Thermoplastic compositions, methods for making thermoplastic compositions, and articles including thermoplastic compositions - Patents.com

Abstract

The thermoplastic composition includes a poly(phenylene ether)-poly(siloxane) block copolymer reaction product in specified amounts, an impact modifier, an organophosphate ester flame retardant, and a second poly(phenylene ether). The composition may be useful in a variety of articles, particularly as a component of an electric vehicle battery.

Description

[Technical field]

[0001] The present invention relates to a thermoplastic composition, a method for making the thermoplastic composition, and an article comprising the thermoplastic composition.

[0002] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims priority to and the benefit of European Patent Application No. 21205340.9, filed October 28, 2021, the contents of which are incorporated herein by reference in their entirety. [Background technology]

[0003] Poly(arylene ethers) are commercially attractive materials due to their unique combination of properties including, for example, high temperature resistance, dimensional and hydrolytic stability, and electrical properties. Summary of the Invention [Problem to be solved by the invention]

[0004] There is a continuing need in the art for poly(arylene ether) compositions that have low flammability, particularly for thin wall applications. In addition to low flammability, it would be further advantageous if the compositions also exhibited high heat resistance, high impact strength, and hydrolysis resistance. [Means for solving the problem]

[0005] The thermoplastic composition comprises 5 to 40 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer reaction product comprising a poly(phenylene ether)-poly(siloxane) block copolymer and a first 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; less than 3 weight percent of a reinforcing filler; less than 0.5 weight percent tricalcium phosphate; and 40 to 90 weight percent of a second poly(phenylene ether), the weight percent of each component being based on the total weight of the composition.

[0006] A method of making the composition includes melt mixing the components of the composition.

[0007] An article includes the composition. For example, an electric vehicle battery component can be extruded from the composition, preferably the electric vehicle battery component is an electric vehicle battery insulating sheet or film.

[0008] The above-mentioned features and other features are illustrated by the following detailed description. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] The present inventors have unexpectedly discovered that certain thermoplastic compositions can provide a combination of desirable properties. More specifically, compositions comprising certain amounts of a poly(phenylene ether)-polysiloxane block copolymer reaction product, a second poly(phenylene ether), a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene, and an organophosphate ester flame retardant can provide a desirable combination of low flammability, high heat resistance, high impact strength, and hydrolysis resistance.

[0010] Thus, one aspect of the present disclosure is a thermoplastic composition. The thermoplastic composition comprises a poly(phenylene ether)-polysiloxane block copolymer reaction product comprising a first poly(phenylene ether) and a poly(phenylene ether)-poly(siloxane) block copolymer. As used herein, the term "poly(phenylene ether)-polysiloxane block copolymer" refers to a block copolymer comprising at least one poly(phenylene ether) block and at least one polysiloxane block.

[0011] The poly(phenylene ether) block of the poly(phenylene ether)-poly(siloxane) block copolymer has the formula (1): [ka] (1) [In the formula, Z 1Each occurrence of is independently a halogen, unsubstituted or substituted C 1~12 hydrocarbyl, provided that the hydrocarbyl group is a tertiary hydrocarbyl, C 1~12 Hydrocarbylthio, C 1~12 Hydrocarbyloxy, or C 2~12 Z is not halohydrocarbyloxy, but is a substituted or unsubstituted aryl group, provided that at least two carbon atoms separate the halogen atom and the oxygen atom. 2 Each occurrence of is independently hydrogen, halogen, unsubstituted or substituted C 1~12 hydrocarbyl, provided that the hydrocarbyl group is a tertiary hydrocarbyl, C 1~12 Hydrocarbylthio, C 1~12 Hydrocarbyloxy, or C 2~12 The term "hydrocarbyl" as used herein, whether used by itself or as a prefix, suffix, or fragment of another term, refers to a residue containing only carbon and hydrogen. The residue may be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched-chain, saturated, or unsaturated. It may also contain combinations of aliphatic, aromatic, straight-chain, cyclic, bicyclic, branched-chain, saturated, and unsaturated hydrocarbon moieties. However, when a hydrocarbyl residue is described as being substituted, it may optionally contain heteroatoms in addition to the carbon and hydrogen members of the substituent residue. Thus, when specifically described as being substituted, the hydrocarbyl residue may also contain one or more carbonyl groups, amino groups, hydroxyl groups, etc., or may contain heteroatoms within the backbone of the hydrocarbyl residue. As an example, Z 1 may 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.

[0012] In one embodiment, the poly(phenylene ether) blocks comprise 2,6-dimethyl-1,4-phenylene ether repeating units, i.e., formula (2): [ka] (2) 2,3,6-trimethyl-1,4-phenylene ether repeat units, or a combination thereof.

[0013] Poly(phenylene ether) may include molecules having aminoalkyl-containing end groups typically located ortho to a hydroxy group. Tetramethyldiphenoquinone (TMDQ) end groups are also often present, typically obtained from 2,6-dimethylphenol-containing reaction mixtures in which tetramethyldiphenoquinone by-product is present. Poly(phenylene ether) may be in the form of homopolymers, copolymers, graft copolymers, ionomers, or block copolymers, as well as combinations thereof.

[0014] The polysiloxane block is a residue of a hydroxyaryl-terminated polysiloxane. In one embodiment, the polysiloxane block is represented by the formula (3): [ka] (3) [In the formula, R 1 and R 2 Each occurrence of is independently hydrogen, C 1~12 Hydrocarbyl or C 1~12 halohydrocarbyl], and the polysiloxane block comprises a repeat unit of formula (4): [ka] (4) [Wherein, Y is hydrogen, C 1~12 Hydrocarbyl, C 1~12 hydrocarbyloxy, or halogen; R 3 and R 4 Each occurrence of is independently hydrogen, C1~12 Hydrocarbyl or C 1~12 In one embodiment, the polysiloxane repeat unit comprises a dimethylsiloxane (-Si(CH3)2O-) unit. In one embodiment, the polysiloxane block further comprises a terminal unit of formula (5): [ka] (5) In the formula, n is 20 to 60 on average.

[0015] The hydroxyaryl-terminated polysiloxane comprises at least one hydroxyaryl end group. In one embodiment, the hydroxyaryl-terminated polysiloxane has a single hydroxyaryl end group, in which case a poly(phenylene ether)-polysiloxane diblock copolymer is formed. In one embodiment, the hydroxyaryl-terminated polysiloxane has two hydroxyaryl end groups, in which case a poly(phenylene ether)-polysiloxane diblock copolymer and / or a poly(phenylene ether)-polysiloxane-poly(phenylene ether) triblock copolymer is formed. It is also possible for the hydroxyaryl-terminated polysiloxane to have a branched structure that allows the formation of three or more hydroxyaryl end groups and the corresponding branched block copolymers.

[0016] In one embodiment, the hydroxyaryl-terminated polysiloxane contains, on average, 20-80 siloxane repeat units, specifically 25-70 siloxane repeat units, more specifically 30-60 siloxane repeat units, even more specifically 35-50 siloxane repeat units, even more specifically 40-50 siloxane repeat units. The number of siloxane repeat units in the polysiloxane block is essentially unaffected by the copolymerization and separation conditions and is therefore equal to the number of siloxane repeat units in the hydroxyaryl-terminated polysiloxane starting material. If not otherwise known, the average number of siloxane repeat units per hydroxyaryl-terminated polysiloxane molecule can be determined by nuclear magnetic resonance (NMR) techniques that compare the intensity of the signal associated with the siloxane repeat unit to the intensity of the signal associated with the hydroxyaryl end group. For example, if the hydroxyaryl-terminated polysiloxane is a polydimethylsiloxane capped with eugenol, a proton nuclear magnetic resonance (NMR) study comparing the integrals of the protons of the dimethylsiloxane resonance and the protons of the methoxy groups of eugenol is performed. 1 The average number of siloxane repeat units can be determined by HNMR techniques.

