Polyamide Compounds for Long Term High Temperature Performance

Abstract

Provided herein is a polymer composition comprising an aromatic polyamide or 6T / DT copolymer containing terephthalic and isophthalic units with high overall aromaticity, together with a heat stabilizer and / or lubricant. The polymer composition demonstrates improved electrical performance in terms of volume resistivity and dielectric strength.

Description

[Technical field]

[0001] Claiming priority

[0001] This application claims priority to U.S. Provisional Application No. 63 / 277,424, filed November 9, 2021, the contents of which are incorporated by reference herein.

[0002] This disclosure relates to polyamide compositions, particularly polyamide compositions having improved electrical performance under demanding conditions. [Background technology]

[0003]

[0003] Polyamide resin compositions are known to have beneficial physical properties such as high melting points, high recrystallization temperatures, faster injection molding cycle times, high flow, toughness, elasticity, chemical resistance, inherent UL94 V2 flame retardancy, and abrasion resistance. These properties often make polyamide resin compositions ideal for high performance automotive and electrical / electronic applications. However, when plastic parts are exposed to high temperatures for extended periods, such as in automotive or electrical / electronic applications, the mechanical properties generally tend to decrease due to thermal oxidation of the polymer. This phenomenon is often referred to as thermal degradation.

[0004]

[0004] In an attempt to improve the thermal degradation characteristics of polymers, heat stabilizers have traditionally been added to polymer compositions. However, the thermal degradation characteristics of existing technologies are usually insufficient for more demanding applications involving exposure to higher temperatures, such as automotive and electrical / electronic applications. Also, the addition of some heat stabilizers often impairs other performance features, such as processability or electrical properties. In many cases, improvements in thermal degradation performance are accompanied by a loss of processability.

[0005]

[0005] Additionally, while the addition of stabilizers to polyamide resins may improve thermal degradation, these additional ingredients may also add other undesirable compounds / elements. For example, the addition of some conventional heat stabilizers often introduces halogen compounds into the composition, which may negatively contribute to the "non-halogen" specification of the polymer composition. This is particularly relevant for flame retardant polymer compositions.

[0006]

[0006] Thus, a need exists for polyamide compositions that can provide effective mechanical performance at higher temperatures, preferably while maintaining other performance features such as, for example, flame retardancy, processability, or electrical properties such as, for example, volume resistivity. Summary of the Invention

[0007]

[0007] In one aspect, a polymer composition is provided that includes an aromatic polyamide comprising terephthalic and isophthalic units and having an overall aromaticity of greater than 31%, a heat stabilizer, and an optional lubricant. Long-term high temperature performance is improved. In one embodiment, the polymer composition exhibits a volume resistivity of greater than 1.0E+10 ohm-cm when measured by IEC 62631 at elevated temperatures such as 150°C. In one embodiment, the polymer composition exhibits a dielectric strength of greater than 25 KV / mm when measured by IEC 60243 at elevated temperatures such as 150°C. Preferably, the polymer composition retains dielectric strength retention under humidity aging. Thus, in one embodiment, the composition exhibits a tensile strength of greater than 85 MPa when moisture treated for 1 K hours at a temperature of 85°C and a relative humidity of 85%, and a volume resistivity of greater than 5.0E+13 ohm-cm when moisture treated for 1 K hours at a temperature of 85°C and a relative humidity of 85%. The aromatic polyamide may have an overall aromaticity of greater than 35%. In one embodiment, the aromatic polyamide comprises adipic acid units in addition to terephthalic and isophthalic acid units and has an overall aromaticity of greater than 32%. The aromatic polyamide may comprise 6I / 6T, 6T / 6I / 66, or 6T / 66 / 6I, or combinations thereof. The difference between the combined content of terephthalic and isophthalic acid units and the content of adipic acid units may range from 30 to 100. The aromatic polyamide may comprise 35 wt% to 100 wt% terephthalic acid units, based on the total weight of the aromatic polyamide. In one embodiment, the aromatic polyamide comprises 10 wt% to 70 wt% isophthalic acid units, based on the total weight of the aromatic polyamide. Some embodiments may also comprise PA6 in an amount of 0 wt% to 10 wt%. The polymer composition comprises 25 wt% to 95 wt% aromatic polyamide, based on the total weight of the polymer composition. In one embodiment, the heat stabilizer is a hindered phenol such as N,N'-hexamethylenebis[3-(3,5-dit-butyl-4-hydroxyphenyl)propionamide. In one embodiment, the lubricant is a montanate.

[0008]

[0008] In one aspect of the present invention, a polymer composition is provided comprising a 6T / DT copolymer having an overall aromaticity of greater than 25%, a heat stabilizer, and an optional lubricant. In one embodiment, the polymer composition exhibits a volume resistivity of greater than 1.0E+10 ohm-cm when measured by IEC 62631 at elevated temperatures such as 150°C. In one embodiment, the polymer composition exhibits a dielectric strength of greater than 25 KV / mm when measured by IEC 60243 at elevated temperatures such as 150°C. Preferably, the polymer composition retains dielectric strength retention under humidity aging. Thus, in one embodiment, the composition exhibits a tensile strength of greater than 85 MPa when moisture treated at a temperature of 85°C and a relative humidity of 85% for 1K hours, and a volume resistivity of greater than 5.0E+13 ohm-cm when moisture treated at a temperature of 85°C and a relative humidity of 85% for 1K hours. The aromatic polyamide may have an overall aromaticity of greater than 31, or more preferably greater than 35%. Some embodiments may also include PA6 in an amount of 0 wt% to 10 wt%. The polymer composition includes 25 wt% to 95 wt% aromatic polyamide, based on the total weight of the polymer composition. In one embodiment, the heat stabilizer is a hindered phenol, such as N,N'-hexamethylene bis[3-(3,5-dit-butyl-4-hydroxyphenyl)propionamide. In one embodiment, the lubricant is a montanate.

[0009]

[0009] In some embodiments, the present disclosure provides a polyamide composition comprising an aromatic polyamide comprising terephthalic and isophthalic units (and optionally adipic units), e.g., PA6T / DT, 6I / 6T, 6T / 6I / 66 or 6T / 66 / 6I or combinations thereof, or PA6T / 6I / 66 or PA6T / 66 / 6I or combinations thereof, and having an overall aromaticity of greater than 20%, e.g., greater than 35% (25 wt% to 95 wt%); a heat stabilizer, e.g., a hindered phenol and / or N,N'-hexamethylenebis[3-(3,5-dit-butyl-4-hydroxyphenyl)propionamide; and an optional lubricant, e.g., montanate, having a tensile strength (as-molded dry) of greater than 146 MPa measured at 23°C and an IEC 613144-1:2002-1:2002-1:2002-1:2002 The polyamide composition has a volume resistivity of more than 1.0E+10 ohm-cm when measured at 150°C according to 62631 and / or a tensile strength of more than 85 MPa when moisture-treated for 1000 hours at a temperature of 85°C and a relative humidity of 85% and a volume resistivity of more than 5.0E+13 ohm-cm when moisture-treated for 1000 hours at a temperature of 85°C and a relative humidity of 85%. The difference between the combined content of terephthalic acid units and isophthalic acid units and the content of adipic acid (and optionally caprolactam) units may range from 30 to 100. The aromatic polyamide may contain 35 wt% to 100 wt% terephthalic acid units and / or 10 wt% to 70 wt% isophthalic acid units, and optionally 0 wt% to 10 wt% PA6, based on the total weight of the aromatic polyamide.

[0010]

[0010] In some embodiments, the present disclosure relates to a polymer composition comprising one or more 6T / DT copolymers; 6I / 6T copolymers comprising terephthalic acid units and isophthalic acid units (and optionally caprolactam units); and terpolymers comprising terephthalic acid units, isophthalic acid units and adipic acid units, having an overall aromaticity of more than 25%, for example more than 30%. The polymer composition further comprises a heat stabilizer; an optional lubricant, and the polymer composition exhibits a tensile strength (as-molded dry) of more than 146 MPa measured at 23°C and a volume resistivity of more than 1.0E+10 ohm-cm measured at 150°C by IEC 62631.

[0011]

[0011] In some embodiments, the present disclosure relates to a polymer composition comprising a 6I / 6T copolymer comprising 25 wt% to 45 wt% terephthalic acid units and 55 wt% to 75 wt% isophthalic acid units, based on the total weight of all units; 0 wt% to 20 wt% caprolactam-based polyamide; a heat stabilizer; and an optional lubricant.

[0012]

[0012] In some embodiments, the present disclosure relates to a polymer composition comprising a 6T / 6I / 66 terpolymer comprising, based on the total weight of all units, 50 wt% to 65 wt% terephthalic acid units; 20 wt% to 30 wt% isophthalic acid units; and 10 wt% to 25 wt% adipic acid units; and 0 wt% to 20 wt% caprolactam-based polyamide; a heat stabilizer; and an optional lubricant.

[0013]

[0013] In some embodiments, the present disclosure relates to a polymer composition comprising a 6T / 66 / 6I terpolymer comprising, based on the total weight of all units, 45 wt% to 60 wt% terephthalic acid units; 12 wt% to 27 wt% isophthalic acid units; and 25 wt% to 40 wt% adipic acid units; and 0 wt% to 20 wt% caprolactam-based polyamide; a heat stabilizer; and an optional lubricant. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014]

[0014] Conventional polyamide compositions often contain heat stabilizer packages that attempt to improve high temperature thermal aging performance. Although examples of heat stabilized compositions are abundant in the art, most, if not all, of these compositions are unable to achieve the very high heat aging performance required for long-term high temperature applications such as automotive or electrical / electronic applications. Furthermore, the addition of some heat stabilizers often impairs other performance features, such as processability or electrical properties such as dielectric strength and volume resistivity, and / or may add other undesirable compounds / elements to the polymer composition, such as excess halogens. However, it has thus been difficult for conventional polyamide compositions to achieve improvements in a particular set of performance features.

[0015]

[0015] The inventors have surprisingly discovered that certain polymers (polymers, copolymers, and / or terpolymers), optionally utilized in specific types, amounts, and ratios (described herein), provide surprising improvements in mechanical performance, such as, for example, elongation, tensile, and / or impact properties, at higher temperatures. The inventors have further discovered that the materials disclosed herein can also surprisingly exhibit improvements in electrical properties, such as, for example, volume resistivity and / or dielectric strength, particularly under demanding conditions such as increased moisture and high temperatures. This is demonstrated over extended periods at higher temperatures. In many cases, aromaticity has been found to contribute to significant and surprising improvements in the aforementioned performance properties. In some cases, these polymers are utilized with one or more other additives of specific types, amounts, and ratios, which results in synergistic compositions with the aforementioned performance advantages. These polymer compositions advantageously provide the aforementioned improvements in mechanical and / or electrical properties while maintaining performance features such as, for example, processability. In other words, the polymer compositions disclosed herein advantageously demonstrate an unexpected balance of performance factors not heretofore achieved.

