Thermoplastic composition, method for the manufacture thereof, and article comprising the composition

Abstract

A thermoplastic composition includes particular amounts of a poly(phenylene ether), an impact modifier including a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene, an organophosphate ester flame retardant, a flame retardant synergist including a phosphazene, and optionally, tricalcium phosphate. The thermoplastic composition can be useful for the manufacture of various articles, particularly for thin wall applications.

Description

22SHPP0036-WO-PCT (SS220055PCT) THERMOPLASTIC COMPOSITION, METHOD FOR THE MANUFACTURE THEREOF, AND ARTICLE COMPRISING THE COMPOSITION CROSS REFERENCE TO RELATED APPLICATION This application claims priority to and the benefit of European Patent Application No. 22216850.2, filed December 28, 2022, the contents of which are hereby incorporated by reference in their entirety. BACKGROUND

[0001] Poly(arylene ether)s are commercially attractive materials because of their unique combination of properties, including, for example, high temperature resistance, dimensional and hydrolytic stability, and electrical properties.

[0002] There is a continuing need in the art for a poly(arylene ether) composition having a low flammability, particularly for thin wall applications. It would be further advantageous if, in addition to low flammability, the composition also exhibited high heat resistance, high impact strength, and hydrolytic resistance SUMMARY

[0003] An aspect of the present disclosure is a thermoplastic composition, comprising: 72 to 85 weight percent of a poly(phenylene ether); 1 to 15 weight percent of an impact modifier comprising a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene; 5 to 20 weight percent of an organophosphate ester flame retardant; 0.1 to 5 weight percent of a flame retardant synergist comprising a phosphazene; optionally, 0.8 to 8 weight percent of tricalcium phosphate; and less than 5 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein weight percent is based on the total weight of the composition.

[0004] Another aspect of the present disclosure is a method of making the composition, the method comprising melt-mixing the components of the composition.

[0005] Another aspect of the present disclosure is an article comprising the composition.

[0006] Another aspect of the present disclosure is an electric vehicle battery component extruded from a composition comprising: 70 to 85 weight percent of a poly(phenylene ether); 1 to 15 weight percent of an impact modifier comprising a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene; 5 to 20 weight percent of an organophosphate ester flame retardant; 0.1 to 5 weight percent of a flame retardant synergist comprising a phosphazene; optionally, 0.8 to 8 weight percent of tricalcium phosphate; and less than 5 weight22SHPP0036-WO-PCT (SS220055PCT) percent of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein weight percent is based on the total weight of the composition; preferably wherein the electric vehicle battery component is an electric vehicle battery insulation sheet or film.

[0007] The above described and other features are exemplified by the following detailed description. DETAILED DESCRIPTION

[0008] The present inventors have unexpectedly discovered that a particular thermoplastic composition can provide a desirable combination of properties. More specifically, a composition which includes particular amounts of a poly(phenylene ether), an impact modifier comprising a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene, an organophosphate ester flame retardant, a flame retardant synergist, and, optionally, tricalcium phosphate can provide a desirable combination of low flammability, high heat resistance, high impact strength, and hydrolytic resistance.

[0009] Accordingly, an aspect of the present disclosure is a thermoplastic composition. The thermoplastic composition comprises a poly(phenylene ether). As used herein, a poly(phenylene ether) comprises repeating structural units according to formula (1)wherein each occurrence of Z1is independently halogen, unsubstituted or substituted C1-12hydrocarbyl provided that the hydrocarbyl group is not tertiary hydrocarbyl, C1-12hydrocarbylthio, C1-12hydrocarbyloxy, or C2-12halohydrocarbyloxy wherein at least two carbon atoms separate the halogen and oxygen atoms; and each occurrence of Z2is independently hydrogen, halogen, unsubstituted or substituted C1-12 hydrocarbyl provided that the hydrocarbyl group is not tertiary hydrocarbyl, C1-12 hydrocarbylthio, C1-12 hydrocarbyloxy, or C2-12 halohydrocarbyloxy wherein at least two carbon atoms separate the halogen and oxygen atoms. As used herein, the term “hydrocarbyl”, whether used by itself, or as a prefix, suffix, or fragment of another term, refers to a residue that contains 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 hydrocarbon moieties. However, when the hydrocarbyl residue is described as substituted, it may, optionally, contain heteroatoms over and above the carbon and22SHPP0036-WO-PCT (SS220055PCT) hydrogen members of the substituent residue. Thus, when specifically described as substituted, the hydrocarbyl residue can also contain one or more carbonyl groups, amino groups, hydroxyl groups, or the like, or it can contain heteroatoms within the backbone of the hydrocarbyl residue. As one example, Z1can be a di-n-butylaminomethyl group formed by reaction of a terminal 3,5-dimethyl-1,4-phenyl group with the di-n-butylamine component of an oxidative polymerization catalyst.

[0010] In an aspect, the poly(phenylene ether) block comprises 2,6-dimethyl-1,4- phenylene ether repeating units, that is, repeating units according to formula (2)2,3,6-trimethyl-1,4-phenylene ether repeating units, or a combination thereof.

[0011] The poly(phenylene ether) can comprise molecules having aminoalkyl-containing end group(s), typically located in a position ortho to the hydroxy group. Also frequently present are tetramethyldiphenoquinone (TMDQ) end groups, typically obtained from 2,6-dimethylphenol-containing reaction mixtures in which tetramethyldiphenoquinone by-product is present. The poly(phenylene ether) can be in the form of a homopolymer, a copolymer, a graft copolymer, an ionomer, or a block copolymer, as well as combinations thereof.

[0012] In an aspect, the poly(phenylene ether) can have an intrinsic viscosity of 0.03 to 2 deciliter per gram (dl / g). For example, the poly(phenylene ether) can have an intrinsic viscosity of greater than 0.25 dl / g, or 0.25 to 1.7 dl / g, specifically 0.25 to 0.7 dl / g, more specifically 0.35 to 0.55 dl / g, even more specifically 0.35 to 0.50 dl / g, or 0.4 to 0.6 dl / g, measured at 25ºC in chloroform using an Ubbelohde viscometer.

[0013] The poly(phenylene ether) can be prepared by an oxidative polymerization method. In such a method, the poly(phenylene ether) is the product of oxidatively polymerizing a monomer mixture comprising a monohydric phenol, which can be as described above.

[0014] The poly(phenylene ether) can be present in the thermoplastic composition in an amount of 72 to 85 weight percent, based on the total weight of the composition. Within this range, the poly(phenylene ether) can be present in an amount of 73 to 85 weight percent, or 72 to 80 weight percent or 73 to 80 weight percent, or 74 to 85 weight percent, or 74 to 80 weight percent, each based on the total weight of the composition.22SHPP0036-WO-PCT (SS220055PCT)

[0015] In addition to the poly(phenylene ether), the thermoplastic composition further includes an impact modifier comprising a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene. For brevity, this component is referred to as the “hydrogenated block copolymer”. The hydrogenated block copolymer can comprise 10 to 90 weight percent of poly(alkenyl aromatic) content and 90 to 10 weight percent of hydrogenated poly(conjugated diene) content, based on the weight of the hydrogenated block copolymer. In an aspect, the hydrogenated block copolymer is a low poly(alkenyl aromatic content) hydrogenated block copolymer in which the poly(alkenyl aromatic) content is 10 to less than 40 weight percent, or 20 to 35 weight percent, or 25 to 35 weight percent, or 30 to 35 weight percent, all based on the weight of the low poly(alkenyl aromatic) content hydrogenated block copolymer. In an aspect, the hydrogenated block copolymer is a high poly(alkenyl aromatic content) hydrogenated block copolymer in which the poly(alkenyl aromatic) content is 40 to 90 weight percent, or 50 to 80 weight percent, or 60 to 70 weight percent, all based on the weight of the high poly(alkenyl aromatic content) hydrogenated block copolymer.