[0017] In one embodiment, the poly(phenylene ether)-polysiloxane block copolymer reaction product has a weight average molecular weight of at least 30,000 grams per mole (g / mol). For example, the reaction product may have a weight average molecular weight of 30,000 to 150,000 g / mol, specifically 35,000 to 120,000 g / mol, more specifically 40,000 to 90,000 g / mol, and even more specifically 45,000 to 70,000 g / mol. In one embodiment, the poly(phenylene ether)-polysiloxane block copolymer reaction product has a number average molecular weight of 10,000 to 50,000 g / mol, specifically 10,000 to 30,000 g / mol, and more specifically 14,000 to 24,000 g / mol.

[0018] In one embodiment, the poly(phenylene ether)-polysiloxane block copolymer reaction product has an intrinsic viscosity of at least 0.3 deciliters / gram as measured by an Ubbelohde viscometer in chloroform at 25° C. In one embodiment, the intrinsic viscosity is from 0.3 to 0.5 deciliters / gram, specifically from 0.31 to 0.5 deciliters / gram, and more specifically from 0.35 to 0.47 deciliters / gram.

[0019] The poly(phenylene ether)-polysiloxane block copolymer is prepared by an oxidative copolymerization method. In this method, the poly(phenylene ether)-polysiloxane block copolymer is the product of a process that includes oxidative copolymerization of a monomer mixture that includes a monohydric phenol and a hydroxyaryl-terminated polysiloxane. In one embodiment, the monomer mixture includes 70 to 99 parts by weight of the monohydric phenol and 1 to 30 parts by weight of the hydroxyaryl-terminated polysiloxane, based on the total weight of the monohydric phenol and the hydroxyaryl-terminated polysiloxane. The hydroxyaryl-diterminated polysiloxane and the monohydric phenol can be as described above.

[0020] The oxidative copolymerization process produces poly(phenylene ether)-polysiloxane block copolymers as the desired product and poly(phenylene ether) (without incorporated polysiloxane blocks) as a by-product. It is not necessary to separate the poly(phenylene ether) from the poly(phenylene ether)-polysiloxane block copolymer. Thus, the poly(phenylene ether)-polysiloxane block copolymer is available as a "reaction product" that contains both poly(phenylene ether) and poly(phenylene ether)-polysiloxane block copolymer. Specific separation procedures, such as precipitation from isopropanol, can be used to ensure that the reaction product is essentially free of residual hydroxyaryl-terminated polysiloxane starting material. In other words, these separation procedures ensure that the polysiloxane content of the reaction product is essentially all in the form of poly(phenylene ether)-polysiloxane block copolymer. Detailed methods for forming the poly(phenylene ether)-polysiloxane block copolymers are described in US Pat. Nos. 8,017,697 and 8,669,332 to Carrillo et al.

[0021] The poly(phenylene ether)-polysiloxane block copolymer reaction product may contain 1 to 30 weight percent siloxane repeat units and 70 to about 99 weight percent phenylene ether repeat units, based on the total weight of the reaction product. It will be understood that the siloxane repeat units are derived from a hydroxyaryl-terminated polysiloxane and the phenylene ether repeat units are derived from a monohydric phenol. In one embodiment, for example, when the poly(phenylene ether)-polysiloxane block copolymer reaction product is purified by precipitation in isopropanol, the siloxane repeat units consist essentially of the residues of the hydroxyaryl-terminated polysiloxane incorporated into the poly(phenylene ether)-polysiloxane block copolymer.

[0022] In one embodiment, the poly(phenylene ether)-polysiloxane block copolymer includes phenylene ether repeat units derived from 2,6-dimethylphenol, 2,3,6-trimethylphenol, and combinations thereof. In one embodiment, the poly(phenylene ether)-polysiloxane block copolymer can, for example, comprise 0.05 to 2 weight percent, specifically 0.1 to 1 weight percent, and more specifically 0.2 to 0.8 weight percent of siloxane groups relative to the total composition.

[0023] The composition comprises the poly(phenylene ether)-polysiloxane block copolymer reaction product in an amount of 5 to 40 weight percent, based on the total weight of the composition. Within this range, the poly(phenylene ether)-polysiloxane block copolymer reaction product may be present in an amount of at least 8 weight percent, or at least 10 weight percent, or at least 12 weight percent, or at least 15 weight percent, or at least 20 weight percent, or at least 22 weight percent, or at least 24 weight percent. Also within this range, the poly(phenylene ether)-polysiloxane block copolymer reaction product may be present in an amount of 35 weight percent or less, or 32 weight percent or less, or 30 weight percent or less, or 28 weight percent or less. In one embodiment, the poly(phenylene ether)-polysiloxane block copolymer reaction product may be present in an amount of 8 to 40 weight percent, or 8 to 35 weight percent, or 8 to 30 weight percent, or 8 to 28 weight percent, or 10 to 28 weight percent.

[0024] In addition to the poly(phenylene ether)-polysiloxane block copolymer reaction product, the thermoplastic composition further comprises a second poly(phenylene ether).

[0025] The second poly(phenylene ether) may have an intrinsic viscosity of greater than 0.25 deciliters per gram, preferably from 0.44 to 0.60 deciliters per gram, and more preferably from 0.44 to 0.50 deciliters per gram, as measured using an Ubbelohde viscometer in chloroform at 25° C. In one embodiment, the second poly(phenylene ether) comprises homopolymers or copolymers of the monomers 2,6-dimethylphenol, 2,3,6-trimethylphenol, and combinations thereof.

[0026] In one embodiment, the second poly(phenylene ether) may have an intrinsic viscosity greater than 0.43 deciliters per gram, and preferably, the second poly(phenylene ether) comprises poly(2,6-dimethyl-1,4-phenylene ether).

[0027] The composition may include the second poly(phenylene ether) in an amount from 40 to 89 weight percent, based on the total weight of the composition. Within this range, the amount of the second poly(phenylene ether) can be from 45 to 89 weight percent, or from 45 to 75 weight percent, or from 50 to 75 weight percent, or from 50 to 70 weight percent, or from 50 to 60 weight percent.

[0028] In one embodiment, the composition may comprise the poly(phenylene ether)-poly(siloxane) block copolymer reaction product and the second poly(phenylene ether) in a total amount of at least 70 weight percent, or from 70 to 94 weight percent, or from 75 to 85 weight percent, based on the total weight of the composition.

[0029] The composition further comprises 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 may comprise a poly(alkenyl aromatic) content of 10 to 90 weight percent and a hydrogenated poly(conjugated diene) content of 90 to 10 weight percent, based on the weight of the hydrogenated block copolymer. In one embodiment, the hydrogenated block copolymer is a low poly(alkenyl aromatic) hydrogenated block copolymer having a poly(alkenyl aromatic) content of less than 10 to 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 one embodiment, the hydrogenated block copolymer is a high poly(alkenyl aromatic content) hydrogenated block copolymer having a poly(alkenyl aromatic content) content of from 40 to 90 weight percent, or from 50 to 80 weight percent, or from 60 to 70 weight percent, all based on the weight of the high poly(alkenyl aromatic content) hydrogenated block copolymer.