[0016]

[0016] In particular, when the polymer aromaticity is kept within a certain range, such as 31%-50%, a synergistic balance of properties including both dielectric strength and volume resistivity is achieved. In contrast, conventional polymer compositions that do not focus on aromaticity and repeat unit content (or may have low aromaticity) manage to achieve mechanical performance, but fail to achieve other concomitant properties such as dielectric strength and / or volume resistivity performance, especially when thermally aged, along with processability benefits. Moreover, unexpected performance such as dielectric strength, volume resistivity, tensile properties, and impact properties in high humidity environments, such as 85°C / 85% relative humidity for 1000+ hours, has also been demonstrated for the compositions of the present disclosure.

[0017] composition Aromatic copolymers (with a specific degree of aromaticity)

[0017] In some embodiments, the aromatic polyamide has a high aromaticity, for example, greater than 30% or greater than 31%. This aromaticity has been found to be particularly advantageous in providing improved electrical properties, such as dielectric strength and volume resistivity. Without being bound by theory, it is inferred that the aromatic content, such as 6T and / or 6I, advantageously contributes to moisture absorption-related and / or glass transition-related characteristics that lead to higher dielectric strength and volume resistivity, especially under demanding conditions such as high temperature and increased moisture levels. While some traditional highly aliphatic formulations may perform well at lower temperatures, these formulations have been found to suffer from retention challenges at higher temperatures, such as 125°C or 150°C, or when exposed to moisture.

[0018] Aromatic polyamides may vary widely in structure, generally having a higher aromaticity. In some embodiments, aromatic polyamides include aromatic repeat units, such as terephthalic acid repeat units and / or isophthalic acid repeat units. In some cases, aromatic polyamides have an overall aromaticity of more than 20%, such as more than 25%, more than 30%, more than 31%, more than 32%, more than 35%, more than 39%, more than 40%, more than 42%, more than 45%, or more than 50%. In terms of range, aromatic polyamides may have an overall aromaticity in the range of 20%-50%, such as 30%-50%, 31%-50%, 32%-50%, 32%-50%, 35%-50%, and in terms of upper limit, aromatic polyamides may have an overall aromaticity of less than 50%, such as less than 49%, less than 45%, less than 40%, or less than 35%.

[0019]

[0019] Advantageously, it has been found that the use of the aforementioned aromatic polyamides provides unexpected processing advantages. For example, when utilizing aromatic polyamides, more molding options are possible, such as water molding, steam molding, etc. In contrast, it has been found that the use of different polyamides requires oil molding, which is generally more expensive and laborious. In some cases, polyamides with lower 6T and / or 6I content and / or higher 66 and / or caprolactam content unexpectedly allow water molding or steam molding. In some cases, the molding process of the present disclosure advantageously does not utilize process-inconvenient oil molding techniques.

[0020]

[0020] The aromatic polyamide comprises hexamethylenediamine (HMD)-terephthalic acid (6T) units in an amount ranging from 20 wt% to 100 wt%, for example, 35 wt% to 100 wt%, 50 wt% to 100 wt%, 45 wt% to 75 wt%, 35 wt% to 60 wt%, 40 wt% to 55 wt%, 45 wt% to 55 wt%, 45 wt% to 50 wt%, or 50 wt% to 70 wt%, based on the total weight of the aromatic polyamide. In terms of the upper limit, the aromatic polyamide may contain less than 100 wt%, such as less than 90 wt%, less than 75 wt%, less than 70 wt%, less than 65 wt%, less than 61 wt%, less than 60 wt%, less than 55 wt%, less than 50 wt%, less than 45 wt%, less than 40 wt%, or less than 35 wt% of 6T units. In terms of the lower limit, the aromatic polyamide may contain more than 34 wt%, such as more than 35 wt%, more than 40 wt%, more than 45 wt%, more than 50 wt%, more than 55 wt%, or more than 59 wt% of 6T.

[0021]

[0021] The aromatic polyamide comprises HMD-isophthalic acid (6I) units in an amount ranging from 10wt% to 75wt%, for example, from 10wt% to 70wt%, from 15wt% to 65wt%, from 10wt% to 35wt%, or from 15wt% to 35wt%, based on the total weight of the aromatic polyamide. With respect to the upper limit, the aromatic polyamide may comprise 6I units less than 75wt%, for example, less than 70wt%, less than 65wt%, less than 50wt%, less than 45wt%, less than 40wt%, less than 35wt%, less than 30wt%, or less than 25wt%. In terms of the lower limit, the aromatic polyamide may contain more than 10 wt% 6I units, such as more than 15 wt%, more than 17 wt%, more than 20 wt%, more than 25 wt%, more than 30 wt%, more than 40 wt%, more than 50 wt%, or more than 60 wt%.

[0022]

[0022] The aromatic polyamide comprises 6 units (caprolactam) and / or 66 units (HMD-adipic acid) in an amount ranging from 5 wt% to 85 wt%, for example 5 wt% to 50 wt%, 5 wt% to 35 wt%, 10 wt% to 40 wt%, 15 wt% to 35 wt%, or 20 wt% to 35 wt%, based on the total weight of the aromatic polyamide. With respect to the upper limit, the aromatic polyamide may comprise 6 units and / or 66 units of less than 85 wt%, for example less than 75 wt%, less than 70 wt%, less than 65 wt%, less than 60 wt%, less than 50 wt%, less than 45 wt%, less than 40 wt%, less than 35 wt%, less than 30 wt%, less than 25 wt%, less than 20 wt%, or less than 15 wt%. In terms of lower limits, the aromatic polyamide may contain more than 0 wt% of 6 and / or 66 units, e.g., more than 5 wt%, more than 10 wt%, more than 15 wt%, more than 20 wt%, more than 25 wt%, more than 30 wt%, more than 34 wt%, or more than 35 wt%.

[0023]

[0023] Importantly, the inventors have found that the aforementioned performance advantages are particularly evident when the content of 6 units (caprolactam) and / or 66 units (HMD-adipic acid) is greater than (or equal to) 15 wt%. In some cases, synergistic performance advantages are achieved when terpolymers are utilized and the content of 6 units and / or 66 units is as discussed. It is inferred that a notable amount of 6 or 66 can contribute to electrical performance and reduce melting point and glass transition temperature (thus making water / steam moldability more feasible) without adversely affecting mechanical performance.

[0024] In some embodiments, the difference (by weight) between the combined content of terephthalic and isophthalic units and the content of caprolactam and / or adipic units is in the range of 20 to 100, such as 20 to 80, 25 to 75, 30 to 100, 30 to 70, 30 to 75, 60 to 100, 30 to 60, or 40 to 60. In terms of the lower limit, the difference (by weight) between the combined content of terephthalic and isophthalic units and the combined content of caprolactam and / or adipic units can be more than 20, such as more than 25, more than 29, more than 30, more than 35, more than 40, more than 45, more than 50, more than 60, more than 70, more than 80, more than 90, more than 95, or more than 99. In some cases, when the 6 and / or 66 content is low or absent, the difference between the combined terephthalic and isophthalic acid units and the adipic acid units content may be equal to the combined terephthalic and isophthalic acid units content (without adipic acid units to subtract). As for the upper limit, the difference between the combined terephthalic and isophthalic acid units content and the adipic acid units content may be less than 100, e.g., less than 85, less than 70, or less than 60.

[0025] In one embodiment, the polyamide is a terpolymer having 6T, 6I, and 66 units. The terpolymer may contain 6T units in an amount ranging from 45 wt% to 75 wt%, for example, 47 wt% to 72 wt%, 50 wt% to 70 wt%, 52 wt% to 68 wt%, 55 wt% to 65 wt%, or 57 wt% to 62 wt%. In terms of the lower limit, the terpolymer may contain more than 45 wt%, for example, more than 47 wt%, more than 50 wt%, more than 52 wt%, more than 55 wt%, or more than 57 wt% of 6T units. In terms of the upper limit, the terpolymer may contain less than 75 wt%, for example, less than 72 wt%, less than 70 wt%, less than 68 wt%, less than 65 wt%, or less than 62 wt% of 6T units. The terpolymer may contain 6I units in an amount ranging from 10 wt% to 40 wt%, for example, 12 wt% to 38 wt%, 15 wt% to 35 wt%, 17 wt% to 32 wt%, 20 wt% to 30 wt%, or 22 wt% to 28 wt%. In terms of the lower limit, the terpolymer may contain more than 10 wt%, for example, more than 12 wt%, more than 15 wt%, more than 17 wt%, more than 20 wt%, or more than 22 wt% of 6I units. In terms of the upper limit, the terpolymer may contain less than 40 wt%, for example, less than 38 wt%, less than 35 wt%, less than 32 wt%, less than 30 wt%, or less than 28 wt% of 6I units. The terpolymer may contain 66 units in an amount ranging from 5 wt% to 35 wt%, e.g., 7 wt% to 32 wt%, 10 wt% to 30 wt%, 12 wt% to 28 wt%, 10 wt% to 25 wt%, 15 wt% to 25 wt%, or 17 wt% to 23 wt%. In terms of the lower limit, the terpolymer may contain more than 5 wt%, e.g., more than 7 wt%, more than 10 wt%, more than 12 wt%, more than 15 wt%, or more than 17 wt% of the 66 units. In terms of the upper limit, the terpolymer may contain less than 35 wt%, e.g., less than 32 wt%, less than 30 wt%, less than 28 wt%, less than 25 wt%, or less than 23 wt% of the 66 units.

[0026] In one embodiment, the terpolymer may contain 6T units in an amount ranging from 38 wt% to 68 wt%, for example, 40 wt% to 65 wt%, 42 wt% to 62 wt%, 45 wt% to 60 wt%, 48 wt% to 57 wt%, or 50 wt% to 55 wt%. In terms of the lower limit, the terpolymer may contain more than 38 wt%, for example, more than 40 wt%, more than 42 wt%, more than 45 wt%, more than 48 wt%, or more than 50 wt% of 6T units. In terms of the upper limit, the terpolymer may contain less than 68 wt%, for example, less than 65 wt%, less than 62 wt%, less than 60 wt%, less than 57 wt%, or less than 55 wt% of 6T units. In one embodiment, the terpolymer may contain 6I units in an amount ranging from 2 wt% to 37 wt%, e.g., 5 wt% to 35 wt%, 7 wt% to 32 wt%, 10 wt% to 30 wt%, 12 wt% to 27 wt%, or 15 wt% to 25 wt%. In terms of the lower limit, the terpolymer may contain more than 2 wt%, e.g., more than 5 wt%, more than 7 wt%, more than 10 wt%, more than 12 wt%, or more than 15 wt% of 6I units. In terms of the upper limit, the terpolymer may contain less than 37 wt%, e.g., less than 35 wt%, less than 32 wt%, less than 30 wt%, less than 27 wt%, or less than 25 wt% of 6I units. In one embodiment, the terpolymer may include 66 units in an amount ranging from 7 wt% to 47 wt%, e.g., 10 wt% to 45 wt%, 12 wt% to 42 wt%, 15 wt% to 40 wt%, 25 wt% to 40 wt%, 17 wt% to 37 wt%, or 20 wt% to 35 wt%. In terms of the lower limit, the terpolymer may include more than 7 wt%, e.g., more than 10 wt%, more than 12 wt%, more than 15 wt%, more than 17 wt%, or more than 20 wt% of the 66 units. In terms of the upper limit, the terpolymer may include less than 47 wt%, e.g., less than 45 wt%, less than 42 wt%, less than 40 wt%, less than 37 wt%, or less than 35 wt% of the 66 units.

