Polyamide blends

Abstract

A polyamide blend includes PA 66 / 6T / X, wherein X is one or more optional comonomers; and an amorphous semi-aromatic polyamide polymer or copolymer including a monomer derived from one or more aromatic diacids.

Description

POLYAMIDE BLENDSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority to U.S. Provisional Patent Application Serial No. 63 / 562,272 filed Mar. 7, 2024, the disclosure of which is incorporated herein in its entirety by reference.BACKGROUND

[0002] The incorporation of flame-retardant (FR) additives into polyamide-based compositions is a conventional approach to improve the flame-retardant properties of the composition. Use of these FR additives usually adds significant cost to the composition and will typically diminish some important properties of final components from the composition, such as strength and impact resistance.

[0003] Retention of mechanical properties of articles and parts from polyamide-based compositions after extended exposure to air at elevated temperatures is difficult to achieve. Various antioxidant and heat stabilizer systems have been employed to improve heat-aging resistance, but some loss of properties after heat-aging at high temperatures is usually still observed. Depending upon the mechanical properties desired, such polyamide-based compositions may be unfilled or filled with reinforcing or non-reinforcing fillers. There is an interplay, however, between the effect of flame-retardant additives and fillers on the flameretardant properties of the composition and on the mechanical and processing properties of the composition. For example, some flame-retardant additives can cause mold deposits and tool corrosion during processing. As such, there is a need for filled or unfilled polyamide compositions that have both desired flame-retardant properties and acceptable processing properties, as well as suitable mechanical properties that are retained with heat-aging.SUMMARY OF THE INVENTION

[0004] Various aspects of the present invention provide a polyamide blend that includes PA 66 / 6T / X, wherein X is one or more optional comonomers. In various aspects, the X is not present in the PA 66 / 6T / X, and the PA 66 / 6T / X is PA 66 / 6T. In various aspects, the X is not present in the PA 66 / 6T / X, and the PA66 / 6T / X is free of comonomers other than adipic acid, terephthalic acid, and HMD. The polyamide blend also includes an amorphoussemi-aromatic polyamide polymer or copolymer including a monomer derived from one or more aromatic diacids.

[0005] Various aspects of the present invention provide a polyamide blend that includes PA 66 / 6T. The polyamide blend also includes an amorphous semi-aromatic polyamide polymer or copolymer including a monomer derived from one or more aromatic diacids.

[0006] Various aspects of the present invention provide a polyamide blend that includes PA 66 / 6T / X. The X is present in the PA 66 / 6T / X, and X is D (i.e., 2- methylpentane-l,5-diamine), I (i.e., isophthalic acid), a lactam (e.g., caprolactam), a diacid, a diamine, an amino acid, or a combination thereof. The PA 66 / 6T / X has a molar percentage of 66, 6T, and X of 50 mol% to 75 mol%, 25 mol% to 45 mol%, and 0.5 mol% to 10 mol%, respectively. The polyamide blend also includes PA 6I / 6T. The PA 6I / 6T has a molar percentage of 61 and 6T of 60 mol% to 80 mol% and 20 mol% to 40 mol%, respectively. The polyamide blend has a mass ratio of the PA 66 / 6T / X to the PA 6I / 6T of 0.1 : 1 to 10: 1.

[0007] Various aspects of the present invention provide a compounded polyamide composition that includes a polyamide blend that includes PA66 / 6T / X. The PA 66 / 6T / X has a molar percentage of 66, 6T, and X of 50 mol% to 75 mol%, 25 mol% to 45 mol%, and 0.5 mol% to 10 mol%, respectively. The polyamide blend also includes PA 6I / 6T. The PA 6I / 6T has a molar percentage of 61 and 6T of 60 mol% to 80 mol% and 20 mol% to 40 mol%, respectively. The polyamide blend has a mass ratio of the PA 66 / 6T / X to the PA 6I / 6T of 0.1 : 1 to 10: 1. The polyamide blend is 10 wt% to 90 wt% of the compounded polyamide composition. The compounded polyamide composition also includes one or more flame retardant additives, wherein the one or more flame retardant additives are 1 wt% to 20 wt% of the compounded polyamide composition.

[0008] Various aspects of the present invention provide a compounded polyamide composition that includes a polyamide blend that includes PA66 / 6T / X. The PA 66 / 6T / X has a molar percentage of 66, 6T, and X of 50 mol% to 75 mol%, 25 mol% to 45 mol%, and 0.5 mol% to 10 mol%, respectively. The polyamide blend also includes PA 6I / 6T. The PA 6I / 6T has a molar percentage of 61 and 6T of 60 mol% to 80 mol% and 20 mol% to 40 mol%, respectively. The polyamide blend has a mass ratio of the PA 66 / 6T / X to the PA 6I / 6T of 0.1 : 1 to 10: 1. The polyamide blend is 20 wt% to 80 wt% of the compounded polyamide composition. The compounded polyamide composition also includes one or more flame retardant additives, wherein the one or more flame retardant additives are 0.1 wt% to 30 wt%or 1 wt% to 20 wt% of the compounded polyamide composition. The compounded polyamide composition also includes glass fibers, wherein the glass fibers are 0.1 wt% to 70 wt% or 1 wt% to 40 wt% of the compounded polyamide composition.

[0009] Various aspects of the present invention provide a molded or extruded article that includes the polyamide blend or the compounded polyamide composition of the present invention.

[0010] Various aspects of the present invention provide a method of forming an article. The method includes extruding or molding the polyamide blend of the present invention to form the article including the polyamide blend.

[0011] Various aspects of the present invention provide a method of forming an article. The method includes extruding or molding the compounded polyamide composition of the present invention to form the article including the compounded polyamide composition.

[0012] Various aspects of the present invention have various advantages. For example, in various aspects, the polyamide blend and / or the compounded polyamide composition of the present invention can have better retention of mechanical properties after heat-aging, as compared to other flame-retardant polyamide compositions having similar flame-retardant properties. In various aspects, the polyamide blend and / or the compounded polyamide composition of the present invention can have better processability, as compared to other flame-retardant polyamide compositions having similar flame-retardant properties. In various aspects, the polyamide blend and / or the compounded polyamide composition of the present invention can have better dimensional stability and better retention of mechanical properties after moisture gain, as compared to other flame-retardant polyamide compositions having similar flame-retardant properties. In various aspects, the polyamide blend and / or the compounded polyamide composition of the present invention can have better CTI (Comparative Tracking Index, measured as per IEC 60112) and / or better resistance to other types of electrical breakdown tests, as compared to other flame-retardant polyamide compositions having similar flame-retardant properties.

[0013] In various aspects, the polyamide blend and / or the compounded polyamide composition of the present invention can achieve equivalent or better flame-retardant properties (e.g., as measured according to UL 94 using 0.40 mm or 0.71 mm thickness flame bars) using a lower weight percentage of flame-retardant additives as compared to other polyamide compositions having similar flame-retardant properties. In various aspects, alower weight percentage of flame-retardant additives can allow the polyamide blend and / or the compounded polyamide composition of the present invention to experience fewer deleterious effects of the flame-retardant additive. For example, in various aspects, a lower weight percentage of flame-retardant additive in the polyamide blend and / or the compounded polyamide composition of the present invention can result in better processability, better mechanical properties, better retention of mechanical properties after heat-aging, or a combination thereof, as compared to other polyamide compositions having a higher percentage of the flame-retardant additive.BRIEF DESCRIPTION OF THE FIGURES

[0014] The drawings illustrate generally, by way of example, but not by way of limitation, various aspects of the present invention.

[0015] FIG. 1 illustrates tensile strength (MPa) for dry-as-molded samples or after heat-aging at 190 °C for various times for Samples A-E and 1, in accordance with various aspects.

[0016] FIG. 2 illustrates unnotched Charpy impact strength at 23 °C (kJ / m2) for dry- as-molded samples or after heat-aging at 190 °C for various times for Samples A-E and 1, in accordance with various aspects.