[0030] In one embodiment, 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 based on comparison with polystyrene standards. In one embodiment, 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 one embodiment, 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.

[0031] The alkenyl aromatic monomer used to prepare the hydrogenated block copolymer is represented by the formula (6): [ka] (6) [In the formula, R 5 and R 6are each independently a hydrogen atom, C 1~8 Alkyl group, or C 2~8 represents an alkenyl group, R 7 and R 11 are each independently a hydrogen atom, C 1~8 Represents an alkyl group, a chlorine atom, or a bromine atom, and R 8 , R 9 , and R 10 are each independently a hydrogen atom, C 1~8 Alkyl group or C 2~8 represents an alkenyl group, or R 8 and R 10 forms a naphthyl group together with the central aromatic ring, or R 9 and R 10 may have a structure according to the formula: ##STR1## where R is an aromatic ring and R is an aromatic ring, and R is an aromatic ring. Particular alkenyl aromatic monomers include, for 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 one embodiment, the alkenyl aromatic monomer is styrene.

[0032] The conjugated dienes used to prepare the hydrogenated block copolymers are C 4~20 It may be a 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 one embodiment, the conjugated diene is 1,3-butadiene, 2-methyl-1,3-butadiene, or combinations thereof. In one embodiment, the conjugated diene is 1,3-butadiene.

[0033] The hydrogenated block copolymer is a copolymer comprising at least one block (A) derived from an alkenyl aromatic compound and at least one block (B) derived from a conjugated diene, the content of aliphatic unsaturated groups in block (B) being at least partially reduced by hydrogenation. In one embodiment, the aliphatic unsaturation in block (B) is reduced by at least 50 percent, or at least 70 percent. The arrangement of blocks (A) and (B) includes linear structures, graft structures, and radial teleblock structures with or without branching. Linear block copolymers include tapered linear structures and non-tapered linear structures. In one embodiment, the hydrogenated block copolymer has a tapered linear structure. In one embodiment, the hydrogenated block copolymer has a non-tapered linear structure. In one embodiment, the hydrogenated block copolymer comprises a (B) block comprising random incorporation of alkenyl aromatic monomers. The structure of the linear block copolymer includes diblock (AB block), triblock (ABA block or BAB block), tetrablock (ABAB block), and pentablock (ABABA block or BABAB block) structures, as well as linear structures containing a total of 6 or more blocks (A) and (B), where the molecular weight of each (A) block may be the same as or different from the molecular weight of the other (A) blocks, and the molecular weight of each (B) block may be the same as or different from the molecular weight of the other (B) blocks. In one embodiment, the hydrogenated block copolymer is a diblock copolymer, a triblock copolymer, or a combination thereof.

[0034] In one embodiment, the hydrogenated block copolymer does not contain residues of monomers other than alkenyl aromatic compounds and conjugated dienes. In one embodiment, the hydrogenated block copolymer is composed of blocks derived from alkenyl aromatic compounds and conjugated dienes. The hydrogenated block copolymer does not contain grafts formed from these or other monomers. It also does not contain heteroatoms, since it is composed of carbon and hydrogen atoms. In one embodiment, the hydrogenated block copolymer contains residues of one or more acid functionalizing agents, such as maleic anhydride. In one embodiment, the hydrogenated block copolymer comprises a polystyrene-poly(ethylene-butylene)-polystyrene triblock copolymer.

[0035] In one embodiment, 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 embodiments, the polystyrene-poly(ethylene-butylene)-polystyrene triblock copolymer can optionally have a weight average molecular weight of 200,000 to 400,000 grams / mole, or 250,000 to 350,000 grams / mole, as determined by size exclusion chromatography using polystyrene standards.

[0036] Methods for preparing hydrogenated block copolymers are known in the art, and many hydrogenated block copolymers are commercially available. Exemplary commercially available hydrogenated block copolymers include polystyrene-poly(ethylene-propylene) diblock copolymers available from Kraton Performance Polymers Inc. as Kraton™ G1701 (having 37 weight percent polystyrene) and G1702 (having 28 weight percent polystyrene); polystyrene-poly(ethylene-butylene)-polystyrene triblock copolymers available from Kraton Performance Polymers Inc. as Kraton™ G1641 (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 polystyrene-poly(ethylene-ethylene / propylene)-polystyrene triblock copolymers available from Kuraray Co., Ltd. as SEPTON™ S4044, S4055, S4077, and S4099.Additional commercially available hydrogenated block copolymers include polystyrene-poly(ethylene) copolymers available from Dynasol as CALPRENE™ H6140 (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 available from Kuraray Co., Ltd. as SEPTON™ 8006 (having 33 weight percent polystyrene) and 8007 (having 30 weight percent polystyrene). polystyrene-poly(ethylene-propylene)-polystyrene (SEPS) copolymers available from Kuraray Co., Ltd. as SEPTON™ 2006 (having 35 weight percent polystyrene) and 2007 (having 30 weight percent polystyrene); oil-extended compounds of these hydrogenated block copolymers available from Kraton Performance Polymers Inc. as Kraton™ G4609 (containing 45% mineral oil and SEBS with 33 weight percent polystyrene) and G4610 (containing 31% mineral oil and SEBS with 33 weight percent polystyrene) and from Asahi Kasei Co., Ltd. as TUFTEC™ H1272 (containing 36% oil and SEBS with 35 weight percent polystyrene). Mixtures of two or more hydrogenated block copolymers can be used. In one embodiment, the hydrogenated block copolymer comprises a polystyrene poly(ethylene-butylene)-polystyrene triblock copolymer having a weight average molecular weight of at least 100,000 grams / mole, or from 200,000 to 400,000 grams / mole.

[0037] The composition comprises the hydrogenated block copolymer in an amount from 1 to 15 weight percent, based on the total weight of the composition. Within this range, the amount of hydrogenated block copolymer can be from 1 to 10 weight percent, or from 3 to 8 weight percent, or from 5 to 10 weight percent, or from 4 to 8 weight percent, or from 5 to 7 weight percent.

[0038] In one embodiment, the composition may optionally further comprise homopolystyrene or high impact polystyrene. As used herein, the term homopolystyrene refers to a homopolymer of styrene. Thus, residues of any monomer other than styrene are excluded from homopolystyrene. Homopolystyrene may be atactic, syndiotactic, or isotactic. In one embodiment, homopolystyrene may be atactic homopolystyrene. In one embodiment, homopolystyrene may have a melt volume flow rate of 1.5 to 5 cubic centimeters per 10 minutes measured at 200° C. and 5 kilograms load according to ISO 1133. High impact polystyrene, also known as HIPS or rubber modified polystyrene, may comprise 80 to 96 weight percent polystyrene, specifically 88 to 94 weight percent polystyrene, and 4 to 20 weight percent polybutadiene, specifically 6 to 12 weight percent polybutadiene, based on the weight of the rubber modified polystyrene. In one embodiment, the rubber-modified polystyrene has an effective gel content of 10 to 35 percent.

