) an NBS (National Bureau of Standards) optical smoke density with flame of less than 5 when measured at four minutes, based on ASTM E-662 (FAR/JAR 25.853); and
(4) a toxic gas release of less than or equal to 100 ppm based on Draeger Tube Toxicity test (Airbus ABD0031, Boeing BSS 7239).
2. The composition of claim 1 , wherein component (a) has less than 20 ppm hydroxyl (—OH) end-groups.
3. The composition of claim 1 , wherein component (a) has a weight average molecular weight (Mw) of 20,000 to 80,000 daltons.
4. The composition of claim 1 , wherein component (a) has a halogen content of less than 1000 ppm, and wherein component (a) has less than 100 ppm benzylic protons.
5. The composition of claim 1 , wherein component (a) has less than or equal to 500 ppm of bis-imide compounds selected from the group consisting of: meta-phenylene diamine bis-phthalimide, meta-phenylene diamine bis-chloro phthalimides, para-phenylene diamine bis-phthalimide, para-phenylene bis-chloro phthalimides, and combinations thereof.
6. The composition of claim 1 , wherein component (b) is a copolymer comprising:
from 50 to 99.9 percent by weight of a polyphenylsulfone (PPSU), and
from 0.1% to 50 percent by weight of a polysulfone (PSU).
7. The composition of claim 1 , wherein component (b) is a copolymer comprising:
80 percent by weight of a polyphenylsulfone (PPSU), and
20 percent by weight of a polysulfone (PSU).
8. The composition of claim 7 , wherein component (b) has a glass transition temperature (Tg) greater than 200 degrees Celsius.
9. The composition of claim 7 , wherein component (b) has a weight average molecular weight (Mw) of 20,000 to 80,000.
10. The composition of claim 1 , wherein component (b) has hydroxyl (—OH) end-groups less than 50 ppm.
11. The composition of claim 1 , wherein component (b) has low oligomer cyclics (n=2,3,4) of less than 5 percent.
12. The composition of claim 1 wherein the silicone copolymer is selected from the group consisting of: resorcinol-based aryl polyester carbonate siloxanes, polyimide siloxanes, polyetherimide siloxanes, polyetherimide sulfone siloxanes, polycarbonate siloxanes, polyestercarbonate siloxanes, polysulfone siloxanes, polyether sulfone siloxanes, polyphenylene ether sulfone siloxanes and mixtures thereof.
13. The composition of claim 1 , wherein component (c) is a polyetherimide-siloxane random copolymer with from 10 to 50 percent by weight siloxane.
14. The composition of claim 1 , wherein component (c) is a polyetherimide-siloxane random copolymer with 10 to 35 percent by weight siloxane.
15. The composition of claim 1 , wherein component (c) is a polyetherimide-siloxane block copolymer with 15 to 30 percent dimethyl siloxane with a block length from 10 to 40 dimethyl siloxane units.
16. The composition of claim 1 , wherein the composition comprises from 1 to 8 percent by weight of component (c).
17. The composition of claim 1 , wherein the composition comprises 4 percent by weight of component (c).
18. The composition of claim 1 , wherein component (d) is present in an amount of from 0.05 to 0.30 percent by weight.
19. The composition of claim 1 , wherein component (d) is a tri-aryl phosphite.
20. The composition of claim 1 , wherein the toxic gas is selected from the group of HCN, CO, NO, NO 2 , SO 2 , H 2 S, HF, HCl, and combinations thereof.
21. The composition of claim 1 , having a melt stability viscosity ratio at 340 degrees Celsius and 10 secs −1 of less than 1, wherein the melt stability viscosity ratio is measured by parallel plate rheometry, and wherein the melt stability viscosity ratio is the ratio of the melt viscosity after 30 minutes at a temperature to the melt viscosity after 10 minutes at the temperature.
22. The composition of claim 1 , wherein the composition is melt processable, such that the composition can be processed by a method selected from the group consisting of injection molding, blow molding, compression molding, profile extrusion, sheet or film extrusion, gas assist molding, structural foam molding, thermoforming, and combinations thereof.
23. The composition of claim 1 , wherein the composition demonstrates shear thinning behavior with a ratio of viscosity at 100 sec −1 and 5,000 sec −1 of less than 10 at 340 degrees Celsius as measured by capillary rheometry.
24. The composition of claim 1 , comprising less than 1500 ppm halogen based on the total weight of components (a) and (b).
25. The composition of claim 1 , comprising less than 100 ppm alkali metals based on the total weight of components (a) and (b).
