Halogen-Free Poly(arylene ether) Composition for Automotive Wiring

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Solution Overview

Problem

There is a need for halogen-free plastics that exhibit the physical properties and chemical resistance required for flexible underhood automotive parts, as existing halogenated resins have negative environmental impacts and are not suitable for exposure to solvents and oils.

Innovation Solution

A composition comprising 10-35 weight percent poly(arylene ether), 15-40 weight percent polyolefin, and 10-35 weight percent hydrogenated block copolymer with a poly(alkenyl aromatic) content of 10-45 weight percent, having a weight average molecular weight greater than or equal to 200,000 atomic mass units, which retains at least 65% of its ribbon tensile strength after immersion in a 50:50 kerosene and SAE 10W30 motor oil mixture at 50°C.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If polyolefin is blended with poly(arylene ether) to improve flexibility and processability, then the flexibility and ease of manufacture are improved, but the chemical resistance to solvents and oils deteriorates

Engineering Contradiction:

ImproveflexibilityVSAvoidchemical resistance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

A hydrogenated block copolymer of an alkenyl aromatic compound and a conjugated diene is used as an intermediary component to mediate between polyolefin and poly(arylene ether). This copolymer provides compatibility between the incompatible polymers while maintaining the chemical resistance needed for automotive applications exposed to solvents and oils.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention creates a composite material system consisting of three components: polyolefin (10-40 wt%), poly(arylene ether) (30-70 wt%), and hydrogenated block copolymer (10-30 wt%). This composite structure combines the flexibility of polyolefin with the chemical resistance of poly(arylene ether), resolving the contradiction between these two properties.

Inventive Principle:

Principle #40Composite materials

2Reliability

If halogenated resin polyvinyl chloride is used to achieve chemical resistance, then the chemical resistance is improved, but the environmental harm increases

Engineering Contradiction:

Improvechemical resistanceVSAvoidenvironmental impact

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The invention eliminates harmful halogenated materials and replaces them with environmentally benign alternatives. The hydrogenated block copolymer system provides the necessary chemical resistance without the environmental harm of halogenated resins, converting a harmful solution into a beneficial one.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention uses conventional, environmentally acceptable polymers (polyolefin and poly(arylene ether)) that can be processed and disposed of without the severe environmental consequences associated with halogenated materials, while still achieving the required performance for automotive applications.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If poly(arylene ether) content is increased to improve chemical resistance, then the chemical resistance is improved, but the flexibility and processability deteriorate

Engineering Contradiction:

Improvechemical resistanceVSAvoidprocessability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The hydrogenated block copolymer acts as a mediator that enables high poly(arylene ether) content (30-70 wt%) to be incorporated while maintaining processability. The copolymer facilitates compatibility between the rigid poly(arylene ether) and the flexible polyolefin, allowing the mixture to be processed effectively.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention optimizes the composition parameters within specific ranges: polyolefin (10-40 wt%), poly(arylene ether) (30-70 wt%), and hydrogenated block copolymer (10-30 wt%). These parameter adjustments balance chemical resistance and processability, with the copolymer content being particularly critical for maintaining manufacturability at high poly(arylene ether) levels.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP2081994B1Poly(arylene ether)/polyolefin composition, method, and article

Publication Date: 2010.04.28 SABIC INNOVATIVE PLASTICS IP BV

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AI summary

A thermoplastic composition includes the product of melt kneading a composition including a poly(arylene ether), a polyolefm, and a high molecular weight hydrogenated block copolymer of an alkenyl aromatic compound and a conjugated diene. The composition exhibits substantially improved chemical resistance compared to a corresponding composition prepared with a lower molecular weight hydrogenated block copolymer. Methods of preparing the composition and articles prepared for the composition are also described. The composition is particularly useful for fabricating halogen-free tubes for sheathing automotive wiring harnesses.