Low toxicity poly(etherimide-siloxane)-aromatic polyketone compositions, method of manufacture, and articles made therefrom

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

25 to less than 95 weight percent poly(etherimide-siloxane) copolymer having a siloxane content of more than 0 to less than 50 weight percent based on the total weight of the poly(etherimide-siloxane) copolymer;

5-75 weight percent of an aromatic polyketone; and

greater than 0 to 15 weight percent of a mineral filler comprising kaolin clay, talc, or a combination comprising at least one of the foregoing, wherein the mineral filler has a particle diameter of 0.1 to 2 micrometers;

wherein the thermoplastic composition has a lower toxicity index than the same thermoplastic composition not including the aromatic ketone, the mineral filler, or both, as determined in accordance with EN 53505, or a lower HCN/benzene ratio than the same thermoplastic composition not including the aromatic polyketone, the mineral filler, or both.

2. A thermoplastic composition comprising, based on the total weight of the composition,

25 to less than 100 weight percent of a poly(etherimide-siloxane) copolymer having a siloxane content of more than 0 to less than 50 weight percent based on the total weight of the poly(etherimide-siloxane) copolymer; and

greater than 0 to 15 weight percent of a mineral filler comprising kaolin clay, talc, or a combination comprising at least one of the foregoing, wherein the mineral filler has a particle diameter of 0.1 to 2 micrometers;

wherein the thermoplastic composition has a lower toxicity index than the same thermoplastic composition not including the mineral filler, as determined in accordance with EN 53505, or a lower HCN/benzene ratio than the same thermoplastic composition not including the mineral filler.

3. The thermoplastic composition of claim 1 , wherein the thermoplastic composition has one or more of the following properties:

a flexural modulus of 150 to 3000 MPa, determined according to ASTM D790;

a flexural strength of greater than 50 MPa, determined according to ASTM D790;

a Shore D hardness of greater than 75, determined according to ASTM D1238;

a tensile modulus of greater than 2500 MPa, determined according to ASTM D638;

a tensile strength of greater than 20 MPa, determined according to ASTM D638;

a tensile elongation of greater than 10%, determined according to ASTM D638 at 23° C.;

a melt flow rate of 5 to 150 g/10 minutes, determined according to ASTM D1238; or

a tear strength of greater than 20 N/mm, determined according to ISO 34-1.

4. The thermoplastic composition of claim 1 , wherein the aromatic polyketone comprises polyetherketone, polyetheretherketone, polyetherketoneketone, polyaryletherketone, or a combination comprising at least one of the foregoing.

5. The thermoplastic composition of claim 1 , wherein the thermoplastic composition comprises 45 to 60 weight percent of a polyetheretherketone.

6. The thermoplastic composition of claim 1 , wherein the thermoplastic composition comprises 4 to 10 weight percent kaolin clay.

7. The thermoplastic composition of claim 1 , wherein the thermoplastic composition has an ITC toxicity value of less than or equal to 15, as determined according to EN50305 test methods.

8. The thermoplastic composition of claim 1 , wherein the composition has a siloxane content of 1 to 25 percent by weight, based on the combined weight of the polymer components.

9. An electrical wire comprising a conductor wire and a covering disposed over the conductor wire, wherein

the covering comprises the thermoplastic composition of claim 1 ; and

the thermoplastic composition coating the conductor wire has one or more of the following properties:

a tensile stress of greater than 30 MPa, determined according to UL-1581 after 24 hours at 23° C.; and

a tensile elongation of greater than 100%, determined according to UL-1581 after 24 hours at 23° C.

10. The electrical wire of claim 9 , wherein the thermoplastic composition coating the conductor wire has one or more of the following properties:

a tensile stress of greater than 30 MPa, determined according to UL-1581 after heat aging for 168 hours at 158° C.;

a tensile elongation of greater than 100%, determined according to UL-1581 after heat aging for 168 hours at 158° C.;

a tensile stress of greater than 30 MPa, determined according to UL-1581 after heat aging for 168 hours at 180° C.; or

a tensile elongation of greater than 100%, determined according to UL-1581 after heat aging for 168 hours at 180° C.; and

wherein the electrical wire achieves a pass rating in the single wire vertical flame propagation test conducted according to EN50265-2-1/IEC60332-1.

11. The electrical wire of claim 9 wherein the thermoplastic composition has a tear strength of greater than 20 N/mm, determined according to ISO 34-1 in the presence of the conductor wire.

12. The electrical wire of claim 9 , wherein the electrical wire achieves a pass rating in the single wire burn test conducted according to UL-1581.

13. The electrical wire of claim 9 , wherein the electrical wire can have an ITC toxicity value of less than 15, measured according to EN50305.

14. The electrical wire of claim 9 , wherein the conductor wire comprises copper, aluminum, lead, gold, silver, iron, nickel, chromium, or an alloy comprising at least one of the foregoing.

15. The electrical wire of claim 9 , wherein the wire has a thickness of 0.1 to 1 millimeter.

16. An article comprising the electrical wire of claim 9 .

17. The article of claim 16 , wherein the article is a construction component, a building component, an electrical device component, a railway vehicle component, an automobile component, a bus component, a marine vehicle component, or an aircraft component.

18. An article comprising the thermoplastic composition of claim 1 .

19. The thermoplastic composition of claim 2 , wherein the thermoplastic composition comprises 4 to 10 weight percent kaolin clay.