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EP-4735528-A1 - PPS-BASED COMPOSITION WITH ENHANCED TOUGHNESS AND FLAME RETARDANCY AND MOLDED ARTICLE USING THE SAME

EP4735528A1EP 4735528 A1EP4735528 A1EP 4735528A1EP-4735528-A1

Abstract

A PPS-based composition comprising: A) of at least one polyphenylene sulfide polymer; B) at least one polyetherimide polymer, C) at least one alkoxysilane, D) optionally at least one thermoplastic elastomer containing epoxy functional groups, and D) optionally an epoxy-modified polysiloxane having enhanced toughness properties. The PPS-based composition comprising components (A)-(E) has a V-0 rating using UL 94 V (2013) standard (0.8 mm thickness) and therefore is a flame-retardant PPS-based composition. An article comprising or made from such a PPS-based composition. Use of the article as a component of an electric vehicle. A method of cooling a battery and/or operating a battery comprising passing a heat transfer fluid in a heat transfer tube comprising or made from the PPS- based composition.

Inventors

  • SATTICH, WILLIAM E.
  • SANSEAU, Olivier

Assignees

  • Syensqo Specialty Polymers USA, LLC

Dates

Publication Date
20260506
Application Date
20240626

Claims (15)

  1. 1 . A PPS-based composition comprising: (A) 45 to 80 wt% of at least one polyphenylene sulfide polymer (hereinafter “PPS polymer”), (B) 10 to 35 wt% of at least one polyetherimide polymer (hereinafter “PEI polymer”), (C) from 0.1 to 2 wt% of at least one alkoxysilane, (D) optionally from 4.5 to 12 wt% of at least one thermoplastic elastomer containing epoxy functional groups (hereinafter “TPE”), (E) optionally from 0.5 to 5 wt% of an epoxy-modified polysiloxane, said wt% being based on the total weight of said PPS-based composition, wherein the combined amounts of components (A), (B), (C), (D) and (E) is 100 wt% or less based on the total weight of said PPS-based composition.
  2. 2. The PPS-based composition according to claim 1 comprising: (D) from 4.5 to 12 wt% of at least one thermoplastic elastomer containing epoxy functional groups (TPE); and (E) from 0.5 to 5 wt% of an epoxy-modified polysiloxane.
  3. 3. The PPS-based composition of claim 1 or 2, wherein the PPS polymer comprises at least 70 mol%, at least 80 mol %, at least 90 mol %, at least 95 mol %, or at least 99 mol %, based on the total number of moles of recurring units in the PPS polymer, of recurring units (Rpps) represented by formula (T):
  4. 4. The PPS-based composition of any one of claims 1 to 3, wherein the PEI polymer comprises at least 75 mol%, at least 85 mol%, at least 95 mol%, or at least 99 mol%, based on the total number of moles of recurring units in the PEI polymer, of recurring units (R PE I) of formula (D-0) to (D-6) and combination thereof: .
  5. 5. The PPS-based composition of any one of claims 1 to 3, wherein the PEI polymer comprises at least 75 mol%, at least 85 mol%, at least 95 mol%, or at least 99 mol%, based on the total number of moles of recurring units in the PEI polymer, of recurring units (R PE I) of formula (E-0) to
  6. (E-6) and combination thereof: The PPS-based composition of any one of claims 1 to 5, wherein the alkoxysilane responds to the following formula: wherein a is an integer of from 0 to 2; p is an integer of from 1 to 3; each R x is independently a linear, branched or cyclic C1 to Cs alkyl group; each Ry is independently a linear or branched C1 to C4 alkyl group; each R z is independently a linear, branched or cyclic C1 to C12 alkanediyl group, optionally containing one or more heteroatom selected from oxygen, sulfur and nitrogen; and wherein FG is hydrogen, an halogen or a functional group selected from amino groups, isocyanate groups and epoxy groups.
  7. 7. The PPS-based composition of any one of claims 1 to 6, wherein the alkoxysilane is selected from the list consisting of compounds represented by formulae (I) to (Lil): (XIII) (XIV) (XV) (XVI) 29 (LI) (Lil)
  8. 8. The PPS-based composition of any one of the preceding claims, wherein the TPE is selected from the group consisting of poly(ethylene-co-glycidylmethacrylate) copolymers, poly(ethylene-co-methyl(meth)acrylate-co-glycidyl acrylate) copolymers, poly(ethylene-co-n-butyl acrylate-co-glycidyl acrylate) copolymers and copolymers of styrene and glycidyl (meth)acrylates, preferably selected from poly(ethylene-co-glycidylmethacrylate) copolymers and/or poly(ethylene-co- methyl(meth)acrylate-co-glycidyl acrylate) copolymers; more preferably selected from poly(ethylene-co-glycidylmethacrylate) copolymers.
