NON-HALOGENATED FLAME RETARDANT AND REINFORCED POLY(ALKYLENE TEREPHTHALATE) POLY(PHENYLENE ETHER) COMPOSITIONS METHODS OF MANUFACTURE AND USES THEREOF

1 . A reinforced flame retardant composition comprising:

30-80 wt % of a polymer component comprising

25-65 wt % of a poly(alkylene terephthalate);

5-25 wt % of a poly(phenylene ether); and

optionally, 5-35 wt % of a polyamide;

5-30 wt % of a reinforcing mineral filler;

5-35 wt % of glass fibers;

4-25 wt % of a flame retardant component comprising

a metal di(C 1-6 alkyl)phosphinate; and

an auxiliary flame retardant comprising a phosphate, a phosphite, a phosphonate, a phosphinate different from the metal di(C 1-6 alkyl)phosphinate, a phosphine oxide, a phosphine, a phosphazene, melamine polyphosphate, melamine cyanurate, melamine pyrophosphate, melamine phosphate, a metal hydroxide, a metal borate, a metal oxide, a metal oxide hydroxide, or a combination thereof,

0.01-2 wt % of a compatibilizing agent;

5-15 wt % of an impact modifier;

optionally, 0.1-10 wt % of an additive composition;

each based on the total weight of the composition,

wherein a molded sample of the composition has a UL94 rating of V0 at a thickness of 1.5 millimeter, a UL94 rating of V0 at a thickness of 1.0 millimeter, a UL94 rating of V0 at a thickness of 0.8 millimeter, a UL94 rating of V0 at a thickness of 0.4 millimeter, or a combination thereof; and

wherein the composition exhibits:

a comparative tracking index of 250-399 volts,

a mean time of arc resistance of at least 120 seconds as determined according to ASTM D495,

or a combination thereof.

2 . The reinforced flame retardant composition of claim 1 , wherein the composition exhibits:

a high voltage tracking resistance of 0-10 millimeters per minute determined according to UL 746.

3 . The reinforced flame retardant composition of claim 1 , wherein the poly(alkylene terephthalate) comprises a poly((C 1-8 alkylene) terephthalate).

4 . The reinforced flame retardant composition of claim 1 , wherein the polyamide is present and comprises nylon-6, nylon-6,6, nylon-4, nylon-4,6, nylon-12, nylon-6,10, nylon-6,9, nylon-6,12, nylon-9T, nylon-6,6 nylon-6, or a combination thereof.

5 . The reinforced flame retardant composition of claim 1 , wherein the poly(phenylene ether) is poly(2,6-dimethyl-1,4-phenylene ether).

6 . The reinforced flame retardant composition of claim 1 , wherein the reinforcing mineral filler comprises talc and the polyamide is present and comprises nylon-6, nylon-6,6, or a combination thereof.

7 . The reinforced flame retardant composition of claim 1 , wherein the metal di(C 1-6 alkyl)phosphinate comprises a metal di(C 1-3 alkyl)phosphinate.

8 . The reinforced flame retardant composition of claim 1 , wherein flame retardant component comprises 4-24 wt % of the metal di(C 1-6 alkyl)phosphinate and 1-21 wt % of the auxiliary flame retardant comprising melamine polyphosphate, melamine cyanurate, melamine pyrophosphate, melamine phosphate a metal hydroxide, a metal borate, a metal oxide, a metal oxide hydroxide, or a combination thereof.

9 . The reinforced flame retardant composition of claim 1 , wherein the additive composition is present and comprises a flow modifier, an antioxidant, a heat stabilizer, a light stabilizer, an ultraviolet light stabilizer, an ultraviolet absorbing additive, a plasticizer, a lubricant, a release agent, an antistatic agent, an anti-fog agent, an antimicrobial agent, a colorant, a surface effect additive, a radiation stabilizer, a flame retardant different from the metal di(C 1-6 alkyl)phosphinate and the auxiliary flame retardant, an anti-drip agent, or a combination thereof.

10 . The reinforced flame retardant composition of claim 1 , wherein the impact modifier comprises styrene-butadiene-styrene, styrene-butadiene rubber, styrene-ethylene-butadiene-styrene, acrylonitrile-butadiene-styrene, acrylonitrile-ethylene-propylene-diene-styrene, styrene-isoprene-styrene, methyl methacrylate-butadiene-styrene, styrene-acrylonitrile, or a combination thereof.

11 . The reinforced flame retardant composition of claim 1 , comprising:

35-65 wt % of the polymer component comprising

5-15 wt % of the poly(2,6-dimethyl-1,4-phenylene) ether; and

30-50 wt % of the poly(butylene terephthalate);

optionally, 5-20 wt % of polyamide;

5-15 wt % talc;

5-15 wt % glass fibers; and

5-23 wt % of the flame retardant component comprising

4-15 wt % of aluminum diethylphosphinate; and

1-8 wt % of melamine polyphosphate;

0.1-1.5 wt % of a compatibilizing agent comprising fumaric acid, maleic acid, maleic anhydride, citric acid, or a combination thereof;

6-8 wt % of styrene-ethylene-butadiene-styrene as the impact modifier; and

0.1-5 wt % of the additive composition,

wherein each is based on the total weight of the composition.

12 . A method for the manufacture of the reinforced flame retardant composition of claim 1 , the method comprising melt blending the components of the composition.

13 . An article comprising the reinforced flame retardant composition of claim 1 .

14 . The article of claim 13 , wherein the article is an injection molded article.

15 . The reinforced flame retardant composition of claim 1 , wherein the reinforcing mineral filler is talc and the auxiliary flame retardant comprises melamine polyphosphate.

16 . The reinforced flame retardant composition of claim 1 , wherein the composition exhibits a comparative tracking index of 600 volts or greater as determined in accordance with UL 746A.

17 . The reinforced flame retardant composition of claim 3 , wherein the poly((C 1-8 alkylene) terephthalate) is a poly(ethylene terephthalate), a poly(butylene terephthalate), or a combination thereof.

18 . The reinforced flame retardant composition of claim 17 , wherein the poly((C 1-8 alkylene) terephthalate) is poly(butylene terephthalate)

19 . The article of claim 13 , wherein the article is an electrical component.

20 . The article of claim 13 , wherein the article is a molded circuit breaker housing.