Electrical connector containing furanoate polyester

Abstract

The present invention relates to an electrical connector including a housing and an electrical contact. The housing includes a polymer of butylene 2,5-furandicarboxylate (PBF), a polymer of butylene bifuranate (PBBf), or a copolymer of butylene 2,5-furandicarboxylate (BF) and butylene bifuranate (BBf), a copolymer of (i) ethylene 2,5-furandicarboxylate (EF) and (ii) one or both of BF and BBf, a copolymer of (i) butylene terephthalate (BT) and (ii) one or more of BF, BBf, and EF, or a combination thereof.

Description

Technical Field

[0001] The disclosed teachings relate to electrical connectors made of bio-based materials.

Background Art

[0002] Electrical connectors, such as automotive connectors, are electromechanical devices used to form electrical circuits by joining electrical conductors. Most electrical connectors are classified as having male and female parts, and the male part, called a plug, connects to the female part, called a socket. This connection may be removable (such as for portable devices), may require tools for assembly and disassembly, or may function as a permanent electrical joint between two points.

[0003] Electrical connectors often include injection-molded parts. Injection molding is a manufacturing process for producing parts by injecting molten material into a mold. Injection molding can be carried out using many materials, including metals, glasses, elastomers, and most commonly thermoplastic and thermosetting polymers (e.g., thermoplastic resins).

[0004] Polybutylene terephthalate (PBT)-based electrical connectors are generally available. PBT has many attractive properties such as high mechanical strength and toughness, high abrasion resistance, excellent dimensional stability, and a high heat distortion temperature (up to 215 °C for glass fiber-reinforced PBT), a fast crystallization rate, high continuous use at high temperatures (e.g., 140 °C) due to low mechanical creep, good chemical resistance, and short processing cycle times in injection molding. Due to these properties, PBT can be found in many applications such as automotive electrical connectors (「automotive connectors」) and keycaps of keyboards, and thus, the global demand for PBT continues to increase. PBT can be synthesized by a two-step process via the melt polycondensation method. First, bis(4-hydroxybutyl) terephthalate (BHBT) is formed by the transesterification of dimethyl terephthalate (DMT) and 1,4-butanediol (BD). Then, BD is removed from BHBT in the polycondensation step to form PBT.

[0005] Other synthetic routes include polymerization after a ring-opening or enzymatic approach.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Non-Patent Documents

[0007]

Non-Patent Document 1

Non-Patent Document 2

Non-Patent Document 3

Non-Patent Document 4

Non-Patent Document 5

Summary of the Invention

Problems to be Solved by the Invention

[0008] Concerns regarding climate change due to global warming caused by greenhouse gas (GHG) emissions are increasing both legislative and social pressures on manufacturers and consumers to reduce carbon emissions. As a result, both manufacturers and consumers are motivated to reduce the use of products derived from petrochemical materials. Furthermore, manufacturers need to replace materials derived from fossil fuels, which generate new carbon emissions, with materials derived from biomass (i.e., renewable carbon) in the not-too-distant future.

[0009] DMT used in the synthesis of PBT is derived from petrochemical feedstocks, and thus the use of PBT results in a positive carbon footprint and should therefore be replaced by bio-based polyesters with similar chemical and physical properties.

[0010] There is a need for a substantially biomass-derived injection-moldable polymer having substantially the same properties as fossil-fuel-derived PBT that can serve as an alternative material to PBT in electrical connector applications.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2A

Figure 2B

Figure 3

Figure 4

Modes for Carrying Out the Invention

[0012] One or more embodiments of the present disclosure are shown by way of example and not limitation in the figures of the accompanying drawings, and like reference numerals indicate like elements.

[0013] Abbreviations BF: Butylene 2,5-furandicarboxylate. BBf: Butylene bifuranate. EF: Ethylene 2,5-furandicarboxylate. BT: Butylene terephthalate. PBT: Polybutylene terephthalate, also called the polymer of butylene terephthalate. PBF: Poly(butylene 2,5-furandicarboxylate), also called the polymer of butylene 2,5-furandicarboxylate. PBBf: Poly(butylene bifuranate), also called the polymer of butylene bifuranate. PEF: Poly(ethylene 2,5-furandicarboxylate), also called the polymer of ethylene 2,5-furandicarboxylate.

[0014]

Chemical formula

[0015] This disclosure describes an improved electrical connector (also referred to herein as a "connector") by replacing a polybutylene terephthalate (PBT)-based electrical connector with a poly(butylene 2,5-furandicarboxylate) (PBF)-based electrical connector. PBF is an aromatic polyester that is chemically similar to PBT and exhibits similar chemical and physical properties, and thus is a potential alternative material for PBT. PBT is derived from fossil fuel-based feedstocks, while PBF is derived from bio-based feedstocks and has a lower carbon footprint than PBT.

[0016] PBF is similar to PBT in that its chemical structure differs only by including a furan ring instead of a benzene ring. The building block of PBF is 2,5-furandicarboxylic acid (FDCA). FDCA can be produced by the catalytic conversion of 5-hydroxymethylfurfural (HMF), which can be generated by the acid-catalyzed dehydration of fructose. PBF, like PBT, can be synthesized in a two-step process by melt polycondensation. First, dimethyl 2,5-furandicarboxylate (DMFD) is formed via the esterification of FDCA with methanol. Second, bis(hydroxybutyl)-2,5-furandicarboxylate (BHFD) is formed via the transesterification of DMFD with 1,4-butanediol (BD). Then, BD is removed from BHFD in the polycondensation step to form PBF. This process is described, for example, in M. Papageorgiou et al., “Evaluation of polyesters from renewable resources as alternatives to the current fossil-based polymers. Phase transitions of poly(butylene 2,5-furan-dicarboxylate)”, Polymer 55, 3846 (2014) (Non-Patent Document 1). Alternative synthetic methods using ring-opening polymerization are described, for example, in J.C. Morales-Huerta et al., “Poly(alkylene 2,5-furandicarboxylate)s (PEF and PBF) by ring opening”, Polymer 87, 148 (2016) (Non-Patent Document 2).

[0017] Due to their chemical similarity, PBF and PBT generally exhibit similar properties. However, PBF shows superior gas diffusion barrier properties against oxygen and CO2 compared to those of PBT. This is based on the lower symmetry of the furan ring in PBF compared to the benzene ring in PBT, which results in very limited local motion in PBF, particularly the flipping of the constrained furan ring and the restricted carbonyl rotation that reduce the diffusion of small molecules.

[0018] Electrical connectors (male or female) can be injection molded using thermoplastic resins. For example, polyamides such as nylon, polyacetals such as polyoxymethylene, polyolefins such as polypropylene, polyesters such as polyethylene terephthalate and PBT, polycarbonate, polyphenylene sulfide, etc. can be mentioned. Among these, PBT is often used because it has desirable mechanical properties (e.g., tensile modulus and tensile strength), electrical properties, heat resistance, water resistance, and good dimensional stability required for electrical connectors. Also, PBT is a semi-crystalline resin with a high crystallization rate and solidifies in a short time, so the productivity is high. Due to these advantages, PBT is widely used as a molding material for the housing of automotive connectors. Conventionally, in the usual practice, to strengthen PBT as a molding material for connector housings, reinforcing additives (e.g., fibers) are added to PBT. Due to the chemical similarity of PBF to PBT, the same technique of adding reinforcing additives can be applied to PBF.

[0019] The disadvantage of PBF compared to PBT regarding use in automotive connectors is a lower melting temperature of 168°C to 186°C compared to the melting temperature of PBT of 221°C to 225°C. The present disclosure also describes blends of PBF and PBT to overcome this disadvantage. As a result, savings in GHG emissions and non-renewable energy utilization (NREU) are achieved, but are reduced in proportion to the reduction in PBT content.

[0020] To overcome the disadvantage of the lower melting temperature of 168°C to 186°C of PBF related to use in automotive connectors, the present disclosure also describes blends and copolymers of PBF and PEF. The melting temperature of PEF is in the range of 202°C to 220°C. Similar to PBF, the basic component of PEF is FDCA. The resulting PEF is a bio-based polymer, and thus significant savings in GHG emissions and NREU are achieved by the combination of PBF and PEF.

[0021] PBF and PEF have a slower crystallization rate resulting from the rigidity of the furan ring compared to PBT. This disclosure also describes the use of nucleating agents, additives, and fillers to increase the crystallization rate and nucleation density of PBF or PEF and related blends, copolymers, and composites. This disclosure also describes the use of poly(butylene bifuranate) (PBBf), also derived from FDCA and 2,2'-bifuran-5,5'-dicarboxylic acid (BFDCA), in electrical connectors. PBBf has a melting temperature of 215 °C to 217 °C. BFDCA, which is a precursor of PBBf, is derived from the homogeneous Pd-catalyzed oxidative homocoupling of methyl 2-furoate (a renewable feedstock) with molecular oxygen as the oxidant, as described in Mingchun Ye et al., "Oxidative coupling of 2-methyl furoate: A scalable synthesis of dimethyl 2,2'-bifuran-5,5'-dicarboxylate", Applied Catalysis A: General, 619, 118138 (2021) (Non-Patent Document 3).

[0022] Table 1 lists the relevant properties of PBT, PBF, PBBf, and PEF. The properties include tensile modulus, tensile strength, elongation at break, glass transition temperature (T g ), and melting temperature (T m ).

[0023]

Table 1

[0024] FIG. 1 shows a perspective view of an exemplary electrical connector housing 100 (e.g., a connector case). The connector housing 100 shows an exemplary housing for a female connector. The connector housing 100 is integrally formed with a housing body 102 and a lock portion 104 at the upper part of the housing body 102. The lock portion 104 can be coupled to a mating connector (not shown). A plurality of mating terminal insertion holes 106 into which mating terminals can be inserted are formed in the housing body 102. A terminal accommodation chamber into which a terminal fitting attached to an electric wire terminal can be inserted communicates with the inner side of each mating terminal insertion hole 106. The connector housing 100 in FIG. 1 is provided with two rows of mating terminal insertion holes 106 arranged vertically. Each row includes ten mating terminal insertion holes 106 arranged horizontally.