[0017] FIG. 3 illustrates tensile strength (MPa) for dry-as-molded samples or after heat-aging at 190 °C for various times for Samples F-H and 2, in accordance with various aspects.

[0018] FIG. 4 illustrates unnotched Charpy impact strength at 23 °C (kJ / m2) for dry- as-molded Samples or after heat-aging at 190 °C for various times for Samples F-H and 2, in accordance with various aspects.

[0019] FIG. 5 illustrates tensile modulus (GPa) for dry-as-molded and conditioned Samples S-U and 7 containing 30% glass fibers and no FR additives.

[0020] FIG. 6 illustrates tensile strength (MPa) for dry-as-molded and conditioned Samples S-U and 7 containing 30% glass fibers and no FR additives.DETAILED DESCRIPTION OF THE INVENTION

[0021] Reference will now be made in detail to certain aspects of the disclosed subject matter. While the disclosed subject matter will be described in conjunction with the enumerated claims, it will be understood that the exemplified subject matter is not intended to limit the claims to the disclosed subject matter.

[0022] Throughout this document, values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “about 0.1% to about 5%” or “about 0.1% to 5%” should be interpreted to include not just about 0.1% to about 5%, but also the individual values (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement “about X to Y” has the same meaning as “about X to about Y,” unless indicated otherwise. Likewise, the statement “about X, Y, or about Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise.

[0023] In this document, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” or “at least one of A or B” has the same meaning as “A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed herein, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.

[0024] In the methods described herein, the acts can be carried out in a specific order as recited herein. Alternatively, in any aspect(s) disclosed herein, specific acts may be carried out in any order without departing from the principles of the invention, except when a temporal or operational sequence is explicitly recited. Furthermore, specified acts can be carried out concurrently unless explicit claim language recites that they be carried out separately or the plain meaning of the claims would require it. For example, a claimed act of doing X and a claimed act of doing Y can be conducted simultaneously within a single operation, and the resulting process will fall within the literal scope of the claimed process.

[0025] The term “about” as used herein can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range, and includes the exact stated value or range.

[0026] The term “substantially” as used herein refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more, or 100%. The term “substantially free of’ as used herein can mean having none or having a trivial amount of, such that the amount of material present does not affect the material properties of the composition including the material, such that about 0 wt% to about 5 wt% of the composition is the material, or about 0 wt% to about 1 wt%, or about 5 wt% or less, or less than, equal to, or greater than about 4.5 wt%, 4, 3.5, 3, 2.5, 2, 1.5, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0.01, or about 0.001 wt% or less, or about 0 wt%.

[0027] As used herein, the term “polymer” refers to a molecule having at least one repeating unit and can include copolymers.Polyamide blend.

[0028] Various aspects of the present invention provide a polyamide blend. The polyamide blend includes PA 66 / 6T / X, wherein X is one or more optional comonomers. The polyamide blend also includes an amorphous semi-aromatic polyamide polymer or copolymer including a monomer derived from one or more aromatic diacids.

[0029] The PA 66 / 6T / X is a random copolymer that can be formed from a solution of 1,6-hexam ethylenediamine (HMD), adipic acid (AA), T (terephthalic acid), and optionally from one or more other comonomers (X). The one or more other comonomers can be present in the PA 66 / 6T / X, or the one or more other comonomers can be absent from the PA 66 / 6T / X (i.e., the PA 66 / 6T / X can be PA 66 / 6T). For example, the PA 66 / 6T / X can be PA 66 / 6T / DI and can be formed from a solution of HMD, AA, T, D (2-methylpentane-l,5-diamine), and I (isophthalic acid). For example, the PA 66 / 6T / X can be PA 66 / 6T and can be formed from a solution of HMD, AA, and T. The PA 66 / 6T can be free of comonomers other than adipic acid, terephthalic acid, and HMD.

[0030] The 66 can be any suitable proportion of the PA 66 / 6T / X, such as 45 mol% to 95 mol% of the PA 66 / 6T / X, or 50 mol% to 75 mol%, or greater than or equal to 45 mol% and less than or equal to 95 mol% and less than, equal to, or greater than 50 mol%, 52, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 72, 74, 80, 85, or 90 mol%.

[0031] The 6T can be any suitable proportion of the PA 66 / 6T / X, such as 1 mol% to 50 mol% of the PA 66 / 6T / X, or 25 mol% to 45 mol%, or greater than or equal to 1 mol% and less than or equal to 50 mol% and less than, equal to, or greater than 5 mol%, 10, 15, 20, 25, 26, 28, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 42, 44, 46, or 48 mol%.

[0032] In various aspects, the X is not present in the PA 66 / 6T / X, and the PA 66 / 6T / X is PA 66 / 6T. In various aspects, the X is not present in the PA 66 / 6T / X, and the PA66 / 6T / X is free of comonomers other than adipic acid, terephthalic acid, and HMD. In various aspects, the X is present in the PA 66 / 6T / X, and the X is D (i.e., 2-methylpentane- 1,5-diamine), I (i.e., isophthalic acid), a lactam (e.g., caprolactam), a diacid, a diamine, an amino acid, or a combination thereof. The X can be DI. The PA 66 / 6T / X can be PA 66 / 6T / DI. The PA 66 / 6T / X can be PA 66 / 6T / DI, and the PA 66 / 6T / DI can be free of comonomers other than adipic acid, terephthalic acid, HMD, 2-methylpentane-l,5-diamine, and isophthalic acid (e.g., 0 mol% to less than 0.1 mol% of the PA 66 / 6T / DI can be comonomers other than adipic acid, terephthalic acid, HMD, 2-methylpentane-l,5-diamine, and isophthalic acid). The X can be any suitable proportion of the PA 66 / 6T / X, such as 0.1 mol% to 20 mol% of the PA 66 / 6T / X, or 0.5 mol% to 10 mol%, or greater than or equal to 0.1 mol% and less than or equal to 20 mol% and less than, equal to, or greater than 0.5 mol%, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 9, 10, 12, 14, 16, or 18 mol%.

[0033] The PA 66 / 6T / X can have a molar percentage of 66, 6T, and X of 45 mol% to 95 mol%, 1 mol% to 50 mol%, and 0.1 mol% to 20 mol%, respectively. The PA 66 / 6T / X can have a molar percentage of 66, 6T, and X of 50 mol% to 75 mol%, 25 mol% to 45 mol%, and 0.5 mol% to 10 mol%, respectively.

[0034] The PA 66 / 6T / X can be a semi-crystalline copolymer. The PA 66 / 6T / X can have any suitable level of amine end groups (AEG), such as an AEG of 30 meq / kg to 120 meq / kg, or 50 meq / kg to 90 meq / kg, or greater than or equal to 30 meq / kg and less than or equal to 120 meq / kg and less than, equal to, or greater than 35 meq / kg, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, or 115 meq / kg. The PA 66 / 6T / X can have an RV of 1.5 to 4, as measured as per ISO 307 with modification of using a 1 w / v% polymer solution in 96% sulfuric acid, or an RV of 1.8 to 3, or greater than or equal to 1.5 and less than or equal to 4 and less than, equal to, or greater than 1.6, 1.7, 1.8, 1.9, 2, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, or 3.9. The PA 66 / 6T / X can have a Tm, as measured according to ISO 11357 from the second heat cycle using a heating rate of 10 °C / min, of 250 °C to 310 °C, 260 °C to 290 °C, 265 °C to 285 °C, or less than or equal to 310°C and greater than or equal to 250 °C and less than, equal to, or greater than 252, 254, 256, 258, 260, 262, 264, 266, 268, 270, 271, 272, 273, 274, 275, 276, 277, 278, 279, 280, 282, 284, 286, 288, 290, 292, 294, 296, 298, 300, 302, 304, 306, or 308 °C.