[0027] In one embodiment, the polyamide is a copolymer having 6T and 6I units. The terpolymer may contain 6T units in an amount ranging from 20wt% to 50wt%, for example 22wt% to 47wt%, 25wt% to 45wt%, 27wt% to 42wt%, 30wt% to 40wt%, or 32wt% to 38wt%. In terms of the lower limit, the copolymer may contain more than 20wt%, for example more than 22wt%, more than 25wt%, more than 27wt%, more than 30wt%, or more than 32wt% of 6T units. In terms of the upper limit, the copolymer may contain less than 50wt%, for example less than 47wt%, less than 45wt%, less than 42wt%, less than 40wt%, or less than 38wt% of 6T units. The copolymer may contain 6I units in an amount ranging from 50 wt% to 80 wt%, for example 52 wt% to 77 wt%, 55 wt% to 75 wt%, 57 wt% to 72 wt%, 60 wt% to 70 wt%, or 62 wt% to 68 wt%. In terms of the lower limit, the copolymer may contain more than 50 wt%, for example more than 52 wt%, more than 55 wt%, more than 57 wt%, more than 60 wt%, or more than 62 wt% of 6I units. In terms of the upper limit, the terpolymer may contain less than 80 wt%, for example less than 77 wt%, less than 75 wt%, less than 72 wt%, less than 70 wt%, or less than 68 wt% of 6I units.

[0028]

[0028] In some embodiments, the polyamide is a copolymer. The copolymer may have the content and aromaticity mentioned herein. For example, the aromatic polyamide may include 6T / DT or 6I / 6T or a combination thereof. 6T / DT has a branched diamine component such as, for example, branched HMD, or 1,5-diamino-2-methylpentane.

[0029] In some embodiments, the content of 6T units is greater than (or equal to) the content of 66 units or 6I units, or the combined content of 66 units and 6I units. In some embodiments, the content of 6T units is at least 1% greater than the content of 66 units or 6I units, or the combined content of 66 units and 6I units, such as at least 3% greater, at least 5% greater, at least 7% greater, at least 10% greater, at least 12% greater, at least 15% greater, at least 17% greater, at least 20% greater, at least 25% greater, at least 30% greater, at least 40% greater, at least 50% greater, at least 75% greater, or at least 100% greater.

[0030]

[0030] In some cases, the ratio of the terephthalic acid content to the isophthalic acid content of the aromatic polyamide can be in the range of, for example, 0.1 to 10, for example, 0.1 to 5, 0.2 to 5, 0.1 to 1, 0.2 to 0.7, 0.2 to 0.8, 1.0 to 3.5, 2.0 to 3.5, 0.3 to 3, 3.5 to 10, 2 to 7, or 0.4 to 3.5. As for the upper limit, the ratio of the terephthalic acid content to the isophthalic acid content of the aromatic polyamide can be less than 10, for example, less than 7, less than 5, less than 4, less than 3.5, less than 2, less than 1, or less than 0.5. As for the lower limit, the ratio of the terephthalic acid content to the isophthalic acid content of the aromatic polyamide can be more than 0.1, for example, more than 0.2, more than 0.5, more than 0.7, more than 1, more than 1.5, more than 2, more than 2.5, or more than 3.0. It has been discovered that maintaining the terephthalic acid content within these molar ranges contributes to the performance benefits discussed above.

[0031]

[0031] Exemplary aromatic polyamides include, but are not limited to, PA6T / 6I / 66 terpolymers. PA6T / 6I / 66 terpolymers may have the 6T, 6I, and PA66 unit contents described above and herein. In some cases, PA6T / 6I / 66 terpolymers include 45wt%-75wt% (45wt%-60wt% or 50wt%-65wt%) of 6T units; 15wt%-65wt% (15wt%-30wt% or 15wt%-35wt%) of 6I units, and 10wt%-40wt% (15wt%-35wt%) of PA66 units.

[0032] Other exemplary aromatic polyamides are PA-4T / 4I; PA-4T / 6I; PA-5T / 5I; PA-6,6 / 6T; PA-6T / 6I; PA-6T / 6I / 6; PA-6T / 6; PA-6T / 6I / 66; PA-6T / 66; PA-6I / 6T, PA-6T / 6; PA-6,6 / 6I / 6; PA-6I / 6; or 6T / 6I / 6, PA-6T / 610; PA-10T / 612; PA-10T / 106; PA-6T / 612 ; PA-6T / 10T; PA-6T / 10I; PA-9T; PA-10T; PA-12T; PA-10T / 10I; PA-10T / 12; PA-10T / 11; PA-6T / 9T; PA-6T / 12T; PA-6T / 10T / 6I; PA-6T / 6I / 6; PA-6T / 61 / 12; MPMD-T; MPMD-I; or polyamide blends with MPMD-T / MPMD-I, such as DT / DI blends; or combinations thereof.

[0033] The number of different types of aromatic polyamides in the provided compositions can be, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or greater than 10. In some embodiments, the one or more aromatic polyamides of the composition include a partially aromatic polyamide. In some embodiments, each aromatic polyamide of the composition is a partially aromatic polyamide. In some embodiments, the one or more aromatic polyamides include an amorphous copolyamide. In some embodiments, each aromatic polyamide is an amorphous copolyamide.

[0034] One exemplary commercially available polyamide product is Amodel A-1006 from Solvay SA.

[0035]

[0035] In some embodiments, the concentration of the aromatic polyamide is in the range of 25 wt% to 95 wt%, e.g., 35 wt% to 85 wt%, 40 wt% to 75 wt%, 25 wt% to 50 wt%, 30 wt% to 50 wt%, 32 wt% to 50 wt%, 35 wt% to 50 wt%, 40 wt% to 50 wt%, 45 wt% to 50 wt%, 47 wt% to 50 wt%, 50 wt% to 70 wt%, 60 wt% to 80 wt%, 55 wt% to 65 wt%, or 65 wt% to 75 wt%, based on the total weight of the polymer composition. In terms of the upper limit, the concentration of polyamide can be less than 95 wt%, e.g., less than 85 wt%, less than 80 wt%, less than 75 wt%, less than 70 wt%, less than 65 wt%, less than 60 wt%, less than 55 wt%, less than 51 wt%, less than 50 wt%, less than 45 wt%, less than 40 wt%, less than 35 wt%, less than 32 wt%, or less than 30 wt%. In terms of the lower limit, the concentration of polyamide can be greater than 25 wt%, e.g., greater than 30 wt%, greater than 32 wt%, greater than 35 wt%, greater than 40 wt%, greater than 45 wt%, greater than 49 wt%, greater than 50 wt%, greater than 55 wt%, greater than 60 wt%, greater than 65 wt%, or greater than 70 wt%. Lower concentrations, e.g., less than 25 wt%, are also contemplated.

[0036]

[0036] The aromatic polyamide may have a melting point in the range of 200°C to 400°C, for example, 270°C to 340°C, 275°C to 330°C, 280°C to 335°C, 285°C to 320°C, 250°C to 350°C, 275°C to 325°C, 260°C to 325°C, 270°C to 320°C, 275°C to 320°C, 280°C to 320°C, 285°C to 315°C, 290°C to 310°C, or 290°C to 320°C.

[0037]

[0037] In terms of the upper limit, the aromatic polyamide may have a melting point of less than 400°C, for example, less than 375°C, less than 365°C, less than 350°C, less than 340°C, less than 330°C, less than 325°C, less than 320°C, less than 315°C, less than 310°C, less than 300°C, less than 290°C, or less than 285°C. In terms of the lower limit, the aromatic polyamide may have a melting point of more than 200°C, for example, more than 250°C, more than 265°C, more than 270°C, more than 275°C, more than 280°C, more than 285°C, more than 290°C, more than 295°C, more than 300°C, more than 305°C, or more than 310°C. In some cases, the polyamide is amorphous, for example 6I / 6T, and does not have its own melting point.

[0038] The aromatic polyamide has a glass transition temperature, T, in the range of 25° C. to 225° C., for example, 50° C. to 200° C., 75° C. to 175° C., 100° C. to 175° C., 125° C. to 175° C., 125° C. to 150° C., 85° C. to 130° C., 90° C. to 125° C., 90° C. to 120° C., 90° C. to 115° C., 90° C. to 110° C., or 95° C. to 110° C. g may have:

[0039] In terms of upper limits, the aromatic polyamide may have a T of less than 225° C., e.g., less than 200° C., less than 190° C., less than 180° C., less than 175° C., less than 150° C., less than 140° C., less than 130° C., less than 125° C., less than 120° C., less than 110° C., less than 105° C., less than 100° C., less than 95° C., less than 93° C., or less than 92° C. g In terms of the lower limit, the aromatic polyamide may have a T of greater than 25° C., e.g., greater than 50° C., greater than 65° C., greater than 75° C., greater than 85° C., greater than 90° C., greater than 95° C., greater than 100° C., greater than 105° C., greater than 110° C., or greater than 115° C. g may have:

[0040]

[0040] As used herein, the limits "greater than" and "less than" may include their associated numbers. In other words, "greater than" and "less than" may be interpreted as "greater than or equal to" and "less than or equal to." It is contemplated that this language may continue to be modified in the claims to include "or equal to." For example, "greater than 4.0" may continue to be modified in the claims to "greater than or equal to 4.0."

[0041] In some cases, the chemical characteristics of the polymer composition (or one or more of its components) contribute, at least in part, to the improved performance. The compositions and parts of the present disclosure may be characterized by their chemical characteristics regardless of the compositional makeup, such as, for example, the individual polyamides of the polymer composition. In some cases, the compositions may have a T of 100° C. to 200° C. or 0° C. to 84° C. g With low T g Polymers or high Tg having a Tg of 0°C to 160°C or 85°C to 130°C g Includes polymers.

