Patent Application
20240076493
This application claims priority to and the benefit of European Patent Application No. 20211295.9, filed on Dec. 2, 2020, the contents of which are incorporated by reference herein in its entirety.
Thermoplastic polymers, including polyetherimides and polysulfones, are useful in the manufacture of articles and components for a wide range of applications, from automotive parts to electronic appliances. Because of beneficial properties such as transparency and impact resistance, polyetherimides and polysulfones have also been used in optical applications including as sensor lenses, optical interconnectors, transceivers, light guides, camera lenses, eyeglass and safety glass lenses, illumination lenses such as light fixtures, flashlight and lantern lenses, and motor vehicle headlight lenses and covers. Since many optical articles are used in a high-temperature environment or have to be processed under harsh conditions, it is desirable for the materials to have the ability to withstand elevated temperatures without deformation or discoloration, and the ability to maintain good optical properties even when processed using conventional molding processes. To date, many optical lenses are made from glass as polymer materials were not able to provide the necessary dimensional stability, particularly for use in single mode fiber optic connectors.
Therefore, there is a continuing need in the art for an improved composition that is particularly well suited for optical applications. It would be particularly advantageous to provide a composition having a low coefficient of thermal expansion and high infrared transmission, while also maintaining other good physical properties, such as tensile properties, flexural properties, and impact strength.
A composition comprises 50 weight percent to 97 weight percent, or 55 weight percent to 95 weight percent of a polyetherimide or a poly(arylene ether sulfone); and 3 weight percent to 50 weight percent of an inorganic filler having a refractive index of 1.60 to 1.68 as determined at a wavelength of 587 nanometers comprising boehmite, calcium carbonate, barium sulfate, wollastonite, or a combination thereof; wherein weight percent is based on the total weight of the composition; and wherein a molded sample of the composition exhibits one or more of: a transmission of greater than 50% in the range of 850 nm to 1100 nm for a 1 mm thick sample, as determined by UV/Vis spectroscopy; a transmission of greater than 40% in the range of 1200 nm to 1330 nm for a 1 mm thick sample, as determined by UV/Vis spectroscopy; and a flow coefficient of thermal expansion, a cross-flow coefficient of thermal expansion, or both of less than 6.5E-5 1/° C. between −40° C. and 85° C., as determined according to ASTM E831.
A method of manufacturing the composition comprises melt-mixing the components of the composition, and optionally, extruding the composition.
An article comprising the composition is also described.
The above described and other features are exemplified by the following detailed description.
The present inventors have unexpectedly discovered that compositions including a polyetherimide, a poly(arylene ether sulfone), or a combination thereof and particular inorganic fillers can provide a desirable combination of properties. In particular, inorganic fillers having a specific refractive index, when mixed with the polyetherimide, poly(arylene ether sulfone), or combination thereof in particular amounts, can provide molded compositions exhibiting low coefficients of thermal expansion (CTE), high infrared (IR) transmission, and good processability. The compositions described herein can be particularly well suited for a variety of articles, specifically articles for optical applications.
A composition is an aspect of the present disclosure. The composition comprises a polyetherimide, a poly(arylene ether sulfone), or a combination thereof.
In an aspect, the composition comprises the polyetherimide. Polyetherimides comprise more than 1, for example 2 to 1000, or 5 to 500, or 10 to 100 structural units of formula (1)
wherein each R is independently the same or different, and is a substituted or unsubstituted divalent organic group, such as a substituted or unsubstituted C6-30 aromatic hydrocarbon group, a substituted or unsubstituted straight or branched chain C4-20 alkylene group, a substituted or unsubstituted C3-8 cycloalkylene group, in particular a halogenated derivative of any of the foregoing. In an aspect R is divalent group of one or more of the following formulas (2)
wherein Q1 is —O—, —S—, —C(O)—, —SO2—, —SO—, —P(Ra)(═O)— wherein Ra is a C1-8 alkyl or C6-12 aryl, —CyH2y— wherein y is an integer from 1 to 5 or a halogenated derivative thereof (which includes perfluoroalkylene groups), or —(C6H10)z— wherein z is an integer from 1 to 4. In an aspect R is m-phenylene, p-phenylene, or a diarylene sulfone, in particular bis(4,4′-phenylene)sulfone, bis(3,4′-phenylene)sulfone, bis(3,3′-phenylene)sulfone, or a combination comprising at least one of the foregoing. In an aspect, at least 10 mole percent or at least 50 mole percent of the R groups contain sulfone groups, and in other aspects no R groups contain sulfone groups.
Further in formula (1), T is —O— or a group of the formula —O—Z—O— wherein the divalent bonds of the —O— or the —O—Z—O— group are in the 3,3′, 3,4′, 4,3′, or the 4,4′ positions, and Z is an aromatic C6-24 monocyclic or polycyclic moiety optionally substituted with 1 to 6 C1-8 alkyl groups, 1 to 8 halogen atoms, or a combination comprising at least one of the foregoing, provided that the valence of Z is not exceeded. Exemplary groups Z include groups of formula (3)
wherein Ra and Rb are each independently the same or different, and are a halogen atom or a monovalent C1-6 alkyl group, for example; p and q are each independently integers of 0 to 4; c is 0 to 4; and Xa is a bridging group connecting the hydroxy-substituted aromatic groups, where the bridging group and the hydroxy substituent of each C6 arylene group are disposed ortho, meta, or para (specifically para) to each other on the C6 arylene group. The bridging group Xa can be a single bond, —O—, —S—, —S(O)—, —S(O)2—, —C(O)—, or a C1-18 organic bridging group. The C1-18 organic bridging group can be cyclic or acyclic, aromatic or non-aromatic, and can further comprise heteroatoms such as halogens, oxygen, nitrogen, sulfur, silicon, or phosphorous. The C1-18 organic group can be disposed such that the C6 arylene groups connected thereto are each connected to a common alkylidene carbon or to different carbons of the C1-18 organic bridging group. A specific example of a group Z is a divalent group of formula (3a)
wherein Q is —O—, —S—, —C(O)—, —SO2—, —SO—, —P(Ra)(═O)— wherein Ra is a C1-8 alkyl or C6-12 aryl, or —CyH2y— wherein y is an integer from 1 to 5 or a halogenated derivative thereof (including a perfluoroalkylene group). In an aspect Z is derived from bisphenol A, such that Q in formula (3a) is 2,2-isopropylidene.
