Electrical tracking resistance compositions, articles formed therefrom, and methods of manufacture thereof

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

50 wt % to 70 wt % of a polyetherimide; and

30 wt % to 50 wt % of a filler comprising talc having a D95 of 2 to 6 micrometers determined by Sedigraph analysis;

wherein the degradation temperature difference between the polyetherimide and the composition is less than 10° C.; and

wherein the composition has a number of drops to tracking at 250 volts of greater than or equal to 50 drops determined according to ASTM D-3638-85.

2. The composition of claim 1 , wherein the composition has a tensile strength greater than or equal to 30 MPa determined according to ASTM D638 and a tensile modulus greater than equal to 4,000 GPa determined according to ASTM D638.

3. The composition of claim 1 , wherein the polyetherimide comprises units of the formula

wherein

R is the same or different, and is a substituted or unsubstituted divalent organic group,

T is —O— or a group of the formula —O—Z—O— wherein the divalent bonds of the —O— or the —O—Z—O— group are in the 3,3′, 3,4′, 4,3′, or the 4,4′ positions; and wherein Z is an aromatic C 6-24 monocyclic or polycyclic moiety optionally substituted with 1 to 6 C 1-8 alkyl groups, 1 to 8 halogen atoms, or a combination thereof, provided that the valence of Z is not exceeded.

4. The composition of claim 3 , wherein

R is a divalent group of the formula

or a combination comprising at least one of the foregoing, wherein Q 1 is —O—, —S—, —C(O)—, —SO 2 —, —SO—, —C y H 2y — wherein y is an integer from 1 to 5 or a halogenated derivative thereof, or —(C 6 H 10 ) z — wherein z is an integer from 1 to 4, and

Z is a divalent group of the formula

wherein Q is —O—, —S—, —C(O)—, —SO 2 —, —SO—, or —C y H 2y — wherein y is an integer from 1 to 5 or a halogenated derivative thereof.

5. The composition of claim 3 , wherein

at least 50 mole percent (mol %) of the R groups are bis(3,4′-phenylene)sulfone, bis(3,3′-phenylene)sulfone, or a combination comprising at least one of the foregoing and the remaining R groups are p-phenylene, m-phenylene or a combination comprising at least one of the foregoing; and Z is 2,2-(4-phenylene)isopropylidene.

6. The composition of claim 1 , comprising, based on the total weight of the composition,

50 wt % to 65 wt % of the polyetherimide; and

35 wt % to 50 wt % of the talc, the talc having a D95 of 3.5 micrometers determined by Sedigraph analysis;

wherein the composition has:

a tensile strength greater than or equal to 50 MPa determined according to ASTM D638; and

a tensile modulus of greater than or equal to 10,000 GPa determined according to ASTM method D638.

7. The composition of claim 1 , wherein the talc has

a D95 of 2.9 micrometers determined by Sedigraph analysis;

wherein the composition has:

a tensile strength greater than or equal to 50 MPa determined according to ASTM D638; and

a tensile modulus of greater than or equal to 10,000 GPa determined according to ASTM method D638.

8. The composition of claim 1 , comprising, based on the total weight of the composition,

50 wt % to 60 wt % of the polyetherimide; and

40 wt % to 50 wt % of the talc, the talc having a D95 of 5.7 micrometers determined by Sedigraph analysis;

wherein the composition has:

a tensile strength greater than or equal to 50 MPa determined according to ASTM D638;

a tensile modulus of greater than or equal to 10,000 GPa determined according to ASTM method D638, and

a heat deflection temperature of greater than or equal to 200° C. measured on 3.2 millimeter injection molded bar at 1.82 MPa stress according to ASTM D648.

9. The composition of claim 1 , comprising, based on the total weight of the composition,

50 wt % to 65 wt % of the polyetherimide, which is a polyetherimide sulfone; and

35 wt % to 50 wt % of the talc;

wherein the composition has:

a tensile strength greater than or equal to 40 MPa determined according to ASTM D638; and

a tensile modulus of greater than or equal to 11,000 GPa determined according to ASTM method D638,

wherein the polyetherimide sulfone comprises units of the formula

wherein

R is a divalent group of the formula

wherein Q 1 is —SO 2 —, and

T is —O— or a group of the formula —O—Z—O— wherein the divalent bonds of the —O— or the —O—Z—O— group are in the 3,3′, 3,4′, 4,3′, or the 4,4′ positions; and wherein Z is an aromatic C 6-24 monocyclic or polycyclic moiety optionally substituted with 1 to 6 C 1-8 alkyl groups, 1 to 8 halogen atoms, or a combination thereof, provided that the valence of Z is not exceeded.

10. The composition of claim 1 , further comprising an additive selected from a processing aid, a heat stabilizer, an ultraviolet light absorber, a colorant, a flame retardant, or a combination comprising at least one of the foregoing.

11. The composition of claim 10 , comprising, based on the total weight of the composition, from 0.0001 to 20 wt % of each additive present in the composition.

12. An insulating material comprising the composition of claim 1 .

13. An article made from the composition of claim 1 , wherein the article is selected from a molded article, a thermoformed article, an extruded film, an extruded sheet, one or more layers of a multi-layer article, a substrate for a coated article, and a substrate for a metallized article.

14. An article made from the composition of claim 1 , wherein the article is a solar apparatus, an electrical junction box, an electrical connector, an electrical vehicle charger, an outdoor electrical enclosure, a smart meter enclosure, a smart grid power node, a photovoltaic frame or a miniature circuit breaker.

15. A method of manufacture of an article, comprising molding, extruding, or casting the composition of claim 1 to form the article.

16. A method of controlling the tracking of an electrical current of an article of manufacture, the method comprising: providing a composition of claim 1 , and processing the composition to form an article of manufacture.

17. The method of claim 16 , wherein the article is a solar apparatus, an electrical junction box, an electrical connector, an electrical vehicle charger, an outdoor electrical enclosure, a smart meter enclosure, a smart grid power node, a photovoltaic frame or a miniature circuit breaker.

18. The composition of claim 1 , wherein the filler further comprises titanium dioxide, zirconium oxide, neutral aluminum oxide, or a combination comprising at least one of the foregoing.