[0025] FIGS. 2A and 2B show schematic views of the configuration of an exemplary electrical connector 200. FIG. 2A is a perspective view of the electrical connector, and FIG. 2B is a cross-sectional view of the electrical connector. The electrical connector 200 is configured to be used, for example, within an electronic control unit (ECU) case of an automobile or the like and is fitted and connected to another corresponding connection device. As shown in the figure, the electrical connector 200 includes a terminal housing 202 having a housing cavity 204 formed therein and terminals 206 (e.g., electrical contacts) as insert parts.

[0026] The electrical connector 200 in FIGS. 2A and 2B includes a plurality of terminals 206. The terminals 206 have a shape in which a rod-shaped conductive metal (e.g., an electrical contact) is bent at a right angle in the middle. The terminals 206 are embedded together in the terminal housing 202 during the molding of the terminal housing 202 and are arranged at predetermined positions. Among the terminals 206, a terminal external connection portion 210 corresponding to the portion extending in the vertical direction extends from a rear rib-shaped portion 208 formed on the back surface of the terminal housing 202 and is connected to an external circuit board or the like. Also, a terminal internal connection portion 212 corresponding to the portion extending in the left-right direction has a terminal tip portion 214 exposed in the housing cavity 204 by a predetermined length.

[0027] FIG. 3 shows an exemplary molding machine 300 for performing an injection molding process. In the injection molding machine 300, one or more fixed molds 301 and the same number of movable molds 302 as the fixed molds 301 are arranged to face each other. By clamping each set of the fixed mold 301 and the movable mold 302, a cavity having the shape of an injection molded product is formed. The molten material is injected into the cavity between the fixed mold 301 and the movable mold 302 and is held in contact with the molten material for a predetermined time until it is sufficiently cooled and solidified. Then, by moving the movable mold 302 in the mold opening direction by a predetermined amount and retracting it from the opposing fixed mold 301 by servo motor control or hydraulic control, the injection molded product can be taken out. The molding machine 300 can be used to manufacture electrical connectors and / or electrical housings such as those described with respect to FIGS. 1, 2A, and 2B from thermoplastic materials including PBF, PBBf, polymer blends (also referred to as "blends"), or any combination of BF, BBf, EF, or BT copolymers, any combination thereof, or any combination thereof in a blend with PBT, or any combination thereof in a blend with PEF.

[0028] (Electrical Connector) According to some embodiments of the present disclosure, an electrical connector includes an electrical housing and electrical contacts. In one embodiment, the electrical contacts are coupled to the electrical housing. The electrical housing can be configured as a female socket including a cavity containing the electrical contacts or as a male plug including a protruding member containing the electrical contacts. Exemplary electrical housings of the present disclosure include the housing 100 described with respect to FIG. 1 and the housing 202 described with respect to FIGS. 2A and 2B.

[0029] In one preferred embodiment, the housing can comprise PBF, PBBf, a copolymer of (i) BF and (ii) BBf, a copolymer of (i) EF and one or both of (ii) BF and BBf, a copolymer of (i) BT and one or more of (ii) BF, BBf, and EF, or any combination thereof. The polymers and / or copolymers can be in any combination, alone or as a polymer blend (mixture). For example, the housing can comprise a copolymer of EF and BF, a copolymer of EF and BBf, a copolymer of EF, BF, and BBf, a copolymer of BT and BF, a copolymer of BT and BBf, a copolymer of BT and EF, a copolymer of BT, BF, and BBf, a copolymer of BT, BF, and EF, a copolymer of BT, BBf, and EF, a copolymer of BT, EF, BF, and BBf, or any combination thereof. For example, the housing can comprise a polymer blend of PBF and PBBf, a polymer blend of PEF and PBF, a polymer blend of PEF and PBBf, a polymer blend of PEF, PBF, and PBBf, a polymer blend of PBT and PBF, a polymer blend of PBT and PBBf, a polymer blend of PBT and PEF, a polymer blend of PBT, PBF, and PBBf, a polymer blend of PBT, PBF, and PEF, a polymer blend of PBT, PBBf, and PEF, a polymer blend of PBT, PBF, PBBf, and PEF, or any combination thereof.

[0030] The housing can comprise any of the following polymers or copolymers, alone or in any combination as a polymer blend: PBF, PBBf, a blend (mixture) or copolymer of BF and BBf, a blend or copolymer of EF and one or both of BF and BBf, or a blend or copolymer of BT and one or more of BF, BBf, and EF.

[0031] The copolymers of BT and BF, BT and BBf, or BT and BF and BBf can contain 1 to 99% by weight, or 1 to 20% by weight (e.g., 1 to 10% by weight, or 10 to 20% by weight), or 20 to 40% by weight (e.g., 20 to 30% by weight, or 30 to 40% by weight), or 40 to 60% by weight (e.g., 40 to 50% by weight, or 50 to 60% by weight), or 60 to 80% by weight (e.g., 60 to 70% by weight, or 70 to 80% by weight), or 80 to 99% by weight (80 to 90% by weight, or 90 to 99% by weight) of BT.

[0032] In some embodiments, the housing further comprises PBT. The housing can comprise, for example, a polymer blend containing PBT in any combination with PBF, PBBf, a copolymer of BF and BBf, a copolymer of BT and BF, a copolymer of BT and BBf, or a copolymer of BT and BF and BBf.

[0033] In some embodiments, the housing comprises a blend of PBT and PBF. The blend of PBT and PBF can contain 1 to 99% by weight, or 1 to 20% by weight (e.g., 1 to 10% by weight, or 10 to 20% by weight), or 20 to 40% by weight (e.g., 20 to 30% by weight, or 30 to 40% by weight), or 40 to 60% by weight (e.g., 40 to 50% by weight or 50 to 60% by weight), or 60 to 80% by weight (e.g., 60 to 70% by weight or 70 to 80% by weight), or 80 to 99% by weight (80 to 90% by weight, or 90 to 99% by weight) of PBT.

[0034] In some embodiments, the housing comprises a blend of PBT and PBBf. The blend of PBT and PBBf can comprise 1 to 99 wt%, or 1 to 20 wt% (e.g., 1 to 10 wt%, or 10 to 20 wt%), or 20 to 40 wt% (e.g., 20 to 30 wt%, or 30 to 40 wt%), or 40 to 60 wt% (e.g., 40 to 50 wt or 50 to 60 wt%), or 60 to 80 wt% (e.g., 60 to 70 wt% or 70 to 80 wt%), or 80 to 99 wt% (80 to 90 wt%, or 90 to 99 wt%) of PBT.

[0035] In some embodiments, the housing comprises a blend of PBT and a copolymer of BF and BBf. The blend of PBT and the copolymer of BF and BBf can comprise 1 to 99 wt%, or 1 to 20 wt% (e.g., 1 to 10 wt%, or 10 to 20 wt%), or 20 to 40 wt% (e.g., 20 to 30 wt%, or 30 to 40 wt%), or 40 to 60 wt% (e.g., 40 to 50 wt or 50 to 60 wt%), or 60 to 80 wt% (e.g., 60 to 70 wt% or 70 to 80 wt%), or 80 to 99 wt% (80 to 90 wt%, or 90 to 99 wt%) of PBT.

[0036] In some embodiments, the housing comprises a copolymer of BF and BBf. The copolymer of BF and BBf can comprise 1 to 99 wt%, or 1 to 20 wt% (e.g., 1 to 10 wt%, or 10 to 20 wt%), or 20 to 40 wt% (e.g., 20 to 30 wt%, or 30 to 40 wt%), or 40 to 60 wt% (e.g., 40 to 50 wt or 50 to 60 wt%), or 60 to 80 wt% (e.g., 60 to 70 wt% or 70 to 80 wt%), or 80 to 99 wt% (80 to 90 wt%, or 90 to 99 wt%) of BBf.

[0037] In some embodiments, the housing comprises a blend of PBF and PBBf. The blend of PBF and PBBf can comprise 1 to 99 wt%, or 1 to 20 wt% (e.g., 1 to 10 wt%, or 10 to 20 wt%), or 20 to 40 wt% (e.g., 20 to 30 wt%, or 30 to 40 wt%), or 40 to 60 wt% (e.g., 40 to 50 wt% or 50 to 60 wt%), or 60 to 80 wt% (e.g., 60 to 70 wt% or 70 to 80 wt%), or 80 to 99 wt% (80 to 90 wt%, or 90 to 99 wt%) of PBF.

[0038] In some embodiments, the housing comprises a copolymer of BF and EF. The copolymer of BF and EF can comprise 1 to 99 wt%, or 1 to 20 wt% (e.g., 1 to 10 wt%, or 10 to 20 wt%), or 20 to 40 wt% (e.g., 20 to 30 wt%, or 30 to 40 wt%), or 40 to 60 wt% (e.g., 40 to 50 wt% or 50 to 60 wt%), or 60 to 80 wt% (e.g., 60 to 70 wt% or 70 to 80 wt%), or 80 to 99 wt% (80 to 90 wt%, or 90 to 99 wt%) of BF.

[0039] In some embodiments, the housing comprises a blend of PBF and PEF. The blend of PBF and PEF can comprise 1 to 99 wt%, or 1 to 20 wt% (e.g., 1 to 10 wt%, or 10 to 20 wt%), or 20 to 40 wt% (e.g., 20 to 30 wt%, or 30 to 40 wt%), or 40 to 60 wt% (e.g., 40 to 50 wt% or 50 to 60 wt%), or 60 to 80 wt% (e.g., 60 to 70 wt% or 70 to 80 wt%), or 80 to 99 wt% (80 to 90 wt%, or 90 to 99 wt%) of PBF.

[0040] The weight percentage of each component in the blend or copolymer is selected based on the desired properties to be achieved in the material. For example, PBT (T m = 221 - 225 °C) and PBF (T mIn a blend (melting at 168 - 186 °C), the weight percentages of PBT and PBF can be selected to obtain the desired melting temperature of the blend between those of the pure polymers.