[0035] The amorphous semi-aromatic polyamide polymer or copolymer can be any suitable amorphous semi-aromatic polyamide polymer (e.g., homopolymer) or copolymer. For example, the amorphous semi-aromatic polyamide polymer or copolymer can include PA 6I / 6T, PA 61, PA DT, PA DI, PA DT / DI, PA 6I / 6N (wherein N represents naphthalene dicarboxylic acid), or a combination thereof (e.g., a combination of such monomers thereof). The amorphous semi-aromatic polyamide polymer or copolymer can have an RV of 1.3 to 3, as measured as per ISO 307 with modification of using a 1 w / v% polymer solution in 96% sulfuric acid, or an RV of 1.5 to 2.5, or greater than or equal to 1.3 and less than or equal to 3 and less than, equal to, or greater than 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, or 2.9.

[0036] The amorphous semi-aromatic polyamide polymer or copolymer can be PA 6I / 6T. The PA 6I / 6T can be a random copolymer formed from a solution of HMD, I, and T. In aspects wherein the amorphous semi-aromatic polyamide polymer or copolymer is PA 6I / 6T, the 61 can be 60 mol% to 99.9 mol% of the PA 6I / 6T, or 60 mol% to 80 mol%, or greater than or equal to 60 mol% and less than or equal to 99.9 mol% and less than, equal to, or greater than 61 mol%, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 78, 80, 85, 90, or 95 mol%. The 6T can be 0.1 mol% to 40 mol% of the PA 6I / 6T, or 20 mol% to 40 mol% of the PA 6I / 6T, or 25 mol% to 35 mol% of the PA 6I / 6T, or greater than or equal to 0.1 mol% and less than or equal to 40 mol% and less than, equal to, or greater than 0.5 mol%, 1, 5, 10, 15, 16, 18, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, or 39 mol%. The PA 6I / 6T can have a molar percentage of 61 and 6T of 60 mol% to 99.9 mol% and 0.1 mol% to 40 mol%, respectively. The PA 6I / 6T can have a molar percentage of 61 and 6T of 60 mol% to 80 mol% and 20 mol% to 40 mol%, respectively. The PA 6I / 6T can be free of comonomers other than isophthalic acid, terephthalic acid, and HMD (e.g., comonomers other than isophthalic acid, terephthalic acid, and HMD can be 0 mol% to less than 0.1 mol% of the PA 6I / 6T).

[0037] The polyamide blend can have any suitable weight ratio of the PA 66 / 6T / X to the amorphous semi-aromatic polyamide copolymer, such as a weight ratio of the PA 66 / 6T / X to the amorphous semi-aromatic polyamide polymer or copolymer of 0.1 : 1 to 10: 1, or 2: 1 to 4: 1, or greater than or equal to 0.1 : 1 and less than or equal to 10: 1 and less than,equal to, or greater than 0.2:1, 0.4: 1, 0.6: 1, 0.8: 1, 1 : 1, 1.2: 1, 1.4: 1, 1.6: 1, 1.8: 1, 2: 1, 2.1 :1, 2.2: 1, 2.3: 1, 2.4: 1, 2.5: 1, 2.6: 1, 2.8: 1, 3: 1, 3.2: 1, 3.4: 1, 3.6: 1, 3.8: 1, 4: 1, 5: 1, 6: 1, 7: 1, 8: 1, or 9: 1.Compounded polyamide composition.

[0038] Various aspects of the present invention provide a compounded polyamide composition that includes the polyamide blend of the present invention, wherein the polyamide blend includes PA 66 / 6T / X and an amorphous semi-aromatic polyamide polymer or copolymer including a monomer derived from one or more aromatic diacids.

[0039] The polyamide blend can be any suitable proportion of the compounded polyamide composition, such as 10 wt% to 99 wt% of the compounded polyamide composition, or 35 wt% to 75 wt%, or 50 wt% to 60 wt%, or greater than or equal to 10 wt% and less than or equal to 99 wt% and less than, equal to, or greater than 15 wt%, 20, 25, 30, 35, 40, 45, 46, 48, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 62, 64, 65, 70, 75, 80, 85, 90, 95, 96, 98, or 99 wt%.

[0040] The compounded polyamide composition can be substantially free of glass fibers or reinforcing filler. Glass fibers or reinforcing filler can be 0 wt% to less than 0.1 wt% of the compounded polyamide composition. The compounded polyamide composition can include one or more reinforcing fillers. The reinforcing filler can be carbon (e.g., carbon fibers), glass (e.g., glass fibers), fibrous materials, an aramid fiber (e.g., Kevlar), cellulose, graphene, silicates, nanotubes, or a combination thereof. The reinforcing filler can be 0.1 wt% to 70 wt% of the compounded polyamide composition, or 20 wt% to 40 wt%, or greater than or equal to 0.1 wt% and less than or equal to 50 wt% and less than, equal to, or greater than 0.5 wt%, 1, 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, 62, 64, 66, or 68 wt%.

[0041] In various aspects, the reinforcing filler is glass fibers. The glass fibers can include one type of glass fibers or multiple types of glass fibers. The glass fibers can include soda-lime glass, fused silica glass, borosilicate glass, lead-oxide glass, aluminosilicate glass, oxide glass, glass with high zirconia content, or a combination thereof. The glass fibers can have a cross-sectional shape that is round, or can have a cross-sectional shape other than round, such as oval, rectangular, multilobal, or H- or I-shaped. The glass fibers can have any suitable dimensions. The glass fibers can have a length of about 0.1 mm to about 500 mm, about 0.1 mm to about 100 mm, about 0.5 mm to about 50 mm, about 1 mm to about 5 mm,or about 0.1 mm or less, or less than or equal to 500 mm and greater than or equal to 0.1 mm and less than, equal to, or greater than about 0.2 mm, 0.4, 0.6, 0.8, 1, 2, 3, 4, 5, 6, 8, 10, 12, 14, 16, 18, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 125, 150, 175, 200, 225, 250, or about 400 mm. The glass fibers can have a diameter (e.g., largest cross-sectional dimension) of about 0.1 microns to about 10 mm in diameter, about 0.001 mm to about 1 mm in diameter, about 5 microns to about 20 microns, or less than or equal to about 10 mm and greater than or equal to about 0.1 microns and or less than, equal to, or greater than about 1 micron, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 24, 26, 28, 30, 35, 40, 45, 50, 60, 70, 80, 90 microns, 0.1 mm, 0.2, 0.4, 0.6, 0.8, 1, 2, 3, 4, 5, 6, 7, 8, 9 mm, or about 10 mm or more.

[0042] The compounded polyamide composition can include one or more antioxidants. The antioxidant can be any suitable antioxidant. In some examples, the antioxidant includes a hindered-phenol antioxidant. In some examples, the antioxidant includes Irganox 1098, Irgafos 168, Irganox B 1171 (a 1 : 1 by weight blend of Irganox 1098 and Irgafos 168), or a combination thereof. The one or more antioxidants can be 0.01 wt% to 10 wt% of the compounded polyamide composition, or 0.1 wt% to 3 wt%, or greater than or equal to 0.01 wt% and less than or equal to 10 wt% and less than, equal to, or greater than 0.05 wt%, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, 8, or 9 wt%.

[0043] The compounded polyamide composition can include one or more flame retardant additives. The one or more flame retardant additives can include a halogencontaining flame-retardant additive, a phosphorus-containing flame-retardant additive, an inorganic flame-retardant additive, a nitrogen-containing flame-retardant additive, a boron- containing flame-retardant additive, a zinc-containing flame-retardant additive, a silicon- containing flame-retardant additive, a graphite-containing flame-retardant additive, or a combination thereof, and can optionally include one or more synergists. The one or more flame retardant additives can include a phosphorus-containing flame-retardant additive or a phosphorus-containing flame-retardant additive with one or more synergists. The one or more flame retardant additives can include an aluminum phosphinate flame retardant. The one or more flame retardant additives can be any suitable proportion of the compounded polyamide composition, such as 0.1 wt% to 30 wt% of the compounded polyamide composition, or 1 wt% to 20 wt%, or greater than or equal to 0.1 wt% and less than or equal to 30 wt% and less than, equal to, or greater than 0.5 wt%, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12,13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, or 29 wt%. The one or more flame retardant additives can be any suitable proportion of the compounded polyamide composition when measured excluding any reinforcing fillers present in the composition such as glass fibers, such as 0.1 wt% to 30 wt% of the compounded polyamide composition excluding reinforcing fillers, or 15 wt% to 25 wt%, or less than or equal to 30 wt% and greater than or equal to 0.1 wt% and less than, equal to, or greater than 0.5 wt%, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, or 29 wt%. In various aspects, the compounded polyamide composition can be substantially free of flame retardant additives, such as having a total amount of flame retardant additives that is 0 wt% to less than 0.1 wt% of the compounded flame retardant composition, or 0 wt% to 0.001 wt%, or less 0.1 wt% and greater than or equal to 0 wt% and less than, equal to, or greater than 0.0001 wt%, 0.0005, 0.001, 0.005, 0.01, or 0.05 wt%.

