Thermoplastic composition, method of making the same, and article comprising the same

Abstract

A thermoplastic composition includes specific amounts of a poly (phenylene ether), an impact modifier (including a hydrogenated block copolymer of an alkenyl arene and a conjugated diene), an organophosphate flame retardant, a flame retardant synergist (including phosphazene), and optionally, tricalcium phosphate. The thermoplastic composition can be used to make various articles, particularly suitable for thin wall applications.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority and the benefit of European Patent Application No. 22216850.2, filed on December 28, 2022, the content of which is incorporated herein by reference in its entirety.

[0003] Background

[0004] Poly(aryl ethers) are commercially attractive materials because they have a unique combination of multiple properties (such as high temperature resistance, dimensional and hydrolysis stability, and electrical properties).

[0005] There is a continuing need in the art for a low flammability poly(aryl ether) composition, particularly suitable for thin wall applications. It would be even more advantageous if the composition also exhibits high heat resistance, high impact strength, and hydrolysis resistance in addition to low flammability.

[0006] Summary

[0007] One aspect herein is a thermoplastic composition comprising: 72 to 85 wt% of poly(phenylene ether); 1 to 15 wt% of an impact modifier comprising a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene; 5 to 20 wt% of an organophosphate flame retardant; 0.1 to 5 wt% of a flame retardant synergist comprising phosphazene; optionally, 0.8 to 8 wt% of tricalcium phosphate; and less than 5 wt% of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein the wt% is based on the total weight of the composition.

[0008] Another aspect herein is a method of preparing the composition, the method comprising melt-mixing the components of the composition.

[0009] Another aspect herein is an article comprising the composition.

[0010] On the other hand, the present invention relates to an electric vehicle battery component, which is extruded from a composition comprising: 70 to 85% by weight of poly(phenylene ether); 1 to 15% by weight of an impact modifier, a hydrogenated block copolymer comprising a vinyl aromatic hydrocarbon and a conjugated diene; 5 to 20% by weight of an organophosphate flame retardant; 0.1 to 5% by weight of a flame retardant synergist containing phosphazene; optionally, 0.8 to 8% by weight of tricalcium phosphate; and less than 5% by weight of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein the percentages by weight are based on the total weight of the composition; preferably, the electric vehicle battery component is an electric vehicle battery insulating sheet or film.

[0011] The above and other features are illustrated by the following detailed description.

[0012] Detailed Description

[0013] The inventors have unexpectedly found that a specific thermoplastic composition can provide an ideal combination of properties. More specifically, a composition comprising a specific amount of poly(phenylene ether), an impact modifier (a hydrogenated block copolymer comprising a vinyl aromatic hydrocarbon and a conjugated diene), an organophosphate flame retardant, a flame retardant synergist, and optionally tricalcium phosphate can provide an ideal combination of low flammability, high heat resistance, high impact strength, and hydrolysis resistance.

[0014] Accordingly, one aspect of the present invention is a thermoplastic composition. The thermoplastic composition comprises poly(phenylene ether). As used herein, poly(phenylene ether) comprises repeating structural units of formula (1)

[0015]

[0016] wherein, Z 1 is independently, each occurrence, a halogen, an unsubstituted or substituted C 1-12 hydrocarbyl group, provided that the hydrocarbyl group is not a tertiary hydrocarbyl group, C 1-12 hydrocarbylthio group, C 1-12 hydrocarbyloxy group or C 2-12 halohydrocarbyloxy group (wherein there are at least two carbon atoms separating the halogen atom from the oxygen atom); Z 2 is independently, each occurrence, hydrogen, a halogen, an unsubstituted or substituted C 1-12 -hydrocarbyl group, provided that the hydrocarbyl group is not a tertiary hydrocarbyl group, C 1-12 hydrocarbylthio group, C 1-12 hydrocarbyloxy group or C 2-12Halogenated hydrocarbyloxy groups (in which there are at least two carbon atoms separating the halogen atom from the oxygen atom). As used herein, the term "hydrocarbyl", whether used alone or as a prefix, suffix, or fragment of another term, refers to a residue containing only carbon and hydrogen. The residue can be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated, or unsaturated. It can also contain combinations of aliphatic, aromatic, straight-chain, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbyl moieties. However, when a hydrocarbyl residue is described as substituted, it can optionally contain heteroatoms in addition to the carbon and hydrogen members of the substituent residue. Thus, when specifically described as substituted, a hydrocarbyl residue can also contain one or more carbonyl groups, amino groups, hydroxyl groups, etc., or it can contain heteroatoms within the backbone of the hydrocarbyl residue. For example, Z 1 can be di-n-butylaminomethyl, formed by the reaction of the terminal 3,5-dimethyl-1,4-phenylene with the di-n-butylamine component of an oxidative polymerization catalyst.

[0017] In one aspect, the poly(phenylene ether) block contains 2,6-dimethyl-1,4-phenylene ether repeating units, i.e., repeating units according to formula (2)

[0018]

[0019] 2,3,6-trimethyl-1,4-phenylene ether repeating units, or combinations thereof.

[0020] The poly(phenylene ether) can contain molecules having aminoalkyl-containing end groups, which are typically located ortho to the hydroxyl groups. In addition, tetramethylbiphenoquinone (TMDQ) end groups are also often present, typically obtained from reaction mixtures containing 2,6-dimethylphenol, which have tetramethylbiphenoquinone by-products. The poly(phenylene ether) can be a homopolymer, copolymer, graft copolymer, ionomer, or block copolymer, and combinations thereof.

[0021] In one aspect, the intrinsic viscosity of the poly(phenylene ether) can be from 0.03 to 2 deciliters per gram (dl / g). For example, the intrinsic viscosity of the poly(phenylene ether) measured with an Ubbelohde viscometer in chloroform at 25 °C can be greater than 0.25 dl / g, or from 0.25 to 1.7 dl / g, particularly from 0.25 to 0.7 dl / g, more particularly from 0.35 to 0.55 dl / g, even more particularly from 0.35 to 0.50 dl / g, or from 0.4 to 0.6 dl / g.

[0022] The poly(phenylene ether) can be prepared by oxidative polymerization. In this method, the poly(phenylene ether) is the product of the oxidative polymerization of a monomer mixture containing monohydroxyphenols, which can be as described above.

[0023] The content of poly(phenylene ether) in the thermoplastic composition can be 72 to 85% by weight, based on the total weight of the composition. Within this range, the content of poly(phenylene ether) can be 73 to 85% by weight, or 72 to 80% by weight, or 73 to 80% by weight, or 74 to 85% by weight, or 74 to 80% by weight, each based on the total weight of the said composition.

[0024] In addition to poly(phenylene ether), the thermoplastic composition further comprises an impact modifier, which comprises a hydrogenated block copolymer of vinyl aromatic hydrocarbon and conjugated diene. For simplicity, this component is referred to as "hydrogenated block copolymer". The hydrogenated block copolymer can comprise 10 to 90% by weight of poly(vinyl aromatic hydrocarbon) and 90 to 10% by weight of hydrogenated poly(conjugated diene) based on its weight. In one aspect, the hydrogenated block copolymer is a hydrogenated block copolymer with a low content of poly(vinyl aromatic hydrocarbon), wherein the content of poly(vinyl aromatic hydrocarbon) is 10 to less than 40% by weight, or 20 to 35% by weight, or 25 to 35% by weight, or 30 to 35% by weight, all based on the weight of the hydrogenated block copolymer with a low content of poly(vinyl aromatic hydrocarbon). In one aspect, the hydrogenated block copolymer is a hydrogenated block copolymer with a high content of poly(vinyl aromatic hydrocarbon), wherein the content of poly(vinyl aromatic hydrocarbon) is 40 to 90% by weight, or 50 to 80% by weight, or 60 to 70% by weight, all based on the weight of the hydrogenated block copolymer with a high content of poly(vinyl aromatic hydrocarbon).