[0041] In some embodiments, the housing further includes additives. The additives can be selected from, but are not limited to, antioxidants, ultraviolet (UV) stabilizers, flame retardants, hydrolysis inhibitors, coloring pigments, nucleating agents, additives or fillers for increasing crystallization rate and / or mechanical strength, additives for laser marking, lubricants, and waxes. For example, the housing includes 0.1 - 3 wt%, 0.1 - 5 wt%, or 0.1 - 10 wt% of an antioxidant such as a sterically hindered phenolic thioether, phosphite, or any combination thereof; for example, the housing includes 0.1 - 10 wt% of a UV stabilizer such as benzotriazole, hydroxybenzophenone, or any combination thereof; for example, the housing includes 1 - 40 wt%, 2 - 30 wt%, or 5 - 25 wt% of a flame retardant such as a phosphate ether, magnesium hydroxide, aluminum diethylphosphinate, or any combination thereof; and / or, for example, the housing includes 0.1 - 10 wt% of a hydrolysis inhibitor such as an acid scavenger; and / or, for example, the housing includes 0.1 - 20 wt% of a coloring pigment such as anthraquinone, iron oxide, carbon black, titanium dioxide, orange pigment. Examples of lubricants include polytetrafluoroethylene (PTFE), esters, and / or metal salts of fatty acids such as zinc stearate, calcium stearate, and adipic acid glycol polyester (AAGP). Examples of nucleating agents or crystallization rate improvers include sodium benzoate, sodium salt of saccharin, boron nitride, organic acids, metal salts, inorganic substances such as CNT, talc, glass fiber, or metal carbonate, and / or coupling agents. Examples of waxes include ethylene bisstearamide.

[0042] In some embodiments, the additive is a discoloring additive for laser marking. This additive has no or substantially no intrinsic color (only a slight intrinsic color) in the visible spectrum range (light wavelengths from about 380 to 750 nm), and generates markings with high color contrast in the visible range under the influence of laser light with a wavelength outside the visible range (less than 380 nm or more than 750 nm). The color contrast can be generated, for example, by the additive changing to a colored product under the influence of laser light from an Nd-YAG laser (wavelength 1064 nm) or an excimer laser (wavelength 308 nm to 351 nm). Any additive having the above characteristics, such as copper phosphate, copper sulfate, basic copper phosphate hydroxide, and copper thiocyanate, for example, 0.02% to 5% of Cu3(PO4)2·Cu(OH)2 can be used for laser marking.

[0043] In some embodiments, the additive is a reinforcing additive. For example, the electrical housing contains 1 to 60 wt%, 2 to 50 wt%, or 5 to 40 wt% of the reinforcing additive. The reinforcing additive can be selected from, but is not limited to, glass fiber, carbon fiber, talc, cellulose, bamboo, softwood, hardwood, flax, kenaf, jute, ramie, coir, kapok, sisal, henequen, abaca, hemp, bagasse, wheat straw, rice husk, corn, sunn, and any combination thereof.

[0044] In some embodiments, the electrical housing of the electrical connector has a tensile modulus in the range of about 1 to 4 GPa, 2 to 4 GPa, 1 to 7 GPa, 3 to 7 GPa, or 5 to 7 GPa, and a tensile strength in the range of about 20 to 70 MPa, 40 to 70 MPa, 20 to 90 MPa, 40 to 90 MPa, 50 to 150 MPa, 90 to 150 MPa, 20 to 95 MPa, or 40 to 95 MPa.

[0045] Exemplary ranges of tensile modulus and tensile strength are provided in Examples I - X. By compounding PBF and / or PBBf, or a copolymer of BF and BBf as a reinforcing additive, the tensile modulus and tensile strength of the electrical housing increase. For example, the tensile modulus of PBF ranges from 1 - 4 GPa, preferably from 2 - 4 GPa, the maximum tensile strength of PBF ranges from 20 - 70 MPa, preferably from 40 - 70 MPa, the tensile modulus of the composite of PBF and the reinforcing additive ranges from 3 - 7 GPa, preferably from 5 - 7 GPa, the maximum tensile strength of the composite of PBF and the reinforcing additive ranges from 50 - 150 MPa, preferably from 90 - 150 MPa, the tensile modulus of the PBF / PBT blend ranges from 1 - 4 GPa, preferably from 2 - 4 GPa, the maximum tensile strength of the PBF / PBT blend ranges from 20 - 70 MPa, preferably from 40 - 70 MPa, the tensile modulus of PBBf ranges from 1 - 4 GPa, preferably from 2 - 4 GPa, the maximum tensile strength of PBBf ranges from 40 - 90 MPa, preferably from 55 - 90 MPa, the tensile modulus of the composite of PBBf and the reinforcing additive ranges from 3 - 7 GPa, preferably from 5 - 7 GPa, the maximum tensile strength of the composite of PBBf and the reinforcing additive ranges from 50 - 150 MPa, preferably from 90 - 150 MPa, the tensile modulus of the PBF / PBBf blend or the copolymer of BF and BBf ranges from 1 - 4 GPa, preferably from 2 - 4 GPa, the maximum tensile strength of the PBF / PBBf blend or the copolymer of BF and BBf ranges from 20 - 90 MPa, preferably from 40 - 90 MPa, the tensile modulus of the PBF / PBBf blend or the copolymer of BF and BBf with the reinforcing additive added ranges from 3 - 7 GPa, preferably from 5 - 7 GPa, and the maximum tensile strength of the PBF / PBBf blend or the copolymer of BF and BBf with the reinforcing additive added ranges from 50 - 150 MPa, preferably from 90 - 150 MPa.

[0046] The tensile modulus of the PBF / PEF blend or the copolymer of BF and EF is in the range of 1 to 4 GPa, preferably in the range of 2 to 4 GPa. The maximum tensile strength of the PBF / PEF blend or the copolymer of BF and EF is in the range of 20 to 95 MPa, preferably in the range of 40 to 95 MPa. The tensile modulus of the PBF / PEF blend or the copolymer of BF and EF with a reinforcing additive is in the range of 3 to 7 GPa, preferably in the range of 5 to 7 GPa. The maximum tensile strength of the PBF / PBBf blend or the copolymer of BF and BBf with a reinforcing additive is in the range of 50 to 150 MPa, preferably in the range of 90 to 150 MPa. The tensile modulus of the PBf / PEF blend or the copolymer of BBf and EF is in the range of 1 to 4 GPa, preferably in the range of 2 to 4 GPa. The maximum tensile strength of the PBBf / PEF blend or the copolymer of BBf and EF is in the range of 20 to 95 MPa, preferably in the range of 40 to 95 MPa. The tensile modulus of the PBBf / PEF blend or the copolymer of BBf and EF with a reinforcing additive is in the range of 3 to 7 GPa, preferably in the range of 5 to 7 GPa. The maximum tensile strength of the PBBf / PEF blend or the copolymer of BBf and EF with a reinforcing additive is in the range of 50 to 150 MPa, preferably in the range of 90 to 150 MPa.

[0047] In some embodiments, the electrical housing of the electrical connector has a load deflection temperature in the range of 60°C to 150°C, 80°C to 150°C, or 100°C to 150°C.

[0048] PBF can be synthesized as described in Papageorgiou et al., "Evaluation of polyesters from renewable resources as alternatives to the current fossil-based polymers. Phase transitions of poly(butylene 2,5-furan-dicarboxylate)", Polymer 55, 3846 (2014) (Non-Patent Document 1) or J.C. Morales-Huerta et al., "Poly(alkylene 2,5-furandicarboxylate)s (PEF and PBF) by ring opening", Polymer 87, 148 (2016) (Non-Patent Document 2). BFDCA, which is the precursor of PBBf, can be synthesized as described in Mingchun Ye et al., "Oxidative coupling of 2-methyl furoate: A scalable synthesis of dimethyl 2,2'-bifuran-5,5'-dicarboxylate", Applied Catalysis A: General, 619, 118138 (2021) (Non-Patent Document 3), and PBBf can be synthesized from the precursor BFDCA as described in T. Kainulainen et al., "Utilizing Furfural-Based Bifuran Diester as Monomer and Comonomer for High-Performance Bioplastics: Properties of Poly(butylene furanoate), Poly(butylene bifuranoate), and Their Copolyesters", Biomacromolecules 21, 743 (2020) (Non-Patent Document 4). The synthesis of random copolymers of BF and BBf is also described in Kainulainen et al., Biomacromolecules 21, 743-752 (2020) (Non-Patent Document 4).The blend of PBF and PEF is described in Poulopoulou et al., "Green polymeric materials: On the dynamic homogeneity and miscibility of furan-based polyester blends", Polymer 174, 187-199 (2019) (Non-Patent Document 5). All of the references cited herein are incorporated by reference in their entirety.

[0049] (Manufacturing Process of Electrical Connector) FIG. 4 is a flowchart showing a process 400 for manufacturing an electrical connector, particularly a housing for an electrical connector. In some embodiments, the electrical connector corresponds to the exemplary connectors described with respect to FIGS. 1 and 2A and 2B. In some embodiments, the electrical housing corresponds to the housing 100 or housing 202 of the electrical connector or connection terminal device described with respect to FIGS. 1 and 2A and 2B.

[0050] In 402, process 400 includes obtaining one or more materials. In some embodiments, the one or more materials are selected from the group consisting of PBF, PBBf, a copolymer of (i) BF and (ii) BBf, a copolymer of (i) EF and (ii) one or both of BF and BBf, a copolymer of (i) BT and (ii) one or more of BF, BBf, and EF, or any combination thereof. The polymers and / or copolymers can be in any combination, alone or as a polymer blend (mixture). For example, the one or more materials can include a copolymer of EF and BF, a copolymer of EF and BBf, a copolymer of EF, BF, and BBf, a copolymer of BT and BF, a copolymer of BT and BBf, a copolymer of BT and EF, a copolymer of BT, BF, and BBf, a copolymer of BT, BF, and EF, a copolymer of BT, BBf, and EF, a copolymer of BT, BF, BBf, and EF, or any combination thereof. For example, the one or more materials can include a polymer blend of PBF and PBBf, a polymer blend of PEF and PBF, a polymer blend of PEF and PBBf, a polymer blend of PEF, PBF, and PBBf, a polymer blend of PBT and PBF, a polymer blend of PBT and PBBf, a polymer blend of PBT and PEF, a polymer blend of PBT, PBF, and PBBf, a polymer blend of PBT, PBF, and PEF, a polymer blend of PBT, PBBf, and PEF, a polymer blend of PBT, PBF, PBBf, and PEF, or any combination thereof.