[0042] Additional polymer (PA6) content

[0042] In some cases, the polyamide composition includes an additional polyamide (in addition to the aromatic copolymer). The additional polyamide may vary widely and may include any polyamide that does not have a content of PA6T, PA6I, and PA66. In some cases, the polyamide composition includes a caprolactam-containing polymer, such as PA6. Advantageously, the inventors have found that the addition of amounts of these polymers provides additional, synergistic property improvements, such as improved high temperature performance and / or processability.

[0043] In some embodiments, the concentration of the additional polyamide ranges from 0 wt% to 10 wt%, for example, 0.01 wt% to 8 wt%, 0.05 wt% to 7 wt%, 0.1 wt% to 5 wt%, 0.1 wt% to 3 wt%, 0.1 wt% to 2 wt%, or 0.1 wt% to 1 wt%, based on the total weight of the polymer composition. With respect to the upper limit, the concentration of the additional polyamide can be less than 10 wt%, for example, less than 9 wt%, less than 8 wt%, less than 7 wt%, less than 6 wt%, less than 5 wt%, less than 4 wt%, less than 3 wt%, less than 2 wt%, or less than 1 wt%. In terms of the lower limit, the concentration of the additional polyamide can be greater than 0.01 wt%, e.g., greater than 0.05 wt%, greater than 0.07 wt%, greater than 0.1 wt%, greater than 0.15 wt%, greater than 0.2 wt%, greater than 0.3 wt%, greater than 0.4 wt%, or greater than 0.5 wt%.

[0044]

[0044] As used herein, the terms "PA66", "nylon 66" and "polyamide 66" refer to homopolymers prepared from hexamethylenediamine and adipic acid monomer subunits. PA66 polyamides can be polyamides that contain a significant portion of PA66 units within the polymer backbone, for example at least 5 wt%, at least 10 wt%, at least 20 wt%, at least 30 wt%, at least 40 wt%, at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, or at least 90 wt% PA66 units. As used herein, the terms "PA6", "nylon 6" and "polyamide 6" refer to homopolymers prepared from caprolactam monomer subunits. As used herein, the terms "PA66 / 6," "nylon 66 / 6," and "polyamide 66 / 6" refer to copolymers prepared from hexamethylenediamine and adipic acid monomer subunits and also incorporating caprolactam monomer subunits. As used herein, the terms "PA66 / 6I," "nylon 66 / 6I," and "polyamide 66 / 6I" refer to copolymers prepared from hexamethylenediamine and adipic acid monomer subunits and also incorporating isophthalic acid monomer subunits.

[0045] Heat stabilizer

[0045] As mentioned above, in some cases the aforementioned aromatic polyamides may be utilized in conjunction with certain heat stabilizers and lubricants. The combination of these components has been found to synergistically result in polymer compositions having improved (heat aged) tensile / impact performance, along with dielectric strength and volume resistivity, among others.

[0046] In some embodiments, the polymer composition includes a heat stabilizer, such as, for example, a phenolic and / or amine stabilizer. In particular, it has been found that certain hindered phenolic stabilizers work unexpectedly well with aromatic polyamides to achieve the performance features described herein. Examples include N,N'-hexamethylene-bis-3-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionamide, bis-(3,3-bis-(4'-hydroxy-3'-tert-butylphenyl)-butanoic acid)-glycol ester, 2,1'-thioethyl bis-(3-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionate, 4-4'-butylidene-bis-(3-methyl-6-tert-butylphenol), triethylene glycol-3-(3-tert-butyl-4-hydroxy-5-methylphenyl)-propionate, or mixtures of these stabilizers. In some cases, synergistic results have been found with N,N'-hexamethylene bis[3-(3,5-dit-butyl-4-hydroxyphenyl)propionamide. Exemplary commercial products are Lowinox® HD98 from Addivant, Irganox® from BASF, and 2,1'-thioethyl bis-(3-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionate. Including, but not limited to, 1098 (phenol).

[0047] Other commercially available products include the AuerStab product line, such as HPA 100, HPA 110, and / or HPA 120 from Treibacher Industrie AG.

[0048] In some embodiments, the heat stabilizer may be selected from the group consisting of phenols, amines, polyols, and combinations thereof.

[0049] For example, the heat stabilizer package may include an amine stabilizer such as a secondary aromatic amine. Examples include an adduct of phenylenediamine with acetone (Naugard A), an adduct of phenylenediamine with linolene, Naugard 445, N,N'-dinaphthyl-p-phenylenediamine, N-phenyl-N'-cyclohexyl-p-phenylenediamine, N,N'-diphenyl-p-phenylenediamine, or a mixture of two or more thereof.

[0050] Other examples include heat stabilizers based on sterically hindered phenols. Examples include N,N'-hexamethylene-bis-3-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionamide, bis-(3,3-bis-(4'-hydroxy-3'-tert-butylphenyl)-butanoic acid)-glycol ester, 2,1'-thioethyl bis-(3-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionate, 4-4'-butylidene-bis-(3-methyl-6-tert-butylphenol), triethylene glycol-3-(3-tert-butyl-4-hydroxy-5-methylphenyl)-propionate, or mixtures of these stabilizers.

[0051] Further examples include phosphites and / or phosphonites. Specific examples including phosphites and phosphonites are triphenyl phosphite, diphenyl alkyl phosphites, phenyl dialkyl phosphites, tris(nonylphenyl) phosphite, trilauryl phosphite, trioctadecyl phosphite, distearyl pentaerythritol diphosphite, tris(2,4-di-tert-butylphenyl) phosphite, diisodecyl pentaerythritol diphosphite, bis(2,4-di-tert-butylphenyl) pentaerythritol diphosphite, bis(2,6-di-tert-butyl-4-methylphenyl) pentaerythritol diphosphite, diisodecyloxy pentaerythritol diphosphite, bis(2,4-di-tert-butyl-6-methylphenyl) pentaerythritol diphosphite, bis(2,4,6-tris-(tert-butylphenyl) pentaerythritol diphosphite, tristearyl sorbitol triphosphite, tetrakis (2,4-di-tert-butylphenyl)-4,4'-biphenylene diphosphonite, 6-isooctyloxy-2,4,8,10-tetra-tert-butyl-12H-dibenzo-[d,g]-1,3,2-dioxaphosphocin, 6-fluoro-2,4,8,10-tetra-tert-butyl-12-methyl-dibenzo[d,g]-1,3,2-dioxaphosphocin, bis(2,4-di-tert-butyl-6-methylphenyl)methyl phosphite, and biphenylene diphosphonite. Particularly preferred are tris[2-tert-butyl-4-thio(2'-methyl-4'-hydroxy-5'-tert-butyl)-phenyl-5-methyl]phenyl phosphite and tris(2,4-di-tert-butylphenyl)phosphite (Hostanox® PAR24: a commercial product from Clariant, Basel or Orgafos 168 from BASF).

[0052] In some cases, the heat stabilizer may contain a radical scavenger, many of which are known. Primary antioxidants react with peroxy and alkoxy radicals to act as "radical" scavengers, and this interaction has been found to be advantageous. Secondary antioxidants react with hydroperoxides to give non-radical products. Hydrolytically stable phosphites protect both the polymer and the primary antioxidant from oxidation.

[0053]

[0053] In some embodiments, the thermal stabilizer comprises a copper-based stabilizer. Without being bound by theory, it is believed that the combination of the activation temperature of the cerium-based thermal stabilizer and the copper-based stabilizer unexpectedly provides thermo-oxidative stabilization in a particularly useful range, such as 190°C to 220°C or 190°C to 210°C. This particular range has been shown to provide performance differences when conventional stabilizer packages are utilized. By utilizing a combination of a copper-based compound and a cerium-based compound in the amounts discussed herein, unexpected thermal stabilization is achieved.

[0054]

[0054] As non-limiting examples, the copper-based heat stabilizer may include monovalent or divalent copper compounds, such as salts of monovalent or divalent copper with inorganic or organic acids, or salts of monovalent or divalent phenols, oxides of monovalent or divalent copper, or complexes of copper salts with ammonia, amines, amides, lactams, cyanides, or phosphines, and combinations thereof. In some preferred embodiments, the copper-based heat stabilizer may include salts of monovalent or divalent copper with hydrohalogen acids, hydrocyanic acids, or aliphatic carboxylic acids, such as copper(I) chloride, copper(I) bromide, copper(I) iodide, copper(I) cyanide, copper(II) oxide, copper(II) chloride, copper(II) sulfate, copper(II) acetate, or copper(II) phosphate. Preferably, the copper-based heat stabilizer is copper iodide and / or copper bromide. The heat stabilizer may be utilized with halide additives, as discussed below. Copper stearate is also contemplated as a second heat stabilizer (rather than as a stearate additive). In some cases, where electrical applications are the end use, a bound copper heat stabilizer may be utilized.

[0055] In some embodiments, the concentration of the heat stabilizer is in the range of 0 wt% to 10 wt%, for example, 0.01 wt% to 8 wt%, 0.05 wt% to 7 wt%, 0.05 wt% to 5 wt%, 0.05 wt% to 3 wt%, 0.05 wt% to 2 wt%, 0.05 wt% to 1 wt%, 0.1 wt% to 1 wt%, or 0.1 wt% to 0.5 wt%, based on the total weight of the polymer composition. With respect to the upper limit, the concentration of the heat stabilizer can be less than 10 wt%, for example, less than 9 wt%, less than 8 wt%, less than 7 wt%, less than 6 wt%, less than 5 wt%, less than 4 wt%, less than 3 wt%, less than 2 wt%, less than 1 wt%, or less than 0.5 wt%. In terms of lower limits, the concentration of the heat stabilizer can be greater than 0.01 wt%, such as greater than 0.05 wt%, greater than 0.07 wt%, greater than 0.1 wt%, greater than 0.15 wt%, or greater than 0.2 wt%.