[0016] In an aspect, the hydrogenated block copolymer has a weight average molecular weight of 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 to polystyrene standards. In an aspect, the hydrogenated block copolymer has a weight average molecular weight of 200,000 to 400,000 g / mol, or 220,000 to 350,000 g / mol. In an aspect, the hydrogenated block copolymer has a weight average molecular weight of 40,000 to 200,000 g / mol, or 40,000 to 180,000 g / mol, or 40,000 to 150,000 g / mol.

[0017] The alkenyl aromatic monomer used to prepare the hydrogenated block copolymer can have the structure according to formula (6)wherein R5and R6each independently represent a hydrogen atom, a C1-8alkyl group, or a C2-8alkenyl group; R7and R11each independently represent a hydrogen atom, a C1-8alkyl group, a chlorine atom, or a bromine atom; and R8, R9, and R10each independently represent a hydrogen atom, a C1-8alkyl group, or a C2-8alkenyl group, or R8and R10are taken together with the central aromatic ring to form a naphthyl group, or R9and R10are taken together with the central aromatic ring to form a naphthyl group. Specific alkenyl aromatic monomers include, for22SHPP0036-WO-PCT (SS220055PCT) example, styrene, chlorostyrenes such as p-chlorostyrene, methylstyrenes such as alpha-methylstyrene and p-methylstyrene, and t-butylstyrenes such as 3-t-butylstyrene and 4-t- butylstyrene. In an aspect, the alkenyl aromatic monomer is styrene.

[0018] The conjugated diene used to prepare the hydrogenated block copolymer can be a C4-20 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, and the like, and combinations thereof. In an aspect, the conjugated diene is 1,3- butadiene, 2-methyl-1,3-butadiene, or a combination thereof. In an aspect, the conjugated diene is 1,3-butadiene.

[0019] The hydrogenated block copolymer is a copolymer comprising (A) at least one block derived from an alkenyl aromatic compound and (B) at least one block derived from a conjugated diene, in which the aliphatic unsaturated group content in the block (B) is at least partially reduced by hydrogenation. In an aspect, the aliphatic unsaturation in the (B) block is reduced by at least 50 percent, or at least 70 percent. The arrangement of blocks (A) and (B) includes a linear structure, a grafted structure, and a radial teleblock structure with or without a branched chain. Linear block copolymers include tapered linear structures and non-tapered linear structures. In an aspect, the hydrogenated block copolymer has a tapered linear structure. In an aspect, the hydrogenated block copolymer has a non-tapered linear structure. In an aspect, the hydrogenated block copolymer comprises a (B) block that comprises random incorporation of alkenyl aromatic monomer. 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), and pentablock (A-B-A-B- A block or B-A-B-A-B block) structures as well as linear structures containing 6 or more blocks in total of (A) and (B), wherein the molecular weight of each (A) block can be the same as or different from that of other (A) blocks, and the molecular weight of each (B) block can be the same as or different from that of other (B) blocks. In an aspect, the hydrogenated block copolymer is a diblock copolymer, a triblock copolymer, or a combination thereof.

[0020] In an aspect, the hydrogenated block copolymer excludes the residue of monomers other than the alkenyl aromatic compound and the conjugated diene. In an aspect, the hydrogenated block copolymer consists of blocks derived from the alkenyl aromatic compound and the conjugated diene. It does not comprise grafts formed from these or any other monomers. It also consists of carbon and hydrogen atoms and therefore excludes heteroatoms. In an aspect, the hydrogenated block copolymer includes the residue of one or more acid functionalizing agents, such as maleic anhydride. In an aspect, the hydrogenated block copolymer comprises a polystyrene-poly(ethylene-butylene)-polystyrene triblock copolymer.22SHPP0036-WO-PCT (SS220055PCT)

[0021] In an aspect, the hydrogenated block copolymer is a polystyrene-poly(ethylene- butylene)-polystyrene triblock copolymer having a polystyrene content of 10 to 50 weight percent, or 20 to 40 weight percent, or 20 to 35 weight percent, or 25 to 35 weight percent, based on the weight of the polystyrene-poly(ethylene-butylene)-polystyrene triblock copolymer. In these aspects, the polystyrene-poly(ethylene-butylene)-polystyrene triblock copolymer can, optionally, have a weight average molecular weight of 200,000 to 400,000 grams per mole, or 250,000 to 350,000 grams per mole, determined by size exclusion chromatography using polystyrene standards.

[0022] Methods for preparing hydrogenated block copolymers are known in the art and many hydrogenated block copolymers are commercially available. Illustrative commercially available hydrogenated block copolymers include the polystyrene-poly(ethylene-propylene) diblock copolymers available from Kraton Performance Polymers Inc. as KRATONTMG1701 (having 37 weight percent polystyrene) and G1702 (having 28 weight percent polystyrene); the polystyrene-poly(ethylene-butylene)-polystyrene triblock copolymers available from Kraton Performance Polymers Inc.as KRATONTMG1641 (having 33 weight percent polystyrene), G1650 (having 30 weight percent polystyrene), G1651 (having 33 weight percent polystyrene), and G1654 (having 31 weight percent polystyrene); and the polystyrene-poly(ethylene- ethylene / propylene)-polystyrene triblock copolymers available from Kuraray as SEPTONTMS4044, S4055, S4077, and S4099. Additional commercially available hydrogenated block copolymers include polystyrene-poly(ethylene-butylene)-polystyrene (SEBS) triblock copolymers available from Dynasol as CALPRENETMH6140 (having 31 weight percent polystyrene), H6170 (having 33 weight percent polystyrene), H6171 (having 33 weight percent polystyrene), and H6174 (having 33 weight percent polystyrene); and from Kuraray as SEPTONTM8006 (having 33 weight percent polystyrene) and 8007 (having 30 weight percent polystyrene); polystyrene-poly(ethylene-propylene)-polystyrene (SEPS) copolymers available from Kuraray as SEPTONTM2006 (having 35 weight percent polystyrene) and 2007 (having 30 weight percent polystyrene); and oil-extended compounds of these hydrogenated block copolymers available from Kraton Performance Polymers Inc.as KRATONTMG4609 (containing 45% mineral oil, and the SEBS having 33 weight percent polystyrene) and G4610 (containing 31% mineral oil, and the SEBS having 33 weight percent polystyrene); and from Asahi as TUFTECTMH1272 (containing 36% oil, and the SEBS having 35 weight percent polystyrene). Mixtures of two of more hydrogenated block copolymers can be used. In an aspect, the hydrogenated block copolymer comprises a polystyrene poly(ethylene-butylene)-22SHPP0036-WO-PCT (SS220055PCT) polystyrene triblock copolymer having a weight average molecular weight of at least 100,000 grams per mole, or 200,000 to 400,000 grams per mole.

[0023] The composition comprises the hydrogenated block copolymer in an amount of 1 to 15 weight percent, based on the total weight of the composition. Within this range, the hydrogenated block copolymer amount can be 1 to 10 weight percent, or 3 to 10 weight percent, or 3 to 8 weight percent, or 5 to 10 weight percent, or 4 to 8 weight percent, or 5 to 7 weight percent.

[0024] In an aspect, impact modifiers other than the hydrogenated block copolymer can be minimized (i.e., present in an amount of less than 1 weight percent) or excluded from the thermoplastic composition. For example, a homopolystyrene or a high impact polystyrene can be excluded from the composition.