In an aspect in formula (1), R is m-phenylene, p-phenylene, or a combination comprising at least one of the foregoing, and T is —O—Z—O— wherein Z is a divalent group of formula (3a). Alternatively, R is m-phenylene, p-phenylene, or a combination comprising at least one of the foregoing, and T is —O—Z—O— wherein Z is a divalent group of formula (3a) and Q is 2,2-isopropylidene. Such materials are available under the trade name ULTEM from SABIC. Alternatively, the polyetherimide can be a copolymer comprising additional structural polyetherimide units of formula (1) wherein at least 50 mole percent (mol %) of the R groups are bis(4,4′-phenylene)sulfone, bis(3,4′-phenylene)sulfone, bis(3,3′-phenylene)sulfone, or a combination comprising at least one of the foregoing and the remaining R groups are p-phenylene, m-phenylene or a combination comprising at least one of the foregoing; and Z is 2,2-(4-phenylene)isopropylidene, i.e., a bisphenol A moiety, an example of which is commercially available under the trade name EXTEM from SABIC.
In an aspect, the polyetherimide is a copolymer that optionally comprises additional structural imide units that are not polyetherimide units, for example imide units of formula (4)
wherein R is as described in formula (1) and each V is the same or different, and is a substituted or unsubstituted C6-20 aromatic hydrocarbon group, for example a tetravalent linker of the formulas
wherein W is a single bond, —O—, —S—, —C(O)—, —SO2—, —SO—, a C1-18 hydrocarbylene group, —P(Ra)(═O)— wherein Ra is a C1-8 alkyl or C6-12 aryl, or —CyH2y— wherein y is an integer from 1 to 5 or a halogenated derivative thereof (which includes perfluoroalkylene groups). These additional structural imide units preferably comprise less than 20 mol % of the total number of units, and more preferably can be present in amounts of 0 mol % to 10 mol % of the total number of units, or 0 to 5 mol % of the total number of units, or 0 mol % to 2 mol % of the total number of units. In an aspect, no additional imide units are present in the polyetherimide.
The polyetherimide can be prepared by any of the methods known to those skilled in the art, including the reaction of an aromatic bis(ether anhydride) of formula (5) or a chemical equivalent thereof, with an organic diamine of formula (6)
wherein T and R are defined as described above. Copolymers of the polyetherimides can be manufactured using a combination of an aromatic bis(ether anhydride) of formula (5) and an additional bis(anhydride) that is not a bis(ether anhydride), for example pyromellitic dianhydride or bis(3,4-dicarboxyphenyl) sulfone dianhydride.
Illustrative examples of aromatic bis(ether anhydride)s include 2,2-bis[4-(3,4-dicarboxyphenoxy)phenyl]Propane dianhydride (also known as bisphenol A dianhydride or BPADA), 3,3-bis[4-(3,4-dicarboxyphenoxy)phenyl]propane dianhydride; 4,4′-bis(3,4-dicarboxyphenoxy)diphenyl ether dianhydride; 4,4′-bis(3,4-dicarboxyphenoxy)diphenyl sulfide dianhydride; 4,4′-bis(3,4-dicarboxyphenoxy)benzophenone dianhydride; 4,4′-bis(3,4-dicarboxyphenoxy)diphenyl sulfone dianhydride; 4,4′-bis(2,3-dicarboxyphenoxy)diphenyl ether dianhydride; 4,4′-bis(2,3-dicarboxyphenoxy)diphenyl sulfide dianhydride; 4,4′-bis(2,3-dicarboxyphenoxy)benzophenone dianhydride; 4,4′-bis(2,3-dicarboxyphenoxy)diphenyl sulfone dianhydride; 4-(2,3-dicarboxyphenoxy)-4′-(3,4-dicarboxyphenoxy)diphenyl-2,2-propane dianhydride; 4-(2,3-dicarboxyphenoxy)-4′-(3,4-dicarboxyphenoxy)diphenyl ether dianhydride; 4-(2,3-dicarboxyphenoxy)-4′-(3,4-dicarboxyphenoxy)diphenyl sulfide dianhydride; 4-(2,3-dicarboxyphenoxy)-4′-(3,4-dicarboxyphenoxy)benzophenone dianhydride; 4,4′-(hexafluoroisopropylidene)diphthalic anhydride; and 4-(2,3-dicarboxyphenoxy)-4′-(3,4-dicarboxyphenoxy)diphenyl sulfone dianhydride. A combination of different aromatic bis(ether anhydride)s can be used.