[0056]

[0056] In some embodiments, when multiple heat stabilizers are used, the polyamide composition comprises a first heat stabilizer in an amount ranging from 0 wt% to 5.0 wt%, for example, 0.01 wt% to 5.0 wt%, 0.01 wt% to 4.0 wt%, 0.02 wt% to 3.0 wt%, 0.03 to 2.0 wt%, 0.03 wt% to 1.0 wt%, 0.04 wt% to 1.0 wt%, 0.05 wt% to 0.5 wt%, 0.05 wt% to 0.2 wt%, or 0.07 wt% to 0.1 wt%. In terms of the lower limit, the polyamide composition may comprise more than 0.01 wt%, e.g., more than 0.02 wt%, more than 0.03 wt%, more than 0.035 wt%, more than 0.04 wt%, more than 0.05 wt%, more than 0.07 wt%, or more than 0.1 wt% of the first heat stabilizer. In terms of the upper limit, the polyamide composition may comprise less than 5.0 wt%, e.g., less than 4.0 wt%, less than 3.0 wt%, less than 2.0 wt%, less than 1.0 wt%, less than 0.5 wt%, less than 0.2 wt%, less than 0.1 wt%, less than 0.05 wt%, or less than 0.035 wt% of the first heat stabilizer. In addition to the first heat stabilizer, the polyamide composition may comprise a second heat stabilizer different from the first heat stabilizer. In some embodiments, the polyamide composition includes a second heat stabilizer in an amount ranging from 0.1 wt% to 2 wt%, e.g., from 0.1 wt% to 0.6 wt%, from 0.13 wt% to 0.81 wt%, from 0.18 wt% to 1.1 wt%, from 0.25 wt% to 1.5 wt%, or from 0.33 wt% to 2 wt%. With respect to the upper limit, the concentration of the second heat stabilizer can be less than 2 wt%, e.g., less than 1.5 wt%, less than 1.1 wt%, less than 0.81 wt%, less than 0.6 wt%, less than 0.45 wt%, less than 0.33 wt%, less than 0.25 wt%, less than 0.18 wt%, or less than 0.13 wt%. In terms of lower limits, the concentration of the second heat stabilizer can be greater than 0.1 wt%, e.g., greater than 0.13 wt%, greater than 0.18 wt%, greater than 0.25 wt%, greater than 0.33 wt%, greater than 0.45 wt%, greater than 0.6 wt%, greater than 0.81 wt%, greater than 1.1 wt%, or greater than 1.5 wt%.

[0057] Flame retardants

[0057] Generally, non-halogenated flame retardants are used due to the desire to avoid the potentially adverse environmental effects of halogenated flame retardants. Halogenated flame retardants are contemplated as well.

[0058] Exemplary non-halogen flame retardants include phosphorus- or melamine-containing flame retardants. Melamine flame retardants are known in the art and include melamine phosphate and melamine cyanurate. Phosphate esters are particularly suitable for use. Such compounds include, for example, alkyl and aryl esters of phosphoric acid, such as trimethyl phosphate, triethyl phosphate, tributyl phosphate, trioctyl phosphate, tributoxyethyl phosphate, triphenyl phosphate, tricresyl phosphate, cresyl diphenyl phosphate, octyl diphenyl phosphate, tri(2-ethylhexyl) phosphate, di-iso-propylphenyl phosphate, trixylenyl phosphate, tris(iso-propylphenyl) phosphate, trinaphthyl phosphate, bisphenol A diphenyl phosphate, and resorcinol diphenyl phosphate. Commonly used triaryl phosphates include, for example, triphenyl phosphate (TPP), cresyl diphenyl phosphate, and tricresyl phosphate. Inorganic phosphate flame retardants, such as ammonium polyphosphate (which acts as an intumescent flame retardant), may also be utilized. Hexaphenoxycyclotriphosphazene (oligomer of phenoxyphosphazene), such as Rabitle FP-100 (high purity) and Rabitle FP-110 (standard grade) from Fushimi Pharmaceutical, exhibits high thermal stability and can be used with these aromatic polyamides. High thermal stability nitrogen compounds, Melam (1,3,5-triazine-2,4,6-triamine-n-(4,6-diamino-1,3,5-triazin-2-yl), Melem (2,5,8-triamino-tri-s-triazine), and Melon (poly[8-amino-1,3,4,6,7,9,9b-heptaazaphenalene-2,5-diyl)imino), can be used as synergists with phosphorus flame retardants.

[0059] Phosphinate flame retardants, including those sold by Exolit® as OP1230 and OP1400, may be used in the compositions described herein. Phosphinate flame retardants may be desirable due to their high thermal stability and / or rust inhibition properties.

[0060] In some embodiments, the concentration of the flame retardant (or flame retardant and synergist) ranges from 0 wt% to 35 wt%, for example, 0.01 wt% to 30 wt%, 1 wt% to 30 wt%, 5 wt% to 27 wt%, 5 wt% to 25 wt%, 7 wt% to 20 wt%, 7 wt% to 17 wt%, 10 wt% to 20 wt%, or 10 wt% to 15 wt%, based on the total weight of the polymer composition. With respect to the upper limit, the concentration of the flame retardant can be less than 35 wt%, for example, less than 30 wt%, less than 27 wt%, less than 25 wt%, less than 20 wt%, less than 17 wt%, or less than 15 wt%. In terms of the lower limit, the concentration of the flame retardant can be greater than 0 wt%, for example greater than 0.01 wt%, greater than 0.1 wt%, greater than 0.5 wt%, greater than 1 wt%, greater than 5 wt%, greater than 7 wt%, or greater than 10 wt%.

[0061]

[0061] These components mentioned herein may be considered optional. In some cases, the compositions of the present disclosure may be expressly excluded in this section, for example, by claim language, from one or more of the aforementioned components. For example, claim language may be modified to state that the compositions, processes, etc. of the present disclosure do not utilize or include one or more of the aforementioned components, for example, the compositions do not include a flame retardant.

[0062] Other Additives In some embodiments, the polymer composition may optionally include one or more additives. In some embodiments, the additives include one or more of catalysts, polymers other than polyamides, adhesion promoters, ions, compounds, preservatives such as heat stabilizers and antioxidants, lubricants, flow improvers, or other ingredients known in the art. The additive(s) may include at least one of inorganic stabilizers, organic stabilizers, flame retardants, lubricants, dyes, pigments, nucleating agents, metal flakes, impact modifiers, antistatic agents, conductive additives, mold release agents, optical brighteners, adhesion promoters, degradation inhibitors, antioxidants, antiozonants, light stabilizers, UV stabilizers, UV absorbers, UV blockers, inorganic heat stabilizers, organic heat stabilizers, processing aids, crystallization accelerators, crystallization retarders, flow aids, reinforcing agents such as fibrous materials and particulate fillers. This is contemplated herein. For example, the compositions of the present disclosure may exclude flame retardants and / or reinforcing agents (or any other of the aforementioned additives). This supports the explicit exclusion of one or more of these ingredients in the claim language.

[0063] In some embodiments, the provided compositions include another heat stabilizer (a second heat stabilizer) other than those described above. The heat stabilizer or stabilizers of the composition may be selected to improve performance, for example, at higher operating temperatures, without significantly adversely affecting the strength or other thermal properties of the material.

[0064] In some embodiments, the polymer composition comprising an aromatic polyamide having an overall aromaticity of more than 31% comprises one or more lubricants selected to serve as processing aids. The type and relative amount of lubricant may be selected to improve the processing of the composition and contribute to the high strength of the material. In some embodiments, the lubricant comprises a wax. In some embodiments, the lubricant consists of a wax. In some embodiments, the wax comprises a fatty acid. In some embodiments, the lubricant is a montanate or a montan-based compound, such as calcium montanate or a (partially) saponified ester of a montan-based wax. Because saponified ester waxes have very high thermal stability, such lubricants have been unexpectedly found to work well with the aromatic polymers and / or thermal stabilizers described above, which unexpectedly contribute to improved mold release when used as discussed herein.

[0065]

[0065] In some embodiments, the lubricant comprises a fatty acid. In some embodiments, the wax comprises a saturated fatty acid. In some embodiments, the lubricant consists of a saturated fatty acid. In some embodiments, the wax comprises stearic acid, behenic acid, or a salt or combination thereof. In some embodiments, the lubricant consists of stearic acid, behenic acid, or a salt or combination thereof. Stearate lubricants may include, for example, zinc stearate, calcium stearate, aluminum distearate, and / or calcium stearate. One example of a commercially available product of a synergistic lubricant is Licocare from Clariant.

[0066] In some embodiments, the combined concentration of one or more lubricants in the composition ranges from 0 wt% to 2 wt%, such as 0.1 wt% to 2 wt%, 0.1 wt% to 0.6 wt%, 0.13 wt% to 0.81 wt%, 0.18 wt% to 1.1 wt%, 0.25 wt% to 1.5 wt%, or 0.33 wt% to 2 wt%. With respect to the upper limit, the concentration of the lubricant can be less than 2 wt%, such as less than 1.5 wt%, less than 1.1 wt%, less than 0.81 wt%, less than 0.6 wt%, less than 0.45 wt%, less than 0.33 wt%, less than 0.25 wt%, less than 0.18 wt%, or less than 0.13 wt%. In terms of the lower limit, the concentration of the lubricant can be greater than 0.1 wt%, e.g., greater than 0.13 wt%, greater than 0.18 wt%, greater than 0.25 wt%, greater than 0.33 wt%, greater than 0.45 wt%, greater than 0.6 wt%, greater than 0.81 wt%, greater than 1.1 wt%, or greater than 1.5 wt%.

[0067] In some embodiments, the polyamide composition includes a lubricant in an amount ranging from 0.1 wt% to 2 wt%, for example, from 0.1 wt% to 0.6 wt%, from 0.13 wt% to 0.81 wt%, from 0.18 wt% to 1.1 wt%, from 0.25 wt% to 1.5 wt%, or from 0.33 wt% to 2 wt%. With respect to the upper limit, the concentration of the lubricant can be less than 2 wt%, for example, less than 1.5 wt%, less than 1.1 wt%, less than 0.81 wt%, less than 0.6 wt%, less than 0.45 wt%, less than 0.33 wt%, less than 0.25 wt%, less than 0.18 wt%, or less than 0.13 wt%. In terms of the lower limit, the concentration of the lubricant can be greater than 0.1 wt%, e.g., greater than 0.13 wt%, greater than 0.18 wt%, greater than 0.25 wt%, greater than 0.33 wt%, greater than 0.45 wt%, greater than 0.6 wt%, greater than 0.81 wt%, greater than 1.1 wt%, or greater than 1.5 wt%.

[0068]

[0068] In some embodiments, the provided compositions include one or more reinforcing agents, such as mineral or fiber reinforcements or combinations thereof. The reinforcing agents may be selected to further improve the strength characteristics of the composition without compromising the desired thermal properties of the composition. The filler material is not particularly limited and may be selected from polyamide fillers known in the art. As non-limiting examples, the fillers may include glass fibers and / or carbon fibers, particulate fillers such as natural and / or synthetic layered silicates, talc, mica, silicates, quartz, titanium dioxide, wollastonite, kaolin, amorphous silicic acid, magnesium carbonate, magnesium hydroxide, chalk, lime, feldspar, barium sulfate, KEVLAR® fibers, basalt fibers, solid or hollow glass spheres or glass powders, mineral fillers based on permanently magnetic or magnetizable metal compounds and / or alloys and / or combinations thereof, and the like, as well as combinations thereof.

