Polyarylene Ether Sulfone Blend With Low OH-Endgroups And Talc

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Solution Overview

Problem

Existing polyarylene ether sulfone polymers used in the E&E segment face challenges with reduced flow and melt stability due to reinforcement with fibers, poor flame retardancy, and high moisture uptake, necessitating improved mechanical performance, processability, and flame retardancy.

Innovation Solution

A blend comprising 50 to 85 wt.% of polyarylene ether sulfone polymer with less than 0.05 wt.% OH-endgroups and 15 to 50 wt.% talc with a volumetric average particle size of less than 10 µm, enhancing mechanical performance, processability, and flame retardancy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If polyarylene ether sulfone polymers are reinforced with fibers or fillers to improve mechanical performance, then stiffness and strength increase, but flow and melt stability deteriorate

Engineering Contradiction:

Improvemechanical performanceVSAvoidflow and melt stability

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The invention changes the chemical parameter of the polymer by reducing OH-endgroups content to less than 0.05 wt.%, which fundamentally alters the polymer's reactivity and interaction with fillers, thereby improving melt stability while maintaining mechanical enhancement from filler reinforcement

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite material system combining polyarylene ether sulfone polymer with specific fillers (talc, silica, alumina) at optimized ratios, where the low OH-endgroups content prevents detrimental reactions between filler surfaces and polymer chains, maintaining both mechanical strength and processing flow

Inventive Principle:

Principle #40Composite materials

2Reliability

If polyamide is added to improve CTI values, then electrical tracking resistance improves, but moisture uptake increases

Engineering Contradiction:

Improvecomparative tracking indexVSAvoidmoisture uptake

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The invention changes the chemical composition parameter by strictly limiting OH-endgroups content to less than 0.05 wt.%, which reduces the polymer's hygroscopicity and prevents moisture absorption that would otherwise occur with polyamide blends, while still achieving improved CTI through controlled filler addition

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If flame retardants are added to improve flame retardancy, then fire resistance improves, but processing stability at elevated temperature deteriorates

Engineering Contradiction:

Improveflame retardancyVSAvoidprocessing stability

Core Design Contradiction:

Object-affected harmful factorsVSStability of the object's composition

Solution Approach 1:

The invention replaces traditional flame retardant additives with intrinsic flame retardancy achieved through low OH-endgroups content polymer structure, eliminating the need for separate flame retardant chemicals that would compromise processing stability, while still achieving good flame retardancy properties

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention creates a composite where inorganic fillers (talc, silica, alumina) provide both flame retardancy and processing stability simultaneously, avoiding the use of organic flame retardants that would degrade at processing temperatures

Inventive Principle:

Principle #40Composite materials

Data Source

PatentEP4646453B1Blend comprising a polyarylene ether sulfone polymer having less than 0.05 wt% oh-end groups and talc having a volumetric average particle size of less than 10 micrometer

Publication Date: 2026.04.01 BASF SE

AI summary

The present invention relates to a blend comprising as components 50 to 85 wt.% of at least one polyarylene ether sulfone polymer having less than 0.05 wt.% OH-endgroups (P1), and 15 to 50 wt.% of talc having a volumetric average particle size (D[4,3]) of less than 10 µm (P2). Another aspect of the present invention is a film made from the blend, and the use of the blend or the film in applications of electrical insulation. Yet another aspect of the present invention is an electronic device comprising a metal conductor, and the blend or the film, wherein the blend or the film at least partially electrical isolates the metal conductor.