Examples of organic diamines include 1,4-butane diamine, 1,5-pentanediamine, 1,6-hexanediamine, 1,7-heptanediamine, 1,8-octanediamine, 1,9-nonanediamine, 1,10-decanediamine, 1,12-dodecanediamine, 1,18-octadecanediamine, 3-methylheptamethylenediamine, 4,4-dimethylheptamethylenediamine, 4-methylnonamethylenediamine, 5-methylnonamethylenediamine, 2,5-dimethylhexamethylenediamine, 2,5-dimethylheptamethylenediamine, 2, 2-dimethylpropylenediamine, N-methyl-bis (3-aminopropyl) amine, 3-methoxyhexamethylenediamine, 1,2-bis(3-aminopropoxy) ethane, bis(3-aminopropyl) sulfide, 1,4-cyclohexanediamine, bis-(4-aminocyclohexyl) methane, m-phenylenediamine, p-phenylenediamine, 2,4-diaminotoluene, 2,6-diaminotoluene, m-xylylenediamine, p-xylylenediamine, 2-methyl-4,6-diethyl-1,3-phenylene-diamine, 5-methyl-4,6-diethyl-1,3-phenylene-diamine, benzidine, 3,3′-dimethylbenzidine, 3,3′-dimethoxybenzidine, 1,5-diaminonaphthalene, bis(4-aminophenyl) methane, bis(2-chloro-4-amino-3,5-diethylphenyl) methane, bis(4-aminophenyl) propane, 2,4-bis(p-amino-t-butyl) toluene, bis(p-amino-t-butylphenyl) ether, bis(p-methyl-o-aminophenyl) benzene, bis(p-methyl-o-aminopentyl) benzene, 1,3-diamino-4-isopropylbenzene, bis(4-aminophenyl) sulfide, bis-(4-aminophenyl) sulfone (also known as 4,4′-diaminodiphenyl sulfone (DDS)), and bis(4-aminophenyl) ether. Any regioisomer of the foregoing compounds can be used. C1-4 alkylated or poly(C1-4)alkylated derivatives of any of the foregoing can be used, for example a polymethylated 1,6-hexanediamine Combinations of these compounds can also be used. In an aspect the organic diamine is m-phenylenediamine, p-phenylenediamine, 4,4′-diaminodiphenyl sulfone, 3,4′-diaminodiphenyl sulfone, 3,3′-diaminodiphenyl sulfone, or a combination comprising at least one of the foregoing. In an aspect, the organic diamine is m-phenylenediamine, p-phenylenediamine, or a combination thereof, preferably m-phenylene.
The polyetherimide can have a melt index of 0.1 grams per minute (g/min) to 10 g/min, as measured by American Society for Testing Materials (ASTM) D1238 at 340° C. to 370° C., using a 6.7 kilogram (kg) weight. In an aspect, the polyetherimide has a weight average molecular weight (Mw) of 1,000 grams/mole to 150,000 grams/mole (g/mol or Daltons (Da)), as measured by gel permeation chromatography, using polystyrene standards. In an aspect the polyetherimide has an Mw of 10,000 g/mol to 80,000 g/mol. Such polyetherimides typically have an intrinsic viscosity greater than 0.2 deciliters per gram (dl/g), or, more specifically, 0.35 dl/g to 0.7 dl/g as measured in m-cresol at 25° C.
In an aspect, the composition comprises the poly(arylene ether sulfone). As used herein, the term “poly(arylene ether sulfone)” can refer to polymers having repeat units of formula (7)
—Arl—SO2—Ar2—O— (7)
wherein each Ar1 and Ar2 is the same or different, and is a group of formula (8)
wherein c is 0 or 1, Ra and R b are each independently a linear or branched C1-10 alkyl, linear or branched C2-10 alkenyl, linear or branched C2-10 alkynyl, C6-18 aryl, C7-20 alkylaryl, C7-20 arylalkyl, C5-10 cycloalkyl, C5-20 cycloalkenyl, linear or branched C1-10 alkylcarbonyl, C6-18 arylcarbonyl, halogen, nitro, cyano, a halogen, C1-12 alkoxy, or C1-12 alkyl, and p and q are each independently integers of 0 to 4. It will be understood that when p or q is less than 4, the valence of each carbon of the ring is filled by hydrogen. Also in formula (8), Xa is a bridging group connecting the two hydroxy-substituted aromatic groups, where the bridging group and the hydroxy substituent of each C6 arylene group are disposed ortho, meta, or para (specifically para) to each other on the C6 arylene group. In an aspect, the bridging group Xa is single bond, —O—, —S—, —S(O)—, —S(O)2—, —C(O)—, or a C1-18 organic group. The C1-18 organic bridging group can be cyclic or acyclic, aromatic or non-aromatic, and can further comprise heteroatoms such as halogens, oxygen, nitrogen, sulfur, silicon, or phosphorous. The C1-18 organic group can be disposed such that the C6 arylene groups connected thereto are each connected to a common alkylidene carbon or to different carbons of the C1-18 organic bridging group. In an aspect, c is 0 or 1, p and q is each 0, and Xa is isopropylidene.
Specific poly(arylene ether sulfone)s that can be used include polyethersulfone (also known as “PES” or “PESU”), which contains at least 85 weight percent of units of formula (8a)
or polyphenylene sulfone (also known as “PPSU” or polyphenylsulfone), which contains at least 85 weight percent of units of formula (8b)
or polyetherethersulfone, which contains at least 85 weight percent of units of formula (8c)
or polysulfone (often referred to as “PSU”), which contains at least 85 weight percent of units of formula (8d)
or a combination comprising at least one of the foregoing poly(arylene ether sulfone)s. Copolymers comprising a combination of at least two types of units of formulas (8a), (8b), (8c), and (8d) can also be used.