[0025] In addition to the poly(phenylene ether) and the impact modifier, the thermoplastic composition further includes an organophosphate ester flame retardant. Exemplary organophosphate ester compounds include phosphate esters comprising phenyl groups, substituted phenyl groups, or a combination of phenyl groups and substituted phenyl groups, bis-aryl phosphate esters based upon resorcinol such as, for example, resorcinol bis(diphenyl phosphate), as well as those based upon bisphenols such as, for example, bisphenol A bis(diphenyl phosphate). In an aspect, the organophosphate ester is selected from tris(alkylphenyl) phosphates (for example, CAS Reg. No.89492-23-9 or CAS Reg. No. 78-33-1), resorcinol bis(diphenyl phosphate) (CAS Reg. No.57583-54-7), bisphenol A bis(diphenyl phosphate) (CAS Reg. No.181028-79-5), triphenyl phosphate (CAS Reg. No.115- 86-6), tris(isopropylphenyl) phosphates (for example, CAS Reg. No.68937-41-7), t-butylphenyl diphenyl phosphates (CAS Reg. No.56803-37-3), bis(t-butylphenyl) phenyl phosphates (CAS Reg. No.65652-41-7), tris(t-butylphenyl) phosphates (CAS Reg. No.78-33-1), and combinations thereof.

[0026] In an aspect the organophosphate ester comprises a bis-aryl phosphate according to formula (7)wherein R is independently at each occurrence a C1-12alkylene group; R16and R17are independently at each occurrence a C1-5alkyl group; R12, R13, and R15are independently a C1-12hydrocarbyl group; R14is independently at each occurrence a C1-12 hydrocarbyl group; n is 1 to22SHPP0036-WO-PCT (SS220055PCT) 25; and s1 and s2 are independently an integer equal to 0, 1, or 2. In an aspect OR12, OR13, OR14and OR15are independently derived from phenol, a monoalkylphenol, a dialkylphenol, or a trialkylphenol.

[0027] As readily appreciated by one of ordinary skill in the art, the bis-aryl phosphate is derived from a 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 an aspect, the bisphenol comprises bisphenol A.

[0028] In an aspect, the organophosphate ester comprises resorcinol bis-diphenyl phosphate, bis-phenol A bis-diphenyl phosphate, or a combination thereof.

[0029] The organophosphate ester can be present in the composition in an amount of 5 to 20 weight percent, based on the total weight of the composition. Within this range, the organophosphate ester can be present in an amount of 7 to 15 weight percent, or 8 to 15 weight percent, or 9 to 14 weight percent.

[0030] The thermoplastic composition further includes a flame retardant synergist comprising a phosphazene. Phosphazenes can include linear of cyclic phosphazenes of the formulaswherein w1 is 3 to 10,000; w2 is 3 to 25, or 3 to 7; and each Rwis independently a C1-12 alkyl, alkenyl, alkoxy, aryl, aryloxy, or polyoxyalkylene group. In the foregoing groups at least one hydrogen atom of these groups can be substituted with a group having an N, S, O, or F atom, or an amino group. For example, each Rwcan be a substituted or unsubstituted phenoxy, an amino, or a polyoxyalkylene group. Any given Rwcan further be a crosslink to another phosphazene group. Exemplary crosslinks include bisphenol groups, for example bisphenol A groups. Examples include phenoxy cyclotriphosphazene, octaphenoxy cyclotetraphosphazene decaphenoxy cyclopentaphosphazene, and the like.

[0031] In an aspect, the phosphazene can be a bis(phenoxy)phosphazene. The bis(phenoxy)phosphazene can be oligomeric or polymeric, and it can be cyclic or linear. In an aspect, the bis(phenoxy)phosphazene is cyclic and has the structure22SHPP0036-WO-PCT (SS220055PCT)wherein m is an integer of 3 to 25; x and y are each independently 0, 1, 2, 3, 4, or 5; and each occurrence of R4and R5is halogen, C1-12alkyl, or C1-12alkoxyl.

[0032] In an aspect, the bis(phenoxy)phosphazene is linear and has the structurewherein n is an integer from 3 to 10,000; X1represents a —N^P(OPh)3 group or a -N^P(O)(OPh) group wherein Ph represents a phenyl group; Y1represents 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 each occurrence of R4and R5is halogen, C1-12 alkyl, or C1-12 alkoxyl.

[0033] In an aspect, the phosphazene can comprise phenoxycyclotriphosphazene, octaphenoxy cyclotetraphosphazene, decaphenoxy cyclopentaphosphazene, or a combination comprising at least one of the foregoing phosphazene compounds.

[0034] The phosphazene flame retardant synergist can be present in an amount of 0.1 to 5 weight percent, based on the total weight of the thermoplastic composition. Within this range, the phosphazene can be present in an amount of 0.5 to 2 weight percent, or 0.5 to 1.5 weight percent, or 0.75 to 1.25 weight percent, each based on the total weight of the composition.

[0035] In addition to the poly(phenylene ether), the impact modifier, the organophosphate ester, and the flame retardant synergist, the thermoplastic composition can optionally further comprise tricalcium phosphate. Tricalcium phosphate (CAS Reg. No.1306- 06-5) has the chemical formula Ca5(OH)(PO4)3 and is also known as hydroxyapatite, hydroxylapatite, tribasic calcium phosphate, pentacalcium hydroxyorthophosphate, and apatite.22SHPP0036-WO-PCT (SS220055PCT)

[0036] When present, tricalcium phosphate can be included in the composition in an amount of 0.8 to 8 weight percent, based on the total weight of the composition. Within this range, the tricalcium phosphate can be present in an amount of 0.8 to 5 weight percent, or 0.8 to 3 weight percent, or 1 to 8 weight percent, or 1 to 5 weight percent, or 1 to 3 weight percent, or 1.2 to 8 weight percent, or 1.2 to 5 weight percent, or 1.2 to 2.8 weight percent, or 1.5 to 2.5 weight percent, each based on the total weight of the composition.

[0037] The thermoplastic composition can optionally further comprise an additive composition. The additive composition comprises one or more additives. The additives can be, for example, stabilizers, mold release agents, lubricants, processing aids, drip retardants, nucleating agents, UV blockers, dyes, pigments, antioxidants, anti-static agents, blowing agents, mineral oil, metal deactivators, antiblocking agents, or a combination thereof. In an aspect, the additive composition can comprise an antioxidant, a lubricant, a thermal stabilizer, an ultraviolet light absorbing additive, a plasticizer, an anti-dripping agent, a mold release agent, an antistatic agent, a dye, a pigment, a laser marking additive, a radiation stabilizer, or a combination thereof. When present, such additives are typically used in a total amount of 0.1 to 10 weight percent, based on the total weight of the composition.

[0038] In an aspect, the composition can comprise an anti-drip agent. Fluorinated polyolefin or polytetrafluoroethylene can be used as an anti-drip agent. Anti-drip agents can also be used, for example a fibril forming or non-fibril forming fluoropolymer such as polytetrafluoroethylene (PTFE). The anti-drip agent can be encapsulated by a rigid copolymer such as, for example styrene acrylonitrile (SAN). PTFE encapsulated in SAN is known as TSAN. Encapsulated fluoropolymers can be made by polymerizing the encapsulating polymer in the presence of the fluoropolymer, for example, in an aqueous dispersion. TSAN can provide significant advantages over PTFE, in that TSAN can be more readily dispersed in the composition. A suitable TSAN can comprise, for example, 50 wt % PTFE and 50 wt % SAN, based on the total weight of the encapsulated fluoropolymer. The SAN can comprise, for example, 75 wt % styrene and 25 wt % acrylonitrile based on the total weight of the copolymer. Alternatively, the fluoropolymer can be pre-blended in some manner with a second polymer, such as for, example, an aromatic polycarbonate resin or SAN to form an agglomerated material for use as an anti-drip agent. Either method can be used to produce an encapsulated fluoropolymer.