[0025] In one aspect, the weight-average molecular weight of the said hydrogenated block copolymer is 40,000 to 400,000 g / mol. The number-average molecular weight and the weight-average molecular weight can be determined by gel permeation chromatography and based on comparison with polystyrene standards. In one aspect, the weight-average molecular weight of the hydrogenated block copolymer is 200,000 to 400,000 g / mol, or 220,000 to 350,000 g / mol. In one aspect, the weight-average molecular weight of the hydrogenated block copolymer is 40,000 to 200,000 g / mol, or 40,000 to 180,000 g / mol, or 40,000 to 150,000 g / mol.

[0026] The vinyl aromatic hydrocarbon monomer used to prepare the hydrogenated block copolymer can have the structure of formula (6)

[0027]

[0028] wherein, R 5 and R 6 each independently represents a hydrogen atom, a C 1-8 alkyl group or a C 2-8 alkenyl group; R 7 and R 11 each independently represents a hydrogen atom, a C 1-8 alkyl group, a chlorine atom or a bromine atom; R8 , R 9 and R 10 each independently represents a hydrogen atom, C 1-8 alkyl or C 2-8 alkenyl, or R 8 and R 10 together with the central aromatic ring form a naphthyl group, or R 9 and R 10 together with the central aromatic ring form a naphthyl group. Specific alkenyl aromatic monomers include, for example, styrene, chlorostyrene (such as p-chlorostyrene), methylstyrene (such as α-methylstyrene and p-methylstyrene), and tert-butylstyrene (such as 3-tert-butylstyrene and 4-tert-butylstyrene). In one aspect, the alkenyl aromatic monomer is styrene.

[0029] The conjugated diene used to prepare the hydrogenated block copolymer can be C 4-20 conjugated diene. Suitable conjugated dienes include, for example, 1,3-butadiene, 2-methyl-1,3-butadiene, 2-chloro-1,3-butadiene, 2,3-dimethyl-1,3-butadiene, 1,3-pentadiene, 1,3-hexadiene, etc., and combinations thereof. In one aspect, the conjugated diene is 1,3-butadiene, 2-methyl-1,3-butadiene or a combination thereof. In one aspect, the conjugated diene is 1,3-butadiene.

[0030] A hydrogenated block copolymer is a copolymer comprising (A) at least one block derived from a vinyl aromatic hydrocarbon and (B) at least one block derived from a conjugated diene, wherein the content of aliphatic unsaturated groups in block (B) is at least partially reduced by hydrogenation. In one aspect, the content of aliphatic unsaturated groups in block (B) is reduced by at least 50%, or at least 70%. The arrangement of blocks (A) and (B) includes linear structures, graft structures, and radial teleblock structures with or without branches. Linear block copolymers include tapered linear structures and non-tapered linear structures. In one aspect, the hydrogenated block copolymer has a tapered linear structure. In one aspect, the hydrogenated block copolymer has a non-tapered linear structure. In one aspect, the hydrogenated block copolymer comprises block (B) which contains randomly incorporated vinyl aromatic hydrocarbon monomers. Linear block copolymer structures include diblock (A-B block), triblock (A-B-A block or B-A-B block), tetrablock (A-B-A-B block), pentablock (A-B-A-B-A block or B-A-B-A-B block) structures, and linear structures containing a total of 6 or more (A) and (B) blocks. Among them, the molecular weight of each (A) block may be the same as or different from that of other (A) blocks, and the molecular weight of each (B) block may be the same as or different from that of other (B) blocks. In one aspect, the hydrogenated block copolymer is a diblock copolymer, a triblock copolymer, or a combination thereof.

[0031] In one aspect, the hydrogenated block copolymer does not contain monomer residues other than vinyl aromatic hydrocarbon compounds and conjugated dienes. In one aspect, the hydrogenated block copolymer consists of blocks derived from vinyl aromatic hydrocarbon compounds and conjugated dienes. It does not contain grafts formed from these or any other monomers. It also consists of carbon atoms and hydrogen atoms and thus does not contain heteroatoms. In one aspect, the hydrogenated block copolymer contains residues of one or more acid functionalizing agents (such as maleic anhydride). In one aspect, the hydrogenated block copolymer contains a polystyrene-poly(ethylene-butene)-polystyrene triblock copolymer.

[0032] In one aspect, the hydrogenated block copolymer is a polystyrene-poly(ethylene-butene)-polystyrene triblock copolymer, and its polystyrene content is 10 to 50% by weight, or 20 to 40% by weight, or 20 to 35% by weight, or 25 to 35% by weight, based on the weight of the polystyrene-poly(ethylene-butene)-polystyrene triblock copolymer. In these aspects, the polystyrene-poly(ethylene-butene)-polystyrene triblock copolymer optionally has a weight average molecular weight of 200,000 to 400,000 g / mol, or 250,000 to 350,000 g / mol, as determined by size exclusion chromatography using polystyrene standards.

[0033] Methods for preparing hydrogenated block copolymers are well known in the art, and many hydrogenated block copolymers are commercially available. Examples of commercially available hydrogenated block copolymers include: polystyrene-poly(ethylene-propylene) diblock copolymers named KRATON TM G1701 (with 37 wt% polystyrene) and G1702 (with 28 wt% polystyrene) provided by Kraton Performance Polymers Inc.; polystyrene-poly(ethylene-butene)-polystyrene triblock copolymers named KRATON TM G1641 (with 33 wt% polystyrene), G1650 (with 30 wt% polystyrene), G1651 (with 33 wt% polystyrene) and G1654 (with 31 wt% polystyrene) provided by Kraton Performance Polymers Inc.; and polystyrene-poly(ethylene-ethylene / propylene)-polystyrene triblock copolymers named SEPTON TM S4044, S4055, S4077 and S4099 provided by Kuraray. Other commercially available hydrogenated block copolymers include polystyrene-poly(ethylene-butene)-polystyrene (SEBS) triblock copolymers named CALPRENE TM H6140 (31 wt% polystyrene), H6170 (33 wt% polystyrene), H6171 (33 wt% polystyrene) and H6174 (33 wt% polystyrene) provided by Dynasol; and polystyrene-poly(ethylene-butene)-polystyrene (SEBS) triblock copolymers named SEPTON TM 8006 (33 wt% polystyrene) and 8007 (30 wt% polystyrene) provided by Kuraray; polystyrene-poly(ethylene-propylene)-polystyrene (SEPS) copolymers named SEPTON TM 2006 (35 wt% polystyrene) and 2007 (30 wt% polystyrene) provided by Kuraray; and oil-extended compounds of these hydrogenated block copolymers, KRATON TM G4609 (containing 45% mineral oil, and SEBS with 33 wt% polystyrene) and G4610 (containing 31% mineral oil, and SEBS with 33% polystyrene) from Kraton Performance Polymers; TUFTEC from Asahi TMH1272 (containing 36% oil and SEBS with 35 wt% polystyrene). Mixtures of two or more hydrogenated block copolymers can also be used. In one aspect, the hydrogenated block copolymer comprises a polystyrene-poly(ethylene-butene)-polystyrene triblock copolymer having a weight-average molecular weight of at least 100,000 g / mol, or from 200,000 to 400,000 g / mol.

[0034] The composition comprises from 1 to 15 wt% of a hydrogenated block copolymer, based on the total weight of the composition. Within this range, the content of the hydrogenated block copolymer can be from 1 to 10 wt%, or from 3 to 10 wt%, or from 3 to 8 wt%, or from 5 to 10 wt%, or from 4 to 8 wt%, or from 5 to 7 wt%.

[0035] In one aspect, other impact modifiers, in addition to the hydrogenated block copolymer, can be minimized (i.e., at a content of less than 1 wt%) or excluded from the thermoplastic composition. For example, homopolystyrene or high-impact polystyrene can be excluded from the composition.