The poly(arylene ether sulfone)s can be linear or branched, having 1 or more, 2 or more, or 5 or more branching points per 1,000 carbon atoms along the polymer chain. In an aspect, the poly(arylene ether sulfone)s are linear, having 10 or fewer, 5 or fewer, 2 or fewer, or 1 or fewer branching points per 1,000 carbon atoms along the polymer chain. In an aspect, the poly(arylene ether sulfone)s have a glass transition temperature (Tg) of greater than 175° C., specifically from 200° C. to 280° C., and more specifically from 255° C. to 275° C. The poly(arylene ether sulfone)s can further have a weight average molecular weight (Mw) of 500 g/mol to 100,000 g/mol, specifically 1,000 g/mol to 75,000 g/mol, more specifically 1,500 g/mol to 50,000 g/mol, and still more specifically 2,000 g/mol to 25,000 g/mol.
Exemplary poly(arylene ether sulfone)s that can be used include those that are available from sources such as Solvay Specialty Polymers, Quadrant EPP, Centroplast Centro, Duneon, GEHR Plastics, Westlake Plastics, Gharda Chemicals, Sumitomo Chemial, and UJU New Materials Co., Ltd. Commercial grades of poly(phenylsulfone)s include those with the trade names RADEL™, UDEL™, ULTRASON™, GAFONE™, and PARYLS™ Poly(arylene ether sulfone)s are commercially available from Solvay Advanced Polymers K. K. under the trademark of VERADEL™, from BASF Corporation under the trademark of ULTRASON™, and from Sumitomo Chemical Co., Ltd. under the trademark of SUMIKAEXCEL™.
Polyphenylene sulfones are commercially available, including the polycondensation product of biphenol with dichloro diphenyl sulfone. Methods for the preparation of polyphenylene sulfones are widely known and several suitable processes have been well described in the art. Two methods, the carbonate method and the alkali metal hydroxide method, are known to the skilled artisan. In the alkali metal hydroxide method, a double alkali metal salt of a dihydric phenol is contacted with a dihalobenzenoid compound in the presence of a dipolar, aprotic solvent under substantially anhydrous conditions. The carbonate method, in which a dihydric phenol and a dihalobenzenoid compound are heated, for example, with sodium carbonate or bicarbonate and a second alkali metal carbonate or bicarbonate is also disclosed in the art, for example in U.S. Pat. No. 4,176,222,
The molecular weight of the polyphenylene sulfone, as indicated by reduced viscosity data in an appropriate solvent such as methylene chloride, chloroform, N-methyipyrrolidone, or the like, can be greater than or equal to 0.3 dl/g, or, more specifically, greater than or equal to 0.4 dl/g and, typically, will not exceed 1.5 dl/g.
The polyphenylene sulfone weight average molecular weight (Mw) can be 10,000 g/mol to 100,000 g/mol as determined by gel permeation chromatography using ASTM D5296 with polystyrene standards. In an aspect the polyphenylene sulfone weight average molecular weight can he 10,000 g/mol to 80,000 g/mol. Polyphenylene sulfones can have glass transition temperatures (Tg) of 180° C. to 250° C., as determined using differential scanning calorimetry (DSC).
In an aspect, the polyetherimide, poly(arylene ether sulfone), or combination thereof can have a transmission of greater than 70% from 850 nm to 1100 nm and from 1200 nm to 1330 nm, determined using a one-millimeter color chip by UV/Vis spectroscopy.
The polyetherimide, poly(arylene ether sulfone), or combination thereof can be present in the composition in an amount of 50 weight percent to 97 weight percent, based on the total weight of the composition. Within this range, the polyetherimide, poly(arylene ether sulfone), or combination thereof can be present in an amount of 55 weight percent to 95 weight percent, or 60 weight percent to 90 weight percent.
In addition to the polyetherimide, poly(arylene ether sulfone), or combination thereof, the composition further comprises an inorganic filler. The inorganic filler has a refractive index of 1.60 to 1.68, or 1.60 to 1.67, or 1.60 to 1.66 as determined at a wavelength of 587 nanometers. The inorganic filler comprises boehmite, calcium carbonate, barium sulfate, wollastonite, or a combination comprising at least one of the foregoing. In an aspect, the inorganic filler comprises boehmite. The foregoing inorganic fillers can optionally include various surface modifications. In an aspect, the inorganic filler does not include any surface modifications.
The inorganic filler can have an average particle size of less than 1 micrometer, as determined by laser light scattering. In an aspect, the inorganic filler can have an average particle size (D50) that is less than 1 micrometer. Within this range, the inorganic filler can have an average particle size (D50) that is less than 0.95 micrometers, or less than 0.75 micrometers, or less than 0.5 micrometers. Also within this range, the inorganic filler can have an average particle size (D50) that is greater than 0.1 micrometer, or greater than 0.25 micrometers, or greater than 0.3 micrometers, or greater than 0.5 micrometers, or greater than 0.75 micrometers. For example, the inorganic filler can have an average particle size (D50) that is 0.1 micrometer to 1 micrometer, or 0.25 micrometer to 1 micrometer, or 0.3 micrometer to 1 micrometer, or 0.5 micrometer to 1 micrometer, or 0.75 micrometer to 1 micrometer, or 0.1 to 0.95 micrometers or 0.25 micrometer to 0.95 micrometers, or 0.3 micrometer to 0.95 micrometers, or 0.5 micrometer to 0.95 micrometers, or 0.75 micrometer to 0.95 micrometers. In an aspect, the inorganic filler can have a high aspect ratio, and the average length of the longest particle dimension can be less than 1 micrometer.