[0069] In some embodiments, the combined concentration of one or more reinforcing agents in the composition ranges from 15 wt% to 60 wt%, such as from 15 wt% to 42 wt%, from 19.5 wt% to 46.5 wt%, from 24 wt% to 51 wt%, from 28.5 wt% to 55.5 wt%, or from 33 wt% to 60 wt%. With respect to the upper limit, the concentration of the reinforcing agent can be less than 60 wt%, such as less than 55.5 wt%, less than 51 wt%, less than 46.5 wt%, less than 42 wt%, less than 37.5 wt%, less than 33 wt%, less than 28.5 wt%, less than 24 wt%, or less than 19.5 wt%. In terms of the lower limit, the reinforcing agent can be more than 15 wt%, such as more than 19.5 wt%, more than 24 wt%, more than 28.5 wt%, more than 33 wt%, more than 37.5 wt%, more than 42 wt%, more than 46.5 wt%, more than 51 wt%, or more than 55.5 wt%.

[0070] In other cases, the polyamide composition is a "neat" composition, e.g., the polyamide composition contains little or no filler. For example, the polyamide composition may contain less than 20 wt %, e.g., less than 17 wt %, less than 15 wt %, less than 10 wt %, or less than 5 wt % of filler. In terms of ranges, the polyamide composition may contain 0.01 wt % to 20 wt %, e.g., 0.1 wt % to 15 wt %, or 0.1 wt % to 5 wt % of filler. In such cases, the amounts of other components may be adjusted accordingly based on the ranges and limits of the aforementioned components. It is contemplated that one skilled in the art may adjust the concentrations of other components of the polyamide composition to take into account the inclusion or non-inclusion of glass fillers.

[0071] Performance characteristics

[0071] An advantage of the compositions disclosed herein is that they can surprisingly simultaneously provide unexpected mechanical performance, such as elongation, tensile, and / or impact properties, and / or unexpected electrical performance, such as dielectric strength, volume resistivity (both at higher temperature and at higher humidity environments). For the reasons discussed above, it is particularly difficult for conventional polyamide compositions to simultaneously provide these different performance characteristics under such temperature and humidity conditions.

[0072] Dielectric strength (23℃, 125℃, 150℃)

[0072] Dielectric strength is a measure of the ability of a polyamide composition to function as an insulator. For purposes of this disclosure, dielectric strength (DS) is the maximum potential that a polyamide composition can withstand before electrical current flows. Dielectric strength is measured using IEC 60243 and is expressed as kilovolts per millimeter of thickness.

[0073]

[0073] While most plastics typically have a dielectric strength of 10KV / mm to 30KV / mm, the polymer composition comprising the aromatic polyamide described herein can demonstrate higher insulation performance. In some embodiments, the polymer composition exhibits a dielectric strength of more than 30KV / mm, such as more than 35KV / mm, more than 38KV / mm, more than 39KV / mm, more than 40KV / mm, more than 41KV / mm, more than 42KV / mm, more than 43KV / mm, more than 44KV / mm, or more than 45KV / mm, as measured at 23°C by IEC 60243.

[0074] At high temperatures, the polymer compositions comprising the aromatic polyamides described herein still have good insulating properties. In some embodiments, the polymer compositions exhibit a dielectric strength of more than 25KV / mm, for example, more than 27KV / mm, more than 35KV / mm, more than 36KV / mm, more than 37KV / mm, more than 38KV / mm, more than 39KV / mm, or more than 40KV / mm, as measured at 125°C by IEC 60243.

[0075] Even under more demanding conditions and high temperatures, the polymer compositions comprising the aromatic polyamides described herein still have good insulating properties. In some embodiments, the polymer compositions exhibit a dielectric strength of more than 25 KV / mm, e.g., more than 27 KV / mm, more than 35 KV / mm, more than 36 KV / mm, more than 37 KV / mm, or more than 38 KV / mm, measured at 150° C. by IEC 60243.

[0076]

[0076] In some embodiments, the polymer composition exhibits a dielectric strength under humid aging (1000+ hours at 85°C / 85%) of greater than 30 KV / mm, e.g., greater than 33 KV / mm, greater than 35 KV / mm, greater than 36 KV / mm, or greater than 37 KV / mm.

[0077]

[0077] In some embodiments, the polymer composition exhibits a dielectric strength retention under humid aging (1000+ hours at 85°C / 85%) of greater than 5%, e.g., greater than 10%, greater than 25%, greater than 35%, greater than 50%, greater than 75%, or greater than 90%.

[0078] Volume resistivity

[0078] The improvement in electrical performance can also be measured by high volume resistivity: to act as an electrical insulator, a polymer composition must have a volume resistivity of greater than 10E+9 ohm-cm.

[0079]

[0079] In some embodiments, polymer compositions comprising the aromatic polyamides described herein exhibit a volume resistivity, when measured at 23°C by IEC 62631, of greater than 1.0E+14 ohm-cm, e.g., greater than 1.5E+14 ohm-cm, greater than 1.0E+15, greater than 7.0E+15, greater than 1.0E+16, greater than 1.3E+16, greater than 1.45E+16, greater than 1.5E+16, or greater than 1.6E+16.

[0080]

[0080] In some embodiments, polymer compositions comprising the aromatic polyamides described herein exhibit a volume resistivity, when measured at 125°C by IEC 62631, of greater than 1.0E+11 ohm-cm, e.g., greater than 8.0E+11 ohm-cm, greater than 1.0E+12, greater than 2.0E+12, greater than 5.0E+12, greater than 1.0E+13, greater than 1.5E+13, greater than 1.75E+13, greater than 2.0E+13, or greater than 1.0E+14.

[0081]

[0081] In some embodiments, polymer compositions comprising the aromatic polyamides described herein exhibit a volume resistivity, when measured at 150°C by IEC 62631, of greater than 1.0E+10 ohm-cm, e.g., greater than 1.0E+11, greater than 5.0E+11, greater than 5.5E+11, greater than 2.0E+11, greater than 1.0E+12, greater than 1.5E+12, or greater than 2.0E+12.

[0082]

[0082] In some embodiments, polymer compositions comprising the aromatic polyamides described herein exhibit a volume resistivity under humid aging (1000+ hours at 85°C / 85%) of greater than 1.0E+13 ohm-cm, e.g., greater than 5.0E+13, greater than 1.0E+14, greater than 5.0E+14, or greater than 1.0E+15.

[0083]

[0083] In some embodiments, the polymer composition exhibits volume resistivity retention under humid aging (1000+ hours at 85°C / 85%) of greater than 5%, e.g., greater than 10%, greater than 25%, greater than 35%, greater than 50%, greater than 75%, or greater than 90%.

[0084] Tensile strength

[0084] It can be beneficial for polymer compositions to have high tensile strength, for example because products made from these compositions have associated resistance to failure resulting from tensile forces. The compositions disclosed herein can advantageously demonstrate no loss in tensile strength compared to conventional polymer compositions that have not been modified to improve high temperature damping properties. Tensile strength can be measured, for example, using standard test methods ASTM D882-18(2018) or ISO 527-2(2012), optionally at 23°C and / or possibly under various heat / humidity aging conditions.

[0085]

[0085] In some embodiments, the polymer composition exhibits a tensile strength (as-molded dry state) of greater than 100 MPa, for example greater than 110 MPa, greater than 130 MPa, greater than 140 MPa, greater than 146 MPa, greater than 150 MPa, greater than 160 MPa, greater than 165 MPa, greater than 170 MPa or greater than 173 MPa.

[0086]

[0086] In some embodiments, the polymer composition exhibits a tensile strength (adjusted to equilibrium moisture) of greater than 75 MPa, such as greater than 85 MPa, greater than 95 MPa, greater than 105 MPa, greater than 110 MPa, greater than 125 MPa, greater than 150 MPa, greater than 165 MPa, or greater than 170 MPa.

[0087]

[0087] In some embodiments, the polymer composition exhibits a tensile strength under humid aging (1000+ hours at 85°C / 85%) of greater than 85 MPa, e.g., greater than 95 MPa, greater than 100 MPa, greater than 105 MPa, greater than 110 MPa, greater than 115 MPa, greater than 120 MPa, or greater than 124 MPa.

[0088] Tensile elongation

[0088] The strength of a polymeric composition may also be characterized in terms of its elongation properties. It may be beneficial for a polymeric material to have high elongation because products made from these materials are often subjected to stretching forces that may cause materials with low elongation to tear or burst. The compositions disclosed herein advantageously demonstrate no loss in elongation compared to conventional polymeric compositions that have not been modified to improve high temperature damping properties. Elongation may be measured, for example, using standard test methods ASTM D882-18 (2018) or ISO 527-2 (2012).

[0089]

[0089] In some embodiments, the polymer composition exhibits a tensile elongation (as-molded dry state) of greater than 1.5, such as greater than 1.75, greater than 1.8, greater than 2.0, greater than 2.05, or greater than 2.1, greater than 2.2, greater than 2.4, or greater than 2.6.

[0090] In some embodiments, the polymer composition exhibits a tensile elongation (adjusted to equilibrium moisture) of greater than 1.5, such as greater than 1.75, greater than 1.8, greater than 2.0, greater than 2.05, greater than 2.1, greater than 2.2, greater than 2.4, greater than 2.6, or greater than 2.8.

[0091] In some embodiments, the polymer composition exhibits a tensile elongation upon humid aging (1000+ hours at 85° C. / 85%) of greater than 1.0, e.g., greater than 1.2, greater than 1.5, greater than 1.7, greater than 1.8;

[0092] Greater than 2.0, greater than 2.1, greater than 2.2, greater than 2.4, or greater than 2.6.

[0092] Tensile Modulus

[0093] The tensile modulus of a polymer composition is an indication of the resistance of the composition to stretching forces. It may be beneficial for a polymer composition to have a low tensile modulus, since a low modulus may increase the elasticity of products made from the composition, making these products more easily amenable to processing steps involving stretching or thermoforming. The compositions disclosed herein may advantageously demonstrate no increase in tensile modulus compared to conventional polymer compositions that have not been modified to improve high temperature damping properties. Tensile modulus may be measured, for example, using standard test methods ASTM D882-18 (2018) or ISO 527-2 (2012).

[0093]

[0094] In some embodiments, the polymer composition exhibits a tensile modulus (as-molded dry state) of greater than 10000 MPa, such as greater than 10500 MPa, greater than 11000 MPa, greater than 11200 MPa, greater than 11500 MPa, or greater than 12000 MPa.

[0094]

[0095] In some embodiments, the polymer composition exhibits a tensile modulus (adjusted to equilibrium moisture) of greater than 8500 MPa, such as greater than 9000 MPa, greater than 9500 MPa, greater than 10000 MPa, greater than 11000 MPa, greater than 12000 MPa, or greater than 13000 MPa.

[0095] Shock-resistance

[0096] The impact strength of a polymer composition is a measure of the resistance of the composition to fracture by shock loading. The compositions disclosed herein can advantageously demonstrate no reduction in impact strength compared to conventional polymer compositions that have not been modified to improve high temperature damping properties. Impact strength can be measured, for example, in terms of notched or unnotched Charpy impact strength using standard test method ISO 179 (2010).