[0051] In some embodiments, process 400 includes obtaining a composition of materials. For example, the one or more materials include a polymer, such as PBF, PBBf, or a copolymer of BF and BBf (e.g., a copolyester), and other materials (e.g., additives, polymers such as PBT or PEF), or are in the form of a composition containing the same. The one or more materials and / or the composition of materials can include any of the materials described with respect to the materials included in the electrical connectors of the present disclosure.

[0052] In some embodiments, the composition further comprises PEF. In such embodiments, process 400 further comprises mixing the PEF with the polymer, blend, or copolymer of one or more materials to form a blend of the PEF and the polymer, blend, or copolymer of one or more materials, thereby forming a blend of the PEF. The mixing can be performed before extruding the melted composition to produce compounded pellets.

[0053] In some embodiments, obtaining one or more materials or compositions can include heating the one or more materials or compositions for a period of time (e.g., 4 to 8 hours at a temperature in the range of 80 °C to 120 °C). The heating dries the one or more materials or compositions. For example, the moisture level of PBF, PBBf, PEF, or PBT can be less than 0.2%, preferably less than 0.03%.

[0054] In some embodiments, one or more materials or compositions need to be compounded to form pellets suitable for injection molding as described below with respect to Example VIII. Compounding can include melting the one or more materials, mixing the materials together, and extruding the one or more materials to produce pellets.

[0055] In 404, process 400 includes melting one or more materials or compositions. Melting includes melt - mixing one or more materials or compositions. For example, the melting point of PBT is 221 - 225 °C, the melting point of PBF is 168 - 186 °C, the melting point of PEF is 202 - 220 °C, and the melting point of PBBf is 215 - 217 °C. As described in Example X below, the materials are mixed in a molten state. In one embodiment, compounding PBF and / or PBBf with any of the above - mentioned additives includes mixing PBF pellets and / or PBBf pellets with the additives in a molten state. In another embodiment, compounding PBF and PBT includes mixing PBF pellets and PBT pellets in a molten state. In another embodiment, compounding PBF and PBT with any of the above - mentioned additives includes mixing PBF and PBT pellets with the additives in a molten state. In another embodiment, compounding BF and BBf copolymers with any of the above - mentioned additives includes mixing BF and BBf copolymer pellets with the additives in a molten state. In another embodiment, compounding PBF and PEF with any of the above - mentioned additives includes mixing PBF and PEF pellets with the additives in a molten state. In another embodiment, compounding BF and EF copolymers with any of the above - mentioned additives includes mixing BF and EF copolymer pellets with the additives in a molten state. In another embodiment, compounding PBBf and PEF with any of the above - mentioned additives includes mixing PBBf and PEF pellets with the additives in a molten state. In another embodiment, compounding BBf and EF copolymers with any of the above - mentioned additives includes mixing BBf and EF copolymer pellets with the additives in a molten state.

[0056] In 406, process 400 includes extruding one or more melted materials or a melted composition to produce compounded pellets. Extrusion refers to a material forming process in which a material is forced to flow (e.g., by pressure) through a die of an extruder (or extruder) to convert the material into a desired shape such as pellets. Extrusion can be used to mix two or more materials by adding the two or more materials to the extruder and flowing them along the extruder. Different materials can be supplied to the extruder separately or as a mixture to form compounded pellets. The extruder may be a single-screw extruder or a twin-screw extruder, and the twin-screw extruder provides better control over the extrusion process. In some embodiments, the compounded pellets formed at 406 are subsequently heated to dry the pellets.

[0057] In some embodiments, the one or more materials include PBF and PBT. In such embodiments, process 400 further includes blending PBF with PBT before extruding the melted composition to produce compounded pellets. The blend of PBT and PBF can include 1 to 99 wt%, or 1 to 20 wt% (e.g., 1 to 10 wt%, or 10 to 20 wt%), or 20 to 40 wt% (e.g., 20 to 30 wt%, or 30 to 40 wt%), or 40 to 60 wt% (e.g., 40 to 50 wt% or 50 to 60 wt%), or 60 to 80 wt% (e.g., 60 to 70 wt% or 70 to 80 wt%), or 80 to 99 wt% (80 to 90 wt%, or 90 to 99 wt%) of PBT. The weight percentages of PBT and PBF can be selected to obtain desired properties in the blend, such as specific melting temperatures between those of the pure polymers.

[0058] In some embodiments, one or more materials include PBBf and PBT. In such embodiments, process 400 further includes blending PBBf with PBT before extruding the melted composition to produce compounded pellets. The blend of PBT and PBBf can include 1 to 99 wt%, or 1 to 20 wt% (e.g., 1 to 10 wt%, or 10 to 20 wt%), or 20 to 40 wt% (e.g., 20 to 30 wt%, or 30 to 40 wt%), or 40 to 60 wt% (e.g., 40 to 50 wt% or 50 to 60 wt%), or 60 to 80 wt% (e.g., 60 to 70 wt% or 70 to 80 wt%), or 80 to 99 wt% (80 to 90 wt%, or 90 to 99 wt%) of PBT. The weight percentages of PBBf and PBT can be selected to obtain desired properties in the blend, such as a specific melting temperature between the pure polymers.

[0059] In some embodiments, one or more materials include PBF and PBBf. In such embodiments, process 400 further includes blending PBF with PBBf before extruding the melted composition to produce compounded pellets. The blend of PBF and PBBf can include 1 to 99 wt%, or 1 to 20 wt% (e.g., 1 to 10 wt%, or 10 to 20 wt%), or 20 to 40 wt% (e.g., 20 to 30 wt%, or 30 to 40 wt%), or 40 to 60 wt% (e.g., 40 to 50 wt% or 50 to 60 wt%), or 60 to 80 wt% (e.g., 60 to 70 wt% or 70 to 80 wt%), or 80 to 99 wt% (80 to 90 wt%, or 90 to 99 wt%) of PBF. The weight percentages of PBF and PBBf can be selected to obtain desired properties in the blend, such as their specific melting temperature between the pure polymers.

[0060] In some embodiments, one or more materials include PBF and PEF. In such embodiments, process 400 further includes blending PBF with PEF before extruding the melted composition to produce compounded pellets. The blend of PBF and PEF can include 1 to 99 wt%, or 1 to 20 wt% (e.g., 1 to 10 wt%, or 10 to 20 wt%), or 20 to 40 wt% (e.g., 20 to 30 wt%, or 30 to 40 wt%), or 40 to 60 wt% (e.g., 40 to 50 wt% or 50 to 60 wt%), or 60 to 80 wt% (e.g., 60 to 70 wt% or 70 to 80 wt%), or 80 to 99 wt% (80 to 90 wt%, or 90 to 99 wt%) of PBF. The weight percentages of PBF and PEF can be selected to obtain desired properties in the blend, such as a specific melting temperature between those of the pure polymers.

[0061] In some embodiments, one or more materials include PBBf and PEF. In such embodiments, process 400 further includes blending PBBf with PEF before extruding the melted composition to produce compounded pellets. The blend of PBBf and PEF can include 1 to 99 wt%, or 1 to 20 wt% (e.g., 1 to 10 wt%, or 10 to 20 wt%), or 20 to 40 wt% (e.g., 20 to 30 wt%, or 30 to 40 wt%), or 40 to 60 wt% (e.g., 40 to 50 wt% or 50 to 60 wt%), or 60 to 80 wt% (e.g., 60 to 70 wt% or 70 to 80 wt%), or 80 to 99 wt% (80 to 90 wt%, or 90 to 99 wt%) of PBBf. The weight percentages of PBBf and PEF can be selected to obtain desired properties in the blend, such as a specific melting temperature between those of the pure polymers.

[0062] In some embodiments, the one or more materials include copolymers of any combination of BF, BBf, EF, or BT, and polymers of any combination of PBF, PBBf, PEF, or PBT. In such embodiments, process 400 further includes blending the copolymer with the polymer before extruding the melted composition to produce compounded pellets. The blend of copolymer and polymer can include 1 to 99 wt%, or 1 to 20 wt% (e.g., 1 to 10 wt%, or 10 to 20 wt%), or 20 to 40 wt% (e.g., 20 to 30 wt%, or 30 to 40 wt%), or 40 to 60 wt% (e.g., 40 to 50 wt%, or 50 to 60 wt%), or 60 to 80 wt% (e.g., 60 to 70 wt%, or 70 to 80 wt%), or 80 to 99 wt% (80 to 90 wt%, or 90 to 99 wt%) of PBF or BF. The weight percentages of the copolyesters of BF, BBf, EF, and / or BT, and the polyesters of PBF, PBBf, PEF, and / or PBT can be selected to obtain desired properties in the blend, such as a specific melting temperature between those of the pure polymers.

[0063] In some embodiments, the composition includes any of the materials described above and one or more additives. The one or more additives can be selected from, but are not limited to, first additives including antioxidants, UV stabilizers, flame retardants, hydrolysis inhibitors, coloring pigments, lubricants, waxes, nucleating agents, laser marking additives, and any combination thereof. Alternatively or additionally, the one or more additives can include second additives. The second additives can include, but are not limited to, reinforcing additives selected from glass fibers, carbon fibers, talc, and any combination thereof. Alternatively or additionally, the second additives can include, but are not limited to, cellulose, bamboo, softwood, hardwood, linen, kenaf, jute, ramie, coir, kapok, sisal, henequen, abaca, hemp, bagasse, straw, rice husk, corn, sunflower, or any combination thereof.