The inorganic filler can be present in the composition in an amount of 3 weight percent to 50 weight percent, based on the total weight of the composition. Within this range, the inorganic filler can be present in an amount of at least 5 weight percent, or at least 8 weight percent, or at least 10 weight percent, or at least 15 weight percent, or at least 20 weight percent. Also within this range, the inorganic filler can be present in an amount of at most 45 weight percent, or at most 42 weight percent, or at most 40 weight percent, or at most 35 weight percent, or at most 30 weight percent. For example, the inorganic filler can be present in an amount of 5 weight percent to 45 weight percent, or 10 weight percent to 40 weight percent. In a specific aspect, the inorganic filler can comprise boehmite and the boehmite can be present in an amount of 5 weight percent to 45 weight percent or 10 weight percent to 40 weight percent.
In an aspect, the composition comprises, consists essentially of, or consists of the polyetherimide, the poly(arylene ether sulfone) or the combination thereof and the inorganic filler. In an aspect, the composition can exclude any component other than the polyetherimide, the poly(arylene ether sulfone) or the combination thereof and the inorganic filler that is not specifically described herein. In an aspect, the composition comprises less than 5 weight percent, or less than 1 weight percent (based on the total weight of the composition) of any thermoplastic polymer other than the polyetherimide, the poly(arylene ether sulfone) or the combination thereof. In an aspect the composition excludes any thermoplastic polymer other than the polyetherimide, the poly(arylene ether sulfone) or the combination thereof. The composition can optionally exclude any inorganic filler other than the boehmite, calcium carbonate, barium sulfate, wollastonite, or combination thereof.
In an aspect, the composition can optionally further comprise an additive composition, comprising one or more additives selected to achieve a desired property, with the proviso that the additive(s) are also selected so as to not significantly adversely affect a desired property of the composition. The additive composition or individual additives can be mixed at a suitable time during the mixing of the components for forming the composition. The additive composition can include an impact modifier, flow modifier, filler (e.g., a particulate polytetrafluoroethylene (PTFE), glass, carbon, mineral, or metal), reinforcing agent (e.g., glass fibers), antioxidant, heat stabilizer, light stabilizer, ultraviolet (UV) light stabilizer, UV absorbing additive, plasticizer, lubricant, release agent (such as a mold release agent), antistatic agent, anti-fog agent, antimicrobial agent, colorant (e.g., a dye or pigment), surface effect additive, radiation stabilizer, flame retardant, anti-drip agent (e.g., a PTFE-encapsulated styrene-acrylonitrile copolymer (TSAN)), or a combination thereof. For example, a combination of a heat stabilizer, mold release agent, and ultraviolet light stabilizer can be used. In general, the additives are used in the amounts generally known to be effective. For example, the total amount of the additive composition (other than any impact modifier, filler, or reinforcing agent) can be 0.001 wt % to 10.0 wt %, or 0.01 wt % to 5 wt %, each based on the total weight of the composition.
In an aspect, the composition can further comprise an additive composition comprising an antioxidant, a thermal stabilizer, a hydrostabilizer, a UV stabilizer, a mold release agent, or a combination comprising at least one of the foregoing.
The composition can be manufactured by various methods generally known in the art. For example, the polyetherimide, poly(arylene ether sulfone), or combination thereof can be blended with the inorganic filler, for example in a high-speed mixer or by handmixing. The blend can be fed into the throat of a twin-screw extruder via a hopper. Alternatively, at least one of the components can be incorporated into the composition by feeding it directly into the extruder at the throat or downstream through a sidestuffer, or by being compounded into a masterbatch with a desired polymer and fed into the extruder. The extruder is generally operated at a temperature higher than that necessary to cause the composition to flow. The extrudate can be immediately quenched in a water bath and pelletized. The pellets so prepared can be one-fourth inch long (i.e., 0.635 centimeters) or less as desired. Such pellets can be used for subsequent molding, shaping, or forming, for example, compression molding, injection molding, or the like.
Molded samples of the composition can exhibit one or more advantageous properties. For example, a molded sample of the composition can exhibit a transmission of greater than 50% in the range of 850 nanometers to 1100 nanometers for a 1 mm thick sample, as determined by UV/Vis spectroscopy operating in transmission mode, over a wavelength range of 400 nanometers to 2000 nanometers with a 4 nanometer interval. A molded sample of the composition can exhibit a transmission of greater than 40%, or greater than 50% in the range of 1200 nanometers to 1330 nanometers for a 1 mm thick sample, as determined by UV/Vis spectroscopy operating in transmission mode, over a wavelength range of 400 nanometers to 2000 nanometers with a 4 nanometer interval . A molded sample of the composition can exhibit a flow or cross-flow coefficient of thermal expansion of less than 6.5E-5 1° C., or less than 5E-5 1/° C. (e.g., 5×10−5 1/° C.) between −40° C. and 85° C., as determined according to ASTM E831. In an aspect, the composition exhibits at least one of the foregoing properties, preferably at least two of the foregoing properties, more preferably each of the foregoing properties.