[0096]

[0097] In some embodiments, the polymer composition has a viscosity of 7.0 kJ / m 2 Above 7.5 kJ / m 2 Super, 8.0kJ / m 2 Super, 8.5kJ / m2 Super, 9.0kJ / m 2 or more than 9.5 kJ / m 2 It exhibits a notched Charpy impact strength (as-molded, dry state) of .

[0097]

[0098] In some embodiments, the polymer composition has a molecular weight of 6.5 kJ / m 2 More than, for example, 7.0 kJ / m 2 Super, 7.5kJ / m 2 Super, 8.0kJ / m 2 Super, 8.5kJ / m 2 Super, 9.0kJ / m 2 or more than 9.5 kJ / m 2 In some embodiments, the polymer composition exhibits a notched Charpy impact strength (adjusted to equilibrium moisture) of greater than 6.5 kJ / m under humid aging (1000+ hours at 85° C. / 85%). 2 Above 7.0 kJ / m 2 Super, 7.5kJ / m 2 Super, 8.0kJ / m 2 Super, 8.5kJ / m 2 Super, 9.0kJ / m 2 or more than 9.5 kJ / m 2 It exhibits ultra-high notched Charpy impact strength.

[0098]

[0099] Improvements in additional performance features are also contemplated.

[0099] Applications (connection parts / automotive parts)

[0100] In some cases, the compositions are particularly useful in electric vehicle applications, such as high voltage connector electric vehicle (EV) applications, such as battery electric vehicles (BEVs) and plug-in hybrid electric vehicles (PHEVs). The aforementioned dielectric strength and volume resistivity have been found to work synergistically in these applications, especially at higher temperatures. EXAMPLES

[0100]

[0101] The present embodiment will now be described in more detail using the following examples and comparative examples. However, the present embodiment is not limited to only these examples.

[0101]

[0102] Six sample compositions were prepared and the aromaticity is shown in Table 1.

[0102] [Table 1]

[0103] Resins A, B, E, and F were combined with additives in the amounts shown in Table 2 and compounded in a twin screw extruder. The compositions were melted, additives were added to the melt, and the resulting mixture was extruded and pelletized. The material was then injection molded into test specimens. The non-halogenated flame retardant additive was Exolit® OP1230, available from Clariant. The heat stabilizer was a sterically hindered phenol antioxidant (NA-246). The lubricant was a high melting emulsifying wax (Licocare RBW 330P TP Vita), available from Clariant. Carbon black (NA-271; 20% C Black in PA6) was also added to Comparative Example C. Comparative Examples A and B were fully compounded resins and were not further processed.

[0104] [Table 2]

[0105] Example 2 has a melting point (Tm) of 313° C. and a crystallization point (Tc) of 256° C. Comparative Example C has a melting point (Tm) of 282° C. and a crystallization point (Tc) of 219° C.

[0106] Volume resistivity

[0105] Volume resistivity values ​​are determined according to IEC 62631-3-1:2016. According to this procedure, a standard specimen (e.g., a 1 meter cube) is placed between two electrodes. A voltage is applied for 60 seconds and the resistance is measured. The volume resistivity is determined as the ratio of the potential gradient (in V / m) parallel to the current in the material to the current density. In SI units, volume resistivity is numerically equal to the DC resistance (in ohms-m or ohms-cm) between the opposing faces of a 1 meter cube of the material.

[0107]

[0106] Resins prepared according to Example 1 were tested at room temperature (23°C), 125°C, and 150°C to determine volume resistivity (VR), with the results shown in Table 2 below. The resins were further tested to determine volume resistivity after exposure to humidity conditions after being in the as-molded dry condition. In Test 1, the resin was exposed to 50% humidity for 48K hours at 23°C prior to testing. In Test 2, the resin was exposed to 85% humidity for 3K hours at 85°C, then 50% humidity for 48K hours at 23°C prior to testing. These results are also shown in Table 3 below.

[0108] [Table 3]

[0109]

[0107] Examples 1 and 2 show less change in volume resistivity from 23° C. to 125° C. than the comparative resin. This indicates increased stability of the resins in Examples 1 and 2 compared to Comparative Examples A, B, C, and D.

[0110] As can be seen from Table 2, Example 1 exhibited excellent volume resistivity over all temperatures tested. Example 2 exhibited excellent volume resistivity over all temperatures tested, even after exposure to high humidity conditions, unlike Comparative Resins A and B. In general, Examples 1 and 2 perform significantly better than the Comparative Resins in all categories.

[0111] Dielectric strength

[0109] Dielectric strength is determined in accordance with ASTM D149 and IEC 60243. According to this procedure, the maximum voltage required to cause dielectric breakdown through a material is measured and expressed as volts per unit thickness, with a higher dielectric strength indicating a better insulator.

[0112] To test a material, typically a plaque between 0.8 and 3.2 mm thick, the plaque is placed between two electrodes and tested by applying a voltage between the two electrodes. The voltage is increased at a uniform rate from zero to breakdown. Breakdown is defined as when electrical burn-through punctures or disintegrates the specimen. The rate of voltage increase is determined by the time it takes the specimen to reach breakdown. The dielectric strength of the material is then calculated by dividing the breakdown voltage by the thickness of the specimen.

[0113]

[0111] Resins prepared according to Example 1 were tested at room temperature (23°C), 125°C, 150°C, and 150°C after 1K hours to determine dielectric strength (DS), with the results shown in Table 4 below. The resins were further tested to determine dielectric strength after exposure to humidity conditions. In Test 3, the resin was exposed to 50% humidity at 23°C for 48k hours before testing. In Test 4, the resin was exposed to 85% humidity at 85°C for 3k hours before testing. These results are also shown in Table 3 below.

[0114] [Table 4]

[0115]

[0112] Examples 1 and 2 provide similar results to or outperform the comparative resin. Of particular note is the performance of Examples 1 and 2 under more severe conditions (tests after exposure to higher temperatures and longer periods of high humidity), which is significantly better than the performance of the comparative resin.

[0116] Example 4 Tensile strength, tensile elongation, and tensile modulus Tensile strength, elongation, and modulus may be measured according to ASTM D638. Tensile strength represents the amount of force that can be applied to a material before it breaks or stretches irrecoverably. Tensile elongation represents the ductility of a material by measuring the increase in length of a sample after breakage and dividing it by the original length. Tensile modulus represents the stiffness of a material by measuring the amount of deformation the material undergoes before it yields.

[0117] Resins prepared according to Example 1 were tested to determine tensile strength (TS) and tensile elongation (TE). Tensile strength was measured under ambient conditions (Test 5), after 48k hours at 23°C and 50% humidity (Test 6), and after 3k hours at 85°C and 85% humidity (Test 7). Tensile elongation was measured under ambient conditions (Test 8), after 48k hours at 23°C and 50% humidity (Test 9), and after 3k hours at 85°C and 85% humidity (Test 10). Tensile modulus (Test 11) is included in Table 4.

[0118] [Table 5]

[0119] Impact and flexural strength Impact strength can be measured by determining the amount of energy absorbed by a sample during fracture. Charpy impact and Charpy notch tests can be used to determine impact strength using ASTM A370, in which a pendulum of known mass and length is dropped onto a notched sample. The energy transferred to the material can be determined by comparing the difference in the height of the pendulum before and after fracture. Flexural strength and flexural modulus represent the stiffness of a material and can be measured according to ASTM D790, where they measure the resistance of a sample to deformation when a force is applied to the sample. Finally, heat distortion temperature can be measured according to ASTM D648. This test determines the temperature at which a sample will deflect a specific distance under load.

[0120]

[0116] Resins prepared according to Example 1 were tested to determine the notched Charpy impact (Test 12), the Charpy impact after more than 48K hours at 23°C and 50% humidity (Test 13), and the Charpy impact after 3K hours at 85°C and 85% humidity (Test 14), with the results shown in Table 5. The test results for flexural strength (Test 15) and flexural modulus (Test 16) are shown in Table 6. The heat distortion temperature at 1.8 MPa (Test 17) is also shown in Table 6.

[0121] [Table 6]

[0122] Embodiment

[0117] The following embodiments are contemplated: All combinations of features and embodiments are contemplated.

[0123]

[0118] Embodiment 1: A polyamide composition comprising: an aromatic polyamide comprising terephthalic acid units and isophthalic acid units and having an overall aromaticity of greater than 20%; a heat stabilizer; and an optional lubricant, wherein the polymer composition exhibits a tensile strength (as-molded, dry state) of greater than 146 MPa measured at 23°C and a volume resistivity of greater than 1.0E+10 ohm-cm when measured at 150°C by IEC 62631.

[0124]

[0119] Embodiment 2: The embodiment of embodiment 1, wherein the aromatic polyamide has an overall aromaticity of greater than 35%.

[0125]

[0120] Embodiment 3: The embodiment of embodiment 1 or 2, wherein the aromatic polyamide comprises repeat units of terephthalic acid, isophthalic acid, and adipic acid, and has an overall aromaticity of greater than 32%.

[0126]

[0121] Embodiment 4: An embodiment of any one of embodiments 1 to 3, wherein the aromatic polyamide comprises PA6T / DT, 6I / 6T, 6T / 6I / 66, or 6T / 66 / 6I, or a combination thereof.

[0127]

[0122] Embodiment 5: The embodiment of any one of embodiments 1 to 4, wherein the aromatic polymer is PA6T / 6I / 66 or PA6T / 66 / 6I or a combination thereof.

[0128]

[0123] Embodiment 6: An embodiment according to any one of embodiments 1 to 5, wherein the difference between the combined content of terephthalic acid units and isophthalic acid units and the content of adipic acid units is in the range of 30 to 100.

[0129]

[0124] Embodiment 7: The embodiment of any one of embodiments 1 to 6, wherein the aromatic polyamide comprises 35 wt% to 100 wt% terephthalic acid units, based on the total weight of the aromatic polyamide.

[0130]

[0125] Embodiment 8: The embodiment of any one of embodiments 1 to 7, wherein the aromatic polyamide comprises 10 wt% to 70 wt% isophthalic acid units, based on the total weight of the aromatic polyamide.

[0131]

[0126] Embodiment 9: The embodiment of any one of embodiments 1 to 8, further comprising 0 wt% to 10 wt% PA6.

[0132]

[0127] Embodiment 10: An embodiment of any one of embodiments 1 to 9, wherein the polymer composition comprises 25 wt% to 95 wt% of an aromatic polyamide, based on the total weight of the polymer composition.

[0133]

[0128] Embodiment 11: The embodiment of any one of embodiments 1 to 10, wherein the heat stabilizer is a hindered phenol.

[0134]

[0129] Embodiment 12: An embodiment according to any one of embodiments 1 to 11, wherein the heat stabilizer is N,N'-hexamethylenebis[3-(3,5-dit-butyl-4-hydroxyphenyl)propionamide.