[0044] The one or more flame-retardant additives can be any suitable flame-retardant additives, such as halogen-containing flame-retardant additives, halogen-containing flameretardant additives with synergists, phosphorus-containing flame-retardant additives, phosphorus-containing flame-retardant additives with one or more synergists, inorganic flame-retardant additives, nitrogen-containing flame-retardant additives, nitrogen- containing flame-retardant additives with synergists, or a combination thereof. The flame-retardant additive can optionally include one or more synergists. A particular flame-retardant additive can be added neat or can be available as or formed into a blend with a polyamide (e.g., a masterbatch) prior to combining with the polyamide in the compounded polyamide composition. In some aspects, the one or more flame retardants can be chosen from Melapur™ MC25, Mastertek® 374115, Exolit® OP 1400, Exolit® OP 1314, Exolit® OP 1230, Exolit® OP 945, Preniphor™ EPFR-MPP300, SAYTEX® HP 7010, Campine PA 261717, Firebrake® 500, or a combination thereof. The one or more flame retardants can be chosen from melamine cyanurate, aluminum diethylphosphinate, melamine polyphosphate, bromopolystyrene, antimony trioxide, dehydrated zinc borate, and a combination thereof, optionally including one or more synergists.

[0045] Broad classes of flame-retardant additives can include, for example: halogencontaining flame-retardant additives, halogen-containing flame-retardant additives with synergists, phosphorus-containing flame-retardant additives, inorganic flame-retardant additives, nitrogen-containing flame-retardant additives, nitrogen-containing flame-retardant additives with synergists; these may be used alone or in combination. Plastics AdditiveHandbook, 5thEd., Ed Hans Zweifel, Hanser, 2000, ISBN 1-56990-295-X, Chapter 12 speaks to the general topic of flame-retardant additives in polyamides and in Table 12.1 p 688 exemplifies typical flame-retardant additives and the levels of various flame-retardant additives used in polyamides. Plastic Additives, 4thEd., ed R Gachter and H Muller, Hanser, 1993, ISBN 3-446-17571-7, Chapter 12 speaks to the general topic and in Table 7 p. 739 exemplifies flame-retardant additives and the levels of flame-retardant additives used in polyamides. Flame-retardant additives for Plastics and Textiles Practical Applications, Ed Edward D. Weil, Sergei V. Levchik, 2nd Edition, Hanser 2016, ISBN: 978-1-56990-578-4, Chapter 5, p. 117 speaks to the topic of flame-retardant additives and exemplifies flameretardant additives and the levels of flame-retardant additives used in polyamides throughout. Manufacturers and providers of flame-retardant additives will often supply guidance on effective formulations, for instance, ICL Industrial Products Ltd produces such a guidance sheet for polyamides: Flame-retardant additives for Polyamides (General Application Data on Flame-Retardant Additives for Polyamides 6 and 6,6).

[0046] Halogen-containing flame-retardant additives can include: brominated polystyrene; poly(dibromostyrene); poly(pentabromobenzylacrylate); brominated polyacrylate; brominated epoxy polymer; epoxy polymers derived from tetrabromobisphenol A and epichlorohydrin; ethylene l,2-bis(pentabromophenyl); Dechlorane plus; chlorinated polyethylene; or mixtures thereof.

[0047] Synergists, such as for use with halogen-containing flame-retardant additives, can include antimony (III) oxide, antimony (V) oxide, sodium antimonate; iron (II) oxide, iron (II / III) oxide, iron (III) oxide, zinc borate, zinc phosphate, zinc stannate, or mixtures thereof.

[0048] Phosphorus-containing flame-retardant additives can include red phosphorus, ammonium polyphosphate, melamine polyphosphate, melamine pyrophosphate, metal dialkylphosphinates (such as aluminum methylethylphosphinate, and aluminum diethylphosphinate), aluminum hypophosphite, or mixtures thereof, with or without the presence of various synergists.

[0049] Inorganic flame-retardant additives can include magnesium hydroxide, alumina monohydrate, alumina trihydrate, aluminum hydroxide, or mixtures thereof. Nitrogen-containing flame-retardant additives can include melamine cyanurate, melamine polyphosphate, melamine pyrophosphate, melamine, melan, or mixtures thereof. Nitrogencontaining flame-retardant additives with synergists can include nitrogen-containing flame-retardant additives together with a synergist, such as but not limited to Novolac resins (e.g., phenol-formaldehyde resins with a formaldehyde to phenol molar ratio of less than one).

[0050] The compounded polyamide composition can include any one or more suitable additives. For example, the other additives can include fillers such as talc, mica, clay, silica, alumina, carbon black, natural fiber, wood flour, wood fibers, non-wood plant fibers, sawdust, wood shavings, newsprint, paper, flax, hemp, wheat straw, rice hulls, kenaf, jute, sisal, peanut shells, soy hulls, or combinations thereof. The composition can include one or more catalysts, acid generators, solvents, compatibilizers, crosslinkers, anti-blocking agents, coupling agents, fillers, heat stabilizers, light stabilizers, antioxidants, impact modifiers, tackifiers, flame retardants, plasticizers, blowing agents, colorants, dyes, fragrances, foaming additives, processing aids, lubricants, adhesion promoters, biocides, antimicrobial additives, or combinations thereof. Non-limiting examples of optional additives include anti-fogging agents, anti-static agents, anti-oxidants, bonding, blowing and foaming agents, dispersants, extenders, smoke suppressants, impact modifiers, initiators, nucleants, pigments, colorants and dyes, optical brighteners, plasticizers, processing aids, release agents, silanes, titanates and zirconates, slip agents, anti -blocking agents, stabilizers, stearates, ultraviolet light absorbers, waxes, catalyst deactivators, or combinations thereof.

[0051] In various aspects, 0.40 mm thickness flame bars of the compounded polyamide composition subjected to a UL 94 flammability test achieve a vertical flame rating (e.g., a conditioned vertical flame rating and / or a dried vertical flame rating) of V-0, V-l, or V-2. In various aspects, 0.71 mm thickness flame bars of the compounded polyamide composition subjected to a UL 94 flammability test achieve a vertical flame rating (e.g., a conditioned vertical flame rating and / or a dried vertical flame rating) of V-0, V-l, or V-2. In various aspects, flame bars of the compounded polyamide composition (e.g., conditioned or dried flame bars) having a thickness of 0.4 mm, 0.71 mm, 1.5 mm, or 3.0 mm subjected to a UL 94 flammability test achieve a classification of V-0, V-l, V-2 in a 50 W Vertical Burning Test. In various aspects, flame bars of the compounded polyamide composition (e.g., conditioned or dried flame bars) having a thickness of 0.4 mm, 0.71 mm, 1.5 mm, or 3.0 mm subjected to a UL 94 flammability test achieve a classification of 5VA or 5VB in a 500 W Vertical Burning Test.

