Multipurpose polyamide polymer compositions and electric vehicle housings made therefrom

Abstract

A polymer composition containing glass fibers and having an excellent balance of properties is disclosed. The polymer composition exhibits a comparative tracking index of greater than about 400 volts and a dielectric strength of greater than about 4 kV / mm. In addition, the polymer composition can have excellent surface properties even if a part of a longer length is molded. The polymer composition may contain at least one stabilizer in combination with calcium phosphate, such as hydroxy calcium phosphate. In one aspect, calcium phosphate is present in the polymer composition in the form of bone black.

Description

[0001] Related applications This application is based upon and claims the benefit of U.S. Provisional Application Serial No. 63 / 442,930, filed February 2, 2023, and U.S. Provisional Application Serial No. 63 / 592,701, filed October 24, 2023, both of which are incorporated herein by reference. Background Art

[0002] With the advent of electric vehicles and the continued advancement of other electronic components, various electrical components, such as connectors and housings, are becoming increasingly important. For example, electric vehicles (including hybrid vehicles) typically have an electric powertrain consisting of an electric propulsion source (e.g., thousands of lithium-ion battery cells) and at least one electric motor. The electric propulsion source provides high-voltage current, which is supplied to the motor through one or more power electronics modules. Consequently, electric vehicles require numerous electrical connectors, connector housings, and other electrical components to transmit this high-voltage current.

[0003] Polyamide compositions, especially when reinforced with glass fiber, are particularly well-suited for producing electrical components and housings for electric vehicles and other industrial applications. In some applications, flame retardancy is desirable. Consequently, various flame retardant packages have been developed for blending with polyamide compositions.

[0004] In other applications, however, high flame retardancy standards may not be required. However, some flame retardancy, including glow-wire resistance, is always required. Other properties that may be important in certain applications include high dielectric strength, high mechanical properties, and a relatively wide operating temperature range (e.g., up to at least 110°C) for the polymer composition. The polymer composition should also exhibit some chemical resistance, and in some applications, laser markability may be desirable.

[0005] While various polyamide polymer compositions have been formulated in the past, there remains a need for improved compositions having an excellent blend of properties as described above. Summary of the Invention

[0006] In general, the present disclosure relates to polyamide compositions that exhibit a unique and beneficial blend of properties. Particularly advantageously, the polyamide compositions of the present disclosure can be formulated to exhibit glow-wire resistance, high dielectric strength, and a relatively high comparative tracking index. The compositions can be formulated without including a flame retardant package.

[0007] For example, in one embodiment, the present disclosure relates to a polymer composition comprising at least one polyamide polymer, a plurality of inorganic fibers, and at least one stabilizer. According to the present disclosure, the polymer composition contains a phosphate, such as calcium phosphate. In one aspect, the phosphate is calcium hydroxyphosphate. The phosphate can be added alone or as part of a pigment, such as a black pigment, to the composition. For example, the black pigment can include bone char. In one embodiment, the pigment can be incorporated into the composition containing the phosphate, and further amounts of the phosphate can be added separately.

[0008] The polymer compositions of the present disclosure may exhibit a glow-wire flammability index of about 900° C. or greater, for example, about 960° C. or greater, as measured according to IEC-60695-2-12:2010 at a wall thickness of 1.5 mm. The compositions may also exhibit a comparative tracking index of about 400 volts or greater, for example, about 450 volts or greater, for example, about 500 volts or greater, for example, about 550 volts or greater, for example, about 600 volts or greater, as measured according to IEC-60112:2003. The polymer compositions may also exhibit a dielectric strength at end-of-life of about 4 kV / mm or greater, for example, about 5 kV / mm or greater. Dielectric strength may be measured according to ASTM test D149-09.

[0009] Although not yet known, it is believed that phosphates (e.g., calcium hydroxyphosphate) may affect one or more properties of the polymer composition in a beneficial manner. For example, the phosphate may be present in the polymer composition in an amount from about 0.01 wt % to about 4 wt %, such as from about 0.05 wt % to about 2.4 wt %, such as from about 0.05 wt % to about 1.2 wt %.

[0010] As described above, the black pigment incorporated into the polyamide composition can include bone char from animal (e.g., mammalian) bones, and optionally carbon black. The bone char can be present in the polymer composition in an amount of about 0.01% to about 4% by weight, such as about 0.05% to about 2.4% by weight, or about 0.05% to about 1.2% by weight. The carbon black can be present in the polymer composition in relatively small amounts, such as about 0.001% to about 1% by weight, such as about 0.001% to about 0.5% by weight.

[0011] As described above, the polymer composition may include at least one stabilizer. In one aspect, the stabilizer may be a hindered phenolic antioxidant. For example, the hindered phenolic antioxidant may include N,N'-hexane-1,6-diylbis(3-(3,5-di-tert-butyl-4-hydroxyphenylpropionamide). The hindered phenolic antioxidant may typically be present in the polymer composition in an amount of about 0.1 wt% to about 0.7 wt%, for example, about 0.2 wt% to about 0.5 wt%.

[0012] In one aspect, at least one stabilizer can be a phosphite antioxidant. The phosphite antioxidant can be present in the polymer composition alone or in combination with a hindered phenolic antioxidant. In one embodiment, the phosphite antioxidant can have the following structure: [RP(OR1)2] m (1) wherein R is a monovalent or polyvalent aliphatic, aromatic or heteroaromatic organic radical; R1 is independently a compound of structure (II) Or two free radicals R1 form a bridging group of structure (III) Where A is a direct bond, O, S, C 1-18 Alkylene (linear or branched) or C 1-18 Alkylene (linear or branched); R2 is independently C 1-12 Alkyl (linear or branched), C 1-12 Alkoxy or C 5-12 Cycloalkyl; n is 0 to 5, and m is 1 to 4. In one embodiment, R is a cyclohexyl, phenyl, phenylene, or biphenyl radical, and R1 is a group of structure (II), wherein m is 2 and n is 2 to 3.

[0013] At least one stabilizer may also be a light stabilizer, such as a hindered amine light stabilizer. The light stabilizer may include one or more of the following general structures: wherein R1, R2, R3 and R5 are independently hydrogen, ether, ester, amine, amide, alkyl, alkenyl, alkynyl, aralkyl, cycloalkyl and aryl, wherein the substituents may contain functional groups; examples of functional groups are alcohols, ketones, anhydrides, imines, siloxanes, ethers, carboxyls, aldehydes, esters, amides, imides, amines, nitriles, ethers, carbamates or any combination thereof.

[0014] In one embodiment, the hindered amine light stabilizer may include an alkyl-substituted piperidinyl compound. For example, the hindered amine light stabilizer may include N,N′-bis(2,2,6,6-tetramethyl-4-piperidinyl)-1,3-benzenedicarboxamide.

[0015] The polymer composition may also include metal oxides, such as silica particles. The silica particles may be present in the polymer composition in an amount of about 0.001 wt % to about 1.5 wt %, such as about 0.001 wt % to about 0.3 wt %.

[0016] The polymer composition may further comprise a lubricant. The lubricant may comprise a partially saponified ester wax of C22 to C36 fatty acids.

[0017] The one or more polyamides are typically present in the polymer composition in an amount of about 50% to about 90% by weight. The one or more polyamides present in the polymer composition can be one or more aliphatic polyamides alone, or a combination of one or more aliphatic polyamides with a semi-aromatic polyamide or a fully aromatic polyamide. Aliphatic polyamides that can be present in the polymer composition include nylon-6, nylon-6,6, copolymers thereof, or combinations thereof.

[0018] The inorganic fibers present in the polymer composition can include glass fibers. Glass fibers can exist in an amount of about 5 wt % to about 50 wt %, for example, about 25 wt % to about 35 wt %. In one embodiment, the average fiber length of the glass fibers can be about 150 microns to about 600 microns.