A molded sample of the composition can optionally further exhibit one or more of the following mechanical properties. For example, a molded sample of the composition can exhibit a flexural modulus, determined according to ASTM D790, of greater than 3600 MPa. A molded sample of the composition can exhibit a tensile modulus, determined according to ASTM D638, of greater than 3700 MPa. A molded sample of the composition can exhibit a notched Izod impact strength at 23° C., determined according to ASTM D256, of greater than 30 J/m. A molded sample of the composition can exhibit an unnotched Izod impact strength at −23° C., determined according to ASTM D256, of greater than 300 J/m. In an aspect, the composition can exhibit at least one of the foregoing mechanical properties, or at least two of the foregoing mechanical properties, or at least three of the foregoing mechanical properties, or each of the foregoing mechanical properties.
In a specific aspect, the composition comprises 60 weight percent to 90 weight percent of the polyetherimide, preferably wherein the polyetherimide comprises repeating units derived from bisphenol A and m-phenylene diamine; 10 weight percent to 40 weight percent of the inorganic filler, preferably wherein the inorganic filler is boehmite; and 0 weight percent to 10 weight percent of an additive composition, preferably 0 weight percent to 1 weight percent. The composition can exhibit one or more of a transmission of greater than 70% in the range of 850 nm to 1100 nm for a 1 mm thick sample, as determined by UV/Vis spectroscopy; a transmission of greater than 70% in the range of 1200-1330 nanometers for a 1 mm thick sample, as determined by UV/Vis spectroscopy; and a flow or cross-flow coefficient of thermal expansion of less than 50 μm/° C. between −40° C. and 85° C., as determined according to ASTM E831.
In another specific aspect, the composition comprises 60 weight percent to 90 weight percent of the poly(arylene ether sulfone); 10 weight percent to 40 weight percent of the inorganic filler, preferably boehmite; and 0 weight percent to 10 weight percent, or 0 weight percent to 1 weight percent of an additive composition; wherein the molded sample of the composition exhibits one or more of: a transmission of greater than 65% in the range of 850 nm 1100 nm for a 1 mm thick sample, as determined by UV/Vis spectroscopy; a transmission of greater than 75% in the range of 1200 nm 1330 nm for a 1 mm thick sample, as determined by UV/Vis spectroscopy; and a flow or cross-flow coefficient of thermal expansion of less than 50 μm/° C. between −40° C. and 85° C., as determined according to ASTM E831.
Articles comprising the composition represent another aspect of the present disclosure. Articles can be prepared, for example, by molding, extruding, or shaping the above-described composition into an article. The composition can be molded into useful shaped articles by a variety of methods, such as injection molding, extrusion, rotational molding, blow molding and thermoforming. Exemplary articles can be in the form of a fiber, a film, a sheet, a pipe, or a molded part. The physical properties of the composition described herein can provide articles that are particularly well-suited for transparent articles, for example for use in optical applications. Such articles can include optical articles, preferably an optic lens, a lens array, transparent materials applications in medical devices, electronic and telecommunications, building and constructions, sensors, antennas, electrodes, thin film optics, thin film substrates, transistors and IR transparent display devices. In an aspect, the article can be a lens for a single mode optical fiber connector.
This disclosure is further illustrated by the following examples, which are non-limiting.
The materials used for the following examples are described in Table 1.
Compositions were prepared by compounding the components of the composition on a Toshiba TEM-37BS twin screw extruder according to the compounding profile shown in Table 2.
Extruded pellets were then molded into testing bars using a Fanuc S-2000i injection molding machine with an Axxicon tool according to the injection molding profile shown in Table 3.
Physical testing of the compositions was carried out according to the following test standards. Notched and Unnotched Izod impact strength was determined in accordance with ASTM D256 using a pendulum energy of 5 lbf/ft. Tensile properties were determined in accordance with ASTM D638 using a test speed of 50 mm/min. Flexural properties were determined in accordance with ASTM D790 using a test speed of 1.27 mm/min. Infrared (IR) transmission was determined using UV/Vis analysis of a 1 mm color chip. UV/Vis analysis was conducted using a Perkin Elmer Lambda 750S spectrometer with a slit width of 2 nanometers, and an integrated sphere with a 10 centimeter diameter. The flow and cross-flow coefficient of thermal expansion (CTE) measurement was carried out according to ASTM E831 and in the range of −40° C. to 85° C. using a DuPont 2940 probe, which provided 0.05 N tension force on the film, at a heating rate of 58° C. per minute.
Compositions and the corresponding physical properties are shown in Tables 4A and 4B.
Comparative example 1 shows the physical properties of PEI alone. As can be seen from Table 4A, this PEI exhibits a high IR transmission (88% at 850 nm and 90% at 1310 nm), but a relatively high flow and cross-flow CTE (5.5E-5 1/° C.).
In order to decrease CTE, boehmite was added as a filler in examples 2-4. Table 4 shows that the flow CTE decreased from 5.5 to 4.62E-5 1/° C. with just 10% loading of boehmite, while the transmission at 1310 nm remained greater than 85%. Upon increasing the filler loading further, the flow CTE was observed to further decrease to 3.78×10−5 1/° C. at 40% loading, with transmission remaining relatively high at 68% at 1310 nm.
Surface treated boehmite was also added to the composition (examples 5-9), which resulted in similarly low flow and cross-flow CTE values, and higher percent transmission even at high loading. In particular, example 9 shows that 40% loading of surface treated boehmite resulted in greater than 80% transmission at 1310 nm.
Calcium carbonate (examples 14 and 15), barium sulfate (example 10) and wollastonite (example 11) were also tested. Similar to boehmite, the flow and cross-flow CTE was observed to decrease and the transmission remained greater than 75% at 1310 nm at 20% loading of each filler type.