[0052] In various aspects, the compounded polyamide composition can retain various mechanical properties after heat-aging. For example, heat-aged specimens of the compounded polyamide composition (e.g., aged at 190 °C for 504 h, 1008 h, or 1512 h) canhave a tensile strength, as measured per ISO 527 using ISO Type 1 A tensile bars, that is at least 55% to 80% of that of the corresponding dry-as-molded specimens, or 50% to 90%, or 60% to 67%, or greater than or equal to 55% and less than or equal to 80% and less than, equal to, or greater than 56%, 58, 60, 61, 62, 63, 64, 65, 66, 67, 68, 70, 72, 74, 76, 78, 80, 82,84, 86, or 88%. Heat-aged specimens of the compounded polyamide composition (e.g., aged at 190 °C for 504 h, 1008 h, or 1512 h) can have an unnotched Charpy impact energy at 23 °C, as measured per ISO 179 using ISO Type 1 impact bars, that is at least 10% to 50% of that of the corresponding dry-as-molded specimens, or 15% to 30%, or 19% to 25%, or greater than or equal to 10% and less than or equal to 50% and less than, equal to, or greater than 12%, 14, 16, 18, 19, 20, 21, 22, 23, 24, 25, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, or 48%. Heat-aged specimens of the compounded polyamide composition (e.g., aged at 190 °C for 504 h, 1008 h, or 1512 h) can have a tensile strain at break, as measured per ISO 527 using ISO Type 1 A tensile bars, is 70% to 100% of the corresponding dry-as-molded specimens, or 80% to 90%, or 80% to 85%, or less than or equal to 100% and greater than or equal to 70% and less than, equal to, or greater than 72%, 74, 76, 78, 79, 80, 81, 82, 83, 84,85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, or 99%.

[0053] In various aspects, the compounded polyamide composition can retain various mechanical properties after conditioning. For example, conditioned samples of the compounded polyamide composition (e.g., conditioned according to the ISO 1110 procedure, holding in a humidity chamber at 70 °C in a 62% relative humidity atmosphere and allowing specimens to gain moisture until they reach consistent mass) can have a tensile modulus, as measured per ISO 527 using ISO Type 1 A tensile bars, that is 90% to 100% of that of the corresponding dry-as-molded specimens, or 95% to 100%, or 97% to 99%, or less than or equal to 100% and greater than or equal to 90% and less than, equal to, or greater than 91%, 92, 93, 94, 95, 96, 97, 98, or 99%. Conditioned samples of the compounded polyamide composition (e.g., conditioned according to the ISO 1110 procedure) can have a tensile strength, as measured per ISO 527 using ISO Type 1 A tensile bars, that is 75% to 100% of that of the corresponding dry-as-molded specimens, or 80% to 95%, or 85% to 90%, or less than or equal to 100% and greater than or equal to 75% and less than, equal to, or greater than 76%, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, or 99%. Conditioned samples of the compounded polyamide composition (e.g., conditioned according to the ISO 1110 procedure) can have a tensile strain at break, as measured per ISO 527 using ISO Type 1 A tensile bars, that is 100% to 120% of that of the corresponding dry-as-molded specimens, or 105% to 120%, or 110% to 115%, or less than or equal to 120% and greater than or equal to 100% and less than, equal to, or greater than 101%, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, or 119%.Article.

[0054] Various aspects of the present invention provide an article that includes the polyamide blend of the present invention or the compounded polyamide composition of the present invention that includes the polyamide blend, wherein the polyamide blend includes PA 66 / 6T / X and an amorphous semi-aromatic polyamide polymer or copolymer including a monomer derived from one or more aromatic diacids. The article can be any suitable article. The article can be a molded or extruded article formed by molding or extruding the polyamide blend or the compounded polyamide composition.

[0055] The article can be any suitable article. For example, the article can be for use with communication devices, electronics, electric power systems, or a combination thereof. For example, the article can be for use with stationary electrics installations, such as poles, buildings, roof-tops, and the like, or moving installations, such as vehicles, aircrafts, bicycles, boats, wearables, cellular phones, and the like. The article can be for use with a radio, AC / DC rectifiers or remote powering units, fiber connectivity enclosures, radio-frequency combiners or diplexers, alarm systems and intrusion systems, AC and DC power distribution panels, radio antennas, radio receivers, electric vehicle battery housings, high-voltage connectors, or a combination thereof.Method of forming an article.

[0056] Various aspects of the present invention provide a method of forming an article. The method can include extruding or molding the polyamide blend of the present invention, wherein the polyamide blend includes PA 66 / 6T / X and an amorphous semiaromatic polyamide polymer or copolymer including a monomer derived from one or more aromatic diacids. The extruding or molding forms the article. The article includes the polyamide blend.

[0057] Various aspects of the present invention provide a method of forming an article. The method can include extruding or molding the compounded polyamide composition that includes the polyamide blend of the present invention. The extruding or molding forms the article. The article includes the compounded polyamide composition.Examples

[0058] Various aspects of the present invention can be better understood by reference to the following Examples which are offered by way of illustration. The present invention is not limited to the Examples given herein.

[0059] In the present Examples, the PA 66 / 6T / X copolymer was PA 66 / 6T / DI copolymer having a molar ratio of 66:6T:DI of 63:35:2. Aqueous salt solutions of nylon 66 salt (adipic acid and HMD), nylon 6T salt (terephthalic acid and HMD), and nylon DI salt (2- methyl-l,5-pentanediamine and isophthalic acid) were each prepared separately, with the diacid and diamine components in equimolar amounts in each case. The PA 66 / 6T / DI copolymer was formed by combining the appropriate quantities of nylon 66 salt solution, nylon 6T salt solution, and nylon DI salt solution. Acetic acid was added to form stabilized ends and assist in control of final polymer molecular weight. Sodium hypophosphite was added to provide catalysis of polyamidation. The combined aqueous solution was heated, and water was removed, to form the PA 66 / 6T / DI, which had an RV of 2.37 and a Tm of 275°C. The PA 66 / 6T / DI was a semi-crystalline copolymer. The RV was determined using 96 wt% sulfuric acid as solvent following ISO 307 except the solution concentration was 1.0 g polymer per 100 mL polymer solution.

[0060] The PA 6I / 6T used in the Examples was EMS Grivory® G21 PA 6I / 6T, an amorphous random copolymer. The PA 6I / 6T has an RV of about 2.0.

[0061] The PA 66 / 6T used in the Examples was a 75:25 (molar) copolymer of the components 66:6T. 6T is a polymer made from terephthalic acid and HMD. The salt mixture at the start of polymerization to form the PA 66 / 6T was 75 mol% 66 salt and 25 mol% 6T salt. The final PA 66 / 6T polymer was a random copolymer with 75 mol% of diacid units from adipic acid and 25 mol% of diacid units from terephthalic acid. The Viscosity Number (VN) was determined to be about 95 mL / g using 90 wt.% formic acid as solvent and following the method of ISO 307.

[0062] The Example compositions contained 0, 12, 14, or 16 wt% of Exolit® OP 1400, an aluminum phosphinate flame retardant also containing a synergist. The Example compositions were compounded with 0.17 to 0.45 wt% Irganox 1098 hindered-phenol antioxidant and 0.15 to 0.20 wt% Irgafos 168 phosphite. The Example compositions contained 30 wt% NEG ChopVantage® HP 3610 glass fibers, which were added to compounding process via a side feeder. The PA66 used in comparative Examples A, C, F, H,J, M, N, R, S, and U was PA66 feedstock resin, labeled as “U4591”, having an RV of 45 in formic acid (measured per ASTM D789) and having an amine end groups (AEG) level of 88 meq / kg. The PA66 used in comparative Examples D and E was PA66 feedstock resin, labeled as “U4800”, having an RV of 48 in formic acid and an AEG level of 50 meq / kg.

[0063] The test methods used in the present Examples included UL 94 standard methods for flame retardancy rating using 0.40 mm and 0.71 mm thickness UL 94 flammability bars. Heat-aging results are given after 1512 h at 190 °C. Tensile testing was performed as per ISO 527 using ISO Type 1 A tensile bars. Charpy impact testing was performed as per ISO 179 using ISO Type 1 impact bars.