[0036] In addition to poly(phenylene ether) and impact modifiers, the thermoplastic composition further comprises an organophosphate flame retardant. Exemplary organophosphate compounds include: phosphates containing phenyl, substituted phenyl, or a combination of phenyl and substituted phenyl; resorcinol-based bisaryl phosphates such as resorcinol bis(diphenyl phosphate); and those based on bisphenol such as bisphenol A bis(diphenyl phosphate). In one aspect, the organophosphate is selected from tris(alkylphenyl) phosphates (e.g., CAS Registry No. 89492-23-9 or CAS Registry No. 78-33-1), resorcinol bis(diphenyl phosphate) (CAS Registry No. 57583-54-7), bisphenol A bis(diphenyl phosphate) (CAS Registry No. 181028-79-5), triphenyl phosphate (CAS Registry No. 115-86-6), tris(isopropylphenyl) phosphate (e.g., CAS Registry No. 68937-41-7), tert-butylphenyl diphenyl phosphate (CAS Registry No. 56803-37-3), bis(tert-butylphenyl)phenyl phosphate (CAS Registry No. 65652-41-7), tris(tert-butylphenyl) phosphate (CAS Registry No. 78-33-1), and combinations thereof.

[0037] In one aspect, the organophosphate comprises a bisaryl phosphate of formula (7)

[0038]

[0039] wherein each occurrence of R is independently C 1-12 alkylene; R 16 and R 17 each occurrence is independently C 1-5 alkyl; R12 , R 13 and R 15 are independently C 1-12 hydrocarbyl groups; each occurrence of R 14 is independently C 1-12 hydrocarbyl when it appears; n is from 1 to 25; and s1 and s2 are independently integers equal to 0, 1, or 2. In one aspect, OR 12 , OR 13 , OR 14 and OR 15 are independently derived from phenol, monoalkylphenol, dialkylphenol, or trialkylphenol.

[0040] It will be readily understood by those skilled in the art that the diaryl phosphate is derived from bisphenol. Exemplary bisphenols include 2,2-bis(4-hydroxyphenyl)propane (bisphenol A), 2,2-bis(4-hydroxy-3-methylphenyl)propane, bis(4-hydroxyphenyl)methane, bis(4-hydroxy-3,5-dimethylphenyl)methane, and 1,1-bis(4-hydroxyphenyl)ethane. In one aspect, the bisphenol includes bisphenol A.

[0041] In one aspect, the organic phosphate includes resorcinol bis(diphenyl phosphate), bisphenol A bis(diphenyl phosphate), or a combination thereof.

[0042] The content of the organic phosphate in the composition can be 5 to 20% by weight based on the total weight of the composition. Within this range, the content of the organic phosphate can be 7 to 15% by weight, or 8 to 15% by weight, or 9 to 14% by weight.

[0043] The thermoplastic composition further includes a flame retardant synergist containing phosphazene. The phosphazene can include a linear or cyclic phosphazene represented by the following formula

[0044] or wherein w1 is from 3 to 10,000; w2 is from 3 to 25 or from 3 to 7; each R w is independently C 1-12 alkyl, alkenyl, alkoxy, aryl, aryloxy, or polyoxyalkenyl. Among the above groups, at least one hydrogen atom in these groups can be substituted by a group having an N, S, O, or F atom or an amino group. For example, each R w can be a substituted or unsubstituted phenoxy, amino, or polyoxyalkenyl. Any given R w can also be crosslinked with another phosphazene group. Exemplary crosslinking includes bisphenol groups, such as bisphenol A groups. Examples include phenoxycyclotriphosphazene, octaphenoxycyclotetraphosphazene, decaphenoxycyclopentaphosphazene, and the like.

[0045] In one aspect, the phosphazene can be bis(phenoxy)phosphazene. The bis(phenoxy)phosphazene can be an oligomer or a polymer and can be cyclic or linear. In one aspect, the bis(phenoxy)phosphazene is cyclic and has the following structure

[0046]

[0047] where m is an integer from 3 to 25; x and y are each independently 0, 1, 2, 3, 4, or 5; and R 4 and R 5 each occurrence is halogen, C 1-12 alkyl, or C 1-12 alkoxy.

[0048] In one aspect, the bis(phenoxy)phosphazene is linear and has the following structure

[0049]

[0050] where n is an integer from 3 to 10,000; X 1 represents a -N=P(OPh)3 group or a -N=P(O)(OPh) group, where Ph represents phenyl; Y 1 represents a -P(OPh)4 group or a -P(O)(OPh)2 group; x and y are each independently 0, 1, 2, 3, 4, or 5; and R 4 and R 5 each occurrence is halogen, C 1-12 alkyl, or C 1-12 alkoxy.

[0051] In one aspect, the phosphazene can include phenoxycyclotriphosphazene, octaphenoxycyclotetraphosphazene, decaphenoxycyclopentaphosphazene, or a combination comprising at least one of the foregoing phosphazene compounds.

[0052] The content of the phosphazene flame retardant synergist can be 0.1 to 5% by weight based on the total weight of the thermoplastic composition. Within this range, the content of the phosphazene can be 0.5 to 2% by weight, or 0.5 to 1.5% by weight, or 0.75 to 1.25% by weight, each based on the total weight of the composition.

[0053] In addition to poly(phenylene ether), impact modifier, organophosphate ester, and flame retardant synergist, the thermoplastic composition optionally further comprises tricalcium phosphate. The chemical formula of tricalcium phosphate (CAS Registry Number: 1306-06-5) is Ca5(OH)(PO4) 3， which is also known as hydroxyapatite, hydroxylapatite, tribasic calcium phosphate, pentacalcium hydroxyorthophosphate, and apatite.

[0054] If tricalcium phosphate is present, its content in the composition can be 0.8 to 8% by weight based on the total weight of the composition. Within this range, the content of tricalcium phosphate can be 0.8 to 5% by weight, or 0.8 to 3% by weight, or 1 to 8% by weight, or 1 to 5% by weight, or 1 to 3% by weight, or 1.2 to 8% by weight, or 1.2 to 5% by weight, or 1.2 to 2.8% by weight, or 1.5 to 2.5% by weight based on the total weight of the composition.

[0055] The thermoplastic composition optionally further comprises an additive composition. The additive composition comprises one or more additives. These additives can be, for example, stabilizers, release agents, lubricants, processing aids, drip retardants, nucleating agents, UV blockers, dyes, pigments, antioxidants, antistatic agents, blowing agents, mineral oils, metal deactivators, antiblocking agents, or combinations thereof. In one aspect, the additive composition can comprise antioxidants, lubricants, heat stabilizers, UV absorbing additives, plasticizers, anti-dripping agents, release agents, antistatic agents, dyes, pigments, laser marking additives, radiation stabilizers, or combinations thereof. When such additives are added, their total amount is generally 0.1 to 10% by weight of the total weight of the composition.

[0056] In one aspect, the composition can comprise an anti-drip agent. Fluorinated polyolefins or polytetrafluoroethylene can be used as the anti-drip agent. The anti-drip agent can also be a fluoropolymer that forms fibrils or does not form fibrils, such as polytetrafluoroethylene (PTFE). The anti-drip agent can be coated with a hard copolymer (such as styrene-acrylonitrile (SAN)). PTFE encapsulated in SAN is called TSAN. The encapsulated fluoropolymer can be prepared by polymerizing the coating polymer in the presence of the fluoropolymer (such as in an aqueous dispersion). TSAN can provide significant advantages compared to PTFE because TSAN is more easily dispersed in the composition. Suitable TSAN can contain, for example, 50 wt% (weight percent) PTFE and 50 wt% SAN (based on the total weight of the encapsulated fluoropolymer). For example, SAN can contain 75 wt% styrene and 25 wt% acrylonitrile based on the total weight of the copolymer. Alternatively, the fluoropolymer can also be premixed with a second polymer (such as an aromatic polycarbonate resin or SAN) in a certain way to form an agglomerated material for use as the anti-drip agent. Either method can be used to produce the encapsulated fluoropolymer.