[0019] All different types of polymeric articles can be molded from the polymer compositions of the present disclosure. The polymer compositions are particularly suitable for molding into components for electrical devices. For example, an electrical device may include a conductive component surrounded by a molded polymer component formed from the polymer compositions of the present disclosure. The molded polymer component may include a housing surrounding the conductive component.

[0020] In one embodiment, the present disclosure may be directed to producing an electrical interface for an electric vehicle. The electrical interface may include an outer cover defining an interior space. The outer cover may be made of a fire-resistant material, such as aluminum. The interior space of the outer cover may accommodate a polymer housing. The polymer housing may be formed from a polymer composition as described above. For example, the polymer housing may be a junction box, a relay box, or any suitable electronic box. In one embodiment, the polymer housing may include a base plate, a housing cover attached to the base plate, and one or more retainer assemblies for securing the electrical connector within the housing.

[0021] Other features and aspects of the disclosure are discussed in greater detail below. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] A full and enabling disclosure is more particularly set forth in the remainder of the specification, including with reference to the accompanying drawings, in which: Figure 1 is a perspective view of one embodiment of an electrical interface that may be made according to the present disclosure; Figure 2 is a perspective view of a high-voltage charging connector that may include the polymer composition of the present disclosure; Figure 3 is a perspective view of a molded electrical housing made in accordance with the present disclosure, which housing can be used to enclose a lithium-ion battery; Figure 4 is a perspective view of a battery insert that may be made according to the present disclosure; and Figure 5 is a perspective assembly view of one embodiment of an electrical distribution box that may employ the polymer composition of the present disclosure.

[0023] In the present specification and drawings, repeated use of reference characters is intended to represent the same or analogous features or elements of the invention. DETAILED DESCRIPTION

[0024] Those skilled in the art will appreciate that the discussion herein is merely to describe exemplary embodiments and is not intended to limit the broader aspects of the invention.

[0025] In general, the present disclosure relates to a polyamide polymer composition comprising a combination of at least one polyamide resin and reinforcing fibers. While reinforcing fibers can improve the mechanical properties of a polymer composition, their presence can adversely affect other properties, including the comparative tracking index. In this regard, various other additives and components are included in the polymer composition to produce a polymer composition with excellent mechanical properties and a beneficial combination of other properties, including a relatively high comparative tracking index. For example, according to the present disclosure, a polymer composition comprising one or more polyamide polymers and reinforcing fibers may further comprise at least one stabilizer, such as a blend of different stabilizers. Furthermore, the polymer composition may contain calcium phosphate. The calcium phosphate may be present in a colorant (e.g., a pigment) and / or added separately. The polymer composition may also contain one or more lubricants.

[0026] It has been found that polymer compositions formulated according to the present disclosure not only have good comparative tracking index performance, but also produce parts with good surface appearance. Particularly advantageously, larger or longer molded parts can be produced, with at least one dimension being greater than about 0.25 meters, such as greater than about 0.5 meters, such as greater than about 0.75 meters, such as greater than about 1 meter, having excellent surface quality and exhibiting little to no warping after molding or after use and exposure to high temperatures.

[0027] The polymer compositions formulated according to the present disclosure can be operated in a temperature range of, for example, -40°C to greater than 110°C (e.g., up to 150°C). It is believed that the combination of calcium phosphate and at least one stabilizer, and optionally in combination with a lubricant, can control nucleation or crystallinity so that parts made from the polymer composition do not warp in high temperature environments. The polymer composition can exhibit a comparative tracking index that is generally greater than about 400V, such as greater than about 450V, such as greater than about 500V, such as greater than about 550V, such as even greater than 600V. In fact, it has been found that the polymer compositions of the present disclosure can maintain a relatively high comparative tracking index even after heat aging. For example, after heat aging at 150°C for 3000 hours, the polymer composition or molded article prepared according to the present disclosure can exhibit a comparative tracking index that is still greater than about 500V, such as greater than about 550V, such as 600V or more.

[0028] Even when measured at the end of life, the polymer composition can have a dielectric strength greater than about 4 kV / mm, such as greater than about 4.5 kV / mm, such as greater than about 5 kV / mm, such as greater than about 5.5 kV / mm, and typically less than about 10 kV / mm. The polymer composition can also exhibit glow-wire resistance greater than about 900°C, such as greater than about 920°C, such as greater than about 940°C, such as greater than about 960°C, and typically less than about 1500°C at a wall thickness of 1.5 mm. In one embodiment, when calcium phosphate is incorporated into a colorant, particularly a black pigment, a polymer article made from the polymer composition can be laser-markable.

[0029] Of particular advantage, all of the aforementioned properties can be achieved without including a flame retardant in the formulation. For example, in one embodiment, the polymer composition is free of phosphorus-based flame retardants and may be free of metal phosphinates, such as aluminum diethylphosphinate. Even without a flame retardant, the polymer composition can be formulated to exhibit an HB flammability rating at 0.8 mm thickness according to Underwriters Laboratory Test 94.

[0030] Due to excellent flame retardancy, excellent mechanical properties and / or excellent thermal stability and improved melt processing properties, the polymer composition of the present disclosure is very suitable for manufacturing all different types of articles and components. The polymer composition is particularly suitable for producing all different types of electrical components. Such components may include high-voltage powertrain connectors and / or charging connectors for electric vehicles and other devices that can be powered by lithium-ion batteries. The polymer composition is also very suitable for producing housings for encapsulating electrical components. In one embodiment, the polymer composition can be used to produce an electrical interface. For example, the electrical interface can be a relay box, a junction box, or any other suitable electronic box. In one aspect, the polymer composition can be used to produce a polymer housing housed in the interior space of an enclosure. The enclosure can be made of a flame retardant material, such as aluminum. The enclosure can have relatively large dimensions, for example, at least one dimension greater than about 0.5 meters, for example, about 0.75 meters to about 3 meters, while having excellent surface properties and little warping.

[0031] Generally speaking, any suitable polyamide can be incorporated into the polymer composition.For example, the polymer composition can include a single polyamide polymer or can include a mixture of different polyamide polymers.

[0032] Generally speaking, the one or more polyamide polymers are present in the polymer composition in an amount of from about 20% to about 95% by weight (including all 1% by weight increments therebetween). For example, the polymer composition can contain an amount greater than about 40% by weight, such as greater than about 50% by weight, such as greater than about 60% by weight, such as greater than about 65% by weight, such as greater than about 70% by weight, such as greater than about 75% by weight, such as greater than about 80% by weight, and typically less than about 90% by weight, such as less than about 85% by weight, such as less than about 80% by weight, such as less than about 75% by weight of one or more polyamides.

[0033] Polyamides generally have CO-NH bonds in their backbone and are obtained by condensation of diamines with dicarboxylic acids, by ring-opening polymerization of lactams, or by self-condensation of aminocarboxylic acids. For example, polyamides may contain aliphatic repeating units derived from aliphatic diamines, which generally have 4 to 14 carbon atoms. Examples of such diamines include linear aliphatic alkylene diamines, such as 1,4-tetramethylethylenediamine, 1,6-hexanediamine, 1,7-heptanediamine, 1,8-octanediamine, 1,9-nonanediamine, 1,10-decanediamine, 1,11-undecanediamine, and 1,12-dodecanediamine; branched aliphatic alkylene diamines, such as 2-methyl-1,5-pentanediamine, 3-methyl-1,5-pentanediamine, 2,2,4-trimethyl-1,6-hexanediamine, 2,4,4-trimethyl-1,6-hexanediamine, 2,4-dimethyl-1,6-hexanediamine, 2-methyl-1,8-octanediamine, and 5-methyl-1,9-nonanediamine; and combinations thereof. Of course, aromatic diamines and / or alicyclic diamines may also be used. Examples of dicarboxylic acid components include aromatic dicarboxylic acids (e.g., terephthalic acid, isophthalic acid, 2,6-naphthalene dicarboxylic acid, 2,7-naphthalene dicarboxylic acid, 1,4-naphthalene dicarboxylic acid, 1,4-benzenedioxy-diacetic acid, 1,3-benzenedioxy-diacetic acid, biphenyl dicarboxylic acid, 4,4'-oxydibenzoic acid, diphenylmethane-4,4'-dicarboxylic acid, diphenylsulfone-4,4'-dicarboxylic acid, 4,4'-biphenyl dicarboxylic acid, etc.), aliphatic dicarboxylic acids (e.g., adipic acid, sebacic acid, etc.), etc. Examples of lactams include pyrrolidone, aminocaproic acid, caprolactam, undecyl lactam, dodecyl lactam, etc. Similarly, examples of aminocarboxylic acids include amino fatty acids, which are compounds in which the aforementioned lactams are ring-opened with water.