[0064] Process 400 further includes injection molding the compounded pellets to form an electrical housing. The injection molding can be performed using an injection molding machine. An exemplary injection molding machine is shown in FIG. 3. The injection molding includes heating the extruded pellets containing one or more materials or compositions to a molten state at 408, and injecting the one or more molten materials into a mold to form an electrical housing at 410. Process 400 optionally includes annealing the formed electrical housing at 412 at 60° C. or higher, or 100° C. or higher. For example, the annealing can be performed at 60-135° C. In some embodiments, the annealing is performed at 115° C. The annealing increases the crystallinity of the electrical housing, thereby improving its strength and durability characteristics.

[0065] In some embodiments, the electrical housing prepared by process 400 can be coupled with one or more electrical contacts (e.g., the rod-shaped conductive metal of terminal 206 in FIGS. 2A and 2B) to form an electrical connector. In some embodiments, the electrical connector is a female or male terminal electrical connector. The terminal electrical connector and / or the electrical housing produced by process 400 can be used in an electronic control unit such as an automobile.

Example

[0066] <Example I: Injection Molding Procedure and Characteristics of PBF> PBF has a melting temperature of about 168 °C to 186 °C. In this example, the PBF resin is injection molded using an injection molding setup (e.g., the molding machine 300 of FIG. 3) to form an electrical connector or an electrical housing (e.g., those described with respect to FIGS. 1 to 2B). The PBF resin is air-dried or vacuum-dried at 80 °C to 120 °C for 4 to 8 hours before injection molding. The moisture level of the environment during drying is less than 0.2% or less than 0.03%. The PBF pellets are heated to a melt (a melt referring to the material in a molten state) at a barrel temperature of an injection molding machine of about 180 °C to 230 °C or about 190 °C to 210 °C before injection. The melt is introduced into a mold maintained at a temperature of 40 °C to 100 °C or a temperature of 60 °C to 80 °C at an injection pressure of 50 to 180 MPa or an injection pressure of 70 to 120 MPa. The intrinsic viscosity (IV) is 0.5 to 1.5 dL / g, and the melt flow index is 5 g / 10 min to 70 g / 10 min within the selected injection molding temperature and load range.

[0067] The tensile modulus of PBF ranges from 1 to 4 GPa or from 2 to 4 GPa, and the maximum tensile strength ranges from 20 to 70 MPa or from 40 to 70 MPa. The properties of the PBF sample are further improved by annealing the molded sample at 60 °C to 135 °C or 115 °C. Annealing increases the crystallinity of the electrical housing, thereby improving its strength and durability.

[0068] PBF can be synthesized as described in Papageorgiou et al., "Evaluation of polyesters from renewable resources as alternatives to the current fossil-based polymers. Phase transitions of poly(butylene 2,5-furan-dicarboxylate)", Polymer 55, 3846 (2014) (Non-Patent Document 1) or J.C. Morales-Huerta et al., "Poly(alkylene 2,5-furandicarboxylate)s (PEF and PBF) by ring opening", Polymer 87, 148 (2016) (Non-Patent Document 2).

[0069] <Example II: Injection Molding Procedure of PBF Blended with Additives> For actual use, the PBF resin can be blended with various additives (see Example VIII for blending). For example, one or more additives including glass fiber, carbon fiber, talc, or natural fillers can be added at 1 to 60 wt% for mechanical strengthening. Natural fillers refer to plant-based filler materials derived from plants (such as grass, shrubs, trees, etc.). Examples of natural fillers include, but are not limited to, cellulose, bamboo, softwood, hardwood, flax, kenaf, jute, ramie, coir, kapok, sisal, henequen, abaca, hemp, bagasse, straw, rice husk, corn, or sunflower.

[0070] In this example, a flame retardant such as phosphate ether, magnesium hydroxide, or aluminum diethylphosphinate can be added in an amount of 1 to 40% by weight. A sterically hindered phenol or thioether or phosphite or combination can be added as an antioxidant in an amount of 0.1 to 10% by weight. An acid scavenger may be added as a hydrolysis inhibitor in an amount of 0.1 to 10% by weight. Benzotriazole or hydroxybenzophenone may be added as a UV stabilizer in an amount of 0.1 to 10% by weight. A coloring pigment may be added in an amount of 20% by weight or less as needed. Other additives include lubricants such as polytetrafluoroethylene ethylene (PTFE), esters, and metal salts of fatty acids such as zinc stearate, calcium stearate, and adipic acid glycol polyester (AAGP), sodium benzoate, sodium salts of saccharin, boron nitride, organic acids, metal salts, CNTs, talc, glass fibers, or inorganic substances such as metal carbonates, and nucleating agents such as coupling agents, and waxes such as ethylene bisstearamide.

[0071] The compounded PBF composite pellets are injection molded using an injection molding setup (e.g., the molding machine 300 described with respect to FIG. 3) to form an electrical housing or electrical connector (e.g., those described with respect to FIGS. 1 - 2B). The PBF composite is air dried or vacuum dried at 80°C to 120°C for 4 to 8 hours prior to injection molding. The moisture level during drying is less than 0.2% or less than 0.03%. The PBF pellets are heated to about 180°C to 230°C or 190°C to 210°C before injecting the melt into a mold maintained at a temperature of 40°C to 100°C or 60°C to 80°C at a pressure of 50 to 220 MPa or at a pressure of 90 to 150 MPa. In the selected injection molding temperature and load range, the intrinsic viscosity (IV) is 0.5 to 1.5 dL / g and the melt flow index is 5 g / 10 min to 70 g / 10 min.

[0072] The tensile modulus of the composite of PBF and the reinforcing additive is in the range of 3 to 7 GPa, or in the range of 5 to 7 GPa, and the maximum tensile strength is in the range of 50 to 150 MPa, or in the range of 90 to 150 MPa.

[0073] <Example III: Injection Molding Procedure of PBF / PBT Blend> As described above, PBF has a melting temperature of about 168 °C to 186 °C, and PBT has a melting point of about 221 °C to 225 °C. In applications where a melting temperature higher than that of pure PBF is required, it may thus be desirable to use a blend of PBF and PBT. The synthesis of such blends is described in the specification of Chinese Patent Application Publication No. 110229480 by X. Zhang et al., "A kind of preparation method of poly-furandicarboxylic acid butanediol ester and polybutylene terephthalate (PBT) blend" (Patent Document 1). The melting point of the blend varies according to the ratio of PBF to PBT. For example, a 50 / 50 blend of PBF / PBT has a melting temperature close to 195 °C to 200 °C.

[0074] In this example, the blend containing PBF and PBT is injection molded using an injection molding setup as described above (e.g., the molding machine 300 in Figure 3) to form an electrical housing or an electrical connector (e.g., those described with respect to Figures 1 to 2B). The compounded PBF and PBT pellets are air-dried or vacuum-dried at 80 °C to 120 °C for 4 to 8 hours before injection molding. In this example, the moisture level during drying is less than 0.2%, or less than 0.03%. The compounded PBF and PBT pellets are heated to 180 °C to 240 °C or 190 °C to 220 °C and then injection molded into a mold maintained at a temperature of 40 °C to 120 °C or 60 °C to 80 °C at a pressure of 50 to 150 MPa or 70 to 120 MPa.

[0075] In this example, the tensile modulus of the PBF / PBT blend is in the range of 1 to 4 GPa, or in the range of 2 to 4 GPa, and the maximum tensile strength is in the range of 20 to 70 MPa or in the range of 40 to 70 MPa. The heat deflection temperature of the blend is expected to be 60 to 150 °C, or 100 to 150 °C.

[0076] <Example IV: Injection Molding Procedure and Characteristics of PBBf> As described above, PBBf has a melting temperature of about 215 °C to 217 °C. In this example, the PBBf resin is injection molded using an injection molding setup (e.g., the injection molding machine 300 of FIG. 3) to form an electrical connector or an electrical housing (e.g., those described with respect to FIGS. 1 to 2B). The PBBf resin is air dried or vacuum dried at 80 °C to 120 °C for 4 to 8 hours before injection molding. The moisture level after drying is less than 0.2%, or less than 0.03%. The PBBf pellets are heated to a barrel temperature of about 220 °C to 280 °C, or 230 °C to 260 °C of the injection molding machine before injecting the melt into a mold set at a temperature of 60 °C to 120 °C, or 80 °C to 110 °C, at an injection pressure of 50 to 180 MPa, or at an injection pressure of 70 to 120 MPa. The intrinsic viscosity (IV) is 0.5 to 1.5 dL / g, and the melt flow index is 5 g / 10 min to 70 g / 10 min in the selected injection molding temperature and load range.

[0077] The tensile modulus of PBBf is in the range of 1 to 4 GPa, or in the range of 2 to 4 GPa, and the maximum tensile strength is in the range of 40 to 90 MPa, or in the range of 55 to 90 MPa.

[0078] BFDCA, which is a precursor of PBBf, can be synthesized as described in Mingchun Ye et al., "Oxidative coupling of 2-methyl furoate: A scalable synthesis of dimethyl 2,2'-bifuran-5,5'-dicarboxylate", Applied Catalysis A: General, 619, 118138 (2021) (Non-Patent Document 3), and PBBf can be synthesized from the precursor BFDCA as described in T. Kainulainen et al., "Utilizing Furfural-Based Bifuran Diester as Monomer and Comonomer for High-Performance Bioplastics: Properties of Poly(butylene furanoate), Poly(butylene bifuranoate), and Their Copolyesters", Biomacromolecules 21, 743 (2020) (Non-Patent Document 4).