[0057] The anti-dripping agent can be added in the form of larger particles, with a number average particle size of 0.3 to 0.7 mm, especially 0.4 to 0.6 mm. The amount of the anti-dripping agent is 0.01 wt% to 5.0 wt% of the total weight of the composition.

[0058] The composition may comprise less than 3 wt%, less than 1 wt% or less than 0.5 wt% of reinforcing filler. In one aspect, the composition may not comprise reinforcing filler.Reinforcing fillers can include, for example, mica, clay, feldspar, quartz, quartzite, perlite, tripoli, diatomaceous earth, aluminum silicate (mullite), synthetic calcium silicate, fused silica, fumed silica, sand, boron-nitride powder, boron-silicate powder, calcium sulfate, calcium carbonate (such as chalk, limestone, marble, and synthetic precipitated calcium carbonate), talc (including fibrous, modular, acicular, and platy talc), wollastonite, hollow or solid glass spheres, silicate spheres, cenospheres, aluminosilicate or (armospheres), kaolin, whiskers (silicon carbide, alumina, boron carbide, iron, nickel, or copper), continuous and chopped carbon or glass fibers, molybdenum disulfide, zinc sulfide, barium titanate, barium ferrite, barium sulfate, heavy spar, TiO2, alumina, magnesia, granular or fibrous aluminum, bronze, zinc, copper, or nickel, glass flakes, flaked silicon carbide, flaked aluminum diboride, flaked aluminum, steel flakes, natural fillers (such as wood flour, fibrous cellulose, cotton, sisal, jute, starch, lignin, ground nut shells, or rice grain husks), reinforced organic fiber fillers (such as poly(ether ketone), polyimide, polybenzoxazole, poly(phenylene sulfide), polyester, polyethylene, aromatic polyamide, aromatic polyimide, polyetherimide, polytetrafluoroethylene, and poly(vinyl alcohol)), and combinations thereof.The filler and reinforcing agent in the minimum amount or excluded from the composition can be coated with a layer of metallic material to promote electrical conductivity, or surface-treated with silanes to improve adhesion and dispersibility with the polymer matrix. In one aspect, the composition can comprise less than 5 wt% of glass fiber. In one aspect, the composition can be free of glass fiber.

[0059] The composition can optionally minimize or exclude additional components not specifically described herein. For example, the composition comprises less than 5 wt%, less than 2 wt%, less than 1 wt% or less than 0.1 wt% of poly(phenylene ether)-poly(siloxane) block copolymer. In one aspect, the composition does not contain poly(phenylene ether)-poly(siloxane) block copolymer. In one aspect, the composition may not contain any thermoplastic polymer other than the aforementioned polymers of the present invention. In one aspect, the composition can minimize or exclude glass fiber. In one aspect, the composition can minimize or exclude homopolystyrene or rubber-modified polystyrene. In one aspect, the composition can minimize (e.g., present in an amount of less than 5 wt%, or less than 2 wt%, or less than 1 wt%, or less than 0.1 wt%) or exclude fluorinated polymers (e.g., poly(trifluoroethylene), polytetrafluoroethylene, poly(hexafluoropropylene), tetrafluoroethylene-hexafluoropropylene copolymer, poly(vinyl fluoride), poly(vinylidene fluoride), polychlorotrifluoroethylene, etc., or combinations thereof), polydimethylsiloxane, silicone oil, paraffin wax, and combinations thereof.

[0060] In a specific aspect, the thermoplastic composition can include 73 - 80 wt% of poly(phenylene ether); 3 - 10 wt% of an impact modifier, a hydrogenated block copolymer containing vinyl aromatic hydrocarbon and conjugated diene; 8 - 15 wt% of an organophosphate flame retardant; 0.5 - 2 wt% of a flame retardant synergist, containing phosphazene; 1 - 3 wt% of tricalcium phosphate; and less than 1 wt% of poly(phenylene ether)-poly(siloxane) block copolymer; wherein the wt% is based on the total weight of the composition. In one aspect, the poly(phenylene ether) can comprise poly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of 0.4 - 0.6 dL / g measured using an Ubbelohde viscometer in chloroform at 25°C; the impact modifier can comprise polystyrene-poly(ethylene-butylene)-polystyrene; the organophosphate flame retardant can comprise bisphenol A bis(diphenyl phosphate); and the phosphazene can comprise phenoxycyclotriphosphazene, octaphenoxycyclotetraphosphazene, decaphenoxycyclopentaphosphazene, or a combination comprising at least one of the aforementioned phosphazenes.

[0061] Accordingly, the compositions of the present invention may comprise 72 to 85 wt% of poly(phenylene ether); 1 to 15 wt% of an impact modifier comprising a hydrogenated block copolymer of vinyl aromatic hydrocarbon and conjugated diene; 5 to 20 wt% of an organophosphate flame retardant; 0.1 to 5 wt% of a flame retardant synergist comprising phosphazene; 0.8 to 8 wt% of tricalcium phosphate; and less than 5 wt% of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein the wt% is based on the total weight of the composition. The intrinsic viscosity of the poly(phenylene ether) may be greater than 0.25 dL / g, or 0.4 to 0.6 dL / g, measured using an Ubbelohde viscometer in chloroform at 25°C. The poly(phenylene ether) may comprise poly(2,6-dimethyl-1,4-phenylene ether). The hydrogenated block copolymer may comprise polystyrene-poly(ethylene-butene)-polystyrene. The organophosphate flame retardant may comprise resorcinol bis(diphenyl phosphate), bisphenol A bis(diphenyl phosphate), resorcinol bis(bis(2,6-dimethylphenyl) phosphate), oligophosphate ester, triphenyl phosphate or a combination thereof, preferably bisphenol A bis(diphenyl phosphate). The phosphazene may have the following structure

[0062] or wherein R1 and R2 are the same or different and are independently hydrogen, halogen, C 1-12 alkoxy or C 1-12 alkyl; m is 3 to 25; X 1 is a —N═P(OPh)3 group or a —N═P(O)OPh group, wherein Ph represents phenyl; Y 1 is a —P(OPh)4 group or a —P(O)(OPh)2 group, wherein Ph represents phenyl; n is 3 to 10,000. The phosphazene compound may include phenoxycyclotriphosphazene, octaphenoxycyclotetraphosphazene, decaphenoxycyclopentaphosphazene, or a combination comprising at least one of the above phosphazene compounds. The thermoplastic composition may comprise less than 1 wt% of a poly(phenylene ether)-poly(siloxane) block copolymer. The composition may be free of poly(phenylene ether)-poly(siloxane) block copolymer. The composition may be free of glass fiber. The composition may further comprise 0.1 to 10 wt% of an additive composition.

[0063] The compositions of the present invention can exhibit an ideal combination of properties. For example, after the molded samples of the composition are conditioned at 23°C for 48 hours and at 70°C for 168 hours, and measured using a 1.0 mm test bar, its UL-94 flammability rating reaches V0; after conditioning at 23°C for 48 hours and at 70°C for 168 hours, and measured using a 0.75 mm test bar, its UL-94 flammability rating reaches V0; after conditioning at 23°C for 48 hours and at 70°C for 168 hours, and measured using a 0.5 mm test bar, its UL-94 flammability rating reaches V0; after conditioning at 23°C for 48 hours and at 70°C for 168 hours, and measured using a 0.3 mm test bar, its UL-94 flammability rating reaches V0. The molded samples of the composition may also optionally exhibit one or both of the following: a heat deflection temperature of greater than or equal to 115°C measured according to ASTM D648 with a load of 1.82 MPa on a 3.2 mm thick bar; and a comparative tracking resistance of PLC0 measured according to ASTM D3638.