[0064] Solution viscosities of aromatic diacid-containing polymers, such as for PA 66 / 6T and PA 66 / 6T / X copolymers, were determined and expressed as Viscosity Number (VN) as per ISO 307 using 90% formic acid as solvent, or as Relative Viscosity (RV) as per ISO 307 with the modification of using a 1 w / v% polymer solution (1.0 g polymer per 100 mL polymer solution) using a solvent of 96% sulfuric acid. RV of PA66 homopolymers was determined as per ASTM D789 using 90% formic acid as solvent. Amine end groups (AEG) were determined by titration of a polymer solution in a phenol / methanol mixture (80:20 w / w) with 0.05 M perchloric acid in propanol; the end point was determined potentiometrically and AEG values are expressed in equivalent units of milliequivalents / kg of polymer (meq / kg). Melting points (Tm) were determined according to ISO 11357 from the second heat cycle using a heating rate of 10 °C / min.

[0065] Unless otherwise stated, all percentage values given in the Tables of the Examples are wt%.

[0066] Table 1 illustrates comparative compositions A-U and Example compositions 1-7, which were compounded on a 26 mm twin-screw extruder or a 28 mm twin-screw extruder. The Example compositions were compounded with 0.17 to 0.45 wt% Irganox 1098 hindered-phenol antioxidant and 0.15 to 0.20 wt% Irgafos 168 phosphite, and also contained 30 wt% short glass fibers. The PA 66 / 6T / X was PA 66 / 6T / DI.

[0067] Table 1. Comparative compositions A-U and Example compositions 1-7. “FR” was Exolit® OP 1400.

[0068] Table 2 illustrates UL 94 flammability test results for Samples A-R and 1-6 using 0.71 mm thickness flame bars, which were conditioned at 23 °C at 50% relative humidity for 48 h.

[0069] Table 2. UL 94 Flammability test results for Samples A-R and 1-6 with 0.71 mm thickness flame bars conditioned at 23 °C at 50% RH for 48 h. “FR” was Exolit® OP 1400.

[0070] Table 3 illustrates UL 94 flammability test results for Samples A-R and 1-6 using 0.40 mm thickness flame bars, which were conditioned at 23 °C at 50% relative humidity for 48 h.

[0071] Table 3. UL 94 Flammability test results for Samples A-H and 1-2 with 0.40 mm thickness flame bars conditioned at 23 °C at 50% RH for 48 h. “FR” was Exolit® OP 1400.

[0072] Table 4A illustrates UL 94 flammability test results for Samples J-R and 3-6 using 0.71 mm thickness flame bars, which were dried at 70 °C for 168 h.

[0073] Table 4A. UL 94 Flammability test results for Samples J-R and 3-6 with 0.71 mm thickness flame bars dried at 70 °C for 168 h. “FR” was Exolit® OP 1400.

[0074] Table 4B illustrates UL 94 flammability test results for Samples J-R and 3-6 using 0.40 mm thickness flame bars, which were dried at 70 °C for 168 h.

[0075] Table 4B. UL 94 Flammability test results for Samples J-R and 3-6 with 0.40 mm thickness flame bars dried at 70 °C for 168 h. “FR” was Exolit® OP 1400.

[0076] Tables 5 A and 5B illustrate mechanical properties for Samples A-H and 1-2, as measured for Dry -As-Molded (DAM) specimens and after heat-aging at 190 °C.

[0077] Table 5 A. Tensile modulus and tensile strength for Samples A-H and 1-2, as measured for Dry- As-Molded (DAM) specimens and after heat-aging at 190 °C.

[0078] Table 5B. Tensile strain at break and unnotched Charpy impact strength for Samples A-H and 1-2, as measured for Dry- As-Molded (DAM) specimens and after heataging at 190 °C.

[0079] Table 6 illustrates mechanical properties for Samples S-U and Sample 7, as measured for Dry-As-Molded (DAM) specimens and specimens which were conditioned according to the ISO 1110 procedure. The ISO 1110 standard procedure is to hold in a humidity chamber at 70 °C in a 62% relative humidity atmosphere, allowing specimens to gain moisture until they reach consistent mass (equilibrium moisture level vs. the atmosphere). For polyamides, this is equivalent (or at least very similar) to the equilibrium moisture level that specimens would reach at 23 °C in a 50% relative humidity atmosphere, given sufficient time to reach equilibrium.

[0080] Table 6. Mechanical Properties for Samples S-U and 7.

[0081] The Samples shown in Table 6 were made without any FR additive. It is observed that tensile modulus as well as tensile strength retention were surprisingly improved for the conditioned Sample 7.

[0082] FIG. 1 illustrates tensile strength (MPa) for dry-as-molded samples or after heat-aging at 190 °C for various times for Samples A-E and 1. FIG. 2 illustrates unnotched Charpy impact strength at 23 °C (kJ / m2) for dry-as-molded Samples or after heat-aging at 190 °C for various times for Samples A-E and 1. FIG. 3 illustrates tensile strength (MPa) for dry-as-molded Samples or after heat-aging at 190 °C for various times for Samples F-H and 2. FIG. 4 illustrates unnotched Charpy impact strength at 23 °C (kJ / m2) for dry-as-molded Samples or after heat-aging at 190 °C for various times for Samples F-H and 2. FIG. 5 illustrates Tensile Modulus (GPa) for dry-as-molded and conditioned Samples S-U and 7, and FIG. 6 illustrates Tensile Strength (MPa) for dry-as-molded and conditioned Samples S-U and 7. Samples S-U and 7 contained 30% glass fibers and no FR additive.

[0083] The unexpected retention of tensile modulus and tensile strength properties for the PA66 / 6T / X + 6I / 6T Samples was observed. These Samples contained 30% glass fibers and no FR additive.

[0084] The terms and expressions that have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the aspects of the present invention. Thus, it should be understood that although the present invention has been specifically disclosed by specific aspects and optional features, modification and variation of the concepts herein disclosed may be resorted to by those of ordinary skill in the art, and that such modifications and variations are considered to be within the scope of aspects of the present invention.Exemplary Aspects.

[0085] The following exemplary aspects are provided, the numbering of which is not to be construed as designating levels of importance:

[0086] Aspect 1 provides a polyamide blend comprising:PA 66 / 6T / X, wherein X is one or more optional comonomers; and an amorphous semi-aromatic polyamide polymer or copolymer comprising a monomer derived from one or more aromatic diacids.

[0087] Aspect 2 provides the polyamide blend of Aspect 1, wherein the amorphous semi-aromatic polyamide polymer or copolymer comprises PA 6I / 6T, PA 61, PA DT, PA DI, PA DT / DI, PA 6I / 6N, or a combination thereof.

[0088] Aspect 3 provides the polyamide blend of any one of Aspects 1-2, wherein the amorphous semi-aromatic polyamide polymer or copolymer is PA 6V6T.

[0089] Aspect 4 provides the polyamide blend of any one of Aspects 1-3, wherein the 66 is 45 mol% to 95 mol% of the PA 66 / 6T / X.

[0090] Aspect 5 provides the polyamide blend of any one of Aspects 1-4, wherein the 66 is 50 mol% to 75 mol% of the PA 66 / 6T / X.

[0091] Aspect 6 provides the polyamide blend of any one of Aspects 1-5, wherein the 6T is 1 mol% to 50 mol% of the PA 66 / 6T / X.

[0092] Aspect 7 provides the polyamide blend of any one of Aspects 1-6, wherein the 6T is 25 mol% to 45 mol% of the PA 66 / 6T / X.

[0093] Aspect 8 provides the polyamide blend of any one of Aspects 1-7, wherein the X is not present in the PA 66 / 6T / X, and wherein the PA 66 / 6T / X is PA 66 / 6T.

[0094] Aspect 9 provides the polyamide blend of any one of Aspects 1-8, wherein the X is not present in the PA 66 / 6T / X, and wherein the PA66 / 6T / X is free of comonomers other than adipic acid, terephthalic acid, and HMD.

[0095] Aspect 10 provides the polyamide blend of any one of Aspects 1-9, wherein the X is present in the PA 66 / 6T / X, and wherein X is D (i.e., 2-methylpentane-l,5-diamine), I (i.e., isophthalic acid), a lactam (e.g., caprolactam), a diacid, a diamine, an amino acid, or a combination thereof.