[0079] <Example V: Injection Molding Procedure of PBBf Blended with Additives> For actual use, the PBBf resin can be compounded with various additives including, but not limited to, glass fiber, carbon fiber, talc, or natural fillers. Such additives can be added in an amount of 1 to 60% by weight for mechanical strengthening. Flame retardants such as phosphate ether, magnesium hydroxide, or aluminum diethylphosphinate can be added in an amount of 1 to 40% by weight. As antioxidants, sterically hindered phenols or thioethers or phosphites or any combination thereof can be added in an amount of 0.1 to 10% by weight. As a hydrolysis inhibitor, an acid scavenger can be added in an amount of 0.1 to 10% by weight. As a UV stabilizer, benzotriazole, hydroxybenzophenone can be added in an amount of 0.1 to 10% by weight. A coloring pigment can be added in an amount of 20% by weight or less as needed. A discoloring additive for laser marking can be added in an amount of 0.02% to 5%. Other additives as needed: lubricants such as polytetrafluoroethylene ethylene (PTFE), esters, and metal salts of fatty acids such as zinc stearate, calcium stearate, and AAGP, sodium benzoate, sodium salts of saccharin, boron nitride, organic acids, metal salts, inorganic substances such as CNT, talc, glass fiber, or metal carbonate, and nucleating agents such as coupling agents, and waxes such as ethylene bisstearamide may be added.

[0080] In this example, the compounded PBBf composite pellets are injection molded using an injection molding setup (e.g., the molding machine 300 in FIG. 3) to form an electrical connector or an electrical housing (e.g., those described with respect to FIGS. 1 to 2B). The PBBf composite is air-dried or vacuum-dried at 80°C to 120°C for 4 to 8 hours before injection molding. The moisture level after drying is less than 0.2% or less than 0.03%. The PBBf composite pellets are heated to a temperature of about 220°C to 280°C or a barrel temperature of 230°C to 260°C of the injection molding machine before injecting the melt into a mold set at a temperature of 60°C to 120°C or a temperature of 80°C to 110°C at an injection pressure of 50 to 220 MPa or an injection pressure of 90 to 150 MPa. The intrinsic viscosity (IV) is 0.5 to 1.5 dL / g, and the melt flow index is 5 g / 10 min to 70 g / 10 min within the selected injection molding temperature and load range.

[0081] The tensile modulus of the composite of PBBf and the reinforcing additive is in the range of 3 to 7 GPa or in the range of 5 to 7 GPa, and the maximum tensile strength is in the range of 50 to 150 MPa or in the range of 90 to 150 MPa.

[0082] <Example VI: Injection Molding Procedure of PBF-PBBf Blend and Copolymer of BF and BBf> As described above, PBF has a melting temperature of about 168°C to 186°C, and PBBf has a melting point of 215°C to 217°C. Thus, in some applications, it is desirable to blend PBF and PBBf or synthesize a random copolymer (e.g., a copolyester) of butylene furanoate (BF) and butylene bifuranate (BBf) derived from FDCA and BFDCA, respectively. The synthesis of the random copolymer of BF and BBf is described in Kainulainen et al., "Utilizing Furfural-Based Bifuran Diester as Monomer and Comonomer for High-Performance Bioplastics: Properties of Poly(butylene furanoate), Poly(butylene bifuranoate), and Their Copolymers", Biomacromolecules 21, 743-752 (2020) (Non-Patent Document 4).

[0083] Depending on the weight % of BF in the blend or copolymer, the melting temperature can range from 168°C to 217°C. In this example, a blend of PBF and PBBf or a copolymer of BF and BBf is injection molded using an injection molding setup (e.g., molding machine 300 of FIG. 3) to form an electrical connector or an electrical housing (e.g., those described with respect to FIGS. 1-2B). The compounded pellets containing the blend of PBF and PBBf or the copolymer of BF and BBf are air dried or vacuum dried at 80°C to 120°C for 4 to 8 hours prior to injection molding. The moisture level during drying is less than 0.2% or less than 0.03%. The blend or copolymer is heated at 180°C to 280°C prior to injection molding and placed in a mold maintained at a temperature of 40°C to 120°C or 60°C to 80°C at a pressure of 50 to 180 MPa or a pressure of 70 to 120 MPa. The tensile modulus of the PBF / PBBf blend or the copolymer of BF and BBf ranges from 1 to 4 GPa or from 2 to 4 GPa, and the maximum tensile strength ranges from 20 to 90 MPa or from 40 to 90 MPa.

[0084] <Example VII: Injection Molding Procedure for PBF / PBBf Blend Containing Additives or Copolymer of BF and BBf> The blend of PBF and PBBf or the copolymer of BF and BBf can be compounded with various additives. The additives can include, but are not limited to, glass fiber, carbon fiber, talc, or natural fillers. Such additives can be added in an amount of 1 to 60% by weight for mechanical reinforcement. As a flame retardant, a flame retardant such as phosphate ether, magnesium hydroxide, aluminum diethylphosphinate can be added in an amount of 1 to 40% by weight. A sterically hindered phenol or thioether or phosphite or combination can be added as an antioxidant in an amount of 0.1 to 10% by weight. An acid scavenger can be added as a hydrolysis inhibitor in an amount of 0.1 to 10% by weight. Benzotriazole, hydroxybenzophenone can be added as a UV stabilizer in an amount of 0.1 to 10% by weight. A coloring pigment may be added in an amount of 20% by weight or less as needed. A discoloring additive for laser marking can be added in an amount of 0.02% to 5%. Other additives may be added as needed: polytetrafluoroethylene ethylene (PTFE), esters, and lubricants such as metal salts of fatty acids such as zinc stearate, calcium stearate, and AAGP, sodium benzoate, sodium salts of saccharin, boron nitride, organic acids, metal salts, inorganic substances such as CNT, talc, glass fiber, or metal carbonate, and nucleating agents such as coupling agents, and waxes such as ethylene bisstearamide.

[0085] The blend of PBF and PBBf or the synthetic copolymer of BF and BBf is injection molded using an injection molding setup (e.g., the molding machine 300 in FIG. 3) to form an electrical connector or an electrical housing (e.g., those described with respect to FIGS. 1 - 2B). The blend or copolymer - based composite is air - dried or vacuum - dried at 80°C to 120°C for 4 to 8 hours before injection molding. In this example, the moisture level during drying is less than 0.2% or less than 0.03%. After heating the blend or copolyester pellets containing additives to about 180°C to 280°C, the melt is injected into a mold maintained at a temperature of 40°C to 120°C or 60°C to 110°C at a pressure of 50 to 220 MPa or a pressure of 90 to 150 MPa. In the selected injection molding temperature and load range, the intrinsic viscosity (IV) is 0.5 to 1.5 dL / g and the melt flow index is 5 g / 10 min to 70 g / 10 min. The tensile modulus of the composite of PBF and the reinforcing additive is in the range of 3 to 7 GPa or in the range of 5 to 7 GPa, and the maximum tensile strength is in the range of 50 to 150 MPa or in the range of 90 to 150 MPa.

[0086] <Example VIII: Injection Molding Procedure for PBF - PEF Blend or Copolymer of BF and EF> As described above, PBF has a melting temperature of about 168°C to 186°C, and PEF has a melting temperature of 202°C to 220°C. Thus, in some applications, it is desirable to blend PBF and PEF or synthesize a random copolymer (e.g., copolyester) of butylene furanoate (BF) and ethylene furanoate (EF). Depending on the weight % of BF in the blend or copolymer, the melting temperature can range from 168°C to 220°C. In this example, a blend of PBF and PEF or a copolymer of BF and EF is injection molded using an injection molding setup (e.g., molding machine 300 of FIG. 3) to form an electrical connector or electrical housing (e.g., those described with respect to FIGS. 1 - 2B). The compounded pellets containing the blend of PBF and PEF or the copolymer of BF and EF are air dried or vacuum dried at 80°C to 120°C for 4 to 8 hours prior to injection molding. The moisture level during drying is less than 0.2% or less than 0.03%. The blend or copolymer is heated to 180°C to 280°C prior to injection molding and placed into a mold maintained at a pressure of 50 to 180 MPa or 70 to 120 MPa and a temperature of 40°C to 120°C or 60°C to 80°C. The tensile modulus of the PBF / PEF blend or the copolymer of BF and BBf ranges from 1 to 4 GPa or from 2 to 4 GPa, and the maximum tensile strength ranges from 20 to 95 MPa or from 40 to 95 MPa.

[0087] <Example IX: Injection Molding Procedure for a Blend of PBF and PEF or a Copolymer of BF and EF Containing Additives> Blends of PBF and PEF or copolymers of BF and EF can be compounded with various additives. The additives can include, but are not limited to, glass fibers, carbon fibers, talc, or natural fillers. Such additives can be added in an amount of 1 to 60% by weight for mechanical reinforcement. As a flame retardant, 1 to 40% by weight of a flame retardant such as phosphate ether, magnesium hydroxide, aluminum diethylphosphinate, etc. can be added. A sterically hindered phenol or thioether or phosphite or combination can be added as an antioxidant in an amount of 0.1 to 10% by weight. An acid scavenger can be added as a hydrolysis inhibitor in an amount of 0.1 to 10% by weight. As a UV stabilizer, 0.1 to 10% by weight of benzotriazole, hydroxybenzophenone can be added. Optionally, a coloring pigment can be added in an amount of 20% by weight or less. A discoloring additive for laser marking can be added in an amount of 0.02% to 5%. Optionally, other additives: polytetrafluoroethylene ethylene (PTFE), esters, and lubricants such as metal salts of fatty acids such as zinc stearate, calcium stearate, and AAGP, sodium benzoate, sodium salts of saccharin, boron nitride, organic acids, metal salts, CNTs, talc, or inorganic substances such as metal carbonates, and nucleating agents such as coupling agents, and waxes such as ethylene bisstearamide can be added.

[0088] The blend of PBF and PEF or the synthetic copolymer of BF and EF is injection molded using an injection molding setup (e.g., the molding machine 300 in FIG. 3) to form an electrical connector or an electrical housing (e.g., those described with respect to FIGS. 1 - 2B). The blend or copolymer - based composite is air - dried or vacuum - dried at 80°C to 120°C for 4 to 8 hours before injection molding. In this example, the moisture level during drying is less than 0.2% or less than 0.03%. After heating the blend containing additives or the copolyester pellets to about 180°C to 280°C, the melt is injected into a mold maintained at a pressure of 50 to 220 MPa or a pressure of 90 to 150 MPa and a temperature of 40°C to 120°C or a temperature of 60°C to 110°C. In the selected injection molding temperature and load range, the intrinsic viscosity (IV) is 0.5 to 1.5 dL / g, and the melt flow index is 5 g / 10 min to 70 g / 10 min. The tensile modulus of the composite of PBF and the reinforcing additive is in the range of 3 to 7 GPa or in the range of 5 to 7 GPa, and the maximum tensile strength is in the range of 50 to 150 MPa or in the range of 90 to 150 MPa.