Examples 12-13 show compositions including a polysulfone and boehmite filler which provided desirably low flow and cross-flow CTE and high IR transmission. Examples 16-17 and 20-21 show compositions including a polysulfone and wollastonite filler. Similar to boehmite, low flow and cross-flow CTE was observed and the transmission remained greater than 70% at 1310 nm at 20% loading, and greater than 50% at 1310 nm at 30% filler loading. Examples 18-19 show compositions including a polysulfone and a calcium carbonate filler, where low flow and cross-flow CTE was observed and the transmission remained greater than 40% at 1310 nm at 20% loading.
This disclosure further encompasses the following aspects.
Aspect 1: A composition comprising: 50 weight percent to 97 weight percent, or 55 weight percent to 95 weight percent of a polyetherimide or a poly(arylene ether sulfone); and 3 weight percent to 50 weight percent of an inorganic filler having a refractive index of 1.60 to 1.68 as determined at a wavelength of 587 nanometers comprising boehmite, calcium carbonate, barium sulfate, wollastonite, or a combination thereof; wherein weight percent is based on the total weight of the composition; and wherein a molded sample of the composition exhibits one or more of: a transmission of greater than 50% in the range of 850 nm to 1100 nm for a 1 mm thick sample, as determined by UV/Vis spectroscopy; a transmission of greater than 40%, or greater than 50% in the range of 1200 nm to 1330 nm for a 1 mm thick sample, as determined by UV/Vis spectroscopy; and a flow coefficient of thermal expansion, a cross-flow coefficient of thermal expansion, or both of less than 6.55E-5 1° C., or less than 5E-5 1/° C. between −40° C. and 85° C., as determined according to ASTM E831.
Aspect 2: The composition of aspect 1, wherein a molded sample of the composition exhibits one or more of: a flexural modulus, determined according to ASTM D790, of greater than 3600 MPa; a tensile modulus, determined according to ASTM D638, of greater than 3700 MPa; a notched Izod impact strength at 23° C., determined according to ASTM D256, of greater than 30 J/m; and an unnotched Izod impact strength at −23° C., determined according to ASTM D256, of greater than 300 J/m.
Aspect 3:The composition of aspect 1 or 2, wherein the composition comprises the polyetherimide.
Aspect 4:The composition of any of aspects 1 to 3, wherein the polyetherimide comprises repeating units of the formula
wherein T is —O— or a group of the formula —O—Z—O— wherein the divalent bonds of the —O—Z—O— group are in the 3,3′, 3,4′, 4,3′, or the 4,4′ positions, and Z is an aromatic C6≥monocyclic or polycyclic moiety optionally substituted with 1 to 6 C1-8 alkyl groups, 1 to 8 halogen atoms, or a combination comprising at least one of the foregoing; and R is a divalent group of one or more of the following formulae
wherein Q1 is —O—, —S—, —C(O)—, —SO2—, —SO—, —P(Ra)(═O)— wherein Ra is a C1-8 alkyl or C6-12 aryl, —CyH2y— wherein y is an integer from 1 to 5 or a halogenated derivative, or —(C6H10)z— wherein z is an integer from 1 to 4.
Aspect 5: The composition of aspect 3, wherein T is —O—Z—O— and Z is derived from bisphenol A and R is m-phenylene, p-phenylene, or a combination thereof, preferably m-phenylene.
Aspect 6: The composition of aspect 1 or 2, wherein the composition comprises the poly(arylene ether sulfone), preferably wherein the poly(arylene ether sulfone) comprises a polyether sulfone, a polyphenylsulfone, or a combination thereof.
Aspect 7: The composition of any of aspects 1 to 6, wherein the inorganic filler comprises boehmite, preferably in an amount of 5 weight percent to 45 weight percent, or 10 weight percent to 40 weight percent.
Aspect 8: The composition of aspect 7, wherein the boehmite has an average particle size of less than 1μm, preferably 0.1 μm to 1 μm.
Aspect 9: The composition of any of aspects 1 to 8, further comprising an additive composition comprising an antioxidant, a thermal stabilizer, a hydrostabilizer, a UV stabilizer, a mold release agent, or a combination comprising at least one of the foregoing.
Aspect 10: The composition of aspect 1, comprising 60 weight percent to 90 weight percent of the polyetherimide comprising repeating units derived from bisphenol A and m-phenylene diamine; 10 weight percent to 40 weight percent of the inorganic filler, preferably boehmite; and 0 weight percent to 10 weight percent, or 0 weight percent to 1 weight percent of an additive composition; wherein the molded sample of the composition exhibits one or more of: a transmission of greater than 70% in the range of 850 nm to 1100 nm for a 1 mm thick sample, as determined by UV/Vis spectroscopy; a transmission of greater than 70% in the range of 1200 nm to 1330 nm for a 1 mm thick sample, as determined by UV/Vis spectroscopy; and a flow coefficient of thermal expansion, a cross-flow coefficient of thermal expansion, or both of less than 50 1/° C. between −40° C. and 85° C., as determined according to ASTM E831.
Aspect 11: The composition of aspect 1, comprising 60 weight percent to 90 weight percent of the poly(arylene ether sulfone); 10 weight percent to 40 weight percent of the inorganic filler, preferably boehmite; and 0 weight percent to 10 weight percent, or 0 weight percent to 1 weight percent of an additive composition; wherein the molded sample of the composition exhibits one or more of: a transmission of greater than 65% in the range of 850 nm to 1100 nm for a 1 mm thick sample, as determined by UV/Vis spectroscopy; a transmission of greater than 75% in the range of 1200 nm to 1330 nm for a 1 mm thick sample, as determined by UV/Vis spectroscopy; and a flow coefficient of thermal expansion, a cross-flow coefficient of thermal expansion, or both of less than 50 1/° C. between −40° C. and 85° C., as determined according to ASTM E831.