[0034] In certain embodiments, "aliphatic" polyamides formed solely from aliphatic monomer units (e.g., diamine and dicarboxylic acid monomer units) are used. Specific examples of such aliphatic polyamides include nylon-4 (poly-α-pyrrolidone), nylon-6 (polycaproamide), nylon-11 (polyundecanamide), nylon-12 (polydodecanamide), nylon-46 (polytetramethylene adipamide), nylon-66 (polyhexamethylene adipamide), nylon-610, and nylon-612. Nylon-6 and nylon-66 are particularly suitable. In one embodiment, for example, either nylon-6 or nylon-66 may be used alone. In other embodiments, blends of nylon-6 and nylon-66 may be used. When such blends are used, the weight ratio of nylon-66 to nylon-6 is typically from 1 to about 2, in some embodiments from about 1.1 to about 1.8, and in some embodiments from about 1.2 to about 1.6.

[0035] Aromatic monomer units may also be included in the polyamide, making it considered semiaromatic (containing aliphatic monomer units and aromatic monomer units) or fully aromatic (containing only aromatic monomer units). For example, suitable semiaromatic polyamides may include: poly(nonylene terephthalamide) (PA9T), poly(nonylene terephthalamide / nonylene sebacamide) (PA9T / 910), poly(nonylene terephthalamide / nonylene dodecanamide) (PA9T / 912), poly(nonylene terephthalamide / 11-aminoundecaneamide) (PA9T / 11), poly(nonylene terephthalamide / 12-aminododecaneamide) (PA9T / 12), poly(decylene terephthalamide / 11-aminoundecaneamide) (PA10T / 11), poly(decylene terephthalamide / 12-aminododecaneamide) (PA10T / 12), poly(decylene terephthalamide / 11-aminoundecaneamide) (PA10T / 12), poly(decylene terephthalamide / 12-aminododecaneamide) (PA10T / 12), poly(decylene terephthalamide / 11-aminoundecaneamide) (PA10T / 11), poly(decylene terephthalamide / 12-aminododecaneamide) (PA10T / 12), poly(decylene terephthalamide / 11-aminoun ... Poly(decylene terephthalamide / decylene dodecane diamide) (PA10T / 1010), Poly(decylene terephthalamide / decylene dodecane diamide) (PA10T / 1012), Poly(decylene terephthalamide / butylene adipamide) (PA10T / 46), Poly(decylene terephthalamide / caprolactam) (PA10T / 6), Poly(decylene terephthalamide / hexylene hexane diamide) (PA10T / 66), Poly(dodecylene terephthalamide / dodecylene dodecane diamide) (PA12T / 1212), Poly(dodecylene terephthalamide / caprolactam) (PA12T / 6), Poly(dodecylene terephthalamide / hexylene hexane diamide) (PA12T / 66), etc.

[0036] In one embodiment, the polymer composition contains primarily aliphatic polyamide polymers, which may be blended with one or more semi-aromatic polyamide polymers or wholly aromatic polyamide polymers.

[0037] The polyamides employed in the polyamide compositions are typically crystalline or semi-crystalline in nature and, therefore, have a measurable melting temperature. The melting temperature can be relatively high, allowing the composition to provide a considerable degree of heat resistance to the resulting part. For example, the polyamide can have a melting temperature of about 220°C or higher, in some embodiments, about 240°C to about 325°C, and in some embodiments, about 250°C to about 335°C. The polyamide can also have a relatively high glass transition temperature, for example, about 30°C or higher, in some embodiments, about 40°C or higher, and in some embodiments, about 45°C to about 140°C. As is well known in the art, the glass transition temperature and melting temperature can be determined using differential scanning calorimetry ("DSC"), for example, as determined by ISO Test Nos. 11357-2:2013 (Glass Transition) and 11357-3:2011 (Melting).

[0038] In one embodiment, the polyamide polymer incorporated into the polymer composition may comprise post-industrial recycled polymer. For example, the recycled polyamide polymer may be obtained from industrial fibers (including tire cord), carpet fibers, textile fibers, films, fabrics (including airbag fabrics), and the like. When incorporated into the polymer composition, the recycled polyamide polymer may optionally be combined with virgin polymer. For example, the weight ratio between the recycled polyamide polymer and the virgin polyamide polymer may be from about 1:10 to about 10:1. For example, the amount of recycled polyamide polymer incorporated into the polymer composition may be greater than about 8% by weight, such as greater than about 10% by weight, such as greater than about 12% by weight, such as greater than about 15% by weight, such as greater than about 18% by weight, such as greater than about 20% by weight, such as greater than about 22% by weight, such as greater than about 30% by weight, such as greater than about 40% by weight, such as greater than about 50% by weight, such as greater than about 70% by weight, such as greater than about 80% by weight, such as greater than about 90% by weight, such as up to 100% by weight. The recycled polyamide is typically present in an amount less than about 90 wt %, such as less than about 70 wt %, such as less than about 50 wt %, such as less than about 45 wt %, such as less than about 35 wt %, such as less than about 30 wt %, based on the total amount of polyamide polymer present.

[0039] Except one or more polyamide polymers, polymer composition of the present disclosure can also contain fortifying fiber, and it can be inorganic fiber.For example, fortifying fiber or inorganic fiber can be present in polymer composition with the amount greater than about 5 % by weight usually, for example, with the amount greater than about 10 % by weight, for example, with the amount greater than about 15 % by weight, for example, with the amount greater than about 20 % by weight, for example, with the amount greater than about 25 % by weight.Fortifying fiber or inorganic fiber can be present in polymer composition with the amount less than about 50 % by weight usually, for example, with the amount less than about 45 % by weight, for example, with the amount less than about 40 % by weight, for example, with the amount less than about 35 % by weight.

[0040] Inorganic fibers typically have a high tensile strength relative to their mass. For example, the ultimate tensile strength of the fibers is typically from about 1,000 MPa to about 15,000 MPa, in some embodiments from about 2,000 MPa to about 10,000 MPa, and in some embodiments from about 3,000 MPa to about 6,000 MPa. High-strength fibers can be formed from materials that are also electrically insulating in nature, such as glass, ceramics (e.g., alumina or silica), and mixtures thereof. Particularly suitable are glass fibers, such as E-glass, A-glass, C-glass, D-glass, AR-glass, R-glass, Si-glass, S2-glass, and mixtures thereof. The inorganic fibers can have a relatively small median diameter, such as about 50 microns or less, in some embodiments from about 0.1 microns to about 40 microns, and in some embodiments from about 2 microns to about 20 microns, as measured using laser diffraction techniques according to ISO 13320:2009 (e.g., using a Horiba LA-960 particle size distribution analyzer). It is believed that the small diameter of such fibers can make their length easier to shorten during melt blending, which can further improve surface appearance and mechanical properties. For example, after the polymer composition is formed, the average length of the inorganic fibers can be relatively small, such as from about 10 microns to about 800 microns, in some embodiments from about 100 microns to about 700 microns, and in some embodiments from about 150 microns to about 600 microns. The inorganic fibers can also have a relatively high aspect ratio (average length divided by nominal diameter), such as from about 1 to about 100, in some embodiments from about 10 to about 60, and in some embodiments from about 30 to about 50.