[0039] When present, homopolystyrene or high impact polystyrene may be present in an amount of from 0 to greater than 15 weight percent, or from 1 to 10 weight percent, based on the total weight of the composition. In one embodiment, homopolystyrene or high impact polystyrene may be excluded from the composition.

[0040] The composition further includes an organophosphate flame retardant. Exemplary organophosphate compounds include phosphate esters containing phenyl groups, substituted phenyl groups, or a combination of phenyl groups and substituted phenyl groups, bisaryl phosphate esters based on resorcinol, such as resorcinol bis(diphenyl phosphate), and bisaryl phosphate esters based on bisphenols, such as bisphenol A bis(diphenyl phosphate). In one embodiment, the organophosphate ester is selected from the group consisting of tris(alkylphenyl)phosphate (e.g., 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)phosphate (e.g., CAS Reg. No. 68937-41-7), t-butylphenyl diphenyl phosphate (CAS Reg. No. 56803-37-3), bis(t-butylphenyl)phenyl phosphate (CAS Reg. No. 65652-41-7), tris(t-butylphenyl) ... Reg. No. 78-33-1), and combinations thereof.

[0041] In one embodiment, the organophosphate ester has the formula (7): [ka] (7) wherein R independently in each occurrence represents 1~12 is an alkylene group, R 16 and R 17 is independent in each occurrence, C 1~5 is an alkyl group, R 12 , R 13 , and R 15 is independently 1~12 is a hydrocarbyl group, R 14 is, independently in each occurrence, C 1~12is a hydrocarbyl group, n is 1 to 25, and s1 and s2 are independently integers equal to 0, 1, or 2. 12 , OR 13 , OR 14 and OR 15 are independently derived from phenol, a monoalkylphenol, a dialkylphenol, or a trialkylphenol.

[0042] As those skilled in the art will readily understand, the bisarylphosphate 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 one embodiment, the bisphenol includes bisphenol A.

[0043] In one embodiment, the organophosphate ester includes resorcinol bis-diphenyl phosphate, bis-phenol A bis-diphenyl phosphate, or a combination thereof.

[0044] The organophosphate ester may be present in the composition in an amount from 5 to 20 weight percent, based on the total weight of the composition. Within this range, the organophosphate ester may be present in an amount from 7 to 15 weight percent, or from 8 to 14 weight percent, or from 8.5 to 12.5 weight percent.

[0045] The thermoplastic composition may further optionally comprise an additive composition. The additive composition comprises one or more additives. The additives may be, for example, stabilizers, release agents, lubricants, processing aids, drip retardants, nucleating agents, UV blocking agents, dyes, pigments, antioxidants, antistatic agents, foaming agents, mineral oils, metal deactivators, antiblocking agents, or combinations thereof. In one embodiment, the additive composition may comprise antioxidants, lubricants, heat stabilizers, UV absorbing additives, plasticizers, anti-drip agents, release agents, antistatic agents, dyes, pigments, laser marking additives, radiation stabilizers, or combinations 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.

[0046] In one embodiment, the composition may include an anti-drip agent. Fluorinated polyolefins or polytetrafluoroethylene may be used as the anti-drip agent. Anti-drip agents, such as fibril-forming or non-fibril-forming fluoropolymers, such as polytetrafluoroethylene (PTFE), may also be used. The anti-drip agent may be encapsulated by a rigid copolymer, such as styrene acrylonitrile (SAN). PTFE encapsulated with SAN is known as TSAN. Encapsulated fluoropolymers may be made, for example, by polymerizing the encapsulating polymer in the presence of the fluoropolymer in an aqueous dispersion. TSAN may offer a significant advantage over PTFE in that it can be more easily dispersed in the composition. A suitable TSAN may, for example, include 50% by weight PTFE and 50% by weight SAN, based on the total weight of the encapsulated fluoropolymer. SAN may, for example, include 75% by weight styrene and 25% by weight 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 an aromatic polycarbonate resin or SAN, to form a granulation for use as an anti-drip agent. Either method can be used to make the encapsulated fluoropolymer.

[0047] 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 mm. The anti-drip agent can be used in an amount of 0.01% to 5.0% by weight, based on the total weight of the composition.

[0048] The composition may include less than 3 weight percent, or less than 1 weight percent, or less than 0.5 weight percent of reinforcing fillers. In one embodiment, reinforcing fillers can be excluded from the composition. Reinforcing fillers include, for example, mica, clay, feldspar, quartz, quartzite, perlite, tripolites, diatomaceous earth, aluminum silicate (mullite), synthetic calcium silicate, fused silica, fumed silica, sand, boron nitride powder, borosilicate powder, calcium sulfate, calcium carbonate (e.g., chalk, limestone, marble, and synthetic precipitated calcium carbonate), talc (including fibrous, modular, needle-like, and flaky talc), wollastonite, hollow or solid glass spheres, silicate spheres, cenospheres, aluminosilicates or (armospheres), kaolin, silicon carbide, Examples of fillers include alumina, boron carbide, iron, nickel, or copper whiskers, continuous and chopped carbon or glass fibers, molybdenum sulfide, zinc sulfide, barium titanate, barium ferrite, barium sulfate, barite, 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 hulls, reinforcing organic fibrous fillers such as poly(ether ketones), polyimides, polybenzoxazoles, poly(phenylene sulfide), polyesters, polyethylenes, aromatic polyamides, aromatic polyimides, polyetherimides, polytetrafluoroethylene, and poly(vinyl alcohol), and combinations thereof. The fillers and reinforcing agents may be coated with a layer of metallic material to enhance electrical conductivity or may be surface treated with silane to improve adhesion and dispersion in the polymer matrix. In one embodiment, the composition may include less than 5 weight percent glass fibers. In one embodiment, the composition may be free of glass fibers.

[0049] The composition may include less than 0.5 weight percent, or less than 0.1 weight percent, or less than 0.01 weight percent tricalcium phosphate. In one embodiment, the composition may be free of 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, tricalcium phosphate, pentacalcium hydroxyorthophosphate, and apatite.

[0050] The composition may optionally minimize or not include additional components not specifically described herein. For example, the composition may include less than 2 weight percent, or less than 1 weight percent, or less than 0.5 weight percent, or less than 0.1 weight percent of any thermoplastic polymer other than the poly(phenylene ether)-poly(siloxane) block copolymer reaction product, the second poly(phenylene ether), the hydrogenated block copolymer, polystyrene, and high impact polystyrene. In one embodiment, the composition may not include any thermoplastic polymer other than the aforementioned polymers of the composition. In one embodiment, the composition may minimize or not include glass fibers. In one embodiment, the composition may minimize or not include homopolystyrene or rubber modified polystyrene.

[0051] In one embodiment, the composition may include 8 to 28 weight percent of a poly(phenylene ether)-polysiloxane block copolymer reaction product; 50 to 75 weight percent of a second poly(phenylene ether); 3 to 10 weight percent of a hydrogenated block copolymer; and 7 to 15 weight percent of an organophosphate ester flame retardant. The composition may be free of tricalcium phosphate and reinforcing fillers.