[0039] The anti-drip agent can be added in the form of relatively large particles having a number average particle size of 0.3 to 0.7 mm, specifically 0.4 to 0.6 millimeters. The anti-drip22SHPP0036-WO-PCT (SS220055PCT) agent can be used in amounts of 0.01 wt% to 5.0 wt%, based on the total weight of the composition.

[0040] The composition can include less than 3 weight percent, or less than 1 weight percent, or less than 0.5 weight percent of a reinforcing filler. In an aspect, reinforcing fillers can be excluded from the composition. 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 carbonates (such as chalk, limestone, marble, and synthetic precipitated calcium carbonates) talc (including fibrous, modular, needle shaped, and lamellar talc), wollastonite, hollow or solid glass spheres, silicate spheres, cenospheres, aluminosilicate or (armospheres), kaolin, whiskers of silicon carbide, alumina, boron carbide, iron, nickel, or copper, continuous and chopped carbon fibers or glass fibers, molybdenum sulfide, zinc sulfide, barium titanate, barium ferrite, barium sulfate, heavy spar, TiO2, aluminum oxide, magnesium oxide, particulate 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, reinforcing organic fibrous fillers such as poly(ether ketone), polyimide, polybenzoxazole, poly(phenylene sulfide), polyesters, polyethylene, aromatic polyamides, aromatic polyimides, polyetherimides, polytetrafluoroethylene, and poly(vinyl alcohol), as well a combination thereof. The fillers and reinforcing agents minimized or exclude from the composition can be coated with a layer of metallic material to facilitate conductivity, or surface treated with silanes to improve adhesion and dispersion with the polymer matrix. In an aspect, the composition can include less than 5 weight percent of glass fibers. In an aspect, the composition can exclude glass fibers.

[0041] The composition can optionally minimize or exclude additional components not specifically described herein. For example, the composition comprises less than 5 weight percent, or less than 2 weight percent, or less than 1 weight percent or less than 0.1 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer. In an aspect, the composition excludes a poly(phenylene ether)-poly(siloxane) block copolymer. In an aspect, the composition can exclude any thermoplastic polymer other than the foregoing polymers of the present composition. In an aspect, the composition can minimize or exclude glass fibers. In an aspect, the composition can minimize or exclude homopolystyrene or rubber-modified polystyrene. In an aspect, the composition can minimize (e.g., present in an amount of less than 5 weight percent, or less than 2 weight percent, or less than 1 weight percent or less than 0.122SHPP0036-WO-PCT (SS220055PCT) weight percent) or exclude a fluorinated polymer (e.g., polytrifluoroethylene, polytetrafluoroethylene, polyhexafluoropropylene, tetrafluoroethylene-hexafluoropropylene copolymers, poly(vinyl fluoride), poly(vinylidene fluoride), polychlorotrifluoroethylene, and the like, or a combination thereof), polydimethylsiloxane, silicone oil, paraffins, and combinations thereof.

[0042] In a specific aspect, the thermoplastic composition can comprise 73 to 80 weight percent of a poly(phenylene ether); 3 to 10 weight percent of an impact modifier comprising a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene; 8 to 15 weight percent of an organophosphate ester flame retardant; 0.5 to 2 weight percent of a flame retardant synergist comprising a phosphazene; 1 to 3 weight percent of tricalcium phosphate; and less than 1 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein weight percent is based on the total weight of the composition. In an aspect, the poly(phenylene ether) can comprise a poly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of 0.4 to 0.6 deciliters per gram, measured at 25°C in chloroform using an Ubbelohde viscometer; the impact modifier can comprise polystyrene-poly(ethylene-butylene)-polystyrene; the organophosphate ester flame retardant can comprise bis-phenol A bis-diphenyl phosphate; and the phosphazene can comprise phenoxycyclotriphosphazene, octaphenoxy cyclotetraphosphazene, decaphenoxy cyclopentaphosphazene, or a combination comprising at least one of the foregoing phosphazenes.

[0043] Accordingly, the composition of the present disclosure can comprise 72 to 85 weight percent of a poly(phenylene ether); 1 to 15 weight percent of an impact modifier comprising a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene; 5 to 20 weight percent of an organophosphate ester flame retardant; 0.1 to 5 weight percent of a flame retardant synergist comprising a phosphazene; 0.8 to 8 weight percent of tricalcium phosphate; and less than 5 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein weight percent is based on the total weight of the composition. The poly(phenylene ether) can have an intrinsic viscosity of greater than 0.25 deciliters per gram, or 0.4 to 0.6 deciliters per gram, measured at 25°C in chloroform using an Ubbelohde viscometer. The poly(phenylene ether) can comprise poly(2,6-dimethyl-1,4-phenylene ether). The hydrogenated block copolymer can comprise polystyrene-poly(ethylene-butylene)-polystyrene. The organophosphate ester flame retardant can comprise resorcinol bis-diphenyl phosphate, bis- phenol A bis-diphenyl phosphate, resorcinol bis(di 2,6-dimethylphenyl) phosphate, oligomeric phosphate ester, triphenyl phosphate, or a combination thereof, preferably bis-phenol A bis- diphenyl phosphate. The phosphazene can have the structure22SHPP0036-WO-PCT (SS220055PCT)wherein R1and R2are the same or different and are independently a hydrogen, a halogen, a C1-12alkoxy, or a C1-12 alkyl; m is 3 to 25; X1is a —N^P(OPh)3 group or a —N^P(O)OPh group, wherein Ph represents a phenyl group; Y1is a —P(OPh)4 group or a —P(O) (OPh)2 group, wherein Ph represents a phenyl group; and n is 3 to 10000. The phosphazene compound can comprise phenoxycyclotriphosphazene, octaphenoxy cyclotetraphosphazene, decaphenoxy cyclopentaphosphazene, or a combination comprising at least one of the foregoing phosphazene compounds. The thermoplastic composition can comprise less than 1 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer. A poly(phenylene ether)-poly(siloxane) block copolymer can be excluded from the composition. The composition can exclude glass fibers. The composition can further comprise 0.1 to 10 weight percent of an additive composition.

[0044] The composition of the present disclosure can exhibit a desirable combination of properties. For example, a molded sample of the composition can exhibit a UL-94 flammability rating of V0, measured using 1.0-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0, measured using 0.75-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0, measured using 0.5-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0, measured using 0.3-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours. A molded sample of the composition can optionally further exhibit one or both of a heat deflection temperature of greater than or equal to 115°C, measured on 3.2mm thick bars using a load of 1.82 MPa according ASTM D648; and a comparative tracking resistance of PLC0 as determined according to ASTM D3638.

[0045] In an aspect, a molded sample of the composition can exhibit a UL-94 flammability rating of V0, measured using 1.0-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0, measured using 0.75- millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-9422SHPP0036-WO-PCT (SS220055PCT) flammability rating of V0, measured using 0.5-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0, measured using 0.3- millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; and a heat deflection temperature of greater than or equal to 115°C, measured on 3.2mm thick bars using a load of 1.82 MPa according ASTM D648; and a comparative tracking resistance of PLC0 as determined according to ASTM D3638.

[0046] The composition of the present disclosure can be manufactured, for example, by melt blending the components of the composition. The components of the composition can be mixed or blended using common equipment such as ribbon blenders, HENSCHELTMmixers, BANBURYTMmixers, drum tumblers, and the like, and the blended composition can subsequently be melt-blended or melt-kneaded. The melt-blending or melt-kneading can be performed using common equipment such as single-screw extruders, twin-screw extruders, multi-screw extruders, co-kneaders, and the like. For example, the present composition can be prepared by melt-blending the components in a twin-screw extruder at a temperature of 270 to 310°C, or 280 to 300°C. The extrudate can be immediately quenched in a water bath and pelletized. The pellets so prepared can be one-fourth inch long or less as desired. Such pellets can be used for subsequent molding, shaping, or forming.