[0041] The polymer composition of the present disclosure also contains phosphates, such as hydroxyphosphates. For example, the phosphate can be hydroxyapatite. For example, the phosphate can be an alkali metal phosphate or an alkaline earth metal phosphate. In a specific embodiment, the phosphate includes calcium phosphate, such as calcium hydroxyphosphate. It is believed that when phosphates are incorporated into the polymer composition, the phosphates can provide many advantages and benefits. Although unknown, it is believed that phosphates can improve surface properties, prevent warping, and when combined with pigments, can maintain the color of the polymer composition. For example, phosphates can increase color stability. One or more phosphates can be present in the polymer composition in an amount greater than about 0.1% by weight, for example, in an amount greater than about 0.3% by weight, for example, in an amount greater than about 0.5% by weight, for example, in an amount greater than about 0.7% by weight, for example, in an amount greater than about 0.9% by weight, for example, in an amount greater than about 1.1% by weight. The phosphate can be present in the polymer composition in an amount less than about 4.2 wt %, such as in an amount less than about 3 wt %, such as in an amount less than about 2.4 wt %, such as in an amount less than about 2 wt %, such as in an amount less than about 1.8 wt %, such as in an amount less than about 1.4 wt %, such as in an amount less than about 1.2 wt %, such as in an amount less than about 1 wt %.

[0042] In one embodiment, a phosphate (e.g., calcium hydroxyphosphate) may be included in a colorant incorporated into the polymer composition. For example, the colorant may be a black pigment. In one embodiment, calcium phosphate or calcium hydroxyphosphate may be included in a pigment with bone char. For example, bone char pigment may be produced by destructive distillation of animal bones under anaerobic conditions to form bone char. The average particle size of the bone char may be from about 0.3 microns to about 50 microns. The bone char pigment may comprise from about 10% to about 20% by weight carbon and from about 90% to about 80% by weight calcium phosphate. For example, the calcium phosphate may be incorporated into the polymer composition solely in the bone char, or it may be added separately to the polymer composition. For example, in one embodiment, the bone char may be incorporated into the polymer composition in combination with an additional amount of calcium phosphate.

[0043] Bone char can typically be present in the polymer composition in an amount greater than about 0.1 wt %, such as greater than about 0.3 wt %, such as greater than about 0.5 wt %, such as greater than about 0.7 wt %, such as greater than about 0.9 wt %, such as greater than about 1.1 wt %. Phosphate can be present in the polymer composition in an amount less than about 6 wt %, such as less than about 4.5 wt %, such as less than about 2.4 wt %, such as less than about 2 wt %, such as less than about 1.8 wt %, such as less than about 1.4 wt %, such as less than about 1.2 wt %, such as less than about 1 wt %.

[0044] In one aspect, the bone char can contain about 70% to about 96% calcium hydroxyphosphate by weight, and the remainder of the composition can essentially comprise carbon black. For example, the amount of carbon black in the bone char can be about 4% to about 30% by weight.

[0045] As described above, calcium hydroxyphosphate can be added to the polymer composition in the form of bone char alone. Alternatively, calcium hydroxyphosphate can be added separately from bone char. In yet another embodiment, calcium hydroxyphosphate can be incorporated into the composition by adding not only bone char but also a greater amount of a source of calcium hydroxyphosphate.

[0046] In one aspect, the polymer composition contains calcium hydroxyphosphate in an amount of from about 0.3% to about 4.2% by weight (including all 0.1% by weight increments therebetween). Calcium hydroxyphosphate added in the form of bone char can be present in the polymer composition in an amount from about 0% to about 100% by weight (based on the total amount of calcium hydroxyphosphate present in the composition). For example, the amount of calcium hydroxyphosphate included in the polymer composition in the form of bone char can be greater than about 20% by weight, such as greater than about 40% by weight, such as greater than about 60% by weight, such as greater than about 80% by weight. Calcium hydroxyphosphate can also be present in the polymer composition in a form other than bone char (e.g., pure form) in an amount from about 0% to about 100% by weight. For example, the amount of calcium hydroxyphosphate not added as bone char present in the polymer composition may be greater than about 20% by weight, such as greater than about 40% by weight, such as greater than about 60% by weight, such as greater than about 80% by weight, and the amount of calcium hydroxyphosphate present may be less than about 90% by weight, such as less than about 70% by weight, such as less than about 50% by weight, such as less than about 30% by weight.

[0047] As mentioned above, carbon black can also be incorporated into the polymer composition in the form of bone char. Carbon black can also be added to the polymer composition separately. The total amount of carbon black present in the polymer composition is generally greater than about 0.001 wt %, for example, greater than about 0.01 wt %, for example, greater than about 0.1 wt %, for example, greater than about 0.3 wt %, for example, greater than about 0.5 wt %, for example, greater than about 0.7 wt %, and generally less than about 1 wt %, for example, less than about 0.7 wt %, for example, less than about 0.5 wt %. Although carbon black can produce a polymer composition with desired overall black color, carbon black also can make the tracking index of the overall composition worse. However, it is believed that calcium hydroxyphosphate offsets the influence of carbon black and maintains the tracking index at a relatively high level, for example, about 600V or higher.

[0048] Incorporating bone char into the polymer compositions of the present disclosure can provide various functional benefits, in addition to its use as a black pigment or to supplement calcium phosphate. For example, when molded into an article, bone char can render the polymer composition laser-markable. For example, upon exposure to laser light, the bone char pigment can change color, for example, to white.

[0049] The polymer composition may also contain a variety of other components and additives. For example, the polymer composition may contain one or more stabilizers. An example of a stabilizer that can be incorporated into the polymer composition is a heat stabilizer including a hindered phenolic antioxidant.

[0050] Examples of such phenolic antioxidants include, for example, calcium bis(ethyl 3,5-di-tert-butyl-4-hydroxybenzylphosphonate) (Irganox® 1425); 1,4-dithio-, S,S-bis(4-tert-butyl-3-hydroxy-2,6-dimethylbenzyl) terephthalate (Cyanox® 1729); triethylene glycol bis(3-tert-butyl-4-hydroxy-5-methylhydrocinnamate); hexamethylene bis(3,5-di-tert-butyl-4-hydroxyhydrocinnamate) (Irganox® 259); 1,2-bis(3,5,di-tert-butyl-4-hydroxyhydrocinnamoyl)hydrazide (Irganox® 1024); 4,4'-di-tert-octyldiphenylamine (Naugalube® 1024). 438R); dioctadecyl (3,5-di-tert-butyl-4-hydroxybenzyl)phosphonate (Irganox® 1093); 1,3,5-trimethyl-2,4,6-tris(3',5'-di-tert-butyl-4'-hydroxybenzyl)benzene (Irganox® 1330); 2,4-bis(octylthio)-6-(4-hydroxy-3,5-di-tert-butylanilino)-1,3,5-triazine (Irganox® 565); isooctyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate (Irganox® 1135); octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate (Irganox® 1076); 3,7-bis(1,1,3,3-tetramethylbutyl)-10H-phenothiazine (Irganox® LO 3); 2,2'-methylenebis(4-methyl-6-tert-butylphenol) monoacrylate (Irganox® 3052); 2-tert-butyl-6-[1-(3-tert-butyl-2-hydroxy-5-methylphenyl)ethyl]-4-methylphenyl acrylate (Sumilizer® TM 4039); 2-[1-(2-hydroxy-3,5-di-tert-pentylphenyl)ethyl]-4,6-di-tert-pentylphenyl acrylate (Sumilizer® GS); 1,3-dihydro-2H-benzimidazole (Sumilizer® MB); 2-methyl-4,6-bis[(octylthio)methyl]phenol (Irganox® 1520); N,N'-trimethylenebis-[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionamide (Irganox® 1019); 4-n-octadecyloxy-2,6-diphenylphenol (Irganox® 1063); 2,2'-ethylenebis[4,6-di-tert-butylphenol] (Irganox® 129); N,N'-hexamethylenebis(3,5-di-tert-butyl-4-hydroxyhydrocinnamic acid) (Irganox® 1098); diethyl(3,5-di-tert-butyl-4-hydroxybenzyl)phosphonate (Irganox® 1222);4,4'-Di-tert-octyldiphenylamine (Irganox® 5057); N-phenyl-1-naphthylamine (Irganox® L 05); tris[2-tert-butyl-4-(3-tert-butyl-4-hydroxy-6-methylphenylthio)-5-methylphenyl]phosphite (Hostanox® OSP 1); zinc dinonyldithiocarbamate (Hostanox® VP-ZNCS 1); 3,9-bis[1,1-dimethyl-2-[(3-tert-butyl-4-hydroxy-5-methylphenyl)propionyloxy]ethyl]-2,4,8,10-tetraoxaspiro[5.5]undecane (Sumilizer® AG80); pentaerythritol tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] (Irganox® 1010); Ethylene-bis(oxyethylene)bis[3-(5-tert-butyl-4-hydroxy-m-tolyl)-propionate (Irganox® 245); 3,5-di-tert-butyl-4-hydroxytoluene (Lowinox BHT, Chemtura), etc.;

