Polyamide composition, method, and article
View Patent ↗A method of forming a polyamide composition includes melt blending specific amounts of a poly(phenylene ether) masterbatch, a first polyamide, glass fibers, and a flame retardant that includes a metal dialkylphosphinate. The poly(phenylene ether) masterbatch is prepared by melt blending specific amounts of a poly(phenylene ether) and a second polyamide. The method provides a polyamide composition with a desirable balance of flame retardancy, melt flow, heat resistance, and mechanical properties, while reducing the amount of metal dialkylphosphinate required by corresponding compositions without the poly(phenylene ether) masterbatch. A corresponding polyamide composition is described, as are the poly(phenylene ether) masterbatch, and a method of reducing the metal dialkylphosphinate content of a flame retardant polyamide composition.
1. A method of forming a polyamide composition, the method comprising:
melt blending components comprising, based on the weight of the polyamide composition,
5 to 30 weight percent of a poly(phenylene ether) masterbatch,
35 to 70 weight percent of a first polyamide,
15 to 40 weight percent glass fibers, and
10 to 20 weight percent of a flame retardant comprising a metal dialkylphosphinate
to form the polyamide composition;
wherein the poly(phenylene ether) masterbatch is the product of melt blending components comprising, based on the weight of the poly(phenylene ether) masterbatch,
35 to 97 weight percent poly(phenylene ether), and
3 to 65 weight percent of a second polyamide.
2. The method of claim 1 , wherein the first polyamide and the second polyamide are independently selected from the group consisting of polyamide-6, polyamide-6,6, polyamide-4,6, polyamide-11, polyamide-12, polyamide-6,10, polyamide-6,12, polyamide 6/6,6, polyamide-6/6,12, polyamide MXD,6, polyamide-6,T, polyamide-6,I, polyamide-6/6,T, polyamide-6/6,I, polyamide-6,6/6,T, polyamide-6,6/6,I, polyamide-6/6,T/6,I, polyamide-6,6/6,T/6,I, polyamide-6/12/6,T, polyamide-6,6/12/6,T, polyamide-6/12/6,I, polyamide-6,6/12/6,I, and combinations thereof.
3. The method of claim 1 , wherein the first polyamide and the second polyamide are independently selected from the group consisting of polyamide-6, polyamide-6,6, and combinations thereof.
4. The method of claim 1 , wherein the first polyamide and the second polyamide comprise polyamide-6,6.
5. The method of claim 1 , wherein the polyamide composition comprises less than or equal to 52 weight percent of the first polyamide and the second polyamide combined.
6. The composition of claim 1 , wherein the poly(phenylene ether) comprises a homopolymer or copolymer of monomers selected from the group consisting of 2,6-dimethylphenol, 2,3,6-trimethylphenol, and combinations thereof.
7. The method of claim 1 , wherein the poly(phenylene ether) comprises a poly(phenylene ether)-polysiloxane block copolymer.
8. The method of claim 1 , wherein the polyamide composition comprises less than or equal to 19 weight percent poly(phenylene ether), based on the weight of the polyamide composition.
9. The method of claim 1 , wherein the polyamide composition comprises less than or equal to 13 weight percent poly(phenylene ether), based on the weight of the polyamide composition.
10. The method of claim 1 , wherein the flame retardant further comprises melamine polyphosphate.
11. The method of claim 1 , wherein the flame retardant further comprises zinc borate.
12. The method of claim 1 , wherein the flame retardant comprises, based on the weight of the polyamide composition, 6 to 13 weight percent of the metal dialkylphosphinate and further comprises 3 to 7 weight percent melamine polyphosphate, and 0.2 to 2 weight percent zinc borate.
13. The method of claim 1 , wherein the poly(phenylene ether) masterbatch further comprises, based on the weight of the poly(phenylene ether) masterbatch, 0.2 to 5 weight percent of a compatibilizing agent for the poly(phenylene ether) and the second polyamide.