[0052] In one embodiment, the composition may comprise a poly(phenylene ether)-polysiloxane block copolymer reaction product comprising a phenylene ether block comprising repeating units derived from 2,6-dimethylphenol and a siloxane block comprising repeating units derived from dimethylsiloxane; a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene; an organophosphate ester flame retardant comprising resorcinol bis-diphenyl phosphate, bis-phenol A bis-diphenyl phosphate, or a combination thereof; and a second poly(phenylene ether) comprising repeating units derived from 2,6-dimethylphenol. In one embodiment, the composition may comprise 8 to 28 weight percent of the poly(phenylene ether)-polysiloxane block copolymer reaction product, 50 to 75 weight percent of the second poly(phenylene ether), 3 to 10 weight percent of the hydrogenated block copolymer, and 7 to 15 weight percent of the organophosphate ester flame retardant comprising resorcinol bis-diphenyl phosphate, bis-phenol A bis-diphenyl phosphate, or a combination thereof.

[0053] The compositions of the present disclosure may comprise 5 to 40 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer reaction product comprising a poly(phenylene ether)-poly(siloxane) block copolymer and a first 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; less than 3 weight percent of a reinforcing filler; less than 0.5 weight percent of tricalcium phosphate; and 40 to 89 weight percent, preferably 45 to 85 weight percent, of a second poly(phenylene ether), the weight percent of each component being based on the total weight of the composition. The poly(phenylene ether)-poly(siloxane) block copolymer reaction product and the second poly(phenylene ether) may be present in a combined amount of at least 70 weight percent, or 70 to 94 weight percent, or 75 to 85 weight percent, based on the total weight of the composition. The first poly(phenylene ether) may have an intrinsic viscosity greater than 0.25 deciliters per gram, or between 0.4 and 0.6 deciliters per gram, as measured in chloroform at 25° C. using an Ubbelohde viscometer, and preferably the poly(phenylene ether) comprises poly(2,6-dimethyl-1,4-phenylene ether). The organophosphate flame retardant may comprise resorcinol bis-diphenyl phosphate, bis-phenol A bis-diphenyl phosphate, resorcinol bis(di 2,6-dimethylphenyl) phosphate, oligomeric phosphate ester, triphenyl phosphate, or combinations thereof, preferably bis-phenol A bis-diphenyl phosphate. The hydrogenated block copolymer may comprise polystyrene-poly(ethylene-butylene)-polystyrene. The composition may comprise 0 to 15 weight percent homopolystyrene or high impact polystyrene. The composition may further comprise 0.1 to 10 weight percent of the additive composition. The composition may be free of glass fibers.The composition may include 8 to 28 weight percent of a poly(phenylene ether)-polysiloxane block copolymer reaction product; 50 to 75 weight percent of a second poly(phenylene ether); 3 to 10 weight percent of a hydrogenated block copolymer; and 7 to 15 weight percent of an organophosphate ester flame retardant. The relative amounts of each component can be adjusted within the ranges above to obtain the desired combination of properties. As will be appreciated by one of skill in the art, the amounts of each component are selected such that their sum equals 100 weight percent.

[0054] The compositions of the present disclosure can exhibit a desirable combination of physical properties. For example, molded samples of the composition may exhibit a UL-94 flammability rating of V0 when measured using a 1.0 millimeter specimen after conditioning for 48 hours at 23° C. and 168 hours at 70° C.; and a UL-94 flammability rating of V0 when measured using a 0.75 millimeter specimen after conditioning for 48 hours at 23° C. and 168 hours at 70° C.; a UL-94 flammability rating of V0 when measured using a 0.5 millimeter specimen after conditioning for 48 hours at 23° C. and 168 hours at 70° C.; a UL-94 flammability rating of V0 when measured using a 0.3 millimeter specimen after conditioning for 48 hours at 23° C. and 168 hours at 70° C.; and a UL-94 flammability rating of V0 when measured using a 0.2 millimeter specimen after conditioning for 48 hours at 23° C. and 168 hours at 70° C. Molded samples of the composition may exhibit a heat deflection temperature of 115° C. or greater, as measured on 3.2 mm thick strips using a load of 1.82 MPa according to ASTM D648. Molded samples of the composition may exhibit a notched Izod impact strength of 240 J / m or greater, as measured according to ASTM D256.

[0055] The compositions of the present disclosure can be prepared, for example, by melt blending the components of the composition. The components of the composition can be mixed or blended using conventional equipment, such as ribbon blenders, HENSCHEL™ mixers, BANBURY™ mixers, drum tumblers, and the like, and the blended composition can then be melt blended or melt kneaded. The melt blending or melt kneading can be carried out using conventional equipment, such as single screw extruders, twin screw extruders, multi-screw extruders, co-kneaders, and the like. For example, the compositions of the present disclosure can be prepared by melt blending the components in a twin screw extruder at a temperature of 270-310°C, or 280-300°C. The extrudate is immediately quenched in a water bath and pelletized. The pellets thus prepared can be ¼ inch or less in length, if desired. Such pellets can be used for subsequent molding, shaping, or forming.

[0056] Shaped, molded, or molded articles comprising the composition represent another aspect of the present disclosure. The composition can be molded into useful shaped articles by various methods, such as injection molding, extrusion, rotational molding, blow molding, and thermoforming. Some examples of articles include electric vehicle battery modules, battery housings, battery cases, battery cell frames, battery cell spacers, battery cell retainers, battery pack insulating films, bus bar holders, terminal covers, electrical or electronic components, thermoset circuit breakers, fuser holders for electrophotographic copiers, photovoltaic junction boxes, photovoltaic connectors, electrical connectors, automotive electrical connectors, relays, charging couplers, appliance parts, automotive parts, portable devices, mobile parts, or stationary electrical components. In one aspect, the article is an extrusion, molding, pultrusion, thermoformed, foamed, layer of a multilayer article, substrate of a coated article, or substrate of a metallized article. In one aspect, the composition may be particularly useful in molded or extruded parts for electric vehicle battery components. For example, the composition may be used in extruded parts for electric vehicle battery components, such as insulating sheets or films for electric vehicle battery components.

[0057] A battery insulation film or sheet represents another embodiment of the present disclosure. The battery insulation film or sheet is extruded from a composition comprising 5-40 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer reaction product comprising a poly(phenylene ether)-poly(siloxane) block copolymer and a first poly(phenylene ether); 1-15 weight percent of an impact modifier comprising a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene; 5-20 weight percent of an organophosphate ester flame retardant; less than 3 weight percent of a reinforcing filler; less than 0.5 weight percent of tricalcium phosphate; and 40-89 weight percent of a second poly(phenylene ether), the weight percent of each component being based on the total weight of the composition. In one embodiment, the extruded film or sheet may have a UL-94 flammability rating of V0 when measured using a 1.0 millimeter specimen after conditioning for 48 hours at 23° C. and 168 hours at 70° C.; a UL-94 flammability rating of V0 when measured using a 0.75 millimeter specimen after conditioning for 48 hours at 23° C. and 168 hours at 70° C.; a UL-94 flammability rating of V0 when measured using a 0.5 millimeter specimen after conditioning for 48 hours at 23° C. and 168 hours at 70° C.; a UL-94 flammability rating of V0 when measured using a 0.3 millimeter specimen after conditioning for 48 hours at 23° C. and 168 hours at 70° C.; and a UL-94 flammability rating of V0 when measured using a 0.2 millimeter specimen after conditioning for 48 hours at 23° C. and 168 hours at 70° C. The extruded film or sheet may exhibit a heat deflection temperature of 115° C. or greater, measured on a 3.2 mm thick strip using a load of 1.82 MPa according to ASTM D648, and a notched Izod impact strength of 240 J / m or greater, measured according to ASTM D256. The battery insulation film may have a thickness of, for example, 50 to 1000 micrometers.