[0064] In one aspect, the molded samples of the composition can exhibit a UL-94 flammability rating of V0 measured using a 1.0 mm test strip after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0 measured using a 0.75 mm test strip after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0 measured using a 0.5 mm test strip after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0 measured using a 0.3 mm test strip after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a heat deflection temperature of greater than or equal to 115°C measured according to ASTM D648 with a load of 1.82 MPa on a 3.2 mm thick bar; and a comparative tracking resistance of PLC0 determined according to ASTM D3638.

[0065] The compositions of the present invention can be prepared, for example, by melt blending the components of the composition. The components of the composition can be mixed using conventional equipment (such as ribbon blenders, HENSCHEL TM mixers, BANBURY TMThey are mixed or blended (e.g., in a mixer, drum mixer, etc.), and then the blended composition can be melt-blended or melt-kneaded. The melt-blending or melt-kneading can be carried out using common equipment (such as single-screw extruders, twin-screw extruders, multi-screw extruders, compounding kneaders, etc.). For example, this composition can be prepared by melt-blending the components in a twin-screw extruder at a temperature of 270 - 310 °C or 280 - 300 °C. The extrudate can be immediately quenched in a water bath and pelletized. The pellets thus obtained can be, as required, a quarter inch long or shorter. Such pellets can be used for subsequent molding, shaping, or forming.

[0066] The shaped, formed, or molded articles containing the said composition represent another aspect herein. The composition can be molded into useful shaped articles by various methods, such as injection molding, extrusion, rotational molding, blow molding, and thermoforming. Some examples of articles include electric vehicle battery modules, battery housings, battery cases, battery cell frames, battery cell spacers, battery cell holders, battery pack insulating films, bus bar holders, terminal covers, electrical or electronic components, thermoset circuit breakers, fuser holders for electrostatic copiers, photovoltaic junction boxes, photovoltaic connectors, electrical connectors, automotive electrical connectors, relays, charge couplers, household appliance parts, automotive parts, portable devices, mobile parts, or fixed electrical components.

[0067] In one aspect, the article is an extruded article, molded article, pultruded article, thermoformed article, foam article, a layer of a multi-layer article, a substrate of a coated article, or a substrate of a metallized article. In one aspect, the composition is particularly suitable for molded or extruded parts of electric vehicle battery components. For example, the composition can be used for extruded parts of electric vehicle battery components, such as insulating sheets or insulating films of electric vehicle battery components.

[0068] The electric vehicle battery component represents another aspect of this article. The electric vehicle battery component can be extruded from a composition comprising: 70 to 85 wt% of poly(phenylene ether); 1 to 15 wt% of an impact modifier, a hydrogenated block copolymer containing vinyl aromatic hydrocarbon and conjugated diene; 5 to 20 wt% of an organophosphate flame retardant; 0.1 to 5 wt% of a flame retardant synergist containing phosphazene; optionally, 0.8 to 8 wt% of tricalcium phosphate; and less than 5 wt% of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein the wt% is based on the total weight of the composition. The variation of each component can be as described above.

[0069] The electric vehicle battery component can be an electric vehicle battery insulating sheet or film. The electric vehicle battery insulating sheet or film can be prepared by extruding the composition of this article to provide the desired sheet or film. In one aspect, the extruded film or sheet can have a UL-94 flammability rating of V0 measured using a 1.0 mm test bar after conditioning at 23 °C for 48 hours and at 70 °C for 168 hours; a UL-94 flammability rating of V0 measured using a 0.75 mm test bar after conditioning at 23 °C for 48 hours and at 70 °C for 168 hours; a UL-94 flammability rating of V0 measured using a 0.5 mm test bar after conditioning at 23 °C for 48 hours and at 70 °C for 168 hours; a UL-94 flammability rating of V0 measured using a 0.3 mm test bar after conditioning at 23 °C for 48 hours and at 70 °C for 168 hours. The extruded film or sheet can optionally further exhibit one or both of the following: a heat distortion temperature greater than or equal to 115 °C measured on a 3.2 mm thick test bar at a load of 1.82 MPa according to ASTM D648; and a relative tracking resistance PLC0 measured according to ASTM D3638. The thickness of the battery insulating film can be, for example, 50 to 1000 μm.

[0070] As described herein, the inventors unexpectedly found that a composition comprising a specific amount of poly(phenylene ether), an impact modifier of a hydrogenated block copolymer containing vinyl aromatic hydrocarbon and conjugated diene, an organophosphate flame retardant, a flame retardant synergist, and optionally tricalcium phosphate can provide certain advantageous properties. Specifically, a combination of high heat resistance, high impact strength, and low flammability can be obtained, which is particularly suitable for thin molded articles. Therefore, significant improvements are provided herein, especially in relation to the battery pack insulating film or sheet extruded from this composition.

[0071] The present invention is further illustrated by the following non-limiting examples. Examples

[0072] The materials used in the following examples are shown in Table 1.

[0073] Table 1

[0074]

[0075]

[0076] Each composition was kneaded using a Toshiba TEM-37BS twin-screw extruder. All components were added through the feed port of the extruder, except for BPADP which was added through a liquid feeder. The extrudate was cooled in a water bath and pelletized. Before injection molding or extrusion molding, the pellets were conditioned at 120 °C for 3 hours. The process parameters used are summarized in Table 2.

[0077] Table 2

[0078]

[0079]

[0080] The test specimens were injection molded on a Toshiba UH1000-110 injection molding machine. During operation, the barrel temperatures were 290 °C, 300 °C, 300 °C, and 290 °C (from the feed throat to the nozzle), and the mold temperature was 90 °C.

[0081] The various properties of the molded parts were tested according to the following standards.

[0082] The melt flow rate value was measured in g / 10 min according to Method B of ASTM D1238-10 at 300 °C and a load of 5 kg. The heat distortion temperature (HDT) was measured in °C according to ASTM D648 using 3.2 mm thick bars at 1.82 MPa or 0.45 MPa. The notched Izod impact strength (NII) value was measured in joules / m according to Method A of ASTM D 256-10 at 23 °C using bars with a cross-sectional dimension of 3.2 mm x 12.7 mm. The unnotched Izod impact strength (UNII) was measured in joules / m according to ASTM D4812 at 23 °C using bars with a cross-sectional dimension of 3.2 mm x 12.7 mm. The tensile properties were measured according to ASTM D638, with a sample thickness of 3.2 mm and a test speed of 5 mm / min.

[0083] The evaluation method for hydrolysis stability was to place the tensile test strips in a hydrolysis chamber at 85 °C and a relative humidity of 85% for 1000 hours. Then the samples were taken out of the hydrolysis chamber for identification. Hydrolysis stability was evaluated by the retention rates of the tensile modulus and tensile stress. A retention rate of the tensile modulus and tensile stress ≥ 90% was identified as "good". If at least one of the retention rates of the tensile modulus or tensile stress was less than 90%, the hydrolysis stability was identified as "poor".