  9. 9. The PPS-based composition of any one of the preceding claims, wherein the epoxy-modified polysiloxane contains at least 70 mol%, at least 80 mol%, at least 85 mol%, at least 90 mol%, or at least 93 mol%, based on the total number of moles of repeating units in the polysiloxane, of a siloxane repeating unit (Rs) represented by any of the following formulae (3a), (3b) or (3c), preferably, a siloxane repeating unit (Rs) represented by formula (3a): wherein n is an integer from 2 to 100, or from 2 to 70, or from 2 to 60.
  10. 10. The PPS-based composition of any one of the preceding claims, wherein the epoxy-modified polysiloxane has at least one pendant epoxy functional group, and wherein the epoxy-modified polysiloxane (E) further contains at least one epoxy-modified siloxane unit (REMS) represented by general formula (4) or (5): wherein - R 2 in formulae (4) and (5) is an C1-C3 alkyl group or a phenyl group; - R 3 in formulae (4) and (5) is a linking group represented by formula (6): -(CH 2 )k-O-CH 2 - (6), in which k is an integer from 1 to 10, preferably from 2 to 8, more preferably from 3 to 6, most preferably being 3; and - m in formulae (4) and (5) is an integer from 1 to 10.
  11. 11 . The PPS-based composition of any one of the preceding claims, wherein the epoxy-modified polysiloxane has at least one terminal epoxy functional group, preferably two terminal epoxy functional groups, and wherein the terminal epoxy functional group in the polysiloxane is represented by one of formulae (7) and (8) as follows: in which R 3 is represented by the formula (6): -(CH2)k-O-CH2- (6), wherein k is an integer from 1 to 10, preferably from 2 to 8, more preferably from 3 to 6, most preferably being 3.
  12. 12. The PPS-based composition of any one of the preceding claims, wherein the epoxy-modified polysiloxane is represented by one of the following formula (9) wherein: - each of Ri, R 2 in formulae (9) and (10) is independently a C1-C3 alkyl group and/or a phenyl group; - R 3 in formulae (9) and (10) is a linking group represented by the formula (6): -(CH 2 )k-O-CH 2 - (6) in which k is an integer from 1 to 10, preferably from 2 to 8, more preferably from 3 to 6, most preferably being 3; and - n varies from 2 to 100, or from 2 to 70, or from 2 to 60.
  13. 13. The PPS-based composition of claim 12, wherein the epoxy-modified polysiloxane is a poly(dimethylsiloxane) (PDMS) or poly(phenylmethylsiloxane) having one or more pendant and/or terminal epoxy functional groups represented by at least one of formulae (7) and (8).
  14. 14. A method for improving flame retardancy of a V-1 rated PPS-based composition comprising at least one polyphenylene sulfide polymer (“PPS polymer”), at least one polyetherimide polymer (“PEI polymer”), at least one alkoxysilane, and optionally at least one thermoplastic elastomer containing epoxy functional groups (“TPE”), said method comprising adding to the V-1 rated PPS-based composition an amount of an epoxy-modified polysiloxane (D) so as to obtain a V-0 rated flameretardant PPS-based composition, said V-0 rated flame-retardant PPS-based composition comprising: (A) 45 to 80 wt% of at least one PPS polymer, (B) 10 to 35 wt% of at least one PEI polymer, (C) from 0.1 to 2 wt% of at least one alkoxysilane, (D) optionally from 4.5 to 12 wt% of at least one TPE, (E) from 0.5 to 5 wt% of the epoxy-modified polysiloxane, said wt% being based on the total weight of the V-0 rated flame-retardant PPS- based composition, wherein the combined amounts of components (A), (B), (C), (D) and (E) is 100 wt% or less based on the total weight of the V-0 rated flame-retardant PPS-based composition, wherein the V-0 and V-1 flame retardancy ratings are measured according to UL 94 V (2013) on a test piece having a thickness of 1 .6 mm or less, preferably a thickness of 0.8 mm.
  15. 15. A molded article, comprising, or made from, the PPS-based composition of any one of claims 1-14, the molded article preferable being selected from the group consisting of tubular members such as heat transfer tubes, coated wires or cables such as magnet wires, slot liners, bobbins such as coil bobbins, slot wedges, power modules, and busbars.