[0135]

[0130] Embodiment 13: An embodiment of any one of embodiments 1 to 12, wherein the lubricant is montanate.

[0136]

[0131] Embodiment 14: An embodiment described in any one of embodiments 1 to 13, wherein the composition exhibits a tensile strength of greater than 85 MPa when moisture-treated for 1000 hours at a temperature of 85°C and a relative humidity of 85%, and a volume resistivity of greater than 5.0E+13 ohm-cm when moisture-treated for 1000 hours at a temperature of 85°C and a relative humidity of 85%.

[0137]

[0132] Embodiment 15: A polymer composition comprising a 6T / DT copolymer having an overall aromaticity of greater than 25%; a heat stabilizer; and an optional lubricant, and exhibiting a tensile strength (as-molded, dry state) of greater than 146 MPa measured at 23°C and a volume resistivity of greater than 1.0E+10 ohm-cm when measured at 150°C according to IEC 62631.

[0138]

[0133] Embodiment 16: A polymer composition comprising a 6I / 6T copolymer comprising terephthalic acid units and isophthalic acid units and having an overall aromaticity of greater than 25%; a heat stabilizer; and an optional lubricant, the polymer composition exhibiting a tensile strength (as-molded, dry state) of greater than 146 MPa measured at 23°C and a volume resistivity of greater than 1.0E+10 ohm-cm when measured at 150°C according to IEC 62631.

[0139]

[0134] Embodiment 17: A polymer composition comprising a terpolymer comprising terephthalic acid units, isophthalic acid units, and adipic acid units and having an overall aromaticity of greater than 25%; a heat stabilizer; and an optional lubricant, the polymer composition exhibiting a tensile strength (as-molded, dry state) of greater than 146 MPa measured at 23°C and a volume resistivity of greater than 1.0E+10 ohm-cm when measured at 150°C according to IEC 62631.

[0140]

[0135] Embodiment 18: A polymer composition comprising: a 6I / 6T copolymer comprising 25 wt% to 45 wt% terephthalic acid units and 55 wt% to 75 wt% isophthalic acid units, based on the total weight of all units; 0 wt% to 20 wt% caprolactam-based polyamide; a heat stabilizer; and an optional lubricant.

[0141]

[0136] Embodiment 19: A polymer composition comprising a 6T / 6I / 66 terpolymer comprising, based on the total weight of all units, 50 wt% to 65 wt% terephthalic acid units; 20 wt% to 30 wt% isophthalic acid units; and 10 wt% to 25 wt% adipic acid units; and 0 wt% to 20 wt% of a caprolactam-based polyamide; a heat stabilizer; and an optional lubricant.

[0142]

[0137] Embodiment 20: A polymer composition comprising a 6T / 66 / 6I terpolymer comprising, based on the total weight of all units, 45 wt% to 60 wt% terephthalic acid units; 12 wt% to 27 wt% isophthalic acid units; and 25 wt% to 40 wt% adipic acid units; and 0 wt% to 20 wt% of a caprolactam-based polyamide; a heat stabilizer; and an optional lubricant.

[0143]

[0138] Embodiment 21: A polymer composition comprising an aromatic polyamide comprising terephthalic acid units and isophthalic acid units and having an overall aromaticity of greater than 31%; a heat stabilizer; and an optional lubricant, the polymer composition exhibiting a volume resistivity of greater than 1.0E+10 ohm-cm when measured at 150°C according to IEC 62631.

[0144]

[0139] Embodiment 22: An embodiment described in embodiment 21, wherein the polymer composition exhibits a dielectric strength of greater than 25 KV / mm when measured at 150°C according to IEC 60243.

[0145]

[0140] Embodiment 23: The embodiment of any one of embodiments 21 to 22, wherein the polymer composition maintains dielectric strength retention under humid aging.

[0146]

[0141] Embodiment 24: The embodiment of any one of embodiments 21 to 23, wherein the aromatic polyamide has an overall aromaticity of greater than 35%.

[0147]

[0142] Embodiment 25: An embodiment according to any one of embodiments 21 to 24, wherein the aromatic polyamide comprises terephthalic acid units, isophthalic acid units and adipic acid units and has an overall aromaticity of greater than 32%.

[0148]

[0143] Embodiment 26: The embodiment of any one of embodiments 21 to 25, wherein the aromatic polyamide comprises 6I / 6T, 6T / 6I / 66, or 6T / 66 / 6I, or a combination thereof.

[0149]

[0144] Embodiment 27: An embodiment of any one of embodiments 21 to 26, wherein the aromatic polymer is PA6T / 6I / 66 or PA6T / 66 / 6I or a combination thereof.

[0150]

[0145] Embodiment 28: An embodiment described in any one of embodiments 21 to 27, wherein the difference between the combined content of terephthalic acid units and isophthalic acid units and the content of adipic acid units is in the range of 30 to 100.

[0151]

[0146] Embodiment 29: The embodiment of any one of embodiments 21 to 28, wherein the aromatic polyamide comprises 35 wt% to 100 wt% terephthalic acid units, based on the total weight of the aromatic polyamide.

[0152]

[0147] Embodiment 30: An embodiment of any one of embodiments 21 to 29, wherein the aromatic polyamide comprises 10 wt% to 70 wt% isophthalic acid units, based on the total weight of the aromatic polyamide.

[0153]

[0148] Embodiment 31: An embodiment of any one of embodiments 21 to 30, further comprising 0 wt% to 10 wt% PA6.

[0154]

[0149] Embodiment 32: An embodiment of any one of embodiments 21 to 31, wherein the polymer composition comprises 25 wt% to 95 wt% of an aromatic polyamide, based on the total weight of the polymer composition.

[0155]

[0150] Embodiment 33: An embodiment of any one of embodiments 21 to 32, wherein the heat stabilizer is a hindered phenol.

[0156]

[0151] Embodiment 34: An embodiment according to any one of embodiments 21 to 33, wherein the heat stabilizer is N,N'-hexamethylenebis[3-(3,5-dit-butyl-4-hydroxyphenyl)propionamide.

[0157]

[0152] Embodiment 35: An embodiment according to any one of embodiments 21 to 34, wherein the lubricant is montanate.

[0158]

[0153] Embodiment 36: An embodiment described in any of embodiments 21 to 35, wherein the composition exhibits a tensile strength of greater than 85 MPa when moisture-treated for 1K hours at a temperature of 85°C and a relative humidity of 85%, and exhibits a volume resistivity of greater than 5.0E+13 ohm-cm when moisture-treated for 1K hours at a temperature of 85°C and a relative humidity of 85%.

[0159]

[0154] Embodiment 37: A polymer composition comprising a 6T / DT copolymer having an overall aromaticity of greater than 25%, a heat stabilizer, and an optional lubricant, and exhibiting a volume resistivity of greater than 1.0E+10 ohm-cm when measured at 150°C according to IEC 62631.

[0160]

[0155] Embodiment 38: An embodiment described in embodiment 37, wherein the polymer composition exhibits a dielectric strength of greater than 25 KV / mm when measured at 150°C according to IEC 60243.

[0161]

[0156] Embodiment 39: An embodiment of any one of embodiments 37 to 38, wherein the heat stabilizer is a hindered phenol.

[0162]

[0157] Embodiment 40: An embodiment according to any one of embodiments 37 to 39, wherein the heat stabilizer is N,N'-hexamethylenebis[3-(3,5-dit-butyl-4-hydroxyphenyl)propionamide.

[0163]

[0158] Embodiment 41: An embodiment according to any one of embodiments 37 to 40, wherein the lubricant is montanate.

[0164]

[0159] Although the present invention has been described in detail, modifications within the spirit and scope of the present invention will be readily apparent to those skilled in the art in view of the foregoing discussion, the relevant knowledge of the art, and the references discussed above in connection with the background art and detailed description, the disclosures of which are fully incorporated herein by reference. In addition, it will be understood that the aspects of the present invention and portions of the various embodiments and various features referred to below and / or in the appended claims may be combined or interchanged either in whole or in part. In the foregoing description of various embodiments, these embodiments referring to different embodiments may be appropriately combined with other embodiments as will be understood by those skilled in the art. Furthermore, it will be understood by those skilled in the art that the foregoing description is by way of example only and is not intended to limit the present invention.

Claims

1. an aromatic polyamide comprising terephthalic acid units and isophthalic acid units and having an overall aromaticity of greater than 31%, or a 6T / DT copolymer having an overall aromaticity of greater than 25%, A heat stabilizer; an optional lubricant; A polymer composition comprising: A polymeric composition exhibiting a volume resistivity greater than 1.0E+10 ohm-cm when measured at 150°C according to IEC 62631.

2. 10. The composition of claim 1, wherein the polymer composition exhibits a dielectric strength of greater than 25 KV / mm when measured at 150°C according to IEC 60243.

3. The composition of claim 1 , wherein the polymer composition maintains dielectric strength retention under humid aging.

4. 10. The composition of claim 1, wherein the aromatic polyamide has an overall aromaticity greater than 35%.

5. 10. The composition of claim 1, wherein the aromatic polyamide comprises terephthalic acid units, isophthalic acid units, and adipic acid units and has an overall aromaticity greater than 32%.

6. 10. The composition of claim 1, wherein the aromatic polyamide comprises 6T / DT, 6I / 6T, 6T / 6I / 66, or 6T / 66 / 6I, or combinations thereof.

7. 2. The composition according to claim 1, wherein the difference between the combined content of terephthalic acid units and isophthalic acid units and the content of adipic acid units is in the range of 30 to 100.

8. 10. The composition of claim 1, wherein the aromatic polyamide comprises 35 wt% to 100 wt% terephthalic acid units, based on the total weight of the aromatic polyamide.

9. 10. The composition of claim 1, wherein the aromatic polyamide comprises 10 wt% to 70 wt% isophthalic acid units, based on the total weight of the aromatic polyamide.

10. 10. The composition of claim 1, further comprising 0 wt% to 10 wt% PA6.

11. 10. The composition of claim 1, wherein the polymer composition comprises 25 wt% to 95 wt% of an aromatic polyamide, based on the total weight of the polymer composition.

12. The composition of claim 1 wherein the heat stabilizer is a hindered phenol.

13. 2. The composition of claim 1, wherein the heat stabilizer is N,N'-hexamethylenebis[3-(3,5-dit-butyl-4-hydroxyphenyl)propionamide].

14. 10. The composition of claim 1, wherein the lubricant is montanate.

15. 15. The composition of any one of claims 1 to 14, which exhibits a tensile strength greater than 85 MPa when moisture treated at a temperature of 85°C and 85% relative humidity for 1 K hour, and a volume resistivity greater than 5.0E+13 ohm-cm when moisture treated at a temperature of 85°C and 85% relative humidity for 1 K hour.