[0096] Aspect 11 provides the polyamide blend of any one of Aspects 1-10, wherein the X is present in the PA 66 / 6T / X, and wherein the X is DI.

[0097] Aspect 12 provides the polyamide blend of any one of Aspects 1-11, wherein the PA 66 / 6T / X is PA 66 / 6T / DI.

[0098] Aspect 13 provides the polyamide blend of any one of Aspects 1-12, wherein the PA 66 / 6T / X is PA 66 / 6T / DI, and wherein the PA 66 / 6T / DI is free of comonomers other than adipic acid, terephthalic acid, HMD, 2-methylpentane-l,5-diamine, and isophthalic acid.

[0099] Aspect 14 provides the polyamide blend of any one of Aspects 1-13, wherein X is 0.1 mol% to 20 mol% of the PA 66 / 6T / X.

[0100] Aspect 15 provides the polyamide blend of any one of Aspects 1-14, wherein X is 0.5 mol% to 10 mol% of the PA 66 / 6T / X.

[0101] Aspect 16 provides the polyamide blend of any one of Aspects 1-15, wherein the PA 66 / 6T / X has a molar percentage of 66, 6T, and X of 45 mol% to 95 mol%, 1 mol% to 50 mol%, and 0.1 mol% to 20 mol%, respectively.

[0102] Aspect 17 provides the polyamide blend of any one of Aspects 1-16, wherein the PA 66 / 6T / X has a molar percentage of 66, 6T, and X of 50 mol% to 75 mol%, 25 mol% to 45 mol%, and 0.5 mol% to 10 mol%, respectively.

[0103] Aspect 18 provides the polyamide blend of any one of Aspects 1-17, wherein the PA 66 / 6T / X is a semi-crystalline copolymer.

[0104] Aspect 19 provides the polyamide blend of any one of Aspects 1-18, wherein the PA 66 / 6T / X has a level of amine end groups (AEG) of 30 meq / kg to 120 meq / kg.

[0105] Aspect 20 provides the polyamide blend of any one of Aspects 1-19, wherein the PA 66 / 6T / X has a level of amine end groups (AEG) of 50 meq / kg to 90 meq / kg.

[0106] Aspect 21 provides the polyamide blend of any one of Aspects 1-20, wherein the PA 66 / 6T / X has an RV of 1.5 to 4.

[0107] Aspect 22 provides the polyamide blend of any one of Aspects 1-21, wherein the PA 66 / 6T / X has an RV of 1.8 to 3.

[0108] Aspect 23 provides the polyamide blend of any one of Aspects 3-22, wherein the 61 is 60 mol% to 99.9 mol% of the PA 6I / 6T.

[0109] Aspect 24 provides the polyamide blend of any one of Aspects 3-23, wherein the 61 is 60 mol% to 80 mol% of the PA 6I / 6T.

[0110] Aspect 25 provides the polyamide blend of any one of Aspects 3-24, wherein the 6T is 0.1 mol% to 40 mol% of the PA 6I / 6T.

[0111] Aspect 26 provides the polyamide blend of any one of Aspects 3-25, wherein the 6T is 20 mol% to 40 mol% of the PA 6I / 6T.

[0112] Aspect 27 provides the polyamide blend of any one of Aspects 3-26, wherein the PA 6I / 6T has a molar percentage of 61 and 6T of 60 mol% to 99.9 mol% and 0.1 mol% to 40 mol%, respectively.

[0113] Aspect 28 provides the polyamide blend of any one of Aspects 3-27, wherein the PA 6I / 6T has a molar percentage of 61 and 6T of 60 mol% to 80 mol% and 20 mol% to 40 mol%, respectively.

[0114] Aspect 29 provides the polyamide blend of any one of Aspects 3-28, wherein the PA 6I / 6T is free of comonomers other than isophthalic acid, terephthalic acid, and HMD.

[0115] Aspect 30 provides the polyamide blend of any one of Aspects 1-29, wherein the amorphous semi-aromatic polyamide polymer or copolymer has an RV of 1.3 to 3.

[0116] Aspect 31 provides the polyamide blend of any one of Aspects 1-30, wherein the amorphous semi-aromatic polyamide polymer or copolymer has an RV of 1.5 to 2.5.

[0117] Aspect 32 provides the polyamide blend of any one of Aspects 1-31, wherein the polyamide blend has a weight ratio of the PA 66 / 6T / X to the amorphous semi-aromatic polyamide polymer or copolymer of 0.1 : 1 to 10: 1.

[0118] Aspect 33 provides the polyamide blend of any one of Aspects 1-32, wherein the polyamide blend has a weight ratio of the PA 66 / 6T / X to the amorphous semi-aromatic polyamide polymer or copolymer of 2: 1 to 4: 1.

[0119] Aspect 34 provides a polyamide blend comprising:PA 66 / 6T / DI, wherein the PA 66 / 6T / DI has a molar percentage of 66, 6T, and DI of 50 mol% to 75 mol%, 25 mol% to 45 mol%, and 0.5 mol% to 10 mol%, respectively; andPA 6I / 6T, wherein the PA 6I / 6T has a molar percentage of 61 and 6T of 60 mol% to 80 mol% and 20 mol% to 40 mol%, respectively;wherein the polyamide blend has a mass ratio of the PA 66 / 6T / DI to the PA 6I / 6T of 0.1 : 1 to 10: 1.

[0120] Aspect 35 provides a compounded polyamide composition comprising the polyamide blend of any one of Aspects 1-34.

[0121] Aspect 36 provides the compounded polyamide composition of Aspect 35, wherein the polyamide blend is 10 wt% to 99 wt% of the compounded polyamide composition.

[0122] Aspect 37 provides the compounded polyamide composition of any one of Aspects 35-36, wherein the polyamide blend is 35 wt% to 75 wt% of the compounded polyamide composition.

[0123] Aspect 38 provides the compounded polyamide composition of any one of Aspects 35-37, wherein the compounded polyamide composition further comprises a reinforcing filler.

[0124] Aspect 39 provides the compounded polyamide composition of Aspect 38, wherein the reinforcing filler is carbon (e.g., carbon fibers), glass (e.g., glass fibers), fibrous materials, an aramid fiber (e.g., Kevlar), cellulose, graphene, silicates, nanotubes, or a combination thereof.

[0125] Aspect 40 provides the compounded polyamide composition of any one of Aspects 38-39, wherein the reinforcing filler is glass fibers.

[0126] Aspect 41 provides the compounded polyamide composition of Aspect 40, wherein the glass fibers comprise soda-lime glass, fused silica glass, borosilicate glass, leadoxide glass, aluminosilicate glass, oxide glass, glass with high zirconia content, or a combination thereof.

[0127] Aspect 42 provides the compounded polyamide composition of any one of Aspects 38-41, wherein the reinforcing filler is 0.1 wt% to 70 wt% of the compounded polyamide composition.

[0128] Aspect 43 provides the compounded polyamide composition of any one of Aspects 38-42, wherein the reinforcing filler is 20 wt% to 40 wt% of the compounded polyamide composition.

[0129] Aspect 44 provides the compounded polyamide composition of any one of Aspects 35-37, wherein the compounded polyamide composition is substantially free of glass fibers or reinforcing filler.

[0130] Aspect 45 provides the compounded polyamide composition of any one of Aspects 35-37, wherein glass fibers or reinforcing filler is 0 wt% to less than 0.1 wt% of the compounded polyamide composition.

[0131] Aspect 46 provides the compounded polyamide composition of any one of Aspects 35-45, wherein the compounded polyamide composition further comprises one or more antioxidants.

[0132] Aspect 47 provides the compounded polyamide composition of Aspect 46, wherein the one or more antioxidants are 0.01 wt% to 10 wt% of the compounded polyamide composition.

[0133] Aspect 48 provides the compounded polyamide composition of any one of Aspects 46-47, wherein the one or more antioxidants are 0.1 wt% to 3 wt% of the compounded polyamide composition.

[0134] Aspect 49 provides the compounded polyamide composition of any one of Aspects 35-48, further comprising one or more flame retardant additives.