Description

PPS-BASED COMPOSITION WITH ENHANCED TOUGHNESS AND FLAME RETARDANCY AND MOLDED ARTICLE USING THE SAME Cross-Reference to Related Applications [0001] This application claims priorities to an application filed on 2023-06-30 in UNITED STATES with Nr 63/511423 and to an application filed 2023-09-15 in EUROPE with Nr 23197744.8, the whole content of each of these applications being incorporated herein by reference for all purposes. Technical Field [0002] The invention generally relates to a PPS-based composition having enhanced toughness properties and which is, in some embodiments, flame-retardant. The invention also pertains to its use in making molded articles, particularly extrusion molded articles, overmolded components and thin-walled molded articles, which may be suitably used for automotive components and thermal management systems, in particular components and systems used in an electric vehicle. Background Art [0003] In many applications, plastics are key materials in driving forward electric mobility. Due to their functional integration and lightweight properties, plastics provide many benefits to automotive engineers solving technical challenges that can hardly be met with metals. [0004] Since an electric powertrain raises different hazards than a combustion powertrain, this challenges plastics with new property requirements. In particular there is a demand for a higher safety against electric malfunctions, which can cause the risk of an electric shock, the occurrence of electric arcs, and other potential sources of ignition. Since plastics are mainly combustible materials, special precautions have to be taken to increase electric vehicle safety and to prevent the ultimate worst-case scenario of a battery cell fire, a so-called thermal runaway. [0005] Batteries have to supply ever greater instantaneous powers and have a high storage capacity. Batteries having operating voltages of several hundred volts are nowadays known. To achieve the desired voltages and currents, it is conventional to connect a plurality of individual battery cells together in parallel and/or in series. [0006] While advancements have been made in electric vehicle batteries that allow them to deliver more power and require less frequent charges, one of the biggest challenges for battery safety is the ability to design an effective cooling system. [0007] For a typical Li-ion battery a temperature above 80°C, even only in a part of its structure, can start exothermal chemical reactions which cause a further temperature increase of the battery, ultimately leading to a complete collapse of the battery with risk of fire and explosion. [0008] For this reason it is nowadays standard to integrate a Battery Thermal management System (BTMS) within commercial battery assemblies, especially when safety, reliability and lifetime of the battery are a significant concern. These BTMSs can be more or less complex, depending on the type of battery, however one common element is the presence of a heat transfer fluid which exchanges heat with the battery thus heating or cooling it. [0009] Several heat transfer systems exist for the thermal management of batteries, such as air cooling, liquid cooling, and direct refrigerant cooling. Among these, liquid cooling is the most commonly used system due to its convenient design and good heat transfer performance. [0010] The use of water, or water/ethylene glycol mixtures, is widespread as heat transfer medium, since this type of heat transfer system is already common in vehicles with conventional drives, i.e. with internal combustion engines. A safety-critical drawback of the use of this water based heat transfer medium is the electrical conductivity thereof. In the event of the heat transfer circuit leaking, for example as a result of an accident, the escaping water or water/ethylene glycol mixture can cause short circuits. As a result fires and other emergency situations can be caused, and this can in turn lead to additional and sometimes considerable damage to the vehicle. In order to reduce this risk, the components of the thermal management system should possess high flame retardant properties. That is why flame-retardant polymer compounds are sought in eMobility applications. [0011] One conventional manner to identify flame retardancy in plastic materials refers to standard tests developed by Underwriters Laboratory (USA), referred to as UL 94 V (vertical burning test) Standard for Safety of Flammability of Plastic Materials for Parts in Devices and Appliances testing. Preferably components of the thermal management system for use in batteries in electric vehicles should comply with standard V-0 rating, which identifies plastic materials for which “burning stops within 10 seconds on a vertical part allowing for drops of plastic that are not inflames”. [0012] Polyphenylene sulfide (hereinafter sometimes abbreviated as "PPS") resin is an engineering plastic having well-balanced properties such as heat r