[0051] In one embodiment, the phenolic antioxidant may be N,N′-hexane-1,6-diylbis(3-(3,5-di-tert-butyl-4-hydroxyphenylpropionamide).

[0052] One or more hindered phenolic antioxidants can typically be present in the polymer composition in an amount greater than about 0.01 wt%, such as in an amount greater than about 0.1 wt%, such as in an amount greater than about 0.2 wt%, such as in an amount greater than about 0.25 wt%, and typically less than about 2 wt%, such as less than about 0.8 wt%, such as less than about 0.5 wt%.

[0053] In one aspect, the polymer composition may further contain a phosphorus-containing antioxidant. The phosphorus-containing antioxidant may include, for example, a phosphinate having the following structure: [RP(OR1)2] m (1) in, R is a monovalent or polyvalent aliphatic, aromatic or heteroaromatic organic radical, such as a cyclohexyl, phenyl, phenylene and / or biphenyl radical; and R1 is independently a compound of structure (II) Or two free radicals R1 form a bridging group of structure (III) in A is a straight bond, O, S, C 1-18 Alkylene (linear or branched) or C 1-18 Alkylidene (linear or branched); R2 is independently C 1-12 Alkyl (linear or branched), C 1-12 Alkoxy or C 5-12 Cycloalkyl; n is 0 to 5, in some embodiments 1 to 4, and in some embodiments 2 to 3; and m is 1 to 4, in some embodiments 1 to 3, and in some embodiments 1 to 2 (eg, 2).

[0054] Particularly preferred are compounds prepared according to the preceding clauses by reacting an aromatic or heteroaromatic system (e.g., benzene, biphenyl, or diphenyl ether) with a phosphorus trihalide (preferably phosphorus trichloride) in the presence of a Friedel-Crafts catalyst (e.g., aluminum chloride, zinc chloride, iron chloride, etc.), followed by reaction with phenols of structures (II) and (III). The present invention also specifically encompasses mixtures containing phosphites produced by an excess of phosphorus trihalide and the aforementioned phenols in a specific reaction sequence.

[0055] In one embodiment, R1 is a group of structure (II). In this group of compounds, antioxidants of general formula (V) are particularly suitable: wherein n is as defined above.

[0056] In one specific embodiment, for example, n in formula (V) is 1, such that the antioxidant is tetrakis(2,4-di-tert-butylphenyl) 4,4'-biphenyl-diphosphonite.

[0057] In one embodiment, the antioxidant may be a reaction product of 2,4-di-tert-butylphenol, phosphorus trichloride, and 1,1'-biphenyl.

[0058] Phosphorus-containing antioxidants or phosphonites can be present in the polymer composition in an amount greater than about 0.01 wt %, for example, greater than about 0.05 wt %, for example, greater than about 0.08 wt %, for example, greater than about 0.12 wt %, for example, greater than about 0.15 wt %, for example, greater than about 0.18 wt %. Phosphorus-containing antioxidants are typically present in an amount less than about 2 wt %, for example, less than about 1 wt %, for example, less than about 0.8 wt %, for example, less than about 0.6 wt %, for example, less than about 0.4 wt %.