[0089] <Example X: Blending of PBF> (Blend of PBF and Additives) As described above, PBF has a melting temperature of about 168°C to 186°C. To improve the durability and processability of PBF for actual applications, PBF can be blended with additives such as antioxidants, UV stabilizers, flame retardants, hydrolysis inhibitors, coloring pigments, lubricants, waxes, nucleating agents, discoloring additives for laser marking, etc. to obtain extrusion pellets.

[0090] In this example, before extrusion, the PBF is air-dried or vacuum-dried at 80°C to 120°C for 4 to 8 hours. The additive is dried as required. The moisture level during drying is less than 0.2% or less than 0.03%. The PBF pellets and the additive are melt-mixed at 180°C to 230°C or 190°C to 210°C. The components are fed together or separately along the extruder using the side feed of the extruder. Extrusion is carried out using a twin-screw or single-screw extruder. Generally, a twin-screw extruder can be more shear-intensive compared to a single-screw extruder. The extruded composition is optionally pelletized and dried to obtain dry pellets for injection molding. The moisture content in the dry pellets is less than 0.2% or less than 0.03%.

[0091] (Compound of PBF with filler and / or additive) For practical use, the PBF can be compounded with various fillers and additives as discussed in the above (Example II). In this example, before extrusion, the PBF is air-dried or vacuum-dried at 80°C to 120°C for 4 to 8 hours. The moisture level during drying is less than 0.2% or less than 0.03%. The PBF pellets and the filler, such as glass fiber, carbon fiber, talc, or natural filler and / or other additives are melt-mixed at 180°C to 230°C or 190°C to 210°C. The components can be fed together or separately along the extruder. The reinforcing additive is fed separately using a side feeder to avoid wear of the reinforcing additive. In a low-shear single-screw extruder, the filler or additive is mixed with the polymer and fed together through the main feeder of the extruder. In a high-shear twin-screw extruder, the filler or additive can be mixed with the polymer or fed separately through the main side feeder of the extruder. Extrusion is carried out using a twin-screw or single-screw extruder. The extruded composition is optionally pelletized and dried to obtain dry pellets for injection molding. The moisture content in the dry pellets is less than 0.2%, preferably less than 0.03%.

[0092] (Formulation of the Blend of PBF and PBT) In this example, before extrusion, PBF is air-dried or vacuum-dried at 80°C to 120°C for 4 to 8 hours. Before extrusion, PBT is air-dried or vacuum-dried at 80°C to 120°C for 4 to 8 hours. The moisture level during drying in both PBF and PBT is less than 0.2% or 0.03%. The PBF and PBT pellets as well as the additives are melt-mixed in an extruder. PBF and PBT are fed together into the extruder and melt-mixed under shear to obtain a PBT / PBF blend. The amount of PBT varies in the range of 1 to 99 wt%, or 1 to 20 wt% (e.g., 1 to 10 wt%, or 10 to 20 wt%), or 20 to 40 wt% (e.g., 20 to 30 wt%, or 30 to 40 wt%), or 40 to 60 wt% (e.g., 40 to 50 wt%, or 50 to 60 wt%), or 60 to 80 wt% (e.g., 60 to 70 wt%, or 70 to 80 wt%), or 80 to 99 wt% (80 to 90 wt%, or 90 to 99 wt%). The extruder temperature ranges from 180°C to 250°C and the extruder temperature is determined by the melting temperature of the PBF / PBT blend, which depends on the PBF / PBT mixing ratio. The extrusion is carried out using a twin-screw or single-screw extruder. The extruder screw speed is 30 to 200 rpm, or 100 rpm or less. The extruded composition is optionally pelletized to obtain dry pellets for injection molding and air-dried or vacuum-dried. The moisture content in the dry pellets is less than 0.2% or 0.03%.

[0093] (Formulation of PBBf and Additives) As mentioned above, PBBf has a melting temperature of about 215°C to 217°C. To improve the durability and processing of PBBf for practical applications, PBBf can be compounded with additives such as antioxidants, UV stabilizers, flame retardants, hydrolysis inhibitors, coloring pigments, lubricants, waxes, nucleating agents, discoloring additives for laser marking, etc. to obtain extrusion pellets.

[0094] In this example, before extrusion, PBBf is air-dried or vacuum-dried at 80°C to 120°C for 4 to 8 hours. The additive is dried as necessary. The moisture level during drying is less than 0.2% or less than 0.03%. The PBBf pellets and the additive are melt-mixed at 220°C to 280°C or 230°C to 260°C. The mixture is fed together along the extruder. Alternatively, the PBBf pellets and the additive are fed separately along the extruder. Extrusion is performed using a twin-screw or single-screw extruder. The screw speed of the extruder varies from 30 to 200 rpm or 100 rpm or less. The extruded composition is optionally pelletized and air-dried or vacuum-dried to obtain dry pellets for injection molding. The moisture content in the dry pellets is less than 0.2% or less than 0.03%.

[0095] (Compound of PBBf with filler and / or additive) For actual use, PBBf can be compounded with various fillers and additives as discussed in Example V above. In this example, before extrusion, PBBf is air-dried or vacuum-dried at 80°C to 120°C for 4 to 8 hours. The moisture level during drying is less than 0.2% or less than 0.03%. The PBBf pellets and the filler, such as glass fiber, carbon fiber, talc, or natural filler and / or other additives are melt-mixed at 220°C to 280°C or 230°C to 260°C. The components are fed together or separately along the extruder. Preferably, the filler is fed partially separately using a side feeder. Extrusion is performed using a twin-screw or single-screw extruder. The extruded composition is optionally pelletized and dried to obtain pellets for injection molding. The moisture content in the dry pellets is less than 0.2%, preferably less than 0.03%.

[0096] (Blend of PBF and PBBf) In this example, before extrusion, PBF and PBBf are air-dried or vacuum-dried at 80 °C to 120 °C for 4 to 8 hours. The moisture level during drying in both PBF and PBBf is less than 0.2% or less than 0.03%. PBF, PBBf, and the additive are fed together into an extruder and melt-mixed under shear to obtain a PBF / PBBf blend. Fillers and / or additives such as glass fiber, carbon fiber, talc, or natural fillers are added together with PBF and PBBf or separately along the extruder. The amount of PBF varies in the range of 1 to 99 wt%, or 1 to 20 wt% (e.g., 1 to 10 wt% or 10 to 20 wt%), or 20 to 40 wt% (e.g., 20 to 30 wt% or 30 to 40 wt%), or 40 to 60 wt% (e.g., 40 to 50 wt% or 50 to 60 wt%), or 60 to 80 wt% (e.g., 60 to 70 wt% or 70 to 80 wt%), or 80 to 99 wt% (80 to 90 wt% or 90 to 99 wt%). The composition of the filler varies in the range of 1 to 60 wt%. The extruder temperature ranges from 180 °C to 280 °C, and the preferred extruder temperature is determined by and set slightly higher than the melting temperature of the PBF / BBf blend, which depends on the PBF / PBBf mixing ratio in the BF / BBf copolyester or the BF to BBf ratio. Extrusion is carried out using a twin-screw or single-screw extruder. The screw speed of the extruder varies from 30 to 200 rpm or 100 rpm or less. The extruded composition is optionally pelletized and dried to obtain dry pellets for injection molding. The moisture content in the dry pellets is less than 0.2%, preferably less than 0.03%.

[0097] (Formulation of PBF / PBBf Blend or Copolymer of BF and BBf with Additive) The PBF / PBBf blend or the copolymer of BF and BBf can be compounded with various additives (e.g., fillers) as discussed in Examples II and V above. In this example, before extrusion, the PBF, PBBf, or the copolymer of BF and BBf is air-dried or vacuum-dried at 80°C to 120°C for 4 to 8 hours. The moisture level during drying is less than 0.2% or less than 0.03%. The polymer, copolymer, and / or one or more fillers such as glass fiber, carbon fiber, talc, natural fillers, and / or other additives are melt-mixed at 180°C to 280°C, and the preferred extruder temperature is determined by and set slightly higher than the melting temperature of the PBF / PBBf blend that depends on the PBF / PBBf mixing ratio or the BF to BBf ratio in the BF / BBf copolyester. The components are fed together or separately along the extruder. Preferably, the filler is fed separately using a side feeder. The extrusion is carried out using a twin-screw or single-screw extruder. The screw speed of the extruder varies from 30 to 200 rpm or 100 rpm or less. The extruded composition is optionally pelletized and dried to obtain dry pellets for injection molding. The moisture content in the dry pellets is less than 0.2% or less than 0.03%.

[0098] (Blend of PBF and PEF) In this example, before extrusion, PBF and PEF are air-dried or vacuum-dried at 80 °C to 120 °C for 4 to 8 hours. The moisture level during drying in both PBF and PEF is less than 0.2% or less than 0.03%. PBF, PEF, and additives are fed together into an extruder and melt-mixed under shear to obtain a PBF / PEF blend. Fillers and / or additives such as glass fiber, carbon fiber, talc, or natural fillers are added together with PBF and PEF or separately along the extruder. The amount of PBF varies in the range of 1 to 99 wt%, or 1 to 20 wt% (e.g., 1 to 10 wt% or 10 to 20 wt%), or 20 to 40 wt% (e.g., 20 to 30 wt% or 30 to 40 wt%), or 40 to 60 wt% (e.g., 40 to 50 wt% or 50 to 60 wt%), or 60 to 80 wt% (e.g., 60 to 70 wt% or 70 to 80 wt%), or 80 to 99 wt% (80 to 90 wt% or 90 to 99 wt%). The composition of the filler varies in the range of 1 to 60 wt%. The extruder temperature ranges from 180 °C to 280 °C, and the preferred extruder temperature is determined by and set slightly higher than the melting temperature of the PBF / PEF blend. Extrusion is carried out using a twin-screw or single-screw extruder. The screw speed of the extruder varies from 30 to 200 rpm or 100 rpm or less. The extruded composition is optionally pelletized and dried to obtain dried pellets for injection molding. The moisture content in the dried pellets is less than 0.2%, preferably less than 0.03%.