14. The method of claim 1 , wherein the polyamide composition excludes electrically conductive fillers.
15. The method of claim 1 , wherein the polyamide composition excludes impact modifiers.
16. A method of forming a polyamide composition, the method comprising:
melt blending components comprising, based on the weight of the polyamide composition,
5 to 14 weight percent of a poly(phenylene ether) masterbatch,
45 to 55 weight percent of a first polyamide comprising polyamide-6,6,
20 to 30 weight percent glass fibers, and
12 to 18 weight percent of a flame retardant comprising a metal dialkylphosphinate, melamine polyphosphate, and zinc borate
to form the polyamide composition;
wherein the poly(phenylene ether) masterbatch is the product of melt blending components comprising, based on the weight of the poly(phenylene ether) masterbatch,
75 to 96.5 weight percent poly(phenylene ether) comprising a homopolymer or copolymer of monomers selected from the group consisting of 2,6-dimethylphenol, 2,3,6-trimethylphenol, and combinations thereof,
3 to 24.5 weight percent of a second polyamide comprising polyamide-6,6, and
0.5 to 4 weight percent of a compatibilizing agent for the poly(phenylene ether) and the second polyamide;
wherein the polyamide composition comprises less than or equal to 13 weight percent poly(phenylene ether), based on the total weight of the composition; and
wherein the polyamide composition excludes electrically conductive fillers and impact modifiers.
17. The method of claim 16 , wherein the poly(phenylene ether) further comprises a poly(phenylene ether)-polysiloxane block copolymer.
18. A polyamide composition prepared according to the method of claim 1 .
19. A polyamide composition, comprising the product of melt blending:
40 to 60 weight percent of a polyamide;
3 to 13 weight percent of a poly(phenylene ether);
12 to 18 weight percent of a flame retardant comprising a metal dialkylphosphinate, melamine polyphosphate, and zinc borate;
0.1 to 2 weight percent of a compatibilizing agent for the polyamide and the poly(phenylene ether); and
20 to 40 weight percent glass fibers;
wherein all weight percents are based on the total weight of the polyamide composition.
20. The polyamide composition of claim 19 ,
wherein the polyamide comprises polyamide-6,6;
wherein the polyamide composition comprises 45 to 55 weight percent of the polyamide;
wherein the poly(phenylene ether) comprises a homopolymer or copolymer of monomers selected from the group consisting of 2,6-dimethylphenol, 2,3,6-trimethylphenol, and combinations thereof;
wherein the polyamide composition comprises 6 to 12 weight percent of the poly(phenylene ether);
wherein the flame retardant comprises 6 to 13 weight percent of the metal dialkylphosphinate, 3 to 7 weight percent of the melamine polyphosphate, and 0.2 to 2 weight percent of the zinc borate; and
wherein the composition comprises 20 to 30 weight percent glass fibers.
21. The polyamide composition of claim 20 , wherein the poly(phenylene ether) further comprises a poly(phenylene ether)-polysiloxane block copolymer.
22. An article comprising a composition comprising the product of melt blending:
40 to 60 weight percent of a polyamide;
3 to 13 weight percent of a poly(phenylene ether);
12 to 18 weight percent of a flame retardant comprising a metal dialkylphosphinate, melamine polyphosphate, and zinc borate;
0.1 to 2 weight percent of a compatibilizing agent for the polyamide and the poly(phenylene ether); and
20 to 40 weight percent glass fibers;
wherein all weight percents are based on the total weight of the polyamide composition.
23. A method of reducing the metal dialkylphosphinate content of a flame retardant polyamide composition, comprising:
melt blending components comprising, based on the weight of the polyamide composition,
5 to 30 weight percent of a poly(phenylene ether) masterbatch,
35 to 70 weight percent of a first polyamide,
15 to 40 weight percent glass fibers, and
10 to 20 weight percent of a flame retardant comprising a metal dialkylphosphinate
to form the polyamide composition;
wherein the poly(phenylene ether) masterbatch is the product of melt blending components comprising, based on the weight of the poly(phenylene ether) masterbatch,
35 to 97 weight percent poly(phenylene ether), and
3 to 65 weight percent of a second polyamide.