[0059] Another stabilizer that may be present in the polymer composition is a hindered amine light stabilizer. Examples of light stabilizers that may be incorporated into the present disclosure include phthalamides. Light stabilizers may also include any compound derived from an alkyl-substituted piperidyl, piperidinyl, or piperazinone compound or a substituted alkoxypiperidinyl compound. Other suitable HALS are derivatives of 2,2,6,6-tetramethylpiperidine. Preferred specific examples of HALS include 2,2,6,6-tetramethyl-4-piperidone, 2,2,6,6-tetramethyl-4-piperidinol, bis-(2,2,6,6-tetramethyl-4-piperidino)-sebacate, a mixture of esters of 2,2,6,6-tetramethyl-4-piperidinol and fatty acids, bis-(2,2,6,6-tetramethyl-4-piperidino)-succinate, bis-(1-octyloxy-2,2,6,6-tetramethyl-4-piperidino)-sebacate, bis-(1,2,2,6,6-pentamethyl-4-piperidino)-sebacate, tetrakis-(2,2,6,6-tetramethyl-4-piperidino)-1,2,3,4 -Butane-tetracarboxylic acid ester, ~ N-butyl-2,2,6,6-tetramethyl-4-piperidinamine, ~ N,N'-bis-(2,2,6,6-tetramethyl-4-piperidinyl)-hexane-1,6-diamine, ~ 2.2'-([2.2.6.6-tetramethyl-4-piperidino)-imino]-bis-[ethanol], ~ 5-(2.2.6.6-tetramethyl-4-piperidino)-2-cyclo-undecyl-oxazole), ~ a mixture of: ~ 2,2,4,4-tetramethyl-21-oxo-7-oxa-3.20-diazadispiro[5.1.11.2]heneicosane-20-propionic acid dodecyl ester and 2.2.4.4tetramethyl-21-oxo-7; Oxa-3,20-diazadispiro[5,1,11,2]heneicosane-20-propionic acid; tetradecyl ester, diacetam 5 (CAS Registry Number: 76505-58-3), malonic acid, [(4-methoxyphenyl)methylene]-, bis(1,2,2,6,6-pentamethyl-4-piperidino) ester, 1,3-benzenedicarboxamide, N,N'-bis(2,2,6,6-tetramethyl-4-piperidino), 3-dodecyl-1-(2,2,6,6-tetramethyl-4-piperidino)-pyrrolidine-2,5-dione, carboxamide, N,N'- 1,6-Hexanediylbis[N-(2,2,6,6-tetramethyl-4-piperidino)],~3-dodecyl-1-(1,2,2,6,6-pentamethyl-4-piperidino)-pyrrolidine-2,5-dione,~1,5-dioxaspiro(5,5)undecane-3,3-dicarboxylic acid,bis(2,2,6,6-tetramethyl-4-piperidino)ester,~1,5-dioxaspiro(5,5)undecane-3,3-dicarboxylic acid,bis(1,2,2,6,6-pentamethyl-4-piperidino) ester, ~bis(1,2,2,6,6-pentamethyl-4-piperidino) (3-5-di-tert-butyl-4-hydroxybenzyl)-butylmalonate, ~tetrakis-(1,2,2,6,6-pentamethyl-4-piperidino)-1,2,3,4-butane-tetra-carboxylate, ~1,2,3,4-butanetetracarboxylic acid, tetrakis(2,2,6,6-tetramethyl-4-piperidino) ester, ~1,2,3,4-butane-tetracarboxylic acid-1,2,3-tris(1,2,2,6,6-pentamethyl-4-piperidino)-4-tridecyl ester, ~8-acetyl-3-dodecyl-7,7,9,9-tetramethyl-1 ,3,8-triazaspiro(4,5)decane-2,4-dione, ~N-2,2,6,6-tetramethyl-4-piperidino-N-amino-oxalamide, ~4-acryloyloxy-1,2,2,6,6-pentamethyl-4-piperidine, ~1,5,8,12-tetrakis[2',4'-bis(1'',2'',2'',6'',6''-pentamethyl-4''-piperidino(butyl)amino)-1',3',5'-triazin-6'-yl]-1,5,8,12-tetraazadodecane, ~1,1'-(1,2-ethane-di-yl)-bis-(3,3',5,5'-tetramethylpiperazinone) (GoodRite 3034), propaneamide, oligomers of 2-methyl-N-(2,2,6,6-tetramethyl-4-piperidino)-2-[(2,2,6,6-tetramethyl-4-piperidino)amino], N-(2-hydroxyethyl)-2,2,6,6-tetramethyl-4-piperidinol and succinic acid, poly[[6-[(1,1,3,3-tetramethylbutyl)amino]-s-triazine-2, 4-diyl][2,2,6,6-tetramethyl-4-piperidino)imino]hexamethylene[(2,2,6,6-tetramethyl-4-piperidino)imino]], ~poly[(6-morpholine-S-triazine-2,4-diyl)[(2.2.6.6-tetramethyl-4-piperidino)-imino]hexamethylene-[(2.2.6.6-tetramethyl-4-piperidino)-imino] ], ~Poly[(6-morpholino-s-triazine-2,4-diyl)[1.2.2.6.6-pentamethyl-4-piperidinyl)imino]-hexamethylene[(2,2,6,6-tetramethyl-4-piperidinyl)imino]], ~Poly(methylpropyl)-3-[(2,2,6,6-tetramethyl-4-piperidinyl)-3-maleimide) of α-methylstyrene and n-(2.2.6.6-tetramethyl-piperidinyl)-4-maleimide and N-stearyl-maleimide -oxy-[4 (2.2.6.6-tetramethyl) -piperidino)] -siloxane copolymer, ~1,2,3,4-butane tetracarboxylic acid, and 8,8,8',8'-tetramethyl-2,4,8,10-tetraoxaspiro [5,5] undecane-3,9-diethanol, 1,2,2,6,6-pentamethyl-4-piperidino ester polymer, ~1,2,3,4-butane tetracarboxylic acid, and 8,8,8',8'-Tetramethyl-2,4,8,10-tetraoxaspiro[5,5]undecane-3,9-diethanol, Polymers of 2,2,6,6-tetramethyl-4-piperidino ester, 7-oxa-3,20-diazadispiro[5,1,11,2]heneicosan-21-one, oligomers of 2,2,4,4-tetramethyl-20-(oxiranylmethyl), 1,3,5-triazine-2,4,6-triamine, N,N''-[1,2-ethanediylbis[[[4,6-bis[butyl(1,2,2,6,6-pentamethyl-4-piperidino)amino]-1,3,5-triazin-2-yl]imino]-3,1-propanediyl]]-bis[N.N''-dibutyl-N.N''-bis(1,2.2.6.6-pentamethyl-4-piperidino)amino] 1,3-Propanediamine, N,N-1,2-ethanediylbis-, polymer with 2,4,6-trichloro-1,3,5-triazine, reaction products with N-butyl-2,2,6,6-tetramethyl-4-piperidinamine, 1,6-hexanediamine, N,N'-bis(2,2,6,6-tetramethyl-4-piperidinyl)-polymer with 2,4,6-trichloro-1,3,5-triazine, reaction products with N-butyl-1-butylamine and N-butyl-2,2,6,6-tetramethyl-4-piperidinamine, 2,9,11,13,15,22,24,26,27,28-decaazatricyclo[21,3,1,110,14]diamine Octadecan-1(27),10,12,14(28),23,25-hexaene-12,25-diamine, N,N'-bis(1,1,3,3-tetramethylbutyl)-2,9,15,22-tetrakis(2,2,6,6-tetramethyl-4-piperidino)-, ~1,1,1''-(1,3,5-triazine-2,4,6-triyltris((cyclohexylimino)-2,1-ethanediyl)tris(3,3,5,5-tetramethylpiperazinone), ~1,1,1''-(1,3,5-triazine-2,4,6-triyltris((cyclohexylimino)-2,1-ethanediyl)tris(3,3,4,5,5-tetramethylpiperazinone) 1,6-Hexanediamine, N,N'-bis(2,2,6,6-tetramethyl-4-piperidino), polymer with 2,4,6-trichloro-1,3,5-triazine, reaction products with 3-bromo-1-propene, n-butyl-1-butylamine and N-butyl-2,2,6,6-tetramethyl-4-piperidinamine, oxidized, hydrogenated, olefins, (C20-24)-4α-, polymer with maleic anhydride, reaction products with 2,2,6,6-tetramethyl-4-piperidinamine, N-2,2,6,6-tetramethyl-4-piperidino-N-amino-oxalamide; 4-acryloyloxy-1,2,2,6,6-pentamethyl-4-piperidine; HALS PB-41 or mixtures thereof.

[0060] In one embodiment, the hindered amine light stabilizer comprises an alkyl-substituted piperidinyl compound. For example, the compound can be a di- or tri-carboxylic acid (ester) amide, such as N,N'-bis(2,2,6,6-tetramethyl-4-piperidinyl)-1,3-benzenedicarboxamide (Nylostab® S-EED).

[0061] One or more light stabilizers can typically be present in the composition in an amount greater than about 0.01 wt%, such as in an amount greater than about 0.05 wt%, such as in an amount greater than about 0.08 wt%, and typically in an amount less than about 2 wt%, such as in an amount less than about 1 wt%, such as in an amount less than about 0.8 wt%, such as in an amount less than about 0.5 wt%, such as in an amount less than about 0.3 wt%, such as in an amount less than about 0.2 wt%.

[0062] In one embodiment, the polyamide polymer composition may further contain a lubricant. Any suitable lubricant may be incorporated into the polymer composition. In one aspect, the lubricant may comprise a partially saponified ester wax. For example, the lubricant may comprise a partially saponified ester wax of a C22 to C36 fatty acid. For example, the fatty acid may comprise a montan wax. In one aspect, the lubricant may comprise 1-methyl-1,3-propanediyl ester. The wax may have an acid value of about 9 mgKOH / g to about 14 mgKOH / g.

[0063] The lubricant can typically be present in the polymer composition in an amount greater than about 0.08 wt%, such as in an amount greater than about 0.1 wt%, such as in an amount greater than about 0.2 wt%, such as in an amount greater than about 0.3 wt%, such as in an amount greater than about 0.4 wt%, and typically in an amount less than about 2.5 wt%, such as in an amount less than about 2 wt%, such as in an amount less than about 1.5 wt%, such as in an amount less than about 1 wt%, such as in an amount less than about 0.8 wt%.

[0064] Another kind of component that can be optionally included in the polymer composition is metal oxide particles, for example silicon dioxide particles.Metal oxide particles or silicon dioxide particles can exist in a relatively small amount.For example, particle can be present in the polymer composition with an amount greater than about 0.001 % by weight, for example with an amount greater than about 0.005 % by weight, for example with an amount greater than about 0.008 % by weight, for example with an amount greater than about 0.01 % by weight, for example with an amount greater than about 0.03 % by weight. Particle usually exists with an amount less than about 1.5 % by weight, for example with an amount less than about 1 % by weight, for example with an amount less than about 0.8 % by weight, for example with an amount less than about 0.5 % by weight, for example with an amount less than about 0.3 % by weight, for example with an amount less than about 0.2 % by weight.

[0065] A variety of additional additives may also be included in the polyamide composition, such as impact modifiers, compatibilizers, particulate fillers (eg, mineral fillers), pigments, and / or other materials added to enhance performance and processability.