[0099] (Blending of PBF / PEF blend or copolymer of BF and EF with additives) The PBF / PEF blend or the copolymer of BF and EF can be compounded with various additives (e.g., fillers) as discussed in Examples (VIII) and (IX) above. In this example, before extrusion, the PBF, PEF, or the copolymer of BF and EF is air-dried or vacuum-dried at 80°C to 120°C for 4 to 8 hours. The moisture level during drying is less than 0.2% or less than 0.03%. The polymer, copolymer, and / or one or more fillers such as glass fibers, carbon fibers, talc, natural fillers, and / or other additives are melt-mixed at 180°C to 280°C, and the preferred extruder temperature is determined by and set slightly higher than the melting temperature of the PBF / PBBf blend that depends on the PBF / PEF mixing ratio or BF to EF ratio in the BF / EF copolymer. The components are fed together or separately along the extruder. Preferably, the filler is fed separately using a side feeder. Extrusion is performed using a twin-screw or single-screw extruder. The screw speed of the extruder varies from 30 to 200 rpm or 100 rpm or less. The extruded composition is optionally pelletized and dried to obtain dry pellets for injection molding. The moisture content in the dry pellets is less than 0.2% or less than 0.03%.

[0100] (Remarks) The above description and drawings are illustrative and should not be construed as limiting. Numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. However, well-known details may not be described in order to avoid obscuring the description. Further, various modifications can be made without departing from the scope of the embodiments.

[0101] The terms used herein generally have their ordinary meaning in the context of the present disclosure and in the particular context in which each term is used. It is understood that the same thing can be said in multiple ways. For example, "resin" is a form of "polymer", and it is recognized that these terms can be used interchangeably in some cases.

[0102] Unless otherwise indicated, the term "about" generally means an inclusion of a variation or range of ± 10%.

[0103] The use of examples anywhere in this specification, including examples of any terms discussed herein, is for illustrative purposes only and is not intended to further limit the scope or meaning of the disclosure or of any illustrative terms. Similarly, the disclosure is not limited to the various embodiments given in this specification.

Claims

1. An electrical connector, comprising: a housing containing one or more materials selected from the group consisting of a polymer of butylene 2,5-furandicarboxylate (PBF), a polymer of butylene bifuranate (PBBf), a copolymer of (i) butylene 2,5-furandicarboxylate (BF) and (ii) butylene bifuranate (BBf), a copolymer of (i) ethylene 2,5-furandicarboxylate (EF) and (ii) one or both of BF and BBf, and a copolymer of (i) butylene terephthalate (BT) and (ii) one or more of BF, BBf, and EF; and an electrical contact. The electrical connector according to claim 1, wherein the housing is configured as a female socket having a cavity for receiving the electrical contact.

2. The electrical connector according to claim 1, wherein the housing is configured as a male plug having a protruding member for receiving the electrical contact.

3. The electrical connector according to any one of claims 1 to 3, wherein the housing contains PBF.

4. The electrical connector according to any one of claims 1 to 3, wherein the housing contains PBBf.

5. The electrical connector according to any one of claims 1 to 3, wherein the housing contains a blend of PBF and PBBf or a copolymer of BF and BBf.

6. The electrical connector according to any one of claims 1 to 3, wherein the housing further contains poly(butylene terephthalate) (PBT).

7. The electrical connector according to any one of claims 1 to 3, wherein the housing contains a blend of PBT and PBF, a blend of PBT and PBBf, or a copolymer of BT and BF, a copolymer of BT or BBf, or a copolymer of BT, BF, and BBf.

8. The electrical connector according to any one of claims 1 to 3, wherein the housing contains poly(ethylene 2,5-furandicarboxylate) (PEF).

9. The electrical connector according to claim 9, wherein the housing contains a blend of PEF and PBF, a blend of PEF and PBBf, or a copolymer of EF and BF, a copolymer of EF and BBf, or a copolymer of EF, BF, and BBf.

10.

11. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ The electrical connector according to any one of claims 1 to 3, wherein the housing further comprises an additive selected from the group consisting of an antioxidant, an ultraviolet (UV) stabilizer, a flame retardant, a hydrolysis inhibitor, a coloring pigment, a discoloration additive for laser marking, a lubricant, a wax, a nucleating agent, and any combination thereof.

12. The electrical connector according to any one of claims 1 to 3, wherein the housing further comprises a reinforcing additive selected from the group consisting of glass fiber, carbon fiber, talc, cellulose, bamboo, softwood, hardwood, flax, kenaf, jute, ramie, coir, kapok, sisal, heneken, abaca, hemp, bagasse, wheat straw, rice husk, corn, sunn, and any combination thereof.

13. The electrical connector according to claim 12, wherein the housing comprises 1 to 60% by weight of the reinforcing additive.

14. A process for producing compounded pellets, comprising: (a) a polymer or copolymer containing one or more materials selected from the group consisting of a polymer of butylene 2,5-furandicarboxylate (PBF), a polymer of butylene bifuranate (PBBf), a copolymer of butylene 2,5-furandicarboxylate (BF) and butylene bifuranate (BBf), a copolymer of BF and ethylene 2,5-furandicarboxylate (EF), a copolymer of BBf and EF, or a copolymer of BF, BBf and EF, and a copolymer of butylene terephthalate (BT) and one or more of BF, BBf and EF ; and (b) melting a composition comprising a first additive including an antioxidant, an ultraviolet (UV) stabilizer, a flame retardant, a hydrolysis inhibitor, a coloring pigment, a discoloration additive for laser marking, a lubricant, a wax, a nucleating agent, or any combination thereof; extruding the melted composition to produce compounded pellets.

15. The process according to claim 14, wherein the composition further comprises a second additive selected from the group consisting of glass fiber, carbon fiber, talc, cellulose, bamboo, softwood, hardwood, flax, kenaf, jute, ramie, coir, kapok, sisal, heneken, abaca, hemp, bagasse, wheat straw, rice husk, corn, sunn, and any combination thereof.

16. The process according to claim 14, wherein the composition further comprises a polymer of butylene terephthalate (PBT). ​ ​ The process according to claim 14, further comprising the step of mixing PBT with the polymer or copolymer to form a blend of PBT and the polymer or copolymer before extruding the melted composition to produce the compounded pellets.

17. The composition contains PBF and PBBf, The process according to claim 14, further comprising the step of mixing PBF and PBBf to form a blend of PBF and PBBf before extruding the melted composition to produce the compounded pellets.

18. The composition contains a polymer of ethylene 2,5-furandicarboxylate (PEF), The process according to claim 14, further comprising mixing PEF with the polymer or copolymer to form a blend of PEF and the polymer or copolymer before extruding the melted composition to produce the compounded pellets.

19. A method of injection molding an electrical housing, comprising: a polymer of butylene 2,5-furandicarboxylate (PBF), a polymer of butylene bifuranate (PBBf), a copolymer of (i) butylene 2,5-furandicarboxylate (BF) and (ii) butylene bifuranate (BBf), a copolymer of (i) ethylene 2,5-furandicarboxylate (EF) and (ii) one or both of BF and BBf, a copolymer of (i) butylene terephthalate (BT) and (ii) one or more of BF, BBf, and EF, or any combination thereof obtaining one or more materials comprising; heating the one or more materials to a molten state; injecting the materials into a mold to form the electrical housing. A method comprising.

20. The one or more materials, a blend of PBF and PBBf, or a copolymer of BF and BBf The method according to claim 19, comprising.

21. The method according to claim 19, wherein the one or more materials further comprise poly(butylene terephthalate) (PBT).

22. The one or more materials, a blend of PBT and PBF, a blend of PBT and PBBf, or a copolymer of BT and BF, a copolymer of BT and BBf, or a copolymer of BT and BF and BBf The method according to claim 19, comprising.

23. The method according to claim 19, wherein the one or more materials further comprise poly(ethylene 2,5-furandicarboxylate) (PEF).

24. The one or more materials are a blend of PEF and PBF, a blend of PEF and PBBf, or a copolymer of EF and BF, a copolymer of EF and BBf, or a copolymer of EF and BF and BBf The method according to claim 19.

25. The one or more materials are a blend of PBT and PEF, a copolymer of BT and EF, or a copolymer of BT and EF and BF, a copolymer of BT and EF and BBf, or a copolymer of BT and EF and BF and BBf The method according to claim 19.

26. The method according to any one of claims 19 to 25, wherein the one or more materials further comprise additives corresponding to antioxidants, ultraviolet (UV) stabilizers, flame retardants, hydrolysis inhibitors, coloring pigments, discoloration additives for laser marking, lubricants, waxes, nucleating agents, or any combination thereof.

27. The method according to any one of claims 19 to 25, wherein the one or more materials further comprise reinforcing additives comprising glass fibers, carbon fibers, talc, cellulose, bamboo, softwood, hardwood, flax, kenaf, jute, ramie, coir, kapok, sisal, henequen, abaca, hemp, bagasse, straw, rice husk, corn, sunflower, or any combination thereof.

28. Before heating the one or more materials to a molten state, a step of melting PBF, PBBf, a blend of PBF and PBBf, or a copolymer of BF and BBf; and a step of extruding the melted PBF, PBBf, a blend of PBF and PBBf, or a copolymer of BF and BBf to produce compounded pellets The method according to any one of claims 19 to 27, further comprising.

29. The method according to any one of claims 19 to 27, further comprising a step of annealing the formed electrical housing at 60 °C or higher, thereby increasing the crystallinity of the electrical housing.

Images