[0058] As described herein, the inventors have unexpectedly discovered that a composition comprising a poly(phenylene ether)-polysiloxane block copolymer, a hydrogenated block copolymer of an alkenyl aromatic and a conjugated diene, an organophosphate ester flame retardant, and a second poly(phenylene ether) in specific amounts can provide certain advantageous properties, particularly for thin molded articles, including a combination of high heat resistance, high impact strength, and low flammability. Thus, the present disclosure provides a significant improvement, particularly when it comes to battery pack insulating films or sheets extruded from the composition. EXAMPLES

[0059] The present disclosure is further illustrated by the following non-limiting examples.

[0060] The materials used in the following examples are shown in Table 1.

[0061] [Table 1]

[0062] The compositions were compounded using a Toshiba TEM-37BS twin screw extruder. All ingredients were added at the feed throat of the extruded except for BPADP which was added via a liquid feeder. The extruded material was cooled in a water bath and pelletized. The pellets were conditioned at 120°C for 3 hours prior to injection molding or extrusion. The processing parameters used are summarized in Table 2.

[0063] [Table 2]

[0064] Test pieces 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 (feed throat to nozzle) and a mold temperature of 90°C.

[0065] The properties of the molded articles were tested according to the following standards.

[0066] The melt flow rate values, expressed in g / 10 min, were measured at a temperature of 300 °C and a load of 5 kilograms according to ASTM D1238-10, procedure B. The heat deflection temperatures (HDT), expressed in °C, were measured at 1.82 MPa or 0.45 MPa using a load bar of 3.2 millimeters thickness according to ASTM D648. The notched Izod impact (NII) strength values, expressed in joules / meter, were measured at 23 °C using a pendulum with cross-sectional dimensions of 3.2 millimeters by 12.7 millimeters according to ASTM D256-10, method A. The unnotched Izod impact strength, expressed in joules / meter, was measured at 23 °C using a pendulum with cross-sectional dimensions of 3.2 millimeters by 12.7 millimeters according to ASTM D4812. The tensile properties were measured according to ASTM D638 with a sample thickness of 3.2 millimeters and a test speed of 5 millimeters / minute.

[0067] Hydrolytic stability was evaluated by placing tensile bars in a hydrolysis chamber at 85°C and 85% relative humidity for 1000 hours. Samples were then removed from the chamber for characterization. Hydrolytic stability was evaluated by retention of tensile modulus and tensile stress. If tensile modulus and tensile stress retention were 90% or greater, it was considered "good." If at least one of tensile modulus or tensile stress retention was less than 90%, the hydrolytic stability was considered "poor."

[0068] Density, expressed in grams per cubic centimeter (g / cc), was measured according to ASTM D-792 or ISO 1183-1, Method A.

[0069] Water absorption, expressed as percent weight change, was measured according to ASTM D-570 or ISO 62, Method 4.

[0070] The flame retardancy of injection molded flame test specimens was measured according to Underwriter's Laboratory Bulletin 94 "Tests for Flammability of Plastic Materials, UL94", 20 mm vertical flame test. Flame test specimens with 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. Sets of 10 to 20 flame test specimens were tested for the UL94 20 mm vertical flame test. For each specimen, the specimen was exposed to a flame for 10 seconds and then removed, and the time it took for the specimen to self-extinguish (first flame time, t1) was recorded. The specimen was then exposed to a flame for 10 seconds again and the time it took for the specimen to self-extinguish (second flame time, t2) and the time after glow (afterglow time, t3) were recorded. To achieve a rating of V-0, the post-flame times t1 and t2 of each individual specimen must be 10 seconds or less, the total post-flame time for all five specimens (t1 + t2 for all five specimens) must be 50 seconds or less, the second post-flame time + afterglow time (t2 + t3) of each individual specimen must be 30 seconds or less, no specimen should burn or blaze up to the holding clamps, and the cotton indicator should not be ignited by flame particles or droplets. To achieve a V-1 rating, the post-flame times t1 and t2 of each individual specimen must be 30 seconds or less, the total post-flame time for all five specimens (t1 + t2 for all five specimens) must be 250 seconds or less, the second post-flame time + afterglow time (t2 + t3) of each individual specimen must be 60 seconds or less, no specimen may burn or blaze to the position of the retaining clamps, and the cotton indicator may not be ignited by flame particles or droplets.To achieve a V-2 rating, the post-flame times t1 and t2 of each individual specimen must be 30 seconds or less, the total post-flame time for all five specimens (t1 + t2 for all five specimens) must be 250 seconds or less, the second post-flame time + afterglow time (t2 + t3) of each individual specimen must be 60 seconds or less, and no specimen may burn or blaze to the position of the retaining clamps, except that the cotton indicator may be ignited by flame particles or droplets.

[0071] The compositions and properties are summarized in Table 3. The amount of each component is provided as a weight percent based on the total weight of the composition.

[0072] [Table 3]

[0073] As shown in Table 3, the composition of Comparative Example 1 exhibited flame retardancy of V0 at 0.75 mm, V2 at 0.5, 0.3 mm, and 0.2 mm. The composition of Comparative Example 2 exhibited improved HDT compared to Comparative Example 1, but exhibited reduced flammability, only achieving a V1 flammability rating at 0.75 mm. The composition of Comparative Example 3 exhibited improved flame retardancy with increased BPADP loading, but the HDT decreased compared to Comparative Example 2. Thus, none of the comparative compositions can achieve a V0 flammability rating at thicknesses below 0.75 mm, nor can they achieve a good balance between flame retardancy and heat resistance (e.g., HDT).

[0074] In contrast, the compositions of Examples 1-8 each exhibited a desirable combination of properties. Most notably, each of these compositions achieved a V0 flammability rating at thicknesses of 1.0, 0.75, 0.5, and 0.3 millimeters. The compositions of Examples 1-8, each containing PPE-Si, achieved a V0 flammability rating at a thickness of 0.3 millimeters, and the compositions of Examples 1-3 even achieved a V0 flammability rating at a thickness of 0.2 millimeters. In contrast, the compositions of Comparative Examples 1-3 achieved a V1 or V2 flammability rating at thicknesses of 0.5 millimeters or less. In addition to high flame retardancy, the compositions of Examples 1-8 also exhibited good hydrolysis resistance, heat resistance, and impact strength.

[0075] Thus, the compositions of the present disclosure can provide a V0 flammability rating at thicknesses of 0.3 mm or less, achieving a desirable balance of thin-wall flammability rating and high heat resistance.

[0076] The compositions of Examples 1 and 2 were further compared to various existing compositions. The results are summarized in Table 4. The composition of Comparative Example 4 is NORYL™ PX9406P, a non-brominated, non-chlorinated flame retardant polyphenylene ether resin obtained from SABIC. The composition of Comparative Example 5 is FORMEX™ CND, a flame retardant polycarbonate obtained from ITW FORMEX. The composition of Comparative Example 6 is FORMEX™ GK, a flame retardant polypropylene obtained from ITW FORMEX.