[0066] In one embodiment, the polymer composition is formulated to have certain combustion control properties. For example, the polymer composition can exhibit slow horizontal burning on a 0.8 mm thick specimen, with a burning rate of less than about 3 inches per minute, or cessation of combustion before the 5-inch mark. For example, the polymer composition can exhibit an HB rating according to UL 94. These properties can be exhibited by a polymer composition that does not contain a flame retardant. For example, in one embodiment, the polymer composition can be free of phosphorus-based flame retardants. For example, the polymer composition can be formulated to be free of metal phosphonates, such as aluminum diethylphosphonate.

[0067] Alternatively, one or more flame retardants may be incorporated into the polymer composition. For example, the polymer composition may contain a combination of a metal phosphinate as described above with a nitrogen synergist and zinc borate. For example, the nitrogen synergist may be melamine phosphate.

[0068] The polyamide, inorganic fiber, and other additives can be melt-processed or blended together. The components can be supplied individually or in combination to an extruder, which includes at least one screw rotatably mounted and housed within a barrel (e.g., a cylindrical barrel) and can define a feed section and a melt section located downstream of the feed section along the length of the screw. The fiber can optionally be added to a location downstream of the polyamide supply point (e.g., a hopper). If desired, a flame retardant can also be added to the extruder downstream of the polyamide supply point. One or more sections of the extruder are typically heated, for example, to a temperature ranging from about 200°C to about 450°C, in some embodiments from about 220°C to about 350°C, and in some embodiments from about 250°C to about 350°C, to form the composition. The screw speed can be selected to achieve the desired residence time, shear rate, melt processing temperature, etc. For example, the screw speed can range from about 50 revolutions per minute (rpm) to about 800 rpm, in some embodiments from about 70 rpm to about 150 rpm, and in some embodiments from about 80 rpm to about 120 rpm. The apparent shear rate during melt blending can also be about 100s -1 to about 10,000s -1 , in some embodiments about 500s -1 to about 5000s -1 , and in some embodiments about 800s -1 to about 1200s -1 The apparent shear rate is equal to 4Q / πR3 ,in Q is the volume flow rate of the polymer melt (“m 3 / s"), and R is the radius ("m") of the capillary (e.g., extruder die) through which the molten polymer flows.

[0069] Regardless of the specific manner in which it is formed, the resulting polyamide composition can have excellent thermal properties. For example, the melt viscosity of the polyamide composition can be low enough to allow it to easily flow into a cavity of a mold having a small size. In a particular embodiment, the melt viscosity of the polyamide composition can be low enough to allow it to flow into a cavity having a small size. -1 The polyamide composition may have a melt viscosity of from about 400 Pascal-seconds to about 1,000 Pascal-seconds ("Pa-s"), in some embodiments from about 450 Pa-s to about 900 Pa-s, and in some embodiments from about 500 Pa-s to about 800 Pa-s, when measured at a shear rate of 1000 rpm. The melt viscosity may be measured according to ISO Test No. 11443:2005 at a temperature 15° C. above the melting temperature of the composition (e.g., 285° C.).

[0070] The polyamide polymer compositions of the present disclosure can be used to produce all different types of molded components and parts. Figures 1 to 5 Examples of articles that may include the polymer composition are shown. Figure 1 , shows one embodiment of a junction box, relay box or other electronic box 50. The electronic box 50 may form part of an electrical interface, including an optional outer cover covering the entire assembly, such as Figure 1 For example, the optional outer cover can be made of a flame retardant material, such as aluminum, and can define an interior space. The electronic box 50 can be accommodated in the interior space of the outer cover.

[0071] As shown, the electronic box 50 includes a housing cover 52 attached to a base plate 54. The electronic box 50 may also include various internal components 56, including a retainer assembly 58. The retainer assembly 58 is used to secure various electrical components, such as an electrical connector 60. The electronic box 50 can be made from the polymer composition of the present disclosure. For example, the entire electronic box assembly can be made from the polymer composition, or various components can be made from the polymer composition.

[0072] The electronics box 50 can serve as an electrical interface for an electric vehicle. For example, the electronics box 50 can serve as an energy and load management device for a battery system. The electronics box 50 can be housed within the battery system of an electric vehicle and can be located, for example, on top of a battery module.

[0073] Now refer to Figure 2, a high-voltage charging plug or connector 10 is shown. As shown, the charging plug 10 is in electrical communication with a voltage source 12 and is connected to an electric vehicle 14. The charging plug or connector 10 may include a connector portion that includes electrical pins that make an electrical connection to a high-voltage circuit contained within the electric vehicle 14. A protective or insulating member extends from a base and surrounds at least a portion of the electrical pins contained within the charging plug 10. At least the base of the protective member may be comprised of the polymer composition of the present disclosure. The polymer composition of the present disclosure may also be used to produce a variety of other components contained within the charging plug 10.

[0074] In one embodiment, the polymer composition of the present disclosure can also be used to produce other housings for accommodating electrical components. Figure 3 , shows a portion of a battery housing 30. The battery housing 30 may include a variety of complex shapes, all of which may be molded from the polymer composition of the present disclosure. Similarly, Figure 4 A battery insert 40 is shown that may also be molded from the polymer composition of the present disclosure. In one embodiment, the battery insert 40 may form part of the housing of a battery and may be used to connect the battery to an electrical connector.

[0075] Apart from Figures 1 to 4 In addition to the structure shown in , various other electrical components, especially those well-suited for electric vehicles, can also employ the polymer compositions of the present disclosure. Figure 5 , an embodiment of a battery system is shown, which includes, for example, a main relay 3, a main fuse 4, a shunt 5, a heating relay 6, a pre-charge relay 7, and a pre-charge resistor 8. The system may also include a relay box. In this particular embodiment, the relay box is formed by a housing including a base 1 and an upper cover 2. Of course, it should also be understood that the box can be a single component or can include other parts. If desired, the base 1 and / or the upper cover 2 can be made of the polymer composition of the present disclosure.

[0076] In the illustrated embodiment, the positive circuit includes a main relay 3 and a main fuse 4 connected in series. The main fuse 4 is electrically connected to the positive output terminal of a battery module (not shown). The upper cover 2 includes a first cover 21 and a second cover 25 that are interconnected. The first cover 21 covers the first area, and the second cover 25 covers the second area. The first and second covers 21, 25 can be connected to form a stepped structure, giving the resulting case a regular shape. The main fuse 4 can be connected in series with the main relay 3 via a connecting bar 31 to form a positive circuit, with the input line of the positive circuit securely supported on the first boss.

[0077] The outer wall of the upper cover 2 has inwardly recessed grooves 23 at the corner positions and at the position where the first box cover 21 and the second box cover 25 are connected. The groove 23 at the upper left corner of the first box cover 21 makes way for the input line of the positive circuit, and the grooves 23 at the upper left and upper right corners of the second box cover 25 make way for the input line and output line of the negative circuit respectively. Furthermore, the upper cover 2 is fixedly connected to the base 1 by bolts. Specifically, the diagonal positions of the accommodating groove have bosses 125 and bosses 127, and the diagonal positions of the upper cover 2 are recessed inward to form a mounting groove. Preferably, a partition 120 is provided on the combined boss, and the partition 120 is located between the input line of the heating circuit and the output line of the positive circuit to achieve physical insulation between the heating circuit and the positive circuit, thereby improving the reliability of the distribution box. In addition, the box also includes an adapter plug 9. The positive circuit, negative circuit, heating circuit and pre-charging circuit are all connected to the external control unit through the adapter plug 9, which avoids the confusion of the internal wiring of the box and reduces the use of wiring harnesses. Example

[0078] The present disclosure may be better understood with reference to the following examples.