[0047] Shaped, formed, or molded articles comprising the composition represent another aspect of the present disclosure. The composition can be molded into useful shaped articles by a variety of methods, such as injection molding, extrusion, rotational molding, blow molding and thermoforming. Some examples of articles include an electric vehicle battery module, battery housing, battery case, battery cell frame, battery cell spacers, battery cell retainers, battery pack insulation film, bus bar holders, terminal covers, an electrical or electronic component, a thermoset circuit breaker, a fuser holder for an electrographic copier, a photovoltaic junction box, photovoltaic connector, an electrical connector, an automotive electrical connector, an electrical relay, a charge coupler, an appliance component, an automotive component, a portable device, a mobile component, or a stationary electrical component. In an aspect, the article is an extruded article, a molded article, pultruded article, a thermoformed article, a foamed article, a layer of a multi-layer article, a substrate for a coated article, or a substrate for a metallized article. In an aspect, the composition can be particularly useful in molded or extruded components for electric vehicle battery components. For example, the composition can be used in an extruded component for an electric vehicle battery component, such as an insultation sheet or film for an electric vehicle battery component.22SHPP0036-WO-PCT (SS220055PCT)

[0048] An electric vehicle battery component represents another aspect of the present disclosure. The electric vehicle battery component can be extruded from a composition comprising: 70 to 85 weight percent of a poly(phenylene ether); 1 to 15 weight percent of an impact modifier comprising a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene; 5 to 20 weight percent of an organophosphate ester flame retardant; 0.1 to 5 weight percent of a flame retardant synergist comprising a phosphazene; optionally, 0.8 to 8 weight percent of tricalcium phosphate; and less than 5 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein weight percent is based on the total weight of the composition. Variations of each component can be as described above.

[0049] The electric vehicle battery component can be an electric vehicle battery insulation sheet or film. The electric vehicle battery insulation sheet or film can be prepared by extruding the composition of the present disclosure to provide the desired sheet or film. In an aspect, the extruded film or sheet can have a UL-94 flammability rating of V0, measured using 1.0-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL- 94 flammability rating of V0, measured using 0.75-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0, measured using 0.5-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0, measured using 0.3-millimeter test bars 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 a heat deflection temperature of greater than or equal to 115°C, measured on 3.2mm thick bars using a load of 1.82 MPa according ASTM D648; and a comparative tracking resistance of PLC0 as determined according to ASTM D3638. The battery insulation film can have a thickness of, for example, 50 to 1000 micrometers.

[0050] As described herein, the present inventor has unexpectedly discovered that a composition including specific amounts of a poly(phenylene ether), an impact modifier comprising a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene, an organophosphate ester flame retardant, a flame retardant synergist, and optionally tricalcium phosphate can provide certain advantageous properties. In particular, a combination of high heat resistance, high impact strength, and low flammability, particularly for thin molded articles, can be obtained. Therefore, a significant improvement is provided by the present disclosure, specifically as it relates to battery pack insulation films or sheets extruded from the composition.

[0051] This disclosure is further illustrated by the following examples, which are non- limiting. EXAMPLES22SHPP0036-WO-PCT (SS220055PCT)

[0052] Materials used in the following examples are described in Table 1. Table 1 Component Description Supplier PPE Poly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of SABIC 0.46 dl / g TCP Tricalcium phosphate having an average particle size of 10 µm Zhangjiagang Taihua Chemical Co., Ltd BPADP Bisphenol A bis-diphenyl phosphate, CAS Reg. No.181028-79-5, obtained Zhejiang as CR741 Wansheng Co., Ltd. Phosphazene Hexaphenoxycyclotriphosphazene oligomer, CAS Reg. No.28212-48-8, Fushimi obtained as RABITLETMFP-110T SEBS Polystyrene-poly(ethylene-butylene)-polystyrene triblock copolymer, Kraton having a polystyrene content of 30-33 weight percent and a negligible melt Performance flow, measured at 260 °C and 5-kilogram load according to ASTM D1238; Polymers, Inc. obtained as KRATON G1651 HIPS High Impact Polystyrene (also known as rubber-modified polystyrene or Demitsu styrene-butadiene copolymer), CAS Reg. No.9003-55-8, having a Chemicals polybutadiene content of 30 weight percent Southeast Asia Pte Ltd. MgO Magnesium oxide, CAS Reg. No.1309-48-4, obtained as KYOWAMAGTMKyowa 150 Chemical Industry Co., Ltd. ZnS Zinc sulfide, CAS Reg. No.1314-98-3; obtained Sachtolith HD-S Taizhou ATS Optical Materials Co., Ltd TBPP Tris(2,4-di-tert-butylphenyl) phosphite, CAS Reg. No.31570-04-4; BASF obtained as IRGAFOSTM168 CB Carbon black pigment, CAS Reg. No.1333-86-4, obtained as Cabot Corp. BLACKPEARLSTM800 or MONARCHTM800 TSAN Poly(styrene-acrylonitrile)-encapsulated polytetrafluoroethylene, having a SABIC polytetrafluoroethylene content of about 50 weight percent.

[0053] Compositions were compounded using a on a Toshiba TEM-37BS twin screw extruder. All components were added at the feed throat of the extruded, exception for BPADP which was added through a liquid feeder. The extrudate was cooled in a water bath and pelletized. Pellets were conditioned at 120°C for 3 hours prior to injection molding or extrusion molding. The processing parameters used are summarized in Table 2. Table 2 Screw Design L-2-1 Feed (Zone 0) Temp. -- Zone 1 Temp. 50 °C Zone 2 Temp. 150 °C Zone 3 Temp. 240 °C Zone 4 Temp. 280 °C Zone 5 Temp. 280 °C Zone 6 Temp. 280 °C Zone 7 Temp. 300 °C Zone 8 Temp. 300 °C22SHPP0036-WO-PCT (SS220055PCT) Zone 9 Temp. 300 °C Zone 10 Temp. 280 °C Zone 11 Temp. 280 °C Zone 12 Temp. -- Die Temp. 290 °C Screw Speed 300 rpm Throughput 20 kg / hr Torque 45% Side Feeder 1 speed 250 rpm

[0054] Test articles were injection molded on a Toshiba UH1000-110 injection molding machine operating at barrel temperatures of 290 °C, 300 °C, 300 °C, and 290 °C (from feed throat to nozzle), and a mold temperature of 90 °C.

[0055] Properties of the molded parts were tested according to the following standards.

[0056] Melt flow rate values, expressed in units of grams per 10 minutes, were determined according to ASTM D 1238-10, Procedure B, at a temperature of 300 °C and a 5 kilogram load. Heat deflection temperature (HDT), expressed in units of °C, was determined according to ASTM D648 at 1.82 MPa or 0.45 MPa using a bar having a thickness of 3.2 millimeters. Notched Izod impact (NII) strength values, expressed in units of joules / meter, were determined according to ASTM D 256-10 Method A at 23 °C using bar cross-sectional dimensions of 3.2 millimeters by 12.7 millimeters. Unnotched Izod impact (UNII), expressed in units of joules / meter, were determined according to ASTM D4812 at 23 °C using bar cross- sectional dimensions of 3.2 millimeters by 12.7 millimeters. Tensile properties were determined according to ASTM D638 at a sample thickness of 3.2 millimeters and a test speed of 5 millimeters per minute.