[0084] The flame retardancy of an injection-molded flame bar is determined by the 20 mm vertical burning flame test of Underwriter’s Laboratory Bulletin 94 “Tests for Flammability of Plastic Materials, UL 94”. Before the test, flame bars with thicknesses of 1.0, 0.75, 0.5, 0.3, and 0.2 mm are conditioned at 23 °C and 50% relative humidity for at least 48 hours, or at 70 °C and 50% relative humidity for 168 hours. In the UL 94 20 mm vertical burning flame test, a group of 10 to 20 flame bars are tested. For each flame bar, a flame is applied for 10 seconds and then removed, and the time required for the flame bar to self-extinguish (the first flaming combustion time, t1) is recorded. Then the flame is reapplied for 10 seconds and removed, and the time required for the flame bar to self-extinguish (the second flaming combustion time, t2) and the post-flame glowing time (non-flaming combustion time, t3) are recorded. To achieve the V0 rating, the flaming combustion times t1 and t2 of each sample must be less than or equal to 10 seconds; and the total flaming combustion time (t1 + t2 of all five samples) of all five samples must be less than or equal to 50 seconds; and the second flaming combustion time plus the non-flaming combustion time (t2 + t3) of each sample must be less than or equal to 30 seconds; and none of the samples can flaming combust or non-flaming combust to the fixture; and the cotton indicator cannot be ignited by burning particles or drips. To achieve the V1 rating, the flaming combustion times t1 and t2 of each sample must be less than or equal to 30 seconds; and the total flaming combustion time (t1 + t2 of all five samples) of all five samples must be less than or equal to 250 seconds; and the second flaming combustion time plus the non-flaming combustion time (t2 + t3) of each sample must be less than or equal to 60 seconds; and none of the samples can flaming combust or non-flaming combust to the fixture; and the cotton indicator cannot be ignited by burning particles or drips. To achieve the V2 rating, the flaming combustion times t1 and t2 of each sample must be less than or equal to 30 seconds; and the total flaming combustion time (t1 + t2 of all five samples) of all five samples must be less than or equal to 250 seconds; and the second flaming combustion time plus the non-flaming combustion time (t2 + t3) of each sample must be less than or equal to 60 seconds; and none of the samples can flaming combust or non-flaming combust to the fixture; but the cotton indicator may be ignited by burning particles or drips.

[0085] The Comparative Tracking Index (CTI) is used to measure the electrical breakdown (tracking) characteristics of insulating materials. Tracking is an indicator of the electrical breakdown performance of the surface of an insulating material. A large voltage difference will gradually form a carbonized track on the material surface, thus forming a conductive leakage path. The CTI test procedure is carried out in accordance with the ASTM D3638 test method. Briefly, the test procedure involves dropping 50 drops of 0.1 wt% ammonium chloride solution onto the surface of the material (with a thickness of 3 mm) drop by drop, and then determining the maximum voltage at which failure occurs. Based on the comparative tracking index, a Comparative Tracking Performance Level Category (PLC) is assigned to the sample. Table 3 lists the Comparative Tracking Performance Level Categories.

[0086] Table 3

[0087]

[0088]

[0089] Table 4 summarizes the composition and its various properties. The amount of each component is expressed as a weight % based on the total weight of the composition.

[0090] Table 4

[0091]

[0092] As shown in Table 4, the composition of Comparative Example 1 (CE1) reaches the V0 rating at 0.75 mm, the V1 rating at 0.5 mm and 0.3 mm, and the HDT at 0.45 Mpa is 133 °C. Comparative Example 2 contains a larger amount of PPE and SEBS instead of HIPS, and its HDT increases to 149 °C, but the vertical burning performance decreases. Comparative Example 3 adds additional BPADP, and its vertical burning performance is improved compared to CE1 and Comparative Example 2 (CE2), but the HDT is lower than that of CE2. Comparative Example 4 contains 2% TCP, and Comparative Example 5 contains TCP and a slightly increased BPADP content. Comparative Example 4 (CE4) shows a vertical burning performance of V1 at 0.5, 0.75 and 1 mm, and V2 at 0.3 mm. Comparative Example 5 (CE5) shows improved vertical burning performance, but the HDT decreases. None of the comparative examples reach the vertical burning rating V0 when the thickness is 0.5 mm or thinner.

[0093] Each of Examples 1 to 4 contains a flame retardant (e.g., BPADP), a flame retardant synergist (e.g., phosphazene), and TCP. All the examples achieved a V0 rating at 0.3 mm and a CTI PLC0 rating. Thus, the inventors unexpectedly found that using a specific combination of flame retardants containing an organophosphate as the main flame retardant and phosphazene as a flame retardant synergist can achieve a V0 rating at a thickness of 0.3 mm or less. In addition, due to the presence of TCP, an ideal balance of flame retardancy rating, high heat resistance, and CTI was also achieved.

[0094] In addition, Examples 5 and 6 showed that a specific combination containing a flame retardant (e.g., BPADP) and a flame retardant synergist (e.g., phosphazene) unexpectedly achieved a V0 rating at 0.3 mm. In addition, an ideal balance among flame retardancy performance, heat resistance, and mechanical properties was also observed.

[0095] Therefore, the present disclosure provides a significant improvement.

[0096] The present disclosure also encompasses the following aspects.

[0097] Aspect 1: A thermoplastic composition comprising: 72 to 85% by weight of poly(phenylene ether); 1 to 15% by weight of an impact modifier comprising a hydrogenated block copolymer of a vinyl aromatic hydrocarbon and a conjugated diene; 5 to 20% by weight of an organophosphate flame retardant; 0.1 to 5% by weight of a flame retardant synergist comprising phosphazene; optionally, 0.8 to 8% by weight of tricalcium phosphate; and less than 5% by weight of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein the % by weight is based on the total weight of the composition.

[0098] Aspect 2: The composition of Aspect 1, wherein a molded sample of the composition exhibits: a UL-94 flammability rating of V0 measured using a 1.0 mm test bar after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0 measured using a 0.75 mm test bar after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0 measured using a 0.5 mm test bar after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0 measured using a 0.3 mm test bar after conditioning at 23°C for 48 hours and at 70°C for 168 hours; and optionally, one or both of the following: a heat distortion temperature greater than or equal to 115°C measured on a 3.2 mm thick bar using a load of 1.82 MPa according to ASTM D648; and a relative tracking resistance PLC0 determined according to ASTM D3638.

[0099] Aspect 3: The thermoplastic composition of Aspect 1 or 2, wherein the poly(phenylene ether) has an intrinsic viscosity greater than 0.25 dL / g, or 0.4 - 0.6 dL / g, measured using an Ubbelohde viscometer in chloroform at 25 °C; preferably wherein the poly(phenylene ether) comprises poly(2,6-dimethyl-1,4-phenylene ether).

[0100] Aspect 4: The thermoplastic composition according to any one of Aspects 1 - 3, wherein the hydrogenated block copolymer comprises polystyrene-poly(ethylene-butylene)-polystyrene.

[0101] Aspect 5: The thermoplastic composition according to any one of Aspects 1 - 4, wherein the organophosphate flame retardant comprises resorcinol bis(diphenyl phosphate), bisphenol A bis(diphenyl phosphate), resorcinol bis(di-2,6-dimethylphenyl) phosphate, oligophosphate ester, triphenyl phosphate, or a combination thereof, preferably bisphenol A bis(diphenyl phosphate).

[0102] Aspect 6: The thermoplastic composition according to any one of Aspects 1 - 5, wherein the phosphazene has the following structure

[0103] Or wherein, R1 and R2 are the same or different and are independently hydrogen, halogen, C 1-12 alkoxy or C 1-12 alkyl; m is 3 - 25; X 1 is a —N=P(OPh)3 group or a —N=P(O)OPh group, where Ph represents phenyl; Y 1 is a —P(OPh)4 group or a —P(O)(OPh)2 group, where Ph represents phenyl; n is 3 - 10000; preferably, the phosphazene compound comprises phenoxycyclotriphosphazene, octaphenoxycyclotetraphosphazene, decaphenoxycyclopentaphosphazene, or a combination comprising at least one of the above phosphazene compounds.

[0104] Aspect 7: The thermoplastic composition according to any one of Aspects 1 - 6, which comprises less than 1 wt% of a poly(phenylene ether)-poly(siloxane) block copolymer, preferably the poly(phenylene ether)-poly(siloxane) block copolymer is not comprised in the composition.

[0105] Aspect 8: The thermoplastic composition according to any one of Aspects 1 - 7, wherein the composition does not contain glass fibers.

[0106] Aspect 9: The thermoplastic composition according to any one of Aspects 1 - 8, further comprising 0.1 - 10 wt% of an additive composition.