Aspect 12: A method of manufacturing the composition of any of aspects 1 to 11, the method comprising melt-mixing the components of the composition, and optionally, extruding the composition.
Aspect 13: An article comprising the composition of any of aspects 1 to 11.
Aspect 14: The article of aspect 13, wherein the article is an optical article, preferably an optic lens, a lens array, transparent materials applications in medical devices, electronic and telecommunications, building and constructions, sensors, antennas, electrodes, thin film optics, thin film substrates, transistors and IR transparent display devices.
The compositions, methods, and articles can alternatively comprise, consist of, or consist essentially of, any appropriate materials, steps, or components herein disclosed. The compositions, methods, and articles can additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any materials (or species), steps, or components, that are otherwise not necessary to the achievement of the function or objectives of the compositions, methods, and articles.
All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. “Combinations” is inclusive of blends, mixtures, alloys, reaction products, and the like. The terms “first,” “second,” and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “a” and “an” and “the” do not denote a limitation of quantity, and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. “Or” means “and/or” unless clearly stated otherwise. Reference throughout the specification to “an aspect” means that a particular element described in connection with the aspect is included in at least one aspect described herein, and may or may not be present in other aspects. The term “combination thereof” as used herein includes one or more of the listed elements, and is open, allowing the presence of one or more like elements not named. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various aspects.
Unless specified to the contrary herein, all test standards are the most recent standard in effect as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.
Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this application belongs. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.
Compounds are described using standard nomenclature. For example, any position not substituted by any indicated group is understood to have its valency filled by a bond as indicated, or a hydrogen atom. A dash (“-”) that is not between two letters or symbols is used to indicate a point of attachment for a substituent. For example, —CHO is attached through carbon of the carbonyl group.
As used herein, the term “hydrocarbyl”, whether used by itself, or as a prefix, suffix, or fragment of another term, refers to a residue that contains only carbon and hydrogen. The residue can be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated, or unsaturated. It can also contain combinations of aliphatic, aromatic, straight chain, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbon moieties. However, when the hydrocarbyl residue is described as substituted, it may, optionally, contain heteroatoms over and above the carbon and hydrogen members of the substituent residue. Thus, when specifically described as substituted, the hydrocarbyl residue can also contain one or more carbonyl groups, amino groups, hydroxyl groups, or the like, or it can contain heteroatoms within the backbone of the hydrocarbyl residue. The term “alkyl” means a branched or straight chain, saturated aliphatic hydrocarbon group, e.g., methyl, ethyl, n-propyl, i-propyl, n-butyl, s-butyl, t-butyl, n-pentyl, s-pentyl, and n- and s-hexyl. “Alkenyl” means a straight or branched chain, monovalent hydrocarbon group having at least one carbon-carbon double bond (e.g., ethenyl (—HC═CH2)). “Alkoxy” means an alkyl group that is linked via an oxygen (i.e., alkyl—O—), for example methoxy, ethoxy, and sec-butyloxy groups. “Alkylene” means a straight or branched chain, saturated, divalent aliphatic hydrocarbon group (e.g., methylene (—CH2-) or, propylene (—(CH2)3—)). “Cycloalkylene” means a divalent cyclic alkylene group, —CnH2n-x, wherein x is the number of hydrogens replaced by cyclization(s). “Cycloalkenyl” means a monovalent group having one or more rings and one or more carbon-carbon double bonds in the ring, wherein all ring members are carbon (e.g., cyclopentyl and cyclohexyl). “Aryl” means an aromatic hydrocarbon group containing the specified number of carbon atoms, such as phenyl, tropone, indanyl, or naphthyl. “Arylene” means a divalent aryl group. “Alkylarylene” means an arylene group substituted with an alkyl group. “Arylalkylene” means an alkylene group substituted with an aryl group (e.g., benzyl). The prefix “halo” means a group or compound including one more of a fluoro, chloro, bromo, or iodo substituent. A combination of different halo atoms (e.g., bromo and fluoro), or only chloro atoms can be present. The prefix “hetero” means that the compound or group includes at least one ring member that is a heteroatom (e.g., 1, 2, or 3 heteroatom(s)), wherein the heteroatom(s) is each independently N, O, S, Si, or P. “Substituted” means that the compound or group is substituted with at least one (e.g., 1, 2, 3, or 4) substituents that can each independently be a C1-9 alkoxy, a C1-9 haloalkoxy, a nitro (—NO2), a cyano (—CN), a C1-6 alkyl sulfonyl (—S(═O)2-alkyl), a C6-12 aryl sulfonyl (—S(═O)2-aryl), a thiol (—SH), a thiocyano (—SCN), a tosyl (CH3C6H4SO2—), a C3-12 cycloalkyl, a C2-12 alkenyl, a C5-12 cycloalkenyl, a C6-12 aryl, a C7-13 arylalkylene, a C4-12 heterocycloalkyl, and a C3-12 heteroaryl instead of hydrogen, provided that the substituted atom's normal valence is not exceeded. The number of carbon atoms indicated in a group is exclusive of any substituents. For example —CH2CH2CN is a C2 alkyl group substituted with a nitrile.
While particular aspects have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.
| Number | Date | Country | Kind |
|---|---|---|---|
| 20211295.9 | Dec 2020 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2021/060885 | 11/23/2021 | WO |