[0057] Hydrolytic stability was assessed by placing tensile bars into a hydrolytic chamber at 85°C and 85% relative humidity for a time of 1000 hours. The samples were then removed from the chamber for characterization. Hydrolytic stability was assessed by retention of tensile modulus and tensile stress. A tensile modulus and tensile stress retention of ^90% was characterized as “good”. If at least one of the tensile modulus or tensile stress retention was <90%, the hydrolytic stability was characterized as “poor”.

[0058] Flame retardancy of injection molded flame bars was determined according to Underwriter’s Laboratory Bulletin 94 “Tests for Flammability of Plastic Materials, UL 94”, 20 mm Vertical Burning Flame Test. Before testing, flame bars with a thicknesses of 1.0, 0.75, 0.5, 0.3, and 0.2 millimeters were 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 9420 mm Vertical Burning Flame Test, a set of ten to twenty flame bars was tested. For each bar, a flame was22SHPP0036-WO-PCT (SS220055PCT) applied for 10 seconds to the bar then removed, and the time required for the bar to self- extinguish (first after flame time, t1) was noted. The flame was then reapplied for 10 seconds and removed, and the time required for the bar to self-extinguish (second after flame time, t2) and the post-flame glowing time (afterglow time, t3) were noted. To achieve a rating of V0, the after flame times t1 and t2 for each individual specimen must have been less than or equal to 10 seconds; and the total after flame time for all five specimens (t1 plus t2 for all five specimens) must have been less than or equal to 50 seconds; and the second after flame time plus the afterglow time for each individual specimen (t2 + t3) must have been less than or equal to 30 seconds; and no specimen can have flamed or glowed up to the holding clamp; and the cotton indicator cannot have been ignited by flaming particles or drops. To achieve a rating of V1, the after flame times t1 and t2 for each individual specimen must have been less than or equal to 30 seconds; and the total after flame time for all five specimens (t1 plus t2 for all five specimens) must have been less than or equal to 250 seconds; and the second after flame time plus the afterglow time for each individual specimen (t2 + t3) must have been less than or equal to 60 seconds; and no specimen can have flamed or glowed up to the holding clamp; and the cotton indicator cannot have been ignited by flaming particles or drops. To achieve a rating of V2, the after flame times t1 and t2 for each individual specimen must have been less than or equal to 30 seconds; and the total after flame time for all five specimens (t1 plus t2 for all five specimens) must have been less than or equal to 250 seconds; and the second after flame time plus the afterglow time for each individual specimen (t2 + t3) must have been less than or equal to 60 seconds; and no specimen can have flamed or glowed up to the holding clamp; but the cotton indicator can have been ignited by flaming particles or drops.

[0059] Comparative Tracking Index (CTI) is used to measure the electrical breakdown (tracking) properties of an insulating material. Tracking is a measure of electrical breakdown on the surface of an insulating material. A large voltage difference gradually creates a conductive leakage path across the surface of the material by forming a carbonized track. The CTI testing procedure was carried out as described in ASTM D3638 test method. Briefly, the testing procedure involved adding 50 drops of a 0.1 wt% ammonium chloride solution dropwise to the surface of the material (3 mm thickness), followed by determination of the maximum voltage at which failure occurred. Based on the tracking index, the sample is assigned a Comparative Tracking Performance Level Category (PLC). Comparative Tracking Performance Level Categories are described in Table 3. Table 3 Tracking Index Range (volts)22SHPP0036-WO-PCT (SS220055PCT) 600 ^ TI 0 400 ^ TI < 600 1 250 ^ TI < 400 2 175 ^ TI < 250 3 100 ^ TI < 175 4 0 ^ TI < 100 5

[0060] Compositions and properties are summarized in Table 4. The amount of each component is provided in weight percent based on the total weight of the composition. Table 4 ComponentUnitCE1 CE5 E6sE2 CE3 CE4 CE5 E1 E2 E3 E4PPE wt% 67 81.58 79.58 79.53 77.53 78.53 77.53 76.53 76.58 78.58 79.08 TCP wt% 2 2 2 2 2 2 BPADP wt% 11 11 13 11 13 11 12 13 13 13 13 Phosphazenwt% 1 1 1 11 1e SEBS wt% 6.12 6.12 6.12 6.12 6.12 6.12 6.12 6.12 6.12 6.12 HIPS wt% 20.7 MgO wt% 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 ZnS wt% 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 TBPP wt% 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 CB wt% 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 TSAN wt% 0.05 0.05 0.05 0.05 0.05 Properties MFRgm / 1in0 21 11.5 19.5 13.9 17.8 12.2 13.7 16.6 19 18.1 18.7HDT@1.82 MPa°C 118 132 122 131 122 133 128 125 120 121 121HDT@0.45 MPa°C 133 149 137 147 138 149 144 141 136 136 135UL94 – 1.0 mm V0 V0 V0 V1 V1 V0 V0 V0 V0 V0 V0 UL94 – 0.75 mmV0 V1 V0 V1 V1 V0 V0 V0 V0 V0 V0UL94 – 0.5 mm V2 V1 V1 V1 V1 V0 V0 V0 V0 V0 V0 UL94 – 0.3 mm V2 V2 V1 V2 V2 V0 V0 V0 V0 V0 V0 CTIPLCPLC PLC PLC PLC PLC PLC PLC PLC PLC PLC 3 2 2 0 0 0 0 0 0 2 2 NII J / m 140 296 235 163 154 187 194 182 165 233 241 UNII J / m 1300 2190 2190 1640 1530 1890 2190 2190 Tens. Strain @brk% 11.4 10.3 8.1 10.3 7.2 11.8 8.0 9.4 7.4 8.7 9.1Tens. Strain @yield% 4.7 4.4 4.2 4.3 4.1 4.3 4.3 4.2 4.1 4.1 4.1Tens. Mod. MPa 2400 2394 2410 2478 2519 2389 2426 2463 2513 2599 2587 Tens. Stress @brkMPa 45 49 47 51 49 50 48 51 51 53 51Tens. Stress @yieldMPa 63 66 65 66 67 68 68 68 66 66 67Hydrolytic resistance, Good Good Good Good Good Good Good Good Good Good Good DH8522SHPP0036-WO-PCT (SS220055PCT)

[0061] As shown in Table 4, the composition of Comparative Example 1 achieved a V0 rating at 0.75mm, a V1 rating at 0.5mm and 0.3mm, and an HDT of 133oC at 0.45 MPa. Comparative Example 2, including a higher amount of PPE and SEBS instead of HIPS, has an increased HDT of 149°C, however the vertical burn performance was decreased. Comparative Example 3, including additional BPADP, exhibited improved vertical burning relative to CE1 and CE2, however the HDT is reduced relative to CE2. Comparative Example 4 includes 2% TCP and Comparative Example 5 includes TCP and a slightly increased amount of BPADP. CE4 exhibited a vertical burn performance of V1 at 0.5, 0.75 and 1 mm, and V2 at 0.3 mm. CE5 exhibited an improved vertical burn performance, but a decreased HDT. None of the comparative examples achieved a vertical burn rating of V0 at a thickness of 0.5 mm or less.

[0062] Examples 1 to 4 each include a flame retardant (e.g., BPADP), a flame retardant synergist (e.g., phosphazene), and TCP. All examples achieved a rating of V0 at 0.3 mm, and a CTI PLC0 rating. Thus the present inventor surprisingly found that a rating of V0 at a thickness of 0.3 mm or less can be achieved with a particular flame retardant package including an organophosphate ester as the primary flame retardant and phosphazene as a flame retardant synergist. Further, a desirable balance of flame rating, high heat resistance and CTI was also achieved due to the presence of TCP.