26. A method comprising melt processing a composition according to claim 1 .
27. The method according to claim 26 , wherein the process further comprises forming a shaped product comprising the composition.
28. The method according to claim 26 , wherein the process comprises one selected from the group consisting of injection molding, blow molding, compression molding, profile extrusion, sheet or film extrusion, gas assist molding, structural foam molding, thermoforming, and combinations thereof.
29. An article comprising the composition of claim 1 .
30. The article of claim 29 , wherein the article is a shaped article.
31. The article of claim 29 , wherein the article is a molded article.
32. The article of claim 29 , wherein the article is at least one selected from the group consisting of: cookware, food service items, medical devices, trays, plates, handles, helmets, animal cages, electrical connectors, enclosures for electrical equipment, engine parts, automotive engine parts, lighting sockets, lighting reflectors, electric motor parts, power distribution equipment, communication equipment, computers, devices having molded snap fit connectors, sheets, films, multilayer sheets, multilayer films, molded parts, extruded profiles, coated parts, fibers, foams, windows, luggage racks, wall panels, chair parts, lighting panels, diffusers, shades, partitions, lenses, skylights, lighting devices, reflectors, ductwork, cable trays, conduits, pipes, cable ties, wire coatings, electrical connectors, air handling devices, ventilators, louvers, insulation, bins, storage containers, doors, hinges, handles, sinks, mirror housing, mirrors, toilet seats, hangers, coat hooks, shelving, ladders, hand rails, steps, carts, trays, cookware, food service equipment, communications equipment, and instrument panels.
33. The article of claim 29 , wherein the article is a component of a conveyance selected from the group consisting of aircraft, trains, buses, ships, and automobiles.
34. The article of claim 29 , having a percent transmittance of greater than 50 percent.
35. The article of claim 29 , having a percent haze below 25 percent.
36. A composition comprising:
(a) from 15 to 85 percent by weight of a polyetherimide (PEI),
(b) from 15 to 85 percent by weight of a polyphenylsulfone (PPSU),
(c) a polyetherimide-siloxane copolymer in an amount from 1 percent by weight to 12 percent by weight, and
(d) from 0 to 0.30 percent by weight of a stabilizer,
wherein an article made from the composition exhibits the following properties:
(1) a time to peak heat release of more than 150 seconds, as measured by FAR 25.853 (OSU test),
(2) a peak heat release less than or equal to 35 kW/m 2 as measured by FAR 25.853 (OSU test),
(3) an NBS (National Bureau of Standards) optical smoke density with flame of less than 5 when measured at four minutes, based on ASTM E-662 (FAR/JAR 25.853), and
(4) a toxic gas release of less than or equal to 100 ppm based on Draeger Tube Toxicity test (Airbus ABD0031, Boeing BSS 7239).
37. A composition comprising:
(a) from 15 to 85 percent by weight of a polyetherimide (PEI), the polyetherimide having less than or equal to 500 ppm of bis-imide compounds selected from the group consisting of: meta-phenylene diamine bis-phthalimide, meta-phenylene diamine bis-chloro phthalimides, para-phenylene diamine bis-phthalimide, para-phenylene bis-chloro phthalimides, and combinations thereof;
(b) from 15 to 85 percent by weight of a polyphenylsulfone (PPSU),
(c) a polyetherimide-siloxane copolymer is present in an amount up to 12 percent by weight, the siloxane copolymer being selected from the group consisting of resorcinol-based aryl polyester carbonate siloxanes, polyimide siloxanes, polyetherimide siloxanes, polyetherimide sulfone siloxanes, polysulfone siloxanes, polyether sulfone siloxanes, polyphenylene ether sulfone siloxanes, polyphenylene ether siloxanes, and combinations thereof; and
(d) from 0 to 0.30 percent by weight of a stabilizer,
wherein an article made from the composition exhibits the following properties:
(1) a time to peak heat release of more than 150 seconds, as measured by FAR 25.853 (OSU test);
(2) a peak heat release less than or equal to 35 kW/m 2 as measured by FAR 25.853 (OSU test);
(3) an NBS (National Bureau of Standards) optical smoke density with flame of less than 5 when measured at four minutes, based on ASTM E-662 (FAR/JAR 25.853); and
(4) a toxic gas release of less than or equal to 100 ppm based on Draeger Tube Toxicity test (Airbus ABD0031, Boeing BSS 7239), the toxic gas being selected from the group of HCN, CO, NO, NO 2 , SO 2 , H 2 S, HF, HCl, and combinations thereof.