[0079] Testing methods of embodiments Tensile modulus, tensile stress and tensile elongation at break: Tensile properties can be tested according to ISO 527:2019 (technically equivalent to ASTM D638-14). Modulus and strength measurements can be performed on identical test strip samples with a length of 80 mm, a thickness of 10 mm, and a width of 4 mm. The test temperature can be 23°C, and the test speed can be 1 mm / min or 5 mm / min.

[0080] Comparative Tracking Index ("CTI") : The Comparative Tracking Index (CTI) can be determined in accordance with the International Standard IEC 60112-2020 to provide a quantitative indication of the performance of a composition as an electrical insulating material under conditions of moisture and / or contamination. In determining the CTI rating of a composition, two electrodes are placed on a molded test specimen. When a 0.1% aqueous solution of ammonium chloride is dropped onto the test specimen, a voltage difference is then established between the electrodes. The maximum voltage at which five (5) specimens can withstand 50 drops during the test without failing is determined. The test voltage range is 100V to 600V in increments of 25V. The voltage value at which fifty (50) drops of electrolyte result in failure is the "Comparative Tracking Index". This value provides an indication of the relative resistance of a material to tracking. According to UL746A, a nominal part thickness of 3mm is considered representative of performance at other thicknesses.

[0081] UL94: The specimens were supported in a vertical position and a flame was applied to the bottom of the specimens. The flame was applied for ten (10) seconds and then removed until the flame stopped, at which point the flame was reapplied for ten (10) seconds and then removed. Two (2) groups of five (5) specimens were tested. The specimen dimensions were 125 mm in length, 13 mm in width and 0.8 mm in thickness or as specified. Both groups were conditioned before and after aging. For the unaged tests, each thickness was tested after conditioning for 48 hours at 23°C and 50% relative humidity. For the aged tests, five (5) specimens of each thickness were tested after conditioning for 7 days at 70°C.

[0082] The following is one embodiment of a polymer formulation according to the present disclosure.

[0083] As shown above, this sample exhibits an excellent balance of properties.

[0084] These and other modifications and variations may be made to the present invention by those of ordinary skill in the art without departing from the spirit and scope of the present invention as more particularly set forth in the appended claims. Furthermore, it should be understood that aspects of the various embodiments may be interchangeable in whole or in part. Furthermore, it will be understood by those of ordinary skill in the art that the foregoing description is merely exemplary and is not intended to limit the present invention as further described in the appended claims.

Claims

1. A polymer composition comprising at least one polyamide polymer, a plurality of inorganic fibers, at least one stabilizer, and a phosphate, wherein the composition exhibits: A glow-wire flammability index of approximately 900°C or higher measured at a wall thickness of 1.5 mm according to IEC-60695-2-12:2010; A comparative tracking index of approximately 600 volts or greater, measured in accordance with IEC 60112:2003; and Dielectric strength of 4kV / mm or higher.

2. The polymer composition of claim 1 , wherein the phosphate comprises calcium hydroxyphosphate and is present in the composition in an amount of about 0.01 wt % to about 4 wt %, such as about 0.05 wt % to about 2.4 wt %, such as about 0.05 wt % to about 1.2 wt %.

3. The polymer composition of any one of the preceding claims, wherein the composition comprises bone char from animal bones.

4. The polymer composition of claim 3, wherein the bone char is present in the polymer composition in an amount of about 0.01 wt% to about 4 wt%, such as about 0.05 wt% to about 2.4 wt%, such as about 0.05 wt% to about 1.2 wt%.

5. The polymer composition of any one of the preceding claims, wherein the composition comprises carbon black in an amount from about 0.001 wt% to about 1 wt%.

6. The polymer composition of any one of the preceding claims, wherein the at least one stabilizer comprises a hindered phenolic antioxidant.

7. The polymer composition of claim 6, wherein the hindered phenolic antioxidant comprises N,N'-hexane-1,6-diylbis(3-(3,5-di-tert-butyl-4-hydroxyphenylpropionamide).

8. The polymer composition according to claim 6 or 7, wherein the hindered phenolic antioxidant is present in the polymer composition in an amount of about 0.1 wt% to about 0.7 wt%, such as about 0.2 wt% to about 0.5 wt%.

9. The polymer composition of any one of the preceding claims, wherein the at least one stabilizer comprises a phosphonite having the structure: [R-P(OR1)2] m   (1) in, R is a monovalent or multivalent aliphatic, aromatic or heteroaromatic organic radical; and R1 is independently a compound of structure (II) Or two free radicals R1 form a bridging group of structure (III) in A is a straight bond, O, S, C 1-18 Alkylene (linear or branched) or C 1-18 Alkylidene (linear or branched); R2 is independently C 1-12 Alkyl (linear or branched), C 1-12 Alkoxy or C 5-12 Cycloalkyl; n is 0 to 5, and m is 1 to 4.

10. The polymer composition of claim 9, wherein R is a cyclohexyl group, a phenyl group, a phenylene group, or a biphenyl group, and R1 is a group of structure (II) wherein m is 2 and n is 2 to 3.

11. The polymer composition of claim 1 , wherein the at least one stabilizer comprises a light stabilizer, and wherein the light stabilizer comprises one or more of the following general structures: in, R1, R2, R3 and R5 are independently hydrogen, ether, ester, amine, amide, alkyl, alkenyl, alkynyl, aralkyl, cycloalkyl and aryl, wherein the substituents can contain functional groups; examples of functional groups are alcohols, ketones, anhydrides, imines, siloxanes, ethers, carboxyls, aldehydes, esters, amides, imides, amines, nitriles, ethers, carbamates or any combination thereof.

12. The polymer composition of claim 11, wherein the light stabilizer comprises an alkyl-substituted piperidinyl compound.

13. The polymer composition of claim 11, wherein the light stabilizer comprises N,N'-bis(2,2,6,6-tetramethyl-4-piperidinyl)-1,3-benzenedicarboxamide.

14. The polymer composition of any preceding claim, further comprising silica particles present in an amount of about 0.001 wt% to about 1.5 wt%, such as about 0.001 wt% to about 0.3 wt%.

15. The polymer composition according to any one of the preceding claims, further comprising a lubricant.

16. The polymer composition of claim 15, wherein the lubricant comprises a partially saponified ester wax of C22 to C36 fatty acids.

17. The polymer composition of any of the preceding claims, wherein the at least one polyamide polymer comprises from about 50% to about 80% by weight of the composition and the inorganic fibers comprise from about 5% to about 50% by weight of the composition.

18. The polymer composition of any one of the preceding claims, wherein the polymer composition is free of phosphorus flame retardants.

19. The polymer composition of any one of the preceding claims, wherein the polymer composition is free of metal phosphinates.

20. The polymer composition of claim 1, wherein the polyamide polymer is an aliphatic polyamide polymer.

21. The polymer composition of claim 20, wherein the aliphatic polyamide polymer is nylon-6, nylon-6,6, a copolymer thereof, or a combination thereof.

22. The polymer composition of claim 21, wherein the aliphatic polyamide polymer is present together with a semi-aromatic polyamide polymer or a wholly aromatic polyamide polymer.

23. The polymeric composition of any of the preceding claims, wherein the inorganic fibers comprise glass fibers, and the glass fibers are present in the polymeric composition in an amount of about 25% to about 35% by weight, and the glass fibers have an average fiber length of about 150 microns to about 600 microns.

24. The polymer composition according to any one of the preceding claims, wherein the polymer composition is laser markable.

25. An electrical interface for an electric vehicle, comprising: an outer cover defining an interior space; as well as A polymer shell housed in the interior space of the outer cover, the polymer shell being formed from the polymer composition of any one of claims 1 to 24.

26. The electrical interface for an electric vehicle of claim 25, wherein the polymer housing comprises a junction box or a relay box.

27. An electrical interface for an electric vehicle according to claim 25 or 26, wherein the outer cover comprises aluminum.

28. An electrical interface for an electric vehicle according to claim 25, 26 or 27, wherein the polymeric housing comprises a base plate attached to a housing cover, the housing comprising at least one retainer assembly for securing an electrical connector.

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