[0063] Additionally, Examples 5 and 6 show that a particular combination of include a flame retardant (e.g., BPADP) and a flame retardant synergist (e.g., phosphazene) can surprisingly achieve a rating of V0 at 0.3 mm. Further, a desirable balance of flame properties, heat resistance, and mechanical properties was observed.

[0064] A significant improvement is therefore provided by the present disclosure.

[0065] This disclosure further encompasses the following aspects.

[0066] Aspect 1: A thermoplastic composition, comprising: 72 to 85 weight percent of a poly(phenylene ether); 1 to 15 weight percent of an impact modifier comprising a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene; 5 to 20 weight percent of an organophosphate ester flame retardant; 0.1 to 5 weight percent of a flame retardant synergist comprising a phosphazene; optionally, 0.8 to 8 weight percent of tricalcium phosphate; and less than 5 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein weight percent is based on the total weight of the composition.

[0067] Aspect 2: The composition of aspect 1, wherein a molded sample of the composition exhibits: a UL-94 flammability rating of V0, measured using 1.0-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0, measured using 0.75-millimeter test bars after conditioning at 23°C for 48 hours22SHPP0036-WO-PCT (SS220055PCT) and at 70°C for 168 hours; a UL-94 flammability rating of V0, measured using 0.5-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0, measured using 0.3-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; and optionally, one or both of a heat deflection temperature of greater than or equal to 115°C, measured on 3.2mm thick bars using a load of 1.82 MPa according ASTM D648; and a comparative tracking resistance of PLC0 as determined according to ASTM D3638.

[0068] Aspect 3: The thermoplastic composition of aspect 1 or 2, wherein the poly(phenylene ether) has an intrinsic viscosity of greater than 0.25 deciliters per gram, or 0.4 to 0.6 deciliters per gram, measured at 25°C in chloroform using an Ubbelohde viscometer; preferably wherein the poly(phenylene ether) comprises poly(2,6-dimethyl-1,4-phenylene ether).

[0069] Aspect 4: The thermoplastic composition of any of aspects 1 to 3, wherein the hydrogenated block copolymer comprises polystyrene-poly(ethylene-butylene)-polystyrene.

[0070] Aspect 5: The thermoplastic composition of any of aspects 1 to 4, wherein the organophosphate ester flame retardant comprises resorcinol bis-diphenyl phosphate, bis-phenol A bis-diphenyl phosphate, resorcinol bis(di 2,6-dimethylphenyl) phosphate, oligomeric phosphate ester, triphenyl phosphate, or a combination thereof, preferably bis-phenol A bis- diphenyl phosphate.

[0071] Aspect 6: The thermoplastic composition of any of aspects 1 to 5, wherein the phosphazene has the structurewherein R1and R2are the same or different and are independently a hydrogen, a halogen, a C1-12alkoxy, or a C1-12alkyl; m is 3 to 25; X1is a —N^P(OPh)3group or a —N^P(O)OPh group, wherein Ph represents a phenyl group; Y1is a —P(OPh)4group or a —P(O) (OPh)2group, wherein Ph represents a phenyl group; and n is 3 to 10000; preferably wherein the phosphazene compound comprises phenoxycyclotriphosphazene, octaphenoxy cyclotetraphosphazene, decaphenoxy cyclopentaphosphazene, or a combination comprising at least one of the foregoing phosphazene compounds.22SHPP0036-WO-PCT (SS220055PCT)

[0072] Aspect 7: The thermoplastic composition of any of aspects 1 to 6, comprising less than 1 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer, preferably wherein a poly(phenylene ether)-poly(siloxane) block copolymer is excluded from the composition.

[0073] Aspect 8: The thermoplastic composition of any of aspects 1 to 7, wherein the composition excludes glass fibers.

[0074] Aspect 9: The thermoplastic composition of any of aspects 1 to 8, further comprising 0.1 to 10 weight percent of an additive composition.

[0075] Aspect 10: The thermoplastic composition of aspect 1, comprising 73 to 80 weight percent of a poly(phenylene ether); 3 to 10 weight percent of an impact modifier comprising a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene; 8 to 15 weight percent of an organophosphate ester flame retardant; 0.5 to 2 weight percent of a flame retardant synergist comprising a phosphazene; 1 to 3 weight percent of tricalcium phosphate; and less than 1 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein weight percent is based on the total weight of the composition.

[0076] Aspect 11: The thermoplastic composition of aspect 10, wherein the poly(phenylene ether) comprises a poly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of 0.4 to 0.6 deciliters per gram, measured at 25°C in chloroform using an Ubbelohde viscometer; the impact modifier comprises polystyrene-poly(ethylene-butylene)-polystyrene; the organophosphate ester flame retardant comprises bis-phenol A bis-diphenyl phosphate; and the phosphazene comprises phenoxycyclotriphosphazene, octaphenoxy cyclotetraphosphazene, decaphenoxy cyclopentaphosphazene, or a combination comprising at least one of the foregoing phosphazenes.

[0077] Aspect 12: The composition of aspect 10 or 11, wherein a molded sample of the composition exhibits: a UL-94 flammability rating of V0, measured using 1.0-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0, measured using 0.75-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0, measured using 0.5-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0, measured using 0.3-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; and a heat deflection temperature of greater than or equal to 115°C, measured on 3.2mm thick bars using a load of 1.82 MPa according ASTM D648; and a comparative tracking resistance of PLC0 as determined according to ASTM D3638.22SHPP0036-WO-PCT (SS220055PCT)

[0078] Aspect 13: A method of making the composition of any one or more of aspects 1 to 12; the method comprising melt-mixing the components of the composition.

[0079] Aspect 14: An article comprising the composition of any of aspects 1 to 12, preferably wherein the article is an electric vehicle battery module, battery insulation sheet or film, battery housing, battery case, battery cell frame, battery cell spacers, battery cell retainers, bus bar holders, terminal covers, an electrical or electronic component, charger adaptor insulation sheet or film, a thermoset circuit breaker, a fuser holder for an electrographic copier, a photovoltaic junction box, photovoltaic connector, an electrical connector, an automotive electrical connector, an electrical relay, a charge coupler, an appliance component, an automotive component, a portable device, a mobile component, or a stationary electrical component.

[0080] Aspect 15: An electric vehicle battery component extruded from a composition comprising: 70 to 85 weight percent of a poly(phenylene ether); 1 to 15 weight percent of an impact modifier comprising a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene; 5 to 20 weight percent of an organophosphate ester flame retardant; 0.1 to 5 weight percent of a flame retardant synergist comprising a phosphazene; optionally, 0.8 to 8 weight percent of tricalcium phosphate; and less than 5 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein weight percent is based on the total weight of the composition; preferably wherein the electric vehicle battery component is an electric vehicle battery insulation sheet or film.

[0081] The compositions, methods, and articles can alternatively comprise, consist of, or consist essentially of, any appropriate materials, steps, or components herein disclosed. The compositions, methods, and articles can additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any materials (or species), steps, or components, that are otherwise not necessary to the achievement of the function or objectives of the compositions, methods, and articles.

[0082] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. “Combinations” is inclusive of blends, mixtures, alloys, reaction products, and the like. The terms “first,” “second,” and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “a” and “an” and “the” do not denote a limitation of quantity, and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. “Or” means “and / or” unless clearly stated otherwise. Reference throughout the specification to “an aspect” means that a particular element described in22SHPP0036-WO-PCT (SS220055PCT) connection with the aspect is included in at least one aspect described herein, and may or may not be present in other aspects. The term “combination thereof” as used herein includes one or more of the listed elements, and is open, allowing the presence of one or more like elements not named. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various aspects.

[0083] Unless specified to the contrary herein, all test standards are the most recent standard in effect as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[0084] Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this application belongs. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.