[0077] These comparative examples were further evaluated for flammability according to UL94 VTM (Vertical Flammability Rating for Thin Materials). The samples were pretreated as described above. To achieve a rating of VTM-0, the post-flame times t1 and t2 of each individual specimen must be 10 seconds or less, the total post-flame time (t1+t2 of all five specimens) must be 50 seconds or less, the second post-flame time + afterglow time (t2+t3) of each individual specimen must be 30 seconds or less, no specimen should burn or flare up to the fixing clamp, and the cotton indicator should not be ignited by flame particles or drops. The thickness at which each composition achieves a rating of VTM-0 is presented in Table 4.

[0078] As shown in Table 4, existing compositions are unable to achieve the combination of flame retardancy, hydrolysis resistance and heat resistance for thin walls. Therefore, the compositions of the present disclosure provide a significant improvement.

[0079] [Table 4]

[0080] The present disclosure further includes the following aspects.

[0081] Aspect 1: A thermoplastic composition comprising: 5 to 40 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer reaction product comprising a poly(phenylene ether)-poly(siloxane) block copolymer and a first 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; less than 3 weight percent of a reinforcing filler; less than 0.5 weight percent tricalcium phosphate; and 40 to 90 weight percent of a second poly(phenylene ether), wherein the weight percent of each component is based on the total weight of the composition.

[0082] Aspect 2: The composition of aspect 1, wherein the second poly(phenylene ether) is present in an amount from 45 to 85 weight percent.

[0083] Aspect 3: The composition of aspect 1 or 2, wherein the poly(phenylene ether)-poly(siloxane) block copolymer reaction product and the second poly(phenylene ether) are present in a combined amount of at least 70 weight percent, or from 70 to 94 weight percent, or from 75 to 85 weight percent, based on the total weight of the composition.

[0084] Aspect 4: The composition of any one of aspects 1 to 3, wherein a molded sample of the composition has a UL-94 flammability rating of V0 when measured using a 1.0 millimeter specimen after conditioning at 23° C. for 48 hours and at 70° C. for 168 hours; and a UL-94 flammability rating of V0 when measured using a 0.75 millimeter specimen after conditioning at 23° C. for 48 hours and at 70° C. for 168 hours. and, optionally, a heat deflection temperature of 115°C or greater, when measured on a 3.2 mm thick specimen using a load of 1.82 MPa in accordance with ASTM D648; and a notched Izod impact strength of 240 J / m or greater, when measured in accordance with ASTM D256.

[0085] Aspect 5: The composition of any one of aspects 1 to 4, wherein the first poly(phenylene ether) has an intrinsic viscosity greater than 0.25 deciliters per gram, or from 0.4 to 0.6 deciliters per gram, as measured in chloroform at 25° C. using an Ubbelohde viscometer, and preferably the poly(phenylene ether) comprises poly(2,6-dimethyl-1,4-phenylene ether).

[0086] Aspect 6: The composition of any one of aspects 1 to 5, wherein the organophosphate flame retardant comprises resorcinol bis-diphenyl phosphate, bis-phenol A bis-diphenyl phosphate, resorcinol bis(di 2,6-dimethylphenyl) phosphate, an oligomeric phosphate ester, triphenyl phosphate, or a combination thereof, preferably bis-phenol A bis-diphenyl phosphate.

[0087] Aspect 7: The composition of any one of aspects 1 to 6, wherein the hydrogenated block copolymer comprises polystyrene-poly(ethylene-butylene)-polystyrene.

[0088] Embodiment 8: The composition of any one of embodiments 1 to 7, comprising 0 to 15 weight percent of homopolystyrene or high impact polystyrene.

[0089] Embodiment 9: The composition according to any one of embodiments 1 to 8, wherein the composition does not contain glass fibers.

[0090] Aspect 10: The composition of any one of aspects 1 to 9, further comprising 0.1 to 10 weight percent of an additive composition.

[0091] Aspect 11: The composition of aspect 1, comprising: 8 to 28 weight percent of the poly(phenylene ether)-polysiloxane block copolymer reaction product; 50 to 75 weight percent of a second poly(phenylene ether); 3 to 10 weight percent of the hydrogenated block copolymer; and 7 to 15 weight percent of an organophosphate flame retardant.

[0092] Example 12: The composition of example 11, wherein the poly(phenylene ether)-polysiloxane block copolymer reaction product and the second poly(phenylene ether) are present in a total amount of at least 75 weight percent, based on the total weight of the composition.

[0093] Embodiment 13: A method for producing a composition according to any one or more of embodiments 1 to 12, comprising melt-mixing the components of the composition.

[0094] Example 14: An article comprising the composition of any one of Examples 1 to 12, preferably an electric vehicle battery module, a battery insulating sheet or film, a battery housing, a battery case, a battery cell frame, a battery cell spacer, a battery cell retainer, a bus bar holder, a terminal cover, an electric or electronic component, a charger adapter insulating sheet or film, a thermoset circuit breaker, a fuser holder for an electrophotographic copier, a photovoltaic junction box, a photovoltaic connector, an electrical connector, an automotive electrical connector, a relay, a charging coupler, an appliance part, an automotive part, a portable device, a mobile part, or a stationary electrical part.

[0095] Example 15: An electric vehicle battery component extruded from the composition of any one of Examples 1 to 12, preferably an electric vehicle battery insulating sheet or film.

[0096] The compositions, methods, and articles can alternatively comprise, consist of, or consist essentially of any suitable materials, steps, or components disclosed herein. The compositions, methods, and articles can additionally or alternatively be formulated to be free, or substantially free, of any materials (or species), steps, or ingredients that are not necessary to the function or accomplishment of the purpose of the compositions, methods, and articles.

[0097] All ranges disclosed herein are inclusive of endpoints, and the endpoints may be combined independently of one another. "Combinations" include blends, mixtures, alloys, reaction products, and the like. Terms such as "first," "second," and the like do not denote any order, quantity, or importance, but are used to distinguish one element from another. The terms "a," "an," and "the" do not denote any limitation of quantity, and should be construed to encompass both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. "Or" means "and / or" unless expressly stated otherwise. References throughout this specification to "an embodiment" mean that the particular element described in connection with that embodiment is included in at least one embodiment described herein and may or may not be present in other embodiments. Any embodiment described herein can be combined with any other embodiment. As used herein, the term "combinations thereof" is open to include one or more of the listed elements and to allow for the presence of one or more similar elements not named. It is further understood that the described elements may be combined in any suitable manner in the various embodiments.

[0098] Unless otherwise specified herein, all test standards are the latest standards in effect as of the filing date of this application or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[0099] Unless otherwise defined, technical and scientific terms used herein have the same meaning as commonly understood by those skilled 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 the terms of this application contradict or conflict with the terms of the incorporated reference, the terms of this application shall take precedence over the conflicting terms of the incorporated reference.

[0100] Compounds are described using standard nomenclature. For example, any position not substituted by any indicated group is understood to have its valency satisfied by the indicated bond or hydrogen atom. A dash ("-") that is not between two letters or symbols is used to indicate the point of attachment of a substituent. For example, -CHO is attached through the carbon of a carbonyl group.