[0135] Aspect 50 provides the compounded polyamide composition of Aspect 49, wherein the one or more flame retardant additives comprise a halogen-containing flameretardant additive, a phosphorus-containing flame-retardant additive, an inorganic flameretardant additive, a nitrogen-containing flame-retardant additive, a boron-containing flameretardant additive, a zinc-containing flame-retardant additive, a silicon-containing flameretardant additive, a graphite-containing flame-retardant additive, or a combination thereof, and optionally including one or more synergists.

[0136] Aspect 51 provides the compounded polyamide composition of any one of Aspects 49-50, wherein the one or more flame retardant additives comprise a phosphorus- containing flame-retardant additive.

[0137] Aspect 52 provides the compounded polyamide composition of any one of Aspects 49-51, wherein the one or more flame retardant additives comprise an aluminum phosphinate flame retardant.

[0138] Aspect 53 provides the compounded polyamide composition of any one of Aspects 49-52, wherein the one or more flame retardant additives are 0.1 wt% to 30 wt% of the compounded polyamide composition.

[0139] Aspect 54 provides the compounded polyamide composition of any one of Aspects 49-53, wherein the one or more flame retardant additives are 1 wt% to 20 wt% of the compounded polyamide composition.

[0140] Aspect 55 provides the compounded polyamide composition of any one of Aspects 35-54, wherein 0.40 mm thickness flame bars of the compounded polyamide composition subjected to a UL 94 flammability test achieve a vertical flame rating of V-0, V- 1, or V-2.

[0141] Aspect 56 provides the compounded polyamide composition of any one of Aspects 35-55, wherein 0.71 mm thickness flame bars of the compounded polyamide composition subjected to a UL 94 flammability test achieve a vertical flame rating of V-0, V- 1, or V-2. Optionally, flame bars of the compounded polyamide composition having a thickness of 0.4 mm, 0.71 mm, 1.5 mm, or 3.0 mm subjected to a UL 94 flammability test can achieve a classification of V-0, V-l, V-2 in a 50 W Vertical Burning Test. Optionally, flame bars of the compounded polyamide composition having a thickness of 0.4 mm, 0.71 mm, 1.5 mm, or 3.0 mm subjected to a UL 94 flammability test can achieve a classification of 5VA or 5VB in a 500 W Vertical Burning Test.

[0142] Aspect 57 provides a compounded polyamide composition comprising: the polyamide blend of Aspect 35, wherein the polyamide blend is 10 wt% to 90 wt% of the compounded polyamide composition; and one or more flame retardant additives, wherein the one or more flame retardant additives are 1 wt% to 20 wt% of the compounded polyamide composition.

[0143] Aspect 58 provides a compounded polyamide composition. the polyamide blend of Aspect 35, wherein the polyamide blend is 20 wt% to 80 wt% of the compounded polyamide composition; and one or more flame retardant additives, wherein the one or more flame retardant additives are 1 wt% to 20 wt% of the compounded polyamide composition; and glass fibers, wherein the glass fibers are 1 wt% to 40 wt% of the compounded polyamide composition.

[0144] Aspect 59 provides a molded or extruded article comprising the polyamide blend of any one of Aspects 1-34 or the compounded polyamide composition of any one of Aspects 35-58.

[0145] Aspect 60 provides the molded or extruded article of Aspect 59, wherein the molded or extruded article is for use with a communication device, electronics, electric power system, or a combination thereof.

[0146] Aspect 61 provides a method of forming an article, the method comprising:extruding or molding the polyamide blend of any one of Aspects 1-34 to form the article comprising the polyamide blend.

[0147] Aspect 62 provides a method of forming an article, the method comprising: extruding or molding the compounded polyamide composition of any one of Aspects 35-58 to form the article comprising the compounded polyamide composition.

[0148] Aspect 63 provides the polyamide blend, compounded polyamide composition, molded or extruded article, or method of forming an article of any one or any combination of Aspects 1-62 optionally configured such that all elements or options recited are available to use or select from.

Claims

CLAIMSWhat is claimed is:

1. A polyamide blend comprising:PA 66 / 6T / X, wherein X is one or more optional comonomers; and an amorphous semi-aromatic polyamide polymer or copolymer comprising a monomer derived from one or more aromatic diacids.

2. The polyamide blend of claim 1, wherein the amorphous semi-aromatic polyamide polymer or copolymer comprises PA 6I / 6T, PA 61, PA DT, PA DI, PA DT / DI, PA 6I / 6N, or a combination thereof.

3. The polyamide blend of claim 1, wherein the amorphous semi-aromatic polyamide polymer or copolymer is a PA 6I / 6T copolymer.

4. The polyamide blend of claim 3, wherein the 61 is 60 mol% to 99.9 mol% of the PA 6I / 6T and the 6T is 0.1 mol% to 40 mol% of the PA 6I / 6T.

5. The polyamide blend of claim 1, wherein the 66 is 45 mol% to 95 mol% of the PA 66 / 6T / X and the 6T is 1 mol% to 50 mol% of the PA 66 / 6T / X.

6. The polyamide blend of claim 1, wherein the X is not present in the PA 66 / 6T / X, and wherein the PA 66 / 6T / X is PA 66 / 6T.

7. The polyamide blend of claim 1, wherein the X is present in the PA 66 / 6T / X, and wherein X is D, I, a lactam, a diacid, a diamine, an amino acid, or a combination thereof.

8. The polyamide blend of claim 1, wherein the X is present in the PA 66 / 6T / X, wherein the X is DI, and wherein the PA 66 / 6T / X is PA 66 / 6T / DI.

9. The polyamide blend of claim 1, wherein the X is 0.1 mol% to 20 mol% of the PA 66 / 6T / X.

10. The polyamide blend of claim 1, wherein the polyamide blend has a weight ratio of the PA 66 / 6T / X to the amorphous semi-aromatic polyamide polymer or copolymer of 0.1 : 1 to 10: 1.

11. A compounded polyamide composition comprising the polyamide blend of claim 1.

12. The compounded polyamide composition of claim 11, wherein the polyamide blend is 10 wt% to 99 wt% of the compounded polyamide composition.

13. The compounded polyamide composition of claim 11, wherein the compounded polyamide composition further comprises a reinforcing filler comprising carbon, glass, fibrous materials, an aramid fiber, cellulose, graphene, silicates, nanotubes, or a combination thereof, wherein the reinforcing filler is 0.1 wt% to 70 wt% of the compounded polyamide composition.

14. The compounded polyamide composition of claim 13, wherein the reinforcing filler is glass fibers.

15. The compounded polyamide composition of claim 11, further comprising one or more flame retardant additives, wherein the one or more flame retardant additives are 0.1 wt% to 30 wt% of the compounded polyamide composition.

16. The compounded polyamide composition of claim 15, wherein the one or more flame retardant additives comprise a phosphorus-containing flame-retardant additive.

17. A polyamide blend comprising:PA 66 / 6T / DI, wherein the PA 66 / 6T / DI has a molar percentage of 66, 6T, and DI of 50 mol% to 75 mol%, 25 mol% to 45 mol%, and 0.5 mol% to 10 mol%, respectively; andPA 6I / 6T, wherein the PA 6I / 6T has a molar percentage of 61 and 6T of 60 mol% to 80 mol% and 20 mol% to 40 mol%, respectively; wherein the polyamide blend has a mass ratio of the PA 66 / 6T / DI to the PA 6I / 6T of 0.1 : 1 to 10: 1.

18. A compounded polyamide composition comprising: the polyamide blend of claim 17, wherein the polyamide blend is 10 wt% to 90 wt% of the compounded polyamide composition; and one or more flame retardant additives, wherein the one or more flame retardant additives are 1 wt% to 20 wt% of the compounded polyamide composition.

19. A molded or extruded article comprising the compounded polyamide composition of claim 11.

20. A method of forming an article, the method comprising: extruding or molding the compounded polyamide composition of claim 11 to form the article comprising the compounded polyamide composition.

Images