[0085] Compounds are described using standard nomenclature. For example, any position not substituted by any indicated group is understood to have its valency filled by a bond as indicated, or a hydrogen atom. A dash ("-") that is not between two letters or symbols is used to indicate a point of attachment for a substituent. For example, -CHO is attached through carbon of the carbonyl group.

[0086] As used herein, the term “hydrocarbyl”, whether used by itself, or as a prefix, suffix, or fragment of another term, refers to a residue that contains 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 hydrocarbon moieties. However, when the hydrocarbyl residue is described as substituted, it may, optionally, contain heteroatoms over and above the carbon and hydrogen members of the substituent residue. Thus, when specifically described as substituted, the hydrocarbyl residue can also contain one or more carbonyl groups, amino groups, hydroxyl groups, or the like, or it can contain heteroatoms within the backbone of the hydrocarbyl residue. The term "alkyl" means a branched or straight chain, saturated aliphatic hydrocarbon group, e.g., methyl, ethyl, n-propyl, i-propyl, n-butyl, s-butyl, t-butyl, n- pentyl, s-pentyl, and n- and s-hexyl. “Alkenyl” means a straight or branched chain, monovalent hydrocarbon group having at least one carbon-carbon double bond (e.g., ethenyl (-HC=CH2)). “Alkoxy” means an alkyl group that is linked via an oxygen (i.e., alkyl-O-), for example methoxy, ethoxy, and sec-butyloxy groups. "Alkylene" means a straight or branched chain,22SHPP0036-WO-PCT (SS220055PCT) saturated, divalent aliphatic hydrocarbon group (e.g., methylene (-CH2-) or, propylene (-(CH2)3- )). “Cycloalkylene” means a divalent cyclic alkylene group, -CnH2n-x, wherein x is the number of hydrogens replaced by cyclization(s). “Cycloalkenyl” means 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" means an aromatic hydrocarbon group containing the specified number of carbon atoms, such as phenyl, tropone, indanyl, or naphthyl. “Arylene” means a divalent aryl group. “Alkylarylene” means an arylene group substituted with an alkyl group. “Arylalkylene” means an alkylene group substituted with an aryl group (e.g., benzyl). The prefix "halo" means a group or compound including one more of a fluoro, chloro, bromo, or iodo substituent. A combination of different halo atoms (e.g., bromo and fluoro), or only chloro atoms can be present. The prefix “hetero” means that the compound or group includes at least one ring member that is a heteroatom (e.g., 1, 2, or 3 heteroatom(s)), wherein the heteroatom(s) is each independently N, O, S, Si, or P. “Substituted” means that the compound or group is substituted with at least one (e.g., 1, 2, 3, or 4) substituents that can each independently be a C1-9alkoxy, a C1-9haloalkoxy, a nitro (-NO2), a cyano (-CN), a C1-6alkyl sulfonyl (-S(=O)2-alkyl), a C6-12aryl sulfonyl (-S(=O)2-aryl), a thiol (-SH), a thiocyano (-SCN), a tosyl (CH3C6H4SO2-), a C3-12cycloalkyl, a C2-12alkenyl, a C5-12cycloalkenyl, a C6-12aryl, a C7-13 arylalkylene, a C4-12 heterocycloalkyl, and a C3-12 heteroaryl instead of hydrogen, provided that the substituted atom’s normal valence is not exceeded. The number of carbon atoms indicated in a group is exclusive of any substituents. For example -CH2CH2CN is a C2 alkyl group substituted with a nitrile.

[0087] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.

Claims

22SHPP0036-WO-PCT (SS220055PCT) CLAIMS 1. A thermoplastic composition, comprising: 72 to 85 weight percent of a poly(phenylene ether); 1 to 15 weight percent of an impact modifier comprising a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene; 5 to 20 weight percent of an organophosphate ester flame retardant; 0.1 to 5 weight percent of a flame retardant synergist comprising a phosphazene; optionally, 0.8 to 8 weight percent of tricalcium phosphate; and less than 5 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer; wherein weight percent is based on the total weight of the composition.

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

3. The thermoplastic composition of claim 1 or 2, wherein the poly(phenylene ether) has an intrinsic viscosity of greater than 0.25 deciliters per gram, or 0.4 to 0.6 deciliters per gram, measured at 25°C in chloroform using an Ubbelohde viscometer; preferably wherein the poly(phenylene ether) comprises poly(2,6-dimethyl-1,4- phenylene ether).22SHPP0036-WO-PCT (SS220055PCT) 4. The thermoplastic composition of any of claims 1 to 3, wherein the hydrogenated block copolymer comprises polystyrene-poly(ethylene-butylene)-polystyrene.

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

6. The thermoplastic composition of any of claims 1 to 5, wherein the phosphazene has theR1 and R2 are the same or different and are independently a hydrogen, a halogen, a C1-12 alkoxy, or a C1-12 alkyl; m is 3 to 25; X1is a —N^P(OPh)3 group or a —N^P(O)OPh group, wherein Ph represents a phenyl group; Y1is a —P(OPh)4 group or a —P(O) (OPh)2 group, wherein Ph represents a phenyl group; and n is 3 to 10000; preferably wherein the phosphazene compound comprises phenoxycyclotriphosphazene, octaphenoxy cyclotetraphosphazene, decaphenoxy cyclopentaphosphazene, or a combination comprising at least one of the foregoing phosphazene compounds.

7. The thermoplastic composition of any of claims 1 to 6, comprising less than 1 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer, preferably wherein a poly(phenylene ether)-poly(siloxane) block copolymer is excluded from the composition.22SHPP0036-WO-PCT (SS220055PCT) 8. The thermoplastic composition of any of claims 1 to 7, wherein the composition excludes glass fibers.

9. The thermoplastic composition of any of claims 1 to 8, further comprising 0.1 to 10 weight percent of an additive composition.

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

11. The thermoplastic composition of claim 10, wherein the poly(phenylene ether) comprises a poly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of 0.4 to 0.6 deciliters per gram, measured at 25°C in chloroform using an Ubbelohde viscometer; the impact modifier comprises polystyrene-poly(ethylene-butylene)-polystyrene; the organophosphate ester flame retardant comprises bis-phenol A bis-diphenyl phosphate; and the phosphazene comprises phenoxycyclotriphosphazene, octaphenoxy cyclotetraphosphazene, decaphenoxy cyclopentaphosphazene, or a combination comprising at least one of the foregoing 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 1.0-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0, measured using 0.75-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; a UL-94 flammability rating of V0, measured using 0.5-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours;22SHPP0036-WO-PCT (SS220055PCT) a UL-94 flammability rating of V0, measured using 0.3-millimeter test bars after conditioning at 23°C for 48 hours and at 70°C for 168 hours; and a heat deflection temperature of greater than or equal to 115°C, measured on 3.2mm thick bars using a load of 1.82 MPa according ASTM D648; and a comparative tracking resistance of PLC0 as determined according to ASTM D3638.

13. A method of making the composition of any one or more of claims 1 to 12; the method comprising melt-mixing the components of the composition.

14. An article comprising the composition of any of claims 1 to 12, preferably wherein the article is an electric vehicle battery module, battery insulation sheet or film, battery housing, battery case, battery cell frame, battery cell spacers, battery cell retainers, bus bar holders, terminal covers, an electrical or electronic component, charger adaptor insulation sheet or film, a thermoset circuit breaker, a fuser holder for an electrographic copier, a photovoltaic junction box, photovoltaic connector, an electrical connector, an automotive electrical connector, an electrical relay, a charge coupler, an appliance component, an automotive component, a portable device, a mobile component, or a stationary electrical component.

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

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