[0101] As used herein, the term "hydrocarbyl", whether used by itself or as a prefix, suffix, or fragment of another term, refers to a residue containing only carbon and hydrogen. The residue may be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated, or unsaturated. It may also contain a combination of aliphatic, aromatic, straight-chain, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbon moieties. However, when a hydrocarbyl residue is described as being substituted, it may optionally contain heteroatoms in addition to the carbon and hydrogen members of the substituent residue. Thus, especially when described as being substituted, the hydrocarbyl residue may also contain one or more carbonyl groups, amino groups, hydroxyl groups, etc., or may contain heteroatoms within the backbone of the hydrocarbyl residue. The term "alkyl" refers to a branched or straight-chain saturated aliphatic hydrocarbon group, such as methyl, ethyl, n-propyl, i-propyl, n-butyl, s-butyl, t-butyl, n-pentyl, s-pentyl, and n- and s-hexyl. "Alkenyl" refers to a straight or branched monovalent hydrocarbon group having at least one carbon-carbon double bond, such as ethenyl (-HC=CH2). "Alkoxy" refers to an alkyl group attached through an oxygen (i.e., alkyl-O-), such as methoxy, ethoxy, and sec-butyloxy groups. "Alkylene" refers to a straight or branched saturated divalent aliphatic hydrocarbon group, such as methylene (-CH2-) or propylene (-(CH2)3-). "Cycloalkylene" refers to a divalent cyclic alkylene group, -C n H 2n-xwhere x is the number of hydrogens replaced by the cyclization. "Cycloalkenyl" refers to a monovalent group having one or more rings and one or more carbon-carbon double bonds within the ring, all of the ring members being carbon (e.g., cyclopentyl and cyclohexyl). "Aryl" refers to an aromatic hydrocarbon group containing a specified number of carbon atoms, such as phenyl, tropone, indanyl, or naphthyl. "Arylene" refers to a divalent aryl group. "Alkylarylene" refers to an arylene group substituted with an alkyl group. "Arylalkylene" refers to an alkylene group substituted with an aryl group (e.g., benzyl). The prefix "halo" refers to a group or compound containing one or more fluoro, chloro, bromo, or iodo substituents. Combinations 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 contains at least one ring member that is a heteroatom (e.g., 1, 2, or 3 heteroatoms), each of which is independently N, O, S, Si, or P. "Substituted" means that the compound or group contains, each of which is independently, C, in place of a hydrogen. 1~9 Alkoxy, C 1~9 Haloalkoxy, nitro (-NO2), cyano (-CN), C 1~6 Alkylsulfonyl (-S(=O)2-alkyl), C 6~12 Arylsulfonyl (-S(=O)2-aryl), thiol (-SH), thiocyano (-SCN), tosyl (CH3C6H4SO2-), C 3~12 Cycloalkyl, C 2~12 Alkenyl, C 5~12 Cycloalkenyl, C 6~12 Aryl, C 7~13 Aryl alkylene, C 4~12 Heterocycloalkyl, and C 3~12 It means that it is substituted with at least one (e.g., 1, 2, 3, or 4) substituents, which may be heteroaryl, but not exceeding the normal valence of the substituted atom. The number of carbon atoms shown in the group is exclusive of any optional substituents. For example, -CH2CH2CN is a C2 alkyl group substituted with a nitrile.

[0102] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents may occur to applicant or those skilled in the art that are not presently foreseen or possible, and it is therefore intended that the appended claims, as filed and as they may be amended, cover all such alternatives, modifications, variations, improvements, and substantial equivalents.

Claims

1. 5 to 40 weight percent of a poly(phenylene ether)-poly(siloxane) block copolymer reaction product comprising a poly(phenylene ether)-poly(siloxane) block copolymer and a first 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 organophosphate flame retardant; less than 3 weight percent reinforcing filler; less than 0.5 weight percent tricalcium phosphate; and 40 to 90 weight percent of a second poly(phenylene ether) A thermoplastic composition comprising: A composition characterized in that the weight percentage of each component is based on the total weight of the composition.

2. 10. The composition of claim 1, wherein the second poly(phenylene ether) is present in an amount of 45 to 85 weight percent based on the total weight of the composition.

3. 10. The composition of claim 1, wherein the poly(phenylene ether)-poly(siloxane) block copolymer reaction product and the second poly(phenylene ether) are present in a combined amount of at least 70 weight percent, or from 70 to 94 weight percent, or from 75 to 85 weight percent, based on the total weight of the composition.

4. 10. The composition of claim 1, wherein a molded sample of the composition comprises: UL-94 flammability rating of V0 when measured using 1.0 millimeter test specimens after conditioning at 23°C for 48 hours and at 70°C for 168 hours; UL-94 flammability rating of V0 when measured using 0.75 millimeter test specimens after conditioning at 23°C for 48 hours and at 70°C for 168 hours; UL-94 flammability rating of V0 when measured using 0.5 millimeter test specimens after conditioning at 23°C for 48 hours and at 70°C for 168 hours; UL-94 flammability rating of V0 when measured using 0.3 millimeter test specimens after conditioning at 23°C for 48 hours and at 70°C for 168 hours; UL-94 flammability rating of V0 when measured using 0.2 millimeter test specimens after conditioning at 23°C for 48 hours and at 70°C for 168 hours; and Depending on the situation, A heat deflection temperature of 115°C or greater when measured on a 3.2 mm thick specimen using a load of 1.82 MPa according to ASTM D648; and a notched Izod impact strength of 240 J / m or greater when measured in accordance with ASTM D256;

5. 10. The composition of claim 1, wherein the first poly(phenylene ether) has an intrinsic viscosity greater than 0.25 deciliters per gram, or from 0.4 to 0.6 deciliters per gram, as measured in chloroform at 25° C. using an Ubbelohde viscometer; and preferably, the poly(phenylene ether) comprises poly(2,6-dimethyl-1,4-phenylene ether).

6. 2. The composition of claim 1, 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 combinations thereof, preferably bis-phenol A bis-diphenyl phosphate.

7. 10. The composition of claim 1, wherein the hydrogenated block copolymer comprises polystyrene-poly(ethylene-butylene)-polystyrene.

8. 10. The composition of claim 1 comprising 0 to 15 weight percent homopolystyrene or high impact polystyrene.

9. 10. The composition of claim 1, wherein the composition is glass fiber-free.

10. 10. The composition of claim 1, further comprising 0.1 to 10 weight percent of an additive composition.

11. 10. The composition of claim 1, 8 to 28 weight percent of said poly(phenylene ether)-polysiloxane block copolymer reaction product; 50 to 75 weight percent of said second poly(phenylene ether); 3 to 10 weight percent of the hydrogenated block copolymer; and 7 to 15 weight percent of said organic phosphate ester flame retardant A composition comprising:

12. 12. The composition of claim 11, wherein the poly(phenylene ether)-poly(siloxane) block copolymer reaction product and the second poly(phenylene ether) are present in a combined amount of at least 75 weight percent, based on the total weight of the composition.

13. 10. A method for making the composition of claim 1, comprising melt-mixing the components of the composition.

14. 10. An article comprising the composition of claim 1, Preferably, the article is an electric vehicle battery module, a battery insulating sheet or film, a battery housing, a battery case, a battery cell frame, a battery cell spacer, a battery cell retainer, a bus bar holder, a terminal cover, an electrical or electronic component, a charger adapter insulating sheet or film, a thermosetting circuit breaker, a fuser holder for an electrophotographic copier, a photovoltaic junction box, a photovoltaic connector, an electrical connector, an automotive electrical connector, a relay, a charging coupler, a home appliance component, an automotive component, a portable device, a mobile component, or a stationary electrical component.

15. 10. An electric vehicle battery component extruded from the composition of claim 1, preferably an electric vehicle battery insulating sheet or film.