[0107] Aspect 10: The thermoplastic composition of Aspect 1, comprising 73 to 80% by weight of poly(phenylene ether); 3 to 10% by weight of an impact modifier, a hydrogenated block copolymer containing vinyl aromatic hydrocarbon and conjugated diene; 8 to 15% by weight of an organophosphate flame retardant; 0.5 to 2% by weight of a flame retardant synergist containing phosphazene; 1 to 3% by weight of tricalcium phosphate; and less than 1% by weight of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein the % by weight is based on the total weight of the composition.

[0108] Aspect 11: The thermoplastic composition of Aspect 10, wherein the poly(phenylene ether) comprises poly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of 0.4 to 0.6 dL / g measured with an Ubbelohde viscometer in chloroform at 25°C; the impact modifier comprises polystyrene-poly(ethylene-butylene)-polystyrene; the organophosphate flame retardant comprises bisphenol A bis(diphenyl phosphate); and the phosphazene comprises phenoxycyclotriphosphazene, octaphenoxycyclotetraphosphazene, decaphenoxycyclopentaphosphazene, or a combination comprising at least one of the foregoing phosphazenes.

[0109] Aspect 12: The composition of Aspect 1 or 11, wherein the molded sample of the composition exhibits: a UL-94 flammability rating of V0 measured using a 1.0 mm test bar after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0 measured using a 0.75 mm test bar after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0 measured using a 0.5 mm test bar after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0 measured using a 0.3 mm test rod after conditioning at 23°C for 48 hours and at 70°C for 168 hours; and a heat distortion temperature greater than or equal to 115°C, measured on a 3.2 mm thick test bar using a load of 1.82 MPa according to ASTM D648; and a comparative tracking resistance of PLC0 as determined according to ASTM D3638.

[0110] Aspect 13: A method of preparing the composition of any one or more of Aspects 1 to 12; the method comprising melt mixing the components of the composition.

[0111] Aspect 14: An article comprising the composition of any one of Aspects 1 to 12, preferably, the article is an electric vehicle battery module, a battery insulating sheet or film, a battery housing, a battery box, a battery cell frame, a battery cell spacer, a battery cell holder, a bus bar support, a terminal cover, an electrical or electronic component, a charger adapter insulating sheet or film, a thermosetting circuit breaker, a fuse support for an electrostatic copier, a photovoltaic junction box, a photovoltaic connector, an electrical connector, an automotive electrical connector, an electrical relay, a charging coupler, a household appliance component, an automotive component, a portable device, a mobile component or a fixed electrical component.

[0112] Aspect 15: An electric vehicle battery component extruded from the following composition, the composition comprising: 70 to 85% by weight of poly(phenylene ether); 1 to 15% by weight of an impact modifier, a hydrogenated block copolymer containing vinyl aromatic hydrocarbon and conjugated diene; 5 to 20% by weight of an organophosphate flame retardant; 0.1 to 5% by weight of a flame retardant synergist containing phosphazene; optionally, 0.8 to 8% by weight of tricalcium phosphate; and less than 5% by weight of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein the % by weight is based on the total weight of the composition; preferably, the electric vehicle battery component is an electric vehicle battery insulating sheet or film.

[0113] The compositions, methods and articles may alternatively comprise, consist of, or consist essentially of any suitable materials, steps or components disclosed herein. Additionally, or alternatively, the compositions, methods and articles may be formulated to be free or substantially free of any materials (or species), steps or components that are not necessary for the function or goal of the compositions, methods and articles.

[0114] All ranges disclosed herein include the endpoints, and these endpoints can be combined with each other independently. "Combination" includes blends, mixtures, alloys, reaction products, etc. The terms "first", "second", etc. do not denote any order, quantity or importance, but are used to distinguish one element from another. The terms "a" and "the" do not denote a limitation of quantity and should be construed to cover both the singular and the plural, unless otherwise stated herein or the context clearly contradicts. "Or" means "and / or", unless otherwise expressly stated. Throughout this specification, "an aspect" refers to a specific element described in connection with that aspect being included in at least one aspect described herein, and may or may not be present in other aspects. The term "combinations thereof" used herein includes one or more of the listed elements and is open-ended, allowing for the presence of one or more similar elements not mentioned. Additionally, it should be understood that the described elements can be combined in any suitable manner in the various aspects.

[0115] Unless otherwise specified herein, all test standards are the latest standards in effect as of the filing date of this application (or, if priority is claimed, as of the filing date of the earliest priority application in which the test standard appears).

[0116] Unless otherwise defined, the meanings of technical and scientific terms used herein are the same as those commonly understood by one of ordinary skill in the art to which this application belongs. All cited patents, patent applications, and other references are hereby incorporated by reference in their entirety. However, if a term in this application conflicts or contradicts a term in an incorporated reference, the term in this application shall control over the conflicting term in the incorporated reference.

[0117] Compounds are described using standard nomenclature. For example, at any position not substituted by any designated group, it is understood that its valence is filled by a designated bond or by a hydrogen atom. A dash (“-”) not between two letters or symbols is used to indicate the point of attachment of a substituent. For example, -CHO is attached through the carbon atom of the carbonyl group.

[0118] As used herein, the term “hydrocarbyl,” whether used alone or as a prefix, suffix, or fragment of another term, refers to a residue containing only carbon and hydrogen. The residue can be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated, or unsaturated. It can also contain combinations of aliphatic, aromatic, straight-chain, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbyl moieties. However, when a hydrocarbyl residue is described as substituted, it can optionally contain heteroatoms in addition to the carbon and hydrogen members of the substituent residue. Thus, when specifically described as substituted, a hydrocarbyl residue can also contain one or more carbonyl groups, amino groups, hydroxyl groups, etc., or it can contain heteroatoms within the backbone of the hydrocarbyl residue. The term “alkyl” refers to a branched or straight-chain saturated aliphatic hydrocarbyl group, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, n-pentyl, sec-pentyl, n-hexyl, and sec-hexyl. “Alkenyl” refers to a straight-chain or branched monovalent hydrocarbyl group having at least one carbon-carbon double bond (e.g., vinyl (-HC═CH2)). “Alkoxy” refers to an alkyl group attached through an oxygen atom (i.e., alkyl-O-), such as methoxy, ethoxy, and sec-butoxy. “Alkylene” refers to a straight-chain or branched saturated divalent aliphatic hydrocarbyl group (e.g., methylene (-CH2-) or propylene (-(CH2)3-)). “Cycloalkylene” refers to a divalent cyclic alkylene, -C n H 2n-x，Wherein x represents the number of hydrogen atoms substituted by cyclization. "Cycloalkenyl" refers to a monovalent group having one or more rings and one or more carbon-carbon double bonds in the ring, wherein all ring members are carbon (e.g., cyclopentyl and cyclohexyl). "Aryl" refers to an aromatic hydrocarbon group containing a specified number of carbon atoms, such as phenyl, tropone, indanyl or naphthyl. "Arylene" refers to a divalent aryl. "Alkylarylene" refers to an arylene substituted by an alkyl. "Arylalkylene" refers to an alkylene substituted by an aryl (e.g., benzyl). The prefix "halogen" refers to a group or compound containing one or more of the substituents fluorine, chlorine, bromine or iodine. There can be combinations of different halogen atoms (e.g., bromine and fluorine), or only chlorine atoms. The prefix "hetero" indicates that a compound or group has at least one ring member that is a heteroatom (e.g., 1, 2 or 3 heteroatoms), wherein the heteroatoms are each independently N, O, S, Si or P. "Substituted" means that a compound or group is substituted by at least one (e.g., 1, 2, 3 or 4) substituent(s) in place of hydrogen, provided that the normal valence of the substituted atom is not exceeded, and the substituents are each independently C 1-9 alkoxy, C 1-9 haloalkoxy, nitro (-NO2), cyano (-CN), C 1-6 alkylsulfonyl (-S(=O)2-alkyl), C 6-12 arylsulfonyl (-S(=O)2-aryl), mercapto (-SH), thiocyano (-SCN), toluenesulfonyl (CH3C6H4SO2-), C 3-12 cycloalkyl, C 2-12 alkenyl, C 5-12 cycloalkenyl, C 6-12 aryl, C 7-13 arylalkyl, C 4-12 heterocycloalkyl, and C 3-12 heteroaryl. The number of carbon atoms shown in the group does not include any substituents. For example, -CH2CH2CN represents a C2 alkyl substituted by a nitrile.

[0119] Although specific embodiments have been described, alternative, modified, variant, improved and substantially equivalent solutions that may not be currently foreseen or may not have been foreseen by the applicant or a person skilled in the art may be contemplated. Accordingly, the appended claims (as filed and as may be amended) are intended to cover all such alternative, modified, variant, improved and substantially equivalent solutions.

Claims

1. A thermoplastic composition comprising: 72 to 85% by weight of poly(phenylene ether); 1 to 15% by weight of an impact modifier comprising a hydrogenated block copolymer of vinyl aromatic hydrocarbon and conjugated diene; 5 to 20% by weight of an organophosphate flame retardant; 0.1 to 5% by weight of a flame retardant synergist comprising phosphazene; Optionally, 0.8 to 8% by weight of tricalcium phosphate; and Less than 5% by weight of poly(phenylene ether)-poly(siloxane) block copolymer; Wherein the % by weight is based on the total weight of the composition.

2. The composition of claim 1, wherein the molded sample of the composition exhibits: A UL-94 flammability rating of V0, measured using a 1.0 mm test bar after conditioning at 23 °C for 48 hours and at 70 °C for 168 hours; A UL-94 flammability rating of V0, measured using a 0.75 mm test bar after conditioning at 23 °C for 48 hours and at 70 °C for 168 hours; A UL-94 flammability rating of V0, measured using a 0.5 mm test bar after conditioning at 23 °C for 48 hours and at 70 °C for 168 hours; A UL-94 flammability rating of V0, measured using a 0.3 mm test bar after conditioning at 23 °C for 48 hours and at 70 °C for 168 hours; and Optionally, one or both of the following A heat distortion temperature greater than or equal to 115 °C, measured according to ASTM D648 on a 3.2 mm thick bar with a load of 1.82 MPa; and A comparative tracking resistance of PLC0, measured according to ASTM D3638.

3. The thermoplastic composition of claim 1 or 2, wherein the intrinsic viscosity of the poly(phenylene ether) is greater than 0.25 dL / g, or 0.4 to 0.6 dL / g, measured using an Ubbelohde viscometer in chloroform at 25 °C; Preferably, wherein the poly(phenylene ether) comprises poly(2,6-dimethyl-1,4-phenylene ether).

4. The thermoplastic composition of any one of claims 1 to 3, wherein the hydrogenated block copolymer comprises polystyrene-poly(ethylene-butene)-polystyrene.

5. The thermoplastic composition according to any one of claims 1 to 4, wherein the organophosphate flame retardant comprises resorcinol bis(diphenyl phosphate), bisphenol A bis(diphenyl phosphate), resorcinol bis(di-2,6-dimethylphenyl) phosphate, oligophosphate ester, triphenyl phosphate, or a combination thereof, preferably bisphenol A bis(diphenyl phosphate).

6. The thermoplastic composition of any one of claims 1 to 5, wherein the phosphazene has the following structure Or Wherein R1 and R2 are the same or different and independently are hydrogen, halogen, C 1-12 alkoxy or C 1-12 alkyl; m is 3 to 25; X 1 is a —N═P(OPh)3 group or a —N═P(O)OPh group, where Ph represents a phenyl group; Y 1 is a —P(OPh)4 group or a —P(O)(OPh)2 group, where Ph represents a phenyl group; and n is 3 to 10000; Preferably, the phosphazene compound comprises phenoxycyclotriphosphazene, octaphenoxycyclotetraphosphazene, decaphenoxycyclopentaphosphazene, or a combination comprising at least one of the foregoing phosphazene compounds.

7. The thermoplastic composition of any one of claims 1 to 6, comprising less than 1% by weight of poly(phenylene ether)-poly(siloxane) block copolymer, preferably the poly(phenylene ether)-poly(siloxane) block copolymer is not contained in the composition.

8. The thermoplastic composition of any one of claims 1 to 7, wherein the composition does not contain glass fiber.

9. The thermoplastic composition according to any one of claims 1 to 8, further comprising 0.1 to 10% by weight of an additive composition.

10. The thermoplastic composition of claim 1, comprising 73 to 80% by weight of poly(phenylene ether); 3 to 10% by weight of an impact modifier comprising a hydrogenated block copolymer of vinyl aromatic hydrocarbon and conjugated diene; 8 to 15% by weight of an organophosphate flame retardant; 0.5 to 2% by weight of a flame retardant synergist comprising phosphazene; 1 to 3% by weight of tricalcium phosphate; and less than 1% by weight of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein % by weight is based on the total weight of the composition.

11. The thermoplastic composition of claim 10, wherein the poly(phenylene ether) comprises poly(2,6-dimethyl-1,4-phenylene ether), and its intrinsic viscosity measured by an Ubbelohde viscometer in chloroform at 25 °C is 0.4 to 0.6 dL / g; the impact modifier comprises polystyrene-poly(ethylene-butene)-polystyrene; the organophosphate flame retardant comprises bisphenol A bis(diphenyl phosphate); and the phosphazene comprises phenoxycyclotriphosphazene, octaphenoxycyclotetraphosphazene, decaphenoxycyclopentaphosphazene, or a combination comprising at least one of the above phosphazenes.

12. The composition of claim 10 or 11, wherein a molded sample of the composition exhibits: a UL-94 flammability rating of V0, measured using a 1.0 mm test bar after conditioning at 23 °C for 48 hours and at 70 °C for 168 hours; a UL-94 flammability rating of V0, measured using a 0.75 mm test bar after conditioning at 23 °C for 48 hours and at 70 °C for 168 hours; a UL-94 flammability rating of V0, measured using a 0.5 mm test bar after conditioning at 23 °C for 48 hours and at 70 °C for 168 hours; a UL-94 flammability rating of V0, measured using a 0.3 mm test bar after conditioning at 23 °C for 48 hours and at 70 °C for 168 hours; and a heat distortion temperature greater than or equal to 115 °C, measured according to ASTM D648 on a 3.2 mm thick bar loaded with 1.82 MPa; and a comparative tracking resistance of PLC0, measured according to ASTM D3638.

13. A method for preparing the composition according to any one or more of claims 1 to 12; the method comprises melt-mixing the components of the composition.

14. An article comprising the composition according to any one of claims 1 to 12, preferably wherein the article is an electric vehicle battery module, a battery insulating sheet or film, a battery housing, a battery box, a battery cell frame, a battery cell spacer, a battery cell holder, a bus bar support, a terminal cover, an electrical or electronic component, a charger adapter insulating sheet or film, a thermosetting circuit breaker, a fuse support for an electrostatic copier, a photovoltaic junction box, a photovoltaic connector, an electrical connector, an automotive electrical connector, an electrical relay, a charging coupler, a household appliance component, an automotive component, a portable device, a mobile component, or a fixed electrical component.

15. An electric vehicle battery component, extruded from a composition, the composition comprising: 70 to 85% by weight of poly(phenylene ether); 1 to 15% by weight of an impact modifier comprising a hydrogenated block copolymer of a vinyl aromatic hydrocarbon and a conjugated diene; 5 to 20% by weight of an organophosphate flame retardant; 0.1 to 5% by weight of a flame retardant synergist containing phosphazene; Optionally, 0.8 to 8% by weight of tricalcium phosphate; and Less than 5% by weight of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein the % by weight is based on the total weight of the composition; Preferably, the electric vehicle battery component is an electric vehicle battery insulating